MPT International 1/2013 (Feb)

Page 1

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Mechanical vacuum pumps (MVP)

Editorial

Emphasis on longs Saying that there are two sides to the world of steel is not an empty phrase. Long products and flat products – these two product groups divide both steelmaking technology and the steel market. Being a regular reader of MPT International, you will have become accustomed to being informed in our journal about new technological developments and innovative equipment in long and flat steel production in a well balanced way. However, once in a while there may be a preponderance of one or the other, as in this current issue in which we are focusing on long products. We start by introducing the new management duo of Schmolz+Bickenbach AG. The Switzerland-based special steel producer has been following an expansion course through acquisitions during the last few years and today has some 10,000 employees. The company owes this growth to a high degree to its former CEO Benedikt Niemeyer and COO Marcel Imhof, who both have left the company successively since the middle of 2012. In this issue, we are introducing the new managers, Johannes Nonn, the new CEO, and Hans-Jürgen Wiecha, who holds the position of CFO. Content-wise, our emphasis is again on production in the works. One of our articles features the new high-strength rebar mill of the B.S.R.M. Group. The authors refer to this mill as a “market-sized” rolling mill plant designed for low to medium-scale output capacity tailored to supply a specific regional market – in this case Bangladesh. Another hot-rolling article describes the latest generation of Bi-Support rolling stands, which comes with various innovative technical features. The authors of both articles stress the importance of having in mind the improvement of the final product quality in order to achieve a higher value added already in the early stages of the production process. A third article, which presents a new straightness measuring system for bar and pipe steel products, forms a perfect complement to this aspect. This new, non-contact system operates inline and has been designed for monitoring production to ensure that the applicable quality specifications are always complied with. Apart from the articles mentioned above, you will find plenty of information on new developments in other technical fields, from raw materials preparation via steelmaking and continuous casting through to automation. I am sure that these articles will offer suggestions from all aspects of steelmaking on how to further and continuously improve one’s production.

Dipl.-Ing. Arnt Hannewald

MPT International 1/2013

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Contents

Volume 36

No. 1 – February 2013

Topical themes 24 European Steel Association Eurofer welcomes EU Parliament resolution on steel industry The steel industry is essential for growth and prosperity in Europe. It is in the interest of the whole European Union and its manufacturing sectors to have a competitive steel industry and to secure supply through domestic production. Strategic initiatives are needed, therefore, to support the sector and to keep it in Europe.

Cover photo: 110-MN open-die forging press with four prestressed columns and a welded steel structure, at Fomas Group, Italy Danieli & C. S.p.A., Buttrio, Italy Contact: www.danieli.com E-mail : info@danieli.com

Editorial A. Hannewald

5 Emphasis on longs

Columns 10 International industry news 58 Technical innovations

Raw materials

Steelmaking

J. Chegwidden

C. Born, R. Granderath

28 Iron ore industry to remain turbulent until 2020 With the disruption of supplies from India, concerns over slowing economic growth in China, the iron ore industry has faced a turbulent time during 2011 and 2012. Roskill’s new report offers a deeper level of insight into the dynamics driving the market and offers a market outlook to 2020.

30 Circular pelletizing technology facilitates compact plants to be integrated on site A new generation of pellet plants featuring a circular induration furnace as its core element was developed by Siemens Metals Technologies. This iron ore agglomeration facility is characterized by its highly compact layout and light-weight construction design. This is the basis for efficient and costeffective installation at a mining site or within an iron and steel complex.

63 Cartoon 64 Literature service 66 In the next issue 66 Imprint 3-D view of a CPT plant

32 Benchmark for heat recovery from the offgas duct at electric arc furnaces Tenova’s steam generation technology was for the first time applied to an EAF at Georgsmarienhütte, Germany, in 2009. Three years later, the projects at the Feralpi plant in Riesa and the Hyundai plant in Incheon extend the scope of this technology through additional innovations.

Continuous casting A. Weyer, J. Frick

36 Secondary cooling concepts VQ KPETGCUG VJG GHƂEKGPE[ CPF ƃGZKDKNKV[ QH UNCD ECUVGTU To ensure the flexible production of different steel grades at variable casting speeds and with a wide range of product dimensions, novel cooling concepts are needed. For secondary cooling, this means that for all cooling strategies an as large as possible control range covering the whole product mix must be attained.

Metallurgical Plant and Technology Advertisers’ index Interview

ABB AB

25

Associazione Italiana di Metallurgia

57

Association for Iron & Steel Technology

18

Dr. Breit GmbH

35

!?QRCJJGLG -DjAGLC Meccaniche S.p.A.

59

26 New executive board at Schmolz+Bickenbach, Switzerland The global special steel producer Schmolz+Bickenbach (10,000 employees) has elected Johannes Nonn as new CEO and Hans-Jürgen Wiecha as new CFO. Ongoing restructuring measures are being implemented according to plan. However, the company is still facing a difficult market environment. Last year, the impact of the international financial and economic crisis was clearly noticeable on revenue and earnings.

Hot rolling S. K. Das, E. Francescatto, A. Taurino, A. Mestroni

42 High-strength rebar production at the new rolling plant at B.S.R.M. in Bangladesh A so-called “market-sized” rolling mill plant is designed for low/medium-scale output capacity tailored for the specific demand of a regional market, but featuring the most advanced technologies for low-cost production of high-strength commercial steel long products. The Danieli QTB, QTR and QTS processes are efficient and cost-saving tools to produce these types of steel.

M. Zuccato, M. Tomba, A. Fontanini, N. Tomba

48 Second generation of Bi-Support rolling stands The conditions of today’s long steel products market with ever smaller profit margins and stronger competition require the use of rolling mills with minimized operational cost and the capability of assuring a final product of very high quality.

Automation 52 Advanced automation system for Dragon Steel’s new hot strip mill Dragon Steel Corporation, a subsidiary of China Steel Corporation, commissioned a new hot strip mill at their greenfield steel facility in Taichung, Taiwan. The new mill is capable to produce about 3 million t/year of a broad variety of high quality steel strip, including low carbon, API, IF, HSLA, BH, electric, and stainless grades.

U. Lettau

56 Condition monitoring of plants and process analysis with a single system An adaptable condition monitoring system has been developed for different application scenarios and in variable sizes. From decentralized monitoring of individual physical machine performance figures up to the central acquisition of all relevant data for a total production, this new condition monitoring system covers a variety of applications and can be used independently of the automation manufacturer. It can be configured individually and connected to any conventional automation solution.

Danieli S.P.A.

8, 9

Evertz Hydrotechnik GmbH & Co. KG

41

Fabris InC.

4

GLAMA Maschinenbau GmbH

45

H&K Industrieanlagen GmbH

61

Instituto Aco Brasil

16

JP Steel Plantech Co.

I.B.C.

Kiro-Nathaus GmbH

17

Maschinenfabrik Köppern GmbH & Co.KG

12

Messe Düsseldorf GmbH

13

Morgardshammar AB

O.B.C.

Pert srl

31

Plakoma GmbH

47

)MLP?B 0SKN -@CPkÈAFCL technik GmbH & Co. KG

35

Siemens VAI Metals Technologies GmbH

51

Siempelkamp Maschinen -und Anlagenbau GmbH & Co.KG

11

SMS Mevac GmbH SMS Siemag AG

I.F.C., 3 22, 23

Tenova spa Verlag Stahleisen GmbH

29 27, 57

Walzengießerei Coswig GmbH PAUL WURTH S.A. 4QWIJKPI OKNN KP * 8 EQPƂIWTCVKQP

Zumbach Electronic AG

21

19, 20 55

Severstal, Russia

Thyssenkrupp AST, Italy

Complete EOT crane package (18 cranes, from scrap yard to finished product) for a 1 Mtpy minimill.

New 600-ton capacity crane for ingot handling in forging plants.

Sabic (Hadeed), Saudi Arabia

Gerdau Aรงominas, Brazil

Complete high-tech EOT crane packages for a 1.5-Mtpy meltshop. New benchmark for technological cranes in the Middle East.

Strategic order in Brazilian flat product market with complete EOT crane package for Ouro Branco Steckel mill plant.

Four main references out of total 487 HIGH-TECH CRANES FOR THE METALS INDUSTRY WITH CAPACITIES RANGING FROM 160 TO 6000 KN. REDUNDANT AND ACTIVE SAFETY DESIGN FEATURES CONCEIVED TO MINIMIZE THE POSSIBILITY OF ACCIDENTS MAINTENANCE-FREE CONCEPT THANKS TO REMOTE CRANE MONITORING SYSTEM.

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International industry news

Personalities Alberto Iperti to head Tenova. Alberto Iperti has been ?NNMGLRCB AFGCD CVCASRGTC MDjACP of Tenova. Alberto Iperti joined the 2CAFGLR EPMSN GL jPQR ?Q NJ?Lning director of TenarisDalmine in Italy and then as managing director of Exiros in Argentina. From 2005 ML FC FCJB RFC MDjAC MD 2CL?PGQ global planning director in Argentina as well. He succeds Gianluigi Nova, who will continue his collaboration on the Tenova board.

Outotec appoints new senior VP. Outotec has appointed Kirsi Nuotto as new senior vice president human capital and member of the executive board. Outotec’s current senior vice president human capital, Ari Jokilaakso, will take up a new position in Outotec as head of research and technology development in the non-ferrous solutions business area.

Board members to leave ThyssenKrupp. Executive board members Olaf Berlien, JĂźrgen Claassen and Edwin Eichler were released from their functions. Further to the negative development of the Steel Americas projects, ThyssenKrupp is currently confronted with the disclosure of a series of corruption and cartel cases. Oliver Burkhard has been appointed as a new member of the executive board. He is to take over as labour director.

Executive changes at Salzgitter. While Johannes Nonn is leaving the company, the responsibility for the steel division at Salzgitter AG will be assumed by Prof. Dr.-Ing. Heinz JĂśrg Fuhrmann, chairman of the executive board.

New chairman at Saar Forge. JĂźrgen Horsthofer has been appointed as new CEO of Saarschmiede GmbH Freiformschmiede, Dillingen, Germany. In addition to his work as chairman, he will be responsible for the sales department.

Management changes at Izhstal. Anatoly Shchetinin has been appointed the new managing director of Izhstal OAO, which is part of the Mechel group. He replaces Konstantin Kretov, who headed the plant since February 2011.

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MPT International 1/2013

Brazil

from 127 x 127 mm to 200 x 200 mm. The three-strand machine will be designed for future extension to up to five strands. Commissioning is scheduled for mid-2013.

Forjasul orders induction heating system. Forjasul Canoas from

Mexico

The Americas

Rio Grande do Sul has placed an order with SMS Elotherm for the supply of an EloForge™ induction heating system. SMS Elotherm will integrate the system into Forjasul’s existing plant and customize the system precisely to the production requirements. With a nominal power of 500 kW, the system will heat up to 1,250 kg/h of steel billets of 51 mm diameter to the required temperature of 1,250°C. Forjasul will commission its new EloForge™ in spring 2013.

Gerdau Corsa to build billet caster. CCR Technologies of Ontario, Canada, has been awarded the complete turnkey supply of a two-strand billet caster for Gerdau Corsa. The new equipment will increase plant productivity and improve product quality. The casting machine will incorporate a highspeed mould tube and a cut-by-weight control system to allow total annual production of 400,000 t/year. The start-up is scheduled for the third quarter of 2013.

Brazil USA

Gerdau to build new melt shop. Gerdau will build a new melt shop with an installed capacity of 650,000 t/year at the Riograndense mill, located in Sapucaia do Sul (RS). This new melt shop will replace the current melt shop, which has an annual production capacity of 450,000 t of steel. The project includes construction of the infrastructure needed to expand the plant, purchase of machinery and equipment, civil construction and facilities. The new melt shop will start up in the second half of 2015.

Brazil

Nucor-Yamato Steel to revamp steel mill. Nucor-Yamato Steel Company in Blytheville, Arkansas, has placed an order with SMS Meer for the modernization and upgrade of its No.1 rolling mill enabling for a wider range of sheet piling products. The package of SMS Meer includes charging and discharging machines for the reheating furnace, primary descaling equipment, a new breakdown stand and three new CCSÂŽ (compact cartridge stand) finishing stands. to replace the existing universal finishing stand. The installation of the new equipment is expected to be completed in early 2014.

)8 FQ $TC\KN VQ DWKNF ITGGPƂGNF minimill. The SIMEC group from Apizaco, Mexico, has placed a minimill order with SMS Concast and SMS Meer. The plant – for GV do Brazil – will be erected near Pindamonhangaba in the Brazilian state of São Paulo. SMS Concast will supply the steelworks and SMS Meer the bar and wire rod mill. The plant will be designed for a production capacity of 520,000 t/year of billets and 400,000 t/year of bars and wire rod, with the possibility of future expansion to 560,000 t/year. The steelworks will operate with a 65 t three-phase electric arc furnace on scrap basis. The EAF will be able to produce 30 melts per day. Subsequent secondary metallurgy treatment will take place in a 65 t ladle furnace. The continuous casting machine will produce billets in the size range

USA

TPCO orders seamless tube mill. TPCO America Corporation from Corpus Christi, Texas, has placed an order with SMS Meer for the supply of a new 10žâ€? (dia. 273 mm) tube mill with PQFÂŽ rolling technology. The plant will produce oil country tubular goods (OCTG) for the crude oil and natural gas industry in the region. This will be the fifth PQFÂŽ plant supplied by SMS Meer to TPCO. The new plant will be designed for a maximum capacity of 534,000 t/ year. Core components of the plant will be the cone-type piercer, the PQFÂŽ mill, the extracting mill and the sizing mill. Rolling of the first tube is scheduled for October 2014.

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International industry news USA

Gallatin Steel to revamp slab caster. Gallatin Steel, Warsaw, Kentucky, has awarded SMS Siemag a contract to design and supply a hydraulic oscillation system to replace the originally supplied electro-mechanical system. SMS Siemag will provide the engineering and supply of the complete mechanical, hydraulic and X-PactÂŽ automation systems. Commissioning is scheduled to take place in the second half of 2013. Gallatin Steel operates a single-strand CSPÂŽ facility, which started up in 1995.

USA

Jemison Demsey Metals orders heavy-gauge strip processing line. Butech Bliss has been selected to design, manufacture and install a new 16 mm x 2,440 mm wide heavy-gauge stretch-levelling cut-tolength line for installation at Jemison Demsey Metals’ new coil processing centre in Decatur, Alabama. The line includes Butech Bliss’ patent pending Synergy Leveling System™ and an AC driven shear with camber compensation. It also comprises systems to measure flatness, width and material thickness. Construction of phase I of the new facility in Decatur, Alabama is currently underway. It is anticipated to be in full production in the third quarter of 2013.

We agglomerate your valuable dusts and fines

In the metallurgical industry we briquette e. g. steel mill residues, sponge iron (hot and cold), chrome ore, nickel

USA

Steel Dynamics to upgrade SBQ plant. Steel Dynamics (SDI) from Fort Wayne, Indiana, awarded the contract for a major expansion of the SBQ (special bar quality) plant at its Pittsboro, Indiana, works to SMS Meer. This upgrade is to integrate a roughing mill and a new three-roll PSMÂŽ (precision sizing mill) into the facility, enabling SDI to roll high-quality SBQ products in the small-diameter precision range. The new roughing mill will be operated in semi-continuous mode consisting of a two-high reversing mill followed by eight rigid housingless stands in H/V configuration which will feed the existing finishing mill. Commissioning of the renewed plant is scheduled for the end of 2013.

powder, copper concentrate, and other ďŹ nes.

USA Briquettes are used for feeding shaft furnaces, BOFs, RHFs, EAFs, and other reduction or melting units. KÜppern – Quality made in Germany. - & & ! & $& & ! ! * - $! %% & ! ! * !) !) - " & ( &* - ' $! $ $ " &

www.koeppern.de

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MPT International 1/2013

ATI Allegheny Ludlum places order for scheduling solution. Broner Metals Solutions has been selected by ATI Allegheny Ludlum to implement a new scheduling project at their specialty metals hot-rolling and processing facility at Brackenridge, Pennsylvania. The new scheduling system will balance the supply of slabs and ingots from multiple ATI melt shops with the rolling sequence required at the mill. Broner will also supply medium to long range capacity planning functions together with order promising capability to help match incoming product mix with the mills complex constraints. The new scheduling system will be integrated with ATI mainframe systems.

International industry news USA

International Trade Fair f o r M e t a l l u r g y, M a c h i n e r y, P l a n t Te c h n o l o g y & Products

Steel Dynamics to expand rail production. Steel Dynamics plans to install a state-of-the-art heattreating system at its Columbia City, Indiana, structural and rail division (SRD). When operational, the system will be capable of producing up to 350,000 t of standard strength and head hardened plain, carbon steel rails for North America’s railroad industry. Commissioning of the system is anticipated before the end of 2013.

The International Tube and Pipe Trade Fair in Russia

Asia China

International Trade Fair for Aluminium and Non-Ferrous Metals, M a t e r i a l s, Te c h n o l o g i e s and Products

Baoshan to modernize hot strip mill. Baoshan Iron & Steel (Baosteel) has awarded SMS Siemag a contract for the modernization of its hot strip mill No. 1 in Shanghai. The order comprises the supply of a new slab sizing press and primary descaler as well as the revamp of a roughing stand. In the roughing mill, Baosteel will replace the drive train of millstand R2. The revamp will take place in two phases. The new descaler will be installed in the summer of 2013. Installation and commissioning of the sizing press will follow in the summer of 2014.

25 – 28 June 2013

China

Xilin orders new wire rod mill. Xilin Iron & Steel from Heilongjiang Province is increasing its production capacities with a new high-speed wire rod mill from SMS Meer. The two-strand mill with ten-stand wire rod blocks will achieve a rolling speed of 120 m/s and be designed to produce 1 million t/year of wire rod. Xilin will produce quality products such as carbon steel, cold-heading grades, welding wires and spring steels in the size range from 5.5 mm to 20 mm diameter using 165 mm square billets as starting material. Commissioning of the mill is scheduled for December 2013.

Krasnaya Presnya Moscow, Russia

www.metallurgy-tube-russia.com

China

Baosteel to relocate Corex plants. Due to declining prices for heavy plate and as part of a strategic realignment of production in the Shanghai area, Baosteel has decided to cease steel production in the Luojing works and dismantle steelmaking installations, including two Corex plants. These plants, supplied by Siemens Metals Technologies, will be dismantled and reassembled at Bayi Iron & Steel, a member of the Baosteel group. Bayi, located in the province of Xinjiang, plans to more than double its current steel production capacity of seven million t/year by 2015. Corex module 1 is scheduled to go into operation at the end of 2014, and module 2 one year later. MPT International 1/2013

13

in conjunction with:

WELDING CUTTING

Messe Düsseldorf GmbH P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany Tel +49(0)211/45 60-01 _ Fax +49(0)211/45 60-7740 RyfischD@messe-duesseldorf.de

www.messe-duesseldorf.de

International industry news

News in brief Salzgitter AG, Germany, has launched a new corporate responsibility portal on its Internet site. The portal provides detailed information on the issue of sustainability within the Salzgitter group.

Deutsche Edelstahlwerke (DEW), Germany, operates a PSM® (precision sizing mill) system with hydraulic roll adjustment under load from SMS Meer at its Siegen-Geisweid site. The PSM® uses the new MEERgauge® system which reduces potential tolerance deviations in RFC jLGQFCB NPMBSAR ?SRMK?RGA?JJW during the rolling process.

At Ruukki Metals and Ruukki Marketing and Communications, employer-employee negotiations have been completed. The negotiations were part of projects initiated in 2012 to improve Ruukki’s competitiveness and have resulted in a workforce reduction of about 250 persons.

ThyssenKrupp VDM, Germany, successfully put on stream two new electroslag remelting (ESR) SLGRQ ,MU jTC #10 SLGRQ ?PC GL MNeration at the Unna melting plant.

Gerdau, USA, built a new continuous casting mill in Monroe, MichiE?L 2FC KGJJ GQ N?PR MD RFC jPQR phase of investments to increase the annual installed capacity of special steel at Monroe to 300,000 t.

Xingtai Iron and Steel, China, signed the FAC for the ESR/ESRR® plant installed by Inteco. The facility can produce billets longer than 9 m and ingots of 600 mm diameters.

CMI (Cockerill Maintenance & Ingénierie) has established a joint venture with Wiset, the technological engineering subsidiary of Wisco. The JV has been named Wuhan Cockerill Engineering and Technology.

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MPT International 1/2013

China

Kunsteel commissions section mill. A new section mill based on technology supplied by GE’s Power Conversion business has recently entered commercial service at the Kunsteel steel mill. GE supplied electrical automation equipment and a new drive, including four HPCi controllers, Ethernet and ProfiBus-DP communication systems. The cold-load testing of the new production line was completed in twelve days.

China

Anhui Tianda to expand tube production. Since 2007, Anhui Tianda Oil Pipe has been operating a PQF® mill from SMS Meer for the production of seamless tubes. Until now the mill has produced tubes up to an outside diameter of 10¾” (273 mm). SMS Meer will upgrade the Anhui Tianda Oil to expand the production range to an outside diameter of 13 3/8” (339.7 mm). Twelve new PQF® stands will allow larger outside diameters to be produced. The new PQF® stands will be installed in the existing mill without any notable modifications.

China

BaoTou Steel to receive iron ore scrapers. In October 2012, Schade Lagertechnik, which belongs to the Aumund group, received a contract from Jiangyin City DADI Machine Make for the supply of six semi-portal iron ore scrapers. The equipment will be for BaoTou Steel Union in Baotou City, Inner Mongolia. The scrapers will be designed for a reclaim rate of 1,650 t/h each. Erection is scheduled to start in August 2013, commissioning is planned for December 2013.

China

chamfering machines finish the ends of up to 40 bars per minute. They will produce round, square and hexagonal profiles. Each machine is designed for a different diameter. The finished products will range from 3 mm to 22 mm. Commissioning is scheduled for the first quarter of 2013.

India

Vizag Steel to modernize converter shop. Vizag Steel has contracted SMS Siemag as the leader of a consortium for the modernization and expansion of their converter shop No. 1 in Visakhapatnam. The aim is to increase annual production from 3.2 to 3.6 million t of steel as well as to improve environmental protection by installing an SMS Siemag gas cleaning system. The scope of supply comprises the engineering and manufacturing of core components for three new 150 t converter vessels with tilting drives, oxygen lances and bottom stirring equipment, the modernization of the primary dedusting system as well as the secondary dedusting system. The gas cleaning system will be executed as a wet dust-collection facility complete with Venturi scrubber. SMS Siemag will be responsible for the entire installation and commissioning work. Commissioning is scheduled for the first quarter of 2014.

India

JSW to implement planning, scheduling and MES solutions. Broner Metals Solutions has been selected by JSW Steel to implement a production planning and scheduling solution, together with Broner’s MES solution, for the JSW Vijaynagar integrated steel complex. The JSW plant currently consists of a large cold rolling mill complex (CRM1). A second cold rolling mill is being built and is planned for completion in August 2013.

Huitong Jincheng to install drawing machines. Huitong Jin-

India

cheng Precision Metal Manufacturing near Shanghai has ordered six drawing machines from SMS Meer, two of which with integrated chamfering machines. The six machines will draw, cut and straighten the bars at a speed of 25 to 120 m/min., while the integrated

Jailaxmi orders vacuum system for steel degasser. Oerlikon Leybold Vacuum will provide Jailaxmi Casting & Alloys another vacuum solution for steel degassing. The new order is for a compact mechanical vacuum system for a 35 t tank degasser.

International industry news Indonesia

Krakatau Steel to implement production management solution. PSI has been contracted by Krakatau Steel to implement the PSImetals production management system as a core solution for flat steel production. The new system will cover steelmaking, continuous casting, hot strip and cold rolling. Implementation is scheduled for the end of 2013.

Indonesia

PT. Gunung places order for environmental technology. PT. Gunung has awarded an order to SMS Siemag for the planning and supply of a gas cleaning system for an electric arc furnace. The system will be operated by speed-controlled fans which will use a minimum of electrical power and have an optimized process-dependent exhaust capacity. PT. Gunung had already ordered the electric arc furnace and a continuous slab caster from SMS Siemag in 2011. All three plants will go into operation in mid-2013.

Japan

Nisshin Steel orders new continuous caster. JP Steel Plantech received an order from Nisshin Steel Corporation for the supply of a new single-strand continuous slab casting machine of the vertical bending type. The machine will be installed at the Shunan works as part of a steel mill modernization.

from the Taiwanese steelmaking company Formosa Heavy Industries Co. to supply four continuous casting lines as part of a new steelmaking plant, Formosa Ha Tinh Steel Corporation, in Vung Ang, Vietnam. The order is specifically for two double-strand continuous slab casters, an eight-strand billet caster and a six-strand bloom caster with a total installed capacity of roughly 8.4 million t/year. The casters are scheduled to go into operation in mid-2015. Hot rolling equipment for the new steel complex will be supplied by Mitsubishi-Hitachi Metals Machinery. The scope of supplies will comprise a complete set of machinery and equipment, including two roughing mill stands, a sizing press, seven finishing mill stands and downcoiler equipment, for an annual production capacity of 5.3 million t as well as services ranging from supervision of installation and training. Operation of the hot rolling equipment is scheduled to start in the first half of 2015. Schade Lagertechnik will supply two tripper carriages for the coal-fired power plant and four tripper carriages for the steelworks, featuring a capacity of 5,400 t/h each. Also to be supplied by Schade Lagertechnik for the power plant and the steelworks are two and four semi-portal scrapers respectively. The steelworks will also have a portal scraper installed for its flux yard. In addition, six mobile discharge machines will be supplied. Complete erection and commissioning of this equipment will be directed by Schade Lagertechnik. Cold commissioning is scheduled for the end of April 2014.

Vietnam

VKS orders new rolling mill for expansion project. JP Steel Plantech has been awarded a contract from VKS Vina Kyoei Steel for the supply of a new rolling mill with an annual capacity of 500,000 t, following a recent meltshop order. The plant is scheduled to commence operation in the second quarter of 2014.

Vietnam

Formosa orders equipment for new steelmaking plant. Siemens Metals Technologies received an order

Europe Italy

Feralpi to modernize billet caster. Acciaierie di Calvisano, belonging to the Feralpi group, commissioned Siemens Metals Technologies with the modernization of the billet caster in the Calvisano works. The aim of the project is to further improve the internal and surface quality of the billets and to be able to cast round (in addition to square) billets. The caster will

News in brief Jiangsu Dajiang Metal Material, China, has issued the FAC for a high-speed electrolytic tinning line supplied by Tenova Strip Processing. The 550 m/min line produces 250,000 t/year of tin plate.

Deutsche Edelstahlwerke Krefeld, Germany, commissioned Inteco to convert one of the existing VAR furnaces, supplied by Inteco in 2007, to a multifunctional furnace, which combines ESR and VAR process technology. A joint patent by Inteco and Deutsche Edelstahlwerke for this new technology is pending.

Jiangsu Tianhuai Steel Pipe, China, commissioned the new 20� PQFŽ tube mill for seamless quality steel tubes supplied by SMS Meer. Production capacity is 500,000 t/ year.

Dragon Steel, Taiwan, put into operation a new continuous casting plant at the Taichung location. The two-strand slab caster was supplied by Siemens VAI Metals Technologies.

Frenzelit Expansion Joint Private Ltd., India, is the name of the Indian joint venture established by Frenzelit Werke, Germany, manufacturers of technical textiles for GLQSJ?RGML jJRP?RGML ?LB QC?JGLE

Gerdau, Spain, has invested in a new water-treatment facility for its Reinosa steelmaking plant. The water treated in the new facility will be used for cooling purposes, resulting in a 50% reduction in water consumption.

Eurofer KMTCB GRQ MDjACQ RM RFC #3 quarter in the centre of Brussels, Belgium. The new address is Avenue Cortenbergh 172, 1000 Brussels.

New head of IIMA. Stuart Horner is the new secretary general of the International Iron Metallics Association (IIMA). His predecessor Frank Griscom retired end of 2012.

MPT International 1/2013

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International industry news be equipped with a new machine head, including moulds and additional technology packages, like electromagnetic stirrer. The strand guide, secondary cooling and cooling bed will also be optimized. The revamped casting plant is scheduled to go into operation at the beginning of 2013.

Russia

ITZ orders gap closing press. Izhorsky Trubny Zavod (ITZ), which is part of the Severstal Group and based in Kolpino near St. Petersburg, has placed an order with SMS Meer for the supply of a new gap closing press with a press force of 25 MN. The machine will be integrated into the existing 18 m JCOE® large-diameter pipe mill, which SMS Meer supplied in 2006. The gap closing press is scheduled to go into operation in the first quarter of 2013.

Switzerland

Swiss Steel to modernize electric arc furnace. Swiss Steel has

placed an order with Siemens Metals Technologies for major modernization work on its EAF in Emmenbrücke. The main goals of the project are to shorten process times and cut conversion cost. Production capacity will rise to 650,000 t/year of steel, while increasing operating safety and reducing maintenance cost. Siemens will install a completely new hydraulic system and equip the furnace with a new tilting platform and gantry. Thanks to a new portal with prismatic electrode lifting columns, the furnace roof, which will also be new, can in future be swiveled via a single-point suspension system. Siemens will also be supplying a special ladle car for the existing tapping pit. The project is due to be completed in August 2013.

machine and a bar straightener. The new bright steel centre can process bars with diameters from 15 to 55 mm and lengths from 2,500 to 7,000 mm. SMS Meer had already supplied a similar installation to Judenburg in 2006.

Ukraine

DMKD to apply pulverized coal injection. DMKD, a company of the Industrial Union of Donbass (ISD), awarded Paul Wurth orders to engineer and supply coal grinding, drying and injection plants for their four blast furnaces operated at the Dneprodzerzhinsk works. Commissioning of the injection plants is planned to take place within 19 months from the contract becoming effective.

Austria

Stahl Judenburg to install new bright steel centre. Stahl Juden-

United Kingdom

burg placed a second order with SMS Meer for the production and supply of a BC 50 bright steel centre. The core elements of the centre are a peeling

Tata Steel Speciality Steels to build VIM furnace. Tata Steel Speciality Steels has chosen SMS Mevac to design a VIM X-eed® vacuum induc-

THE MOST IMPORTANT EVENTOFBRAZIL

STEELCHAIN The Brazil Steel Institute celebrates its 50th anniversary,

MAY 8th and 9th RIO DE JANEIRO

working hard for the support of the production infrastructure, jobs preservation and to restore competitiveness. Professor of Harvard, Dani Rodrik and the CEO of Research & Consulting Group AG, Joachim

SULAMÉRICA CONVENTION CENTER

Schröder, will be some of the speakers.

eventos@acobrasil.org.br | (+55 21) 2524-6917 |

www.acobrasil.org.br/congresso2013/english th

Registrations until March 25 , 2013, with 15% discount Institutional Support

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International industry news tion melting furnace for its Stocksbridge site. The facility will produce high-purity steels and specialist alloys for the aerospace industry. The project is currently in the design phase and is intended to go into production in 2014, pending final capital approval. The VIM unit for Tata Steel comprises an 8 t vacuum induction melting crucible together with the associated vacuum pumping, material charging and process control equipment. All core components will be designed to allow Tata to increase the melt size to 18 t at a later date.

Germany

construction of the new battery 3 and its commissioning in 2010. The modernization included the incorporation of a new charging-gas capture system and the implementation of independent pressure control in each individual coke-oven chamber. A second quenching tower was built, the gas desulphurization system renewed and the coke ovens’ heating arrangements were optimized. All facilities for coke-oven gas cleaning have been updated to meet the latest technological and environmental standards.

Companies

segment and will be integrated with PANalytical, supplier of instrumentation and services for X-ray diffraction (XRD) and X-ray fluorescence (XRF) spectrometry.

RHI opens fusion plant in Norway. Refractories specialists RHI have built a fusion plant for magnesia raw materials in Norway. In this fusion plant, magnesia obtained from sea water is converted to fused magnesia at temperatures of about 2,800°C. With a capacity of approximately 85,000 t/year, the plant is one of the largest worldwide. This new plant will make the company independent from Asian fused magnesia imports.

Zentralkokerei Saar completes modernization project. Optimization of coke production and the reduction of emissions were the essential targets of the modernization project at Zentralkokerei Saar GmbH (ZKS), a joint subsidiary of AG der Dillinger Hüttenwerke and Saarstahl AG. The project started in 2007 and has now been completed by restarting the totally renovated battery 1, following the

Spectris to acquire ASD. Spectris plc has signed an agreement to acquire Analytical Spectral Devices Inc. (ASD), a manufacturer of near-infrared (NIR) instrumentation solutions and applications expertise for materials measurement and research. ASD, which is based in Boulder, CO (USA), will become part of the materials analysis

ArcelorMittal to sell interest in Kalagadi Manganese. A definitive agreement has been reached whereby Mrs. Mashile-Nkosi, or her nominee, which may be a consortium of some of the existing Kalahari Resources shareholders, will acquire ArcelorMittal’s 50% interest in Kalagadi Manganese. On completion of the

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International industry news

Personalities Ferriola to succeed DiMicco at Nucor. Daniel R. DiMicco, chairman and CEO, Nucor Corporation, has passed on his responsibilities to current president and COO, John J. Ferriola. DiMicco will remain with Nucor as executive chairman.

Amedick new CEO at Siemens DT. Jürgen Amedick took over the leadership of the Large Drives business unit of the Siemens Drive Technologies Division. Amedick follows Jürgen Brandes, who took over the leadership of the Rail Automation business unit in the Infrastructure & Cities sector. Most recently, Amedick headed the Products segment of the Large Drives business unit.

CMC names new chairman. Effective January 1, 2013, Joseph JT?P?BM AFGCD CVCASRGTC MDjACP and president of Commercial Metals Company (CMC), also became the chairman of the board of CMC, while Anthony Massaro, CMC’s former chairman, became lead director.

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MPT International 1/2013

transaction, Kalahari Resources will hold 40% interest in Kalagadi Manganese. Mrs. Mashile-Nkosi, or her nominee, will hold 50% with the remaining 10% interest held by the Industrial Development Corporation of South Africa Limited.

B&W is now Samson Materials Handling. B&W Mechanical Handling has evolved into Samson Materials Handling. This reflects the key role SAMSON™ equipment has played in the company’s most successful bulk materials handling projects. Samson is part of the Aumund group, which also includes Aumund Fördertechnik and Schade Lagertechnik.

Outotec receives marketing rights for zinc fuming technology. Outotec has received the global marketing rights for the Ausmelt Top Submerged Lance (TSL) technology for the fuming of zinc bearing residues from Korea Zinc Company. Prior to the Outotec acquisition of Ausmelt Ltd in 2010, Ausmelt had granted exclusive marketing rights of its TSL zinc fuming technology to Korea Zinc Company. Outotec and Korea Zinc have now agreed to terminate the marketing agreement to enable each company to develop their respective businesses in a mutually beneficial way.

Chemetall opens surface treatment facility in USA. The new Fives acquires KEODS. Fives has completed the acquisition of KEODS, a French company providing metallurgical assistance. This deal adds expert steelmaking consultancy skills focused on carbon flat products for the automotive industry to the steel portfolio of the Fives group.

Chemetall facility in Blackman Township, Michigan, USA, produces almost one thousand chemical products for applications in surface treatment, metal fabrication, cleaning and sanitizing. The facility includes a semi-automated waste treatment system to markedly reduce process waste water.

Engineering, supply, erection, commissioning, training and after-sales services: Blast furnace technology and the entire equipment range Cokemaking plants Sinter plants Recycling Technologies & Direct Reduction Plants Environmental technologies in cokemaking, sintering, ironmaking, direct reduction

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Proven solutions coupled with all-round innovative engineering and the latest technologies! Paul Wurth S.A.ÊUÊÎÓ]ÊÀÕiÊ`½ Ã>ViÊUÊ*°"°Ê ÝÊÓÓÎÎÊUÊ £äÓÓÊ ÕÝi L ÕÀ} /i °\Ê­³ÎxÓ®Ê{ Çä £ÊUÊ >Ý\Ê­³ÎxÓ®Ê{ Çä ÓÓä ÊUÊ«>Õ ÜÕÀÌ J«>Õ ÜÕÀÌ °V ÊUÊÜÜÜ°«>Õ ÜÕÀÌ °V Ê Subsidiaries: Brazil, Chile, Czech Republic, Germany, India, Italy, Japan, Korea, Mexico, P.R. China, Russia, South Africa, Spain, Taiwan, Ukraine, U.S.A., Vietnam

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Blast Furnace Plants engineering & construction of complete blast furnace plants, modernisations, rebuilds and relines.

BF Technology & Equipment cooling & lining concepts and systems, automation, top charging technology, special equipment.

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Auxiliary Plants hot blast stoves, stockhouse, pulverized coal injection, slag granulation and dewatering.

Coke Making Plants complete plants and batteries, coke oven gas by-products recovery systems and auxiliary plants, centralised supervision and process control.

Recycling Technologies multiple hearth based technology: PRIMUSŽ, rotary hearth based technology: RedIron™, RedSmelt™.

Environmental Protection BF top gas cleaning, aspiration systems, hot blast stove heat recovery, coke oven gas treatment, sinterplant off-gas cleaning.

PAUL WURTH – LEADING IN IRONMAKING TECHNOLOGY SAF E T Y S IED

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International industry news

Events 20 – 22 February 2013 Cairo, Egypt Organizers: Arabian-German Exhibitions & Publishing Ltd. www.arabiangerman.com

Metal & Steel Egypt 2013. The fourth edition of this key international B2B gathering for steel, steel fabrication, foundry and metal works professionals in the MENA will run concurrently with FABEX Middle East 2013, the international exhibition for steel structure, sheet metal, metal forming, finishing, welding and services.

9 – 11 April 2013 Suzhou, China Organizers: China Iron & Steel Association (CISA) www.metallurgyexpo.org

China (Suzhou) International Metallurgical Industry Expo. This international technology exhibition will accompany the China International Steel & Raw Materials Conference, which – organized by the China Iron and Steel Association – every year draws a large attendance with its highlevel corporate and government speakers, wide range of topics and many opportunities for networking.

11 – 13 April 2013 Mumbai, India Organizers: Federation of Indian Chambers of Commerce (FICCI) www.indiasteelexpo.in India Steel 2013. This international exhibition and conference will provide a platform to producers, consumers, business visitors and other key decision makers from steel and other related industries to interact. The events will offer opportunities to discuss and showcase latest products, technology, machinery, equipment, applications and developments in the steel industry.

Personalities Personnel changes at U.S. Steel. United States Steel Corporation recently announced changes in the company’s public affairs department. Erin DiPietro was named manager, executive communications, Courtney Boone was named manager, media relations, and Sarah Cassella was named public affairs representative II.

New head of communications at AISI. Lisa Harrison has been named senior vice president, communications, of the American Iron and Steel Institute (AISI). Lisa Harrison succeeds Nancy Gravatt, who has been appointed senior vice president, communications, for the National Mining Association.

Hrusovsky resigns at Essar Steel Algoma. James Hrusovsky PCQGELCB ?Q AFGCD CVCASRGTC MDjACP of Essar Steel Algoma and as a director of the company. Kalyan %FMQF AFGCD AMKKCPAG?J MDjACP has been appointed chief executive MDjACP ML ?L GLRCPGK @?QGQ

MPT International 1/2013

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The entire steelmaking process chain from a single source. Two companies, one standard: asserting our technological leadership in metallurgical plant and machinery construction. That’s why, in the future, Paul Wurth S.A. Luxembourg will operate as an independent company within the SMS group. Gaining even

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SMS group

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Paul Wurth S.A.

Phone: +49 211 881-0 Fax: +49 211 881-4902

communications@sms-group.com www.sms-group.com

32, rue d’Alsace L-1122 Luxembourg

Phone: +352 4970-1 Fax: +352 4970-2209

paulwurth@paulwurth.com www.paulwurth.com

International industry news

European Steel Association welcomes EU Parliament resolution on steel industry The steel industry is essential for growth and prosperity in Europe. It is in the interest of the whole European Union and its manufacturing sectors to have a competitive steel industry and to secure supply through domestic production. Strategic initiatives are needed, therefore, to support the sector and to keep it in Europe. This is the message the European Parliament sends to the commission and the member states in its resolution on the EU steel industry adopted in December 2012. The resolution was adopted against the backdrop of a new study summing up that emission targets set by EU climate policies are unachievable for the European steel industry.

Eurofer – the European Steel Association, Brussels, Belgium Contact: www.eurofer.eu E-mail: mail@eurofer.be

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On December 13, 2012, the EU Parliament applauded EU industry commissioner Antonio Tajani’s initiative to develop a “European action plan” for the steel sector, stressing the need to have it presented as soon as possible. All tools available on EU level helping the industry invest and modernize should be included in the plan. The resolution lists instruments such as increased research, development & innovation, targeted investment by the European Investment Bank and an active policy for skills, requalification and retraining of workers, amongst other things. The action plan should also address the high cost of raw materials and energy, which, the resolution explains, “are a threat to the steel industry’s competitiveness”. The resolution acknowledges the steel industry as the backbone of innovation and value creation for many industrial sectors such as the automotive, construction and mechanical engineering. It recognizes the European steel industry as a high-technology industry which “must be retained by taking immediate action to avoid their relocation outside of EU territory”. It also stresses that strong efforts are necessary since the industry is suffering from a substantial drop in demand caused by the ongoing economic crisis. The EU Parliament is aware that keeping the steel industry in Europe also presupposes a level playing field with its international competitors. In this context the resolution calls on the EU Commission to ensure reciprocity in trade politics. It also recommends to keep up the prior surveillance system for imports of steel products and to include that system in the action plan. Also, the EU Parliament recommends establishing a tripartite body formed by the trade unions, the industry and the EU Commission to work towards further development of the European steel industry. Eurofer – the European Steel Association – applauds the resolution: “The parliament rightly points out the strategic role and the technological leadership of our industry. And it clearly defines most, though not all, political issues that have

to be worked on urgently to keep our industry competitive on the global markets,” Gordon Moffat says. The director general of the European Steel Association stresses that EU climate targets also need to be discussed if global competitiveness of the European steel industry is to be maintained: “Climate targets not based on technological possibilities and imposed via an isolated EU emissions trading scheme also are a factor that will force the relocation of the industry.” Moffat welcomes the support for commissioner Tajani’s initiative: “Making the changes in policies necessary for a positive impact on industrial competitiveness will be challenging. This initiative indeed needs support, not only from the parliament but also from the very top of the European Commission.”

EU emission targets are not achievable for steel companies Emission targets set by EU climate policies are unachievable for the European steel industry. This is the conclusion of a study recently published by the European Commission’s Joint Research Centre (JRC – the European Commission’s in-house science service). It shows that the industry can reach a maximum of 11% to 19% CO2 emission reductions up to 2030 if it applies current best technologies and innovative solutions that may become available in the future. The 2030 target set by the EU emissions trading scheme (ETS), however is a reduction of 37.4%. The 2030 milestone in the European Commission’s “Roadmap for moving to a low carbon economy in 2050” is 43% to 48% for ETS-sector industries. The JRC report demonstrates that it is impossible for steel companies to meet these emissions targets. The report is titled “Prospective scenarios on energy efficiency and CO2 emissions in the EU iron & steel industry” [1]. The researchers have developed scenarios that illustrate the influence of different prices for fuel and resources as well as CO2 emissions allowances on the energy effi-

International industry news ciency performance of the industry. The agreement setting the same framework or lightweight, fuel-efficient cars – all of report finds that higher prices are “inef- for the global competitors of the Europe- these rely on innovative steel solutions an steel industry. It risks relocation of the for construction and production. The fective as major levers of change”. The maximum abatement values of industry to regions outside Europe with- CO2 balance of steel is positive in this life11% to 19% the authors have identified out comparable regulations. cycle perspective. The amount of emisrefer to the two major steel production Without a globally competitive steel sions the material can save in application routes via electric arc furnaces and blast industry Europe would lose the back- is significantly higher than the amount furnaces. Both values are based on a sce- bone of its industrial base. Steel is indis- emitted in the production phase. nario with a carbon price of 200 euros pensable for industrial value chains and per tonne. This shows that even under closely connected to key industry sec- References: the pressure of an extremely high car- tors. Steel is also the basis for technolo- [1] N. Pardo, J.A. Moya, K. Vatopoulos: Prospective Scenarios on Energy Efficiency and CO2 bon price the steel industry will not be gies that are urgently needed to achieve Emissions in the EU Iron & Steel Industry. (ISBN 978-92-79-26971-4) JRC Scientific and able to develop and implement tech- the CO2-mitigation targets of the EuropePolicy Reports. The European Commission, nologies for reductions beyond 19%. an Union: highly efficient power plants, Joint Research Centre, Institute for Energy The authors conclude that “demand- reliable supplies of renewable energies and Transport, Luxembourg, EU, 2012 pull measures supported by the public authorities (through CO2 prices) do not appear to be significant in bringing about changes in the industry”. This is further illustrated by the so-called baseline scenario, for which the study assumes a carbon price of 39 euros per tonne in 2030. In this setting the abatement potential is 11% to 14% and does not differ significantly from the 200 euros per tonne scenario. The report confirms the reasons behind the European steel industry’s deep concerns about climate policies in the European Union: “If an allowance price of 200 euros is not enough to bring about technologies for meeting EU emissions targets, it is certainly more than enough to drive the industry out of the market,” says Gordon Moffat, director general of Eurofer. “This study, carried out by the commission’s own research body, shows that our claims about emission targets being unachievable for the industry and a serious For more than half a century we have built up knowledge and experience leading to danger for Europe’s industrilong-term solutions for all types of roll force measurement installations in hot and cold rolling mills worldwide. We provide reliable and user-friendly measurement systems al base are more than justibased on the unique Pressductor technology in combination with our installation fied. It also highlights how design and maintenance know-how. Our leading position as a reliable partner is well summarized by one of our customers: the European steel industry “Millmate Roll Force load cells combined with precision-machined pressure plates is under constant pressure to certainly contributes to better control of the rolling process, safe stable rolling, improved strip/plate quality and reduced scrap. MRF load cells and Millmate reduce emissions while necController MC400 is an unbeatable combination”. www.abb.com/pressductor essary technologies to do so are unavailable.” Carbon pricing, the JRC ABB AB study proves, is ineffective Force Measurement Phone: +46 21 32 50 00 for a globally traded basic Fax: +46 21 34 00 05 material like steel, as long as there is no international

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MPT International 1/2013

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0GY GZGEWVKXG DQCTF CV URGEKCN UVGGN RTQFWEGT 5EJOQN\ $KEMGPDCEJ 5YKV\GTNCPF The global special steel producer Schmolz+Bickenbach (10,000 employees) has elected Johannes Nonn as new CEO and Hans-JĂźrgen Wiecha as new CFO. Ongoing restructuring measures are being implemented according to plan. However, the company GQ QRGJJ D?AGLE ? BGDjASJR K?PICR environment. Last year, the impact of the international jL?LAG?J ?LB CAMLMKGA APGQGQ was clearly noticeable on revenue and earnings.

5EJOQN\ $KEMGPDCEJ #), EmmenbrĂźcke, Switzerland Contact: www.schmolz-bickenbach.com

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MPT International 1/2013

Schmolz+Bickenbach is one of the world’s leading producers of stainless long steels as well as tool steels, and one of the ten largest companies for alloy and high-alloy special and engineering steels. Headquartered in Emmen, Switzerland, the group has a total of approximately 10,000 employees. Major steel production sites of the group are located in Germany, Switzerland and the USA. The board of directors of the group has elected Johannes Nonn as new CEO and Hans-JĂźrgen Wiecha as new CFO of the company. Both have taken over their new functions on 1 February 2013. Marcel Imhof, as long-serving COO, has temporarily headed the company since the departure of the former CEO Benedikt Niemeyer in June 2012. Imhof will stay on to accompany the new CEO’s and CFO’s introduction to their new responsibilities before then relinquishing his operational functions on grounds of age after more than 35 years with the group. The CFO ad interim, Oliver Karst, will continue to hold a position of responsibility within the group. “After a carefully conducted selection process, the board of directors is delighted to be able to place the management of the group in the hands of two professionally and personally highly qualified individuals,â€? comments chairman of the board of directors Hans-Peter Zehnder on the renewal of the executive board. “The board of directors thanks Marcel Imhof and Oliver Karst for their exceptional and successful endeavours in the transitional phase. Together with the new management generation we will now, as foreseen, press forward with the realignment of the management organization and the corporate culture.â€? Since 2010, the newly appointed CEO, Johannes Nonn (born 1965), has been a member of the executive board of Salzgitter AG, Germany, with responsibility for the steel division. In this position he was responsible for revenue of around EUR 4 billion and around 8,500 employees. From 2002 to 2009, Johannes Nonn headed the areas of sales, supply chain management and logistics of Salzgitter Flachstahl GmbH, first as a

member of the executive management, from 2006 as president of the executive management and member of the executive board of Salzgitter Stahl GmbH. Johannes Nonn began his career in 1991 with VIAG, where until 2002 he was active in various functions within the VIAG/KlĂśckner Group. Johannes Nonn completed his studies in industrial engineering at Kaiserslautern university in 1991. From his career to date, he has outstanding knowledge of the steel industry and many years of experience in customer-oriented and process-optimized business establishment and expansion. Since 2005, the newly elected CFO, Hans-JĂźrgen Wiecha (born 1962), has been CFO of the company Gerresheimer AG, Germany. The company generates sales revenue of around EUR 1.2 billion and employs around 11,000 employees. Hans-JĂźrgen Wiecha joined Gerresheimer in 2000 as director of corporate finance, with responsibility for treasury, accounting and taxes. In 2004, he has been granted general power of attorney and his responsibilities were expanded to include mergers and acquisitions. Hans-JĂźrgen Wiecha previously spent seven years in several positions of responsibility with the VEBA Oel AG group, finally as manager of controlling, accounting and treasury. He began his professional career in 1989 with what is today PricewaterhouseCoopers. HansJĂźrgen Wiecha completed his studies at the university of Siegen with a degree in business administration in 1989. Thanks to his career to date, he has extensive specialist knowledge and experience as a financial executive.

0GY OCPCIGOGPV QH &GWVUEJG 'FGNUVCJNYGTMG )OD* JĂźrgen Horsthofer, CEO of Deutsche Edelstahlwerke GmbH (DEW), Germany, left the company at his own wish on 31 December 2012. Johannes Nonn is to take over the presidency of the executive management of this largest operating unit of the group ad interim

%QORCP[ RTQĆ‚NG from 1 February 2013. The other exist- develop their full positive impact in the ing members of the executive manage- following years. ment, Dirk Wallesch (Controlling), JĂźrIn the first nine months of 2012, gen Alex (Engineering) and Burkhard Schmolz+Bickenbach was influenced by Hartmann (Human Resources), retain a weakening global economy. In particutheir former functions. In addition, lar, as the year progressed, the sovereign Martin LĂśwendick (born 1972) shall debt crisis caused market conditions in be appointed to the executive man- Europe to become increasingly unceragement of DEW with responsibility for sales. Martin LĂśwendick has worked for Schmolz+Bickenbach since 2010 as head of business development. He previously spent 11 years with McKinsey as a consultant. In that function he advised DEW on various projects. He is currently a member of the supervisory board of DEW as well as a member of the steering committee for the restructuring measures that are now being implement- *CPU ,Ă˜TIGP 9KGEJC %(1 ,QJCPPGU 0QPP %'1 ed at DEW.

4GUVTWEVWTKPI OGCUWTGU EQPVKPWG CEEQTFKPI VQ RNCP In the business areas affected, the lower order situation has already been responded to with an extensive restructuring and cost-saving programme. This will permanently lower the break-even point of those companies. The restructuring measures that were announced at half-year are being implemented according to plan. Additional cost-reduction projects have also been initiated throughout the entire group. The restructuring and cost-saving measures that were implemented will be partly reflected in the income development in the current fiscal year, but will only

tain, as well as the continuing price pressure on steel products, resulted in an unsatisfactory development of revenue and earnings for the group. By contrast, in the North American market, particularly in the first half-year, business developed positively, but could not compensate the losses of volume and margin in Europe. The development of revenue for the first nine months of 2012 differed greatly in the individual regions. While Europe (particularly Germany) experienced total revenue reductions of 11.5%, in North America and the rest of the world, substantial increases in revenue of 26.8% and 11.6%, respectively, were attained. There was an equally variable development of sales volume

and revenue in the individual product groups. In the stainless steel segment, the volume remained virtually stable at -1.6% below the previous-year period. This was mainly attributable to the good export-driven order situation of the German automobile manufacturers, which could so far almost absorb the downward trend of the South European automotive industry. On the other hand, as a result of the fall in price of the alloying elements, revenue from stainless steel declined by 7.4%. In tool steel, despite the increased volume associated with commissioning of the new plant of A. Finkl & Sons Co. (USA), sales volume fell by a total of 6.4% in response to the subdued demand from mechanical engineering in Europe. However, as a result of the improved product mix, revenue remained virtually stable at -0.5% relative to the comparable period last year. The largest reductions were in engineering steel, in both sales volume (-9.1%) and sales revenue (-9.3%). The clouded market environment continues to cause a cautious stance on the part of the steel consumers, which manifests itself as rescheduling of orders and postponements of deliveries. In the second half of 2012, in the markets that are important for Schmolz+Bickenbach, the economic development has clearly weakened further. It is therefore expected that the total development of sales volume and revenue in fiscal year 2012 will have been lower than the previous year.

Raw materials

Iron ore industry to remain turbulent until 2020 With the disruption of supplies from India, concerns over slowing economic growth in China, and the effects of large stockpiles forcing the price of iron ore through a series of QSNNMQCB fNPGAC kMMPQt RFC iron ore industry has faced a turbulent time during 2011 and 2012. While the price of iron ore appears set to make a partial recovery, Roskill’s new report offers a deeper level of insight into the dynamics driving the market, and offers a market outlook to 2020.

Bygone years, from 2006 to 2011, the promise of a high return on investment led to a decrease in the concentration of corporate control of seaborne trade in iron ore. During this period, the share of seaborne traded iron ore controlled by Rio Tinto, BHP Billiton and Vale (the “Big Three”) fell to 57.3% of the world total. London, UK based Roskill Information Services expect this trend to reverse to 2020, as the limited availability of capital will make securing project financing increasingly difficult for emerging producers. Much of the increase in capacity is expected to come from capacity expansions in Australia and Brazil and from projects backed by leading steel producers seeking to secure future supply.

New capacity will exceed growth in demand Downward revisions in the long-term outlook for iron ore demand and prices are likely to lead to the delay, suspension or cancellation of a large number of projects. Nonetheless, Roskill estimates that 425 million t/year of nameplate capacity will be added from the middle of 2012 to the end of 2014 and that capacity additions will continue to exceed 100 million t/year through to 2020. These additions are likely to exceed demand growth and mostly represent low to medium-cost operations. Consequently, producers at the higher end of the cost curve – particularly those in China – will gradually find themselves unable to compete in the open market.

Demand for steel is expected to grow at a slower rate

Judith Chegwidden, Roskill Information Services Ltd., London, England, UK Contact: www.roskill.com/iron-ore E-mail: jchegwidden@roskill.co.uk

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MPT International 1/2013

In 2012, a destocking phase among steel producers depressed demand for iron ore, and the World Steel Association expects apparent consumption of finished steel products to grow by only 2.1% in 2012, down from 6.2% in 2011. A partial recovery appears likely, as the construction sector in China and increased infrastructure spending will support growth in demand. During the period to 2020, however, rising demand from other emerging nations

is unlikely to fully offset the slowing pace of growth in the intensity of steel use in China, as this country approaches a peak in per capita steel consumption. Roskill expects growth in apparent crude steel use to average 2.9% per year from 2012 to 2020. Owing to the ongoing shift of steel production to countries with a higher use of iron ore per unit of steel, Roskill forecasts that demand for iron ore, at 3.1% per year, will marginally outpace steel demand, despite a relative increase in the use of scrap metal. Uncertainty over the Eurozone affects the iron ore industry through its effect on demand, as well as on the reduced availability and higher cost of capital. Revisions of figures on Chinese growth targets and performance are likely to result in further short-term peaks and troughs, although much of the adjustment to a more realistic outlook has already taken place – albeit some rebound from excessive and unwarranted pessimism may be expected. Other risk factors include growing resource nationalism, particularly in Africa, highly unpredictable energy costs, rising labour costs, and the fate of the Indian mining industry following the mining bans in Goa and Karnataka states. Following the slump in prices from June to September 2012, Roskill expects prices to remain stable until the end of 2014, while a restocking phase may push prices during 2013, although large fluctuations are not unlikely. As new capacity comes on-stream, the industry’s price floor will gradually drop and Roskill expects that a lower price level will be repeatedly tested and eventually broken towards 2015. In its baseline scenario, and adjusting for inflation, Roskill expects that prices may trend downwards during 2016 to 2020. The report contains 350 pages, 182 tables and 63 figures. It provides a detailed view of the iron ore industry, with subsections on resources, world production, leading mining and processing companies, world consumption, demand by end-use sector, international trade and prices. It provides forecasts of supply/demand balance and prices.

References: [1] Iron Ore: Market Outlook to 2020, 7th Edition, 2012. Roskill Information Services Ltd, London, UK

10) .#45+0) 53#&+5+10 +0 5''./#-+0) '017# '.5 *124 +4 .'#&'3 +0 5*' &'4+)0 #0& 4622.: 1( .'%53+% 3% 630#%'4 1045''.; 5'%*01.1): #&.' 630#%'4 "#%66/ ')#44+0) !0+54 #0& '#5 '%17'3: 60+54 13' 5*#0 4 *#7' $''0 &'4+)0'& #0& /#06(#%563'& &63+0) :'#34= 46%%'44(6. *+4513: '017# '.5 *124 +4 5*' 180'3 1( 5*' 1045''.; 5'%*01.1): 5*' %105+06164 (''&+0) #0& 23' *'#5+0) 1( 4%3#2 51 5*' 13' 5*#0 1045''.; 4:45'/4 *#7' $''0 +045#..'& #3160& 5*' 813.& #..18+0) %6451/'34 51 #%*+'7' 5*' *+)*'45 231&6%5+10 '((+%+'0%: '017# ' 0'3): # 0'8 %1/2#0: 1( '017# '.5 *124 2317+&'4 5#+.13 /#&' 41.65+104 (13 *'#5 3'%17'3: +0 #.. '0'3): +05'04+7' +0&6453+'4 +)+5#. ')6.#5+10 0,'%5+10 :45'/; #0& < 1(( )#4 3'#. 5+/' 4:45'/ %1/2.'5' 5*' 5'%*01.1)+%#. 1(('3 51 5*' 45''. +0&6453: '017# '.5 *124 #&7#0%'& 5'%*01.1)+'4 (13 45''./#-+0)

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Raw materials

Circular pelletizing technology facilitates compact plants to be integrated on site A new generation of pellet plants featuring a circular induration furnace as its core element was developed by Siemens Metals Technologies. Referred to as circular pelletizing technology (CPT), this iron ore agglomeration facility is characterized by its highly compact layout and light-weight construction design. This is the basis for CDjAGCLR ?LB AMQR CDDCARGTC installation at a mining site or within an iron and steel complex. Pellet production capacities range from 800,000 t/year up to three million t/ year and the quality of the NCJJCRQ A?L @C kCVG@JW ?BHSQRCB according to production requirements.

Watch the video related to this article using your smartphone and this QR code. As an alternative you can watch it on the Internet: http://youtu.be/R1XWWR6M7cI

Siemens AG, Industry Sector – Metals Technologies, Linz, Austria Contact: www.siemens.com/metals E-mail: rainer.schulze@siemens.com

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MPT International 1/2013

Figure 1. 3-D schematic view of the circular pelletizing plant (1 – raw material dosing and balling, 2 – additive storage and grinding, 3 – mixing, 4 – induration furnace, 5 – screening, s UVQTCIG RKNG s ICU ENGCPKPI s EQCN ICUKƂECVKQP

The ever-higher portion of fine and ultrafine iron ore from mining sites means that the pelletizing process is becoming more important for ore agglomeration. This has led to an increased interest by steel producers to invest in their own pellet plants to become independent of escalating prices for pellets on the global market. Up until now, however, space requirements and high investment costs for a conventional plant generally precluded its installation within an existing steelworks. As an answer to this situation and simultaneously to reduce the capital expenditures for new facilities, Siemens Metals Technologies recently developed circular pelletizing technology. This solution is based on the well-proven travelling-grate pelletizing process, however, the circularly designed induration furnace greatly reduces the footprint of the pelletizing plant. Overall space requirements for circular pelletizing technology are approximately one half of those needed for a conventional pellet plant. Costs for civil works, equipment and steel structure are reduced accordingly and plant installation can be completed far more quickly. The circular induration furnace also results in a more efficient utilization of installed equipment because nearly twice the

number of pallet cars are always inside of the induration furnace compared to a straight-type induration furnace of the same capacity. The intelligent and maximized reuse of hot gases minimizes the energy consumption required for pelletizing and, in combination with total recycling loops for waste materials and even steel mill reverts, a low environmental impact is ensured by the process. The installation of circular pelletizing technology within a steelworks not only allows producers to become independent of erratic prices for commercially available pellets, the chemistry and quality of the pellets can also be flexibly adjusted to meet the requirements of blast furnaces or direct-reduction plants. The world’s first circular pelletizing technology plant is currently under construction in Orissa State, India (figure 1). Total space requirements for the complete facility, which extends from raw material dosing and balling to process gas cleaning and which also includes a coal-gasification plant to generate burner fuel, is less than two hectares. Start-up is scheduled for the second half of 2013 after which the plant will be capable of producing 1.2 million tons of pellets per year for the Indian iron and steel industry.

Steelmaking

Benchmark for heat recovery from the offgas duct of electric arc furnaces Energy optimization is currently in the focus of many activities in steel plants. Tenova’s iRecovery® steam generation technology U?Q DMP RFC jPQR RGKC ?NNJGCB RM an EAF at Georgsmarienhütte, Germany, in 2009. Three years later, the projects at the Feralpi NJ?LR GL 0GCQ? ?LB RFC &WSLB?G NJ?LR GL 'LAFCML CVRCLB RFC scope of this technology RFPMSEF ?BBGRGML?J GLLMT?RGMLQ 2FGQ ?PRGAJC BCQAPG@CQ RFC LCU innovative aspects, compares RFC BCTCJMNKCLR @CRUCCL RFC RUM NPMHCARQ ?LB CVNJ?GLQ RFC GLRCPCQRGLE AMLACNR MD KGVCB steam usage.

Optimization for industrial furnaces in steel plants, such as EAFs in the meltshop, and walking beam and pushertype furnaces in the rolling mill, is widely discussed. However, there are only very few basic targets: product quality, maximized output, maintenance cost, operation cost, with the latter referring to energy consumption in the first place. In the face of increasing energy cost and challenging environmental standards, especially energy issues have been heavily discussed recently. The good news is that there are already numerous different tools and methods available to decrease the input of primary energy, for example through advanced control and automation systems with sophisticated process measurement sensors for the EAF or regenerative burners in the rolling mills. The bad news is that there are limits to the technology. Once a furnace has reached a high standard, it becomes more and more difficult – and therefore expensive – to achieve additional energy savings. This is the moment to consider heat recovery. Heat recovery has to follow the objective of savings on energy input, as it is always better to avoid 1 MWh input than to recover 1 MWh. Nevertheless, even with an optimized furnace a huge potential remains. For a state-of-the-art furnace with all common high-efficiency equipment in place, heat recovery is the biggest source for energy efficiency improvement.

Description of the technology

!?PQRCL MPL 0?JD %P?LBCP?RF Tenova Re Energy GmbH "ÝQQCJBMPD %CPK?LW Contact: www.tenova-reenergy.com # K?GJ PCCLCPEW BC RCLMT?EPMSN AMK

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MPT International 1/2013

The biggest source of energy losses is the off-gas. Typically, roughly 30% of the primary energy input is lost through the off-gas. Lower values are known for furnaces with scrap preheating like the Consteel technology; higher values are known, for example, for DRI feeding. Table 1 shows the potential of different EAF types. Approved standard technology for EAF off-gas heat recovery is available from Tenova; the product is called iRecovery® and available for two levels.

With level 1, the off-gas can be cooled down to 600°C in a steam generating offgas duct. Level 2 enables the off-gas to be cooled down to 200°C using a waste heat boiler. The iRecovery® duct is made up of tubes of the same look and the same working principle as a conventional off-gas duct with cold-water cooling circuit. The main difference is the pressure and temperature level inside; while cold water cooling circuits typically operate within a temperature range from 20 to 50°C, an iRecovery® system operates with water of approximately 180 to 250°C towards the ducting and decouples the off-gas energy by means of evaporation. This mixture of steam and water is guided into a steam drum where the steam and water are separated. While the steam is taken out (and replaced by condensate/fresh water), the water returns to the circuit. It is worth mentioning that the key advantage of heat recovery is not obtained at the cost of operational disadvantages. On the contrary, iRecovery® brings additional advantages: - no more dew point problems – elements are always above dew point of sulphuric acid, - no more inner corrosion – self-passivation of tubes by the Schikorr reaction, - less thermal stress – constant temperature of all elements during all operation phases, - lower water consumption – iRecovery® is a closed-loop system, cooling towers consume 3 – 8% of water during every loop, - lower water volume flow due to higher heat transfer resulting in smaller pumps, smaller piping, lower maintenance cost, - higher safety in different emergency situations by different redundant backup levels. In the 1980s and 1990s, the forerunner technology of iRecovery®, the former ECS (evaporative cooling system), was often used for reheating furnaces for what we now consider as additional advantages. There are quite a number of examples for furnaces that operate with

Steelmaking an ECS without taking advantage of the generated steam.

EAF using “little” chemical energy

EAF using “high” chemical energy

*GOSGB QRCCJ

(CEVQTU KPƃWGPEKPI VJG JGCV recovery potential The first important parameter for the amount of decoupled energy is of course the remaining temperature of the off-gas downstream the heat recovery system. As described above, the basic decision is whether to cool down to approximately 600°C (duct, iRecovery® level 1) or to go down to 200°C (duct and boiler, iRecovery® level 2). It is also possible to have mixed forms with unusually long ducts or very large post-combustion chambers and resulting temperatures somewhere between the two levels. The second key parameter is the amount of dilution air. Numerous furnaces still work with huge amounts of dilution air; although this strategy increases the volume of the bag house filter and the required fan power, it is still a cheap and reliable way of reducing offgas temperatures. For heat recovery purposes much dilution air is counterproductive because of a simple logic: air is sucked into the system at ambient temperature and leaves it at about 200°C. Every cubic metre of air going through the stack carries away the energy content of the temperature difference. The higher the off-gas volume is, the higher the lost energy becomes. For example, if an amount of 80,000 m³/h (s.t.p.) off-gas (burned natural gas) of 1,500°C is sent through an iRecovery®

EAF with DRI charge

385 kWh/tls

Slag Scrap preheating

Consteel EAF

50 kWh/tls --

--

50 kWh/tls

--

170 kWh/tls

240 kWh/tls

130 kWh/tls

260 kWh/tls

0?BG?RGML

10 kWh/tls

10 kWh/tls

10 kWh/tls

15 kWh/tls

Cooling water

65 kWh/tls

70 kWh/tls

60 kWh/tls

80 kWh/tls

680 kWh/tls

755 kWh/tls

685 kWh/tls

790 kWh/tls

Off-gas

Total output

Table 1. Energy output of different EAF types, 80 – 120 t tapping weight

system, bringing down the temperature to 250°C, approximately 7 MW of energy remain in the off-gas. If the same amount of off-gas is mixed with 100,000 m³/h (s.t.p.) of dilution air to 700°C before entering the iRecovery® system, approximately 15.5 MW of energy remain in the off-gas at 250°C, reducing the systems’ efficiency by approximately 22% [1]. Summarizing the factors described above, three main factors determine the heat recovery potential of an EAF: the operation scheme, the targeted offgas temperature and the amount of dilution air.

iRecovery® level 1 and level 2 at GMH and Feralpi Riesa GMH. The German steelmaker Georgsmarienhütte GmbH (GMH) operates a 140 t/h DC EAF. A unique feature of this EAF was the existing duct cooling system. When GMH converted the steel production route from blast furnace to EAF in 1996, some of the main components of the cooling system from

the former plants were kept in place and used for the new EAF meltshop. Later, in 2007, GMH decided to replace the ECS after almost 25 years of continuous operation, including the earlier period when it was used for the BOF shop. The cooling system had deteriorated considerably. However, GMH also wanted to replace the steam from a gas fired boiler house with steam generated in the new iRecovery® system. These technical challenges were solved by steam buffering, with two steam buffers working with the Ruth principle. Additionally some energy is stored in the feed water tank during energy peaks. This first iRecovery® system for an EAF was commissioned in early 2009 and has been producing steam without major problems. Heat recovery was introduced in the meltshop. GMH had chosen a level 1 system at the time. Only the waste gas duct is used for heat recovery. After the iRecovery® duct, a water quenching tower is installed. No downstream oxygen control system is installed. The efficiency of the system is summarized in table 2.

Figure 1. 5KORNKƂGF UEJGOG QH CP K4GEQXGT[® system MPT International 1/2013

33

Steelmaking Feralpi. Elbe-Stahlwerke Feralpi GmbH operates a 133 t/h AC EAF at its steel works in Riesa, Germany. In 2011 the decision was made to retrofit the furnace with a level 2 iRecoveryÂŽ system including oxygen control. The main point for Feralpi was the chance to sell steam to a local energy carrier, finally used by a near-by tyre plant. The plant is currently under construction and will be commissioned in early 2013.

meltshop. There were many “first time details� in the engineering, and it is generally a good idea not to use too many new aspects in one project. With the experience of three years of stable operation, it is time to go for a new benchmark. For upcoming projects the decision between the two stages must be individually evaluated: level 1 or level 2 must follow the steam demand/usage. When power generation or only steam deGMH EAF

Feralpi Riesa EAF

Furnace capacity

140 t/h

133 t/h

Tap-to-tap time

59 min

45 min

240 kWh/tls

165 kWh/tls

-DD E?Q NMUCP BSPGLE NMUCP ML

44,800 kW

30,000 kW

"CAMSNJCB GL JCTCJ BSPGLE NMUCP ML

18,000 kW

13,000 kW

(n.a.)

12,300 kW

18,000 kW

25,300 kW

Off-gas energy

"CAMSNJCB GL JCTCJ "CAMSNJCB JCTCJ JCTCJ iRecoveryÂŽ efficiency

42%

84%

Steam temperature

216°C

250°C / 228°C

28.5 t/h

40.8 t/h

12 t

5t

Off-gas temperature after level 1

650°C

665°C

Off-gas temperature after level 2

(n.a.)

200°C

1RC?K ECLCP?RGML BSPGLE NMUCP ML 1RC?K @SDDCPGLE A?N?AGRW

Table 2. Comparison of iRecoveryÂŽ U[UVGOU CV )/* CPF (GTCNRK 4KGUC CXGTCIG Ć‚IWTGU

The main difference is – of course – the off-gas temperature behind the iRecoveryŽ, thus causing the difference between 42% and 84% energy decoupling.

Reasons for the different decisions It is clearly visible that the iRecoveryŽ waste heat boiler achieves higher efficiency. Of course, the investment cost become higher, but not in the same proportion. The cost of steam capacity (t/H) decrease when the complete potential is used. For two reasons GMH decided to choose only the waste gas duct solution. The main reason is the steam demand. Feralpi can use all the steam (details described below), whereas GMH’s main steam consumer has been the vacuum degasser. When the decision for iRecoveryŽ was made in 2007, additional investment in power generation was not attractive with the given price for electrical energy. The production of additional steam would only have led to condensing more steam. In the meantime power has become more expensive and Feralpi decided to go for power generation. Second, in the GMH project, Tenova for the first time adapted the iRecoveryŽ technology from the rolling mill to the 34

MPT International 1/2013

mand is the main purpose, the decision is simple: synergies of scale can be realized with increasing electrical output, in these cases level 2 is the way to go.

Steam use GMH. The main steam consumer here is the vacuum degasser, on average consuming 7 t/h of steam, followed by heating energy during winter. Steam is also sold to an Air Liquide oxygen production plant on site. The fourth heat sink is the standby for the fired boilers, which are kept under pressure to guarantee constant steam supply when the EAF is shut down. This standby is kept up with a small portion of steam from iRecoveryÂŽ. During cold winter days, the steam is completely used, during summer some excess steam must be condensed. Generally speaking, the payback from iRecoveryÂŽ is realized by avoiding costs for natural gas. In the past, steam was produced with gas-fired boilers; iRecoveryÂŽ has reduced the gas consumption of the boiler house by 95%. Feralpi. 10 t/h of steam are sold to the local energy carrier Stadtwerke Riesa GmbH, which conducts the steam directly to a nearby Goodyear tyre facto-

ry. The steam for the Goodyear plant has been produced with natural gas, as for Stadtwerke Riesa buying/selling steam has been more attractive than generating steam themselves. As at GMH the boilers of Stadtwerke Riesa are kept under pressure to guarantee a constant steam supply towards the tyre maker when the EAF is shut down. Another 20 t/h of steam are consumed by a Turboden ORC turbine producing up to 2.5 MW of electrical energy. Financial details are of course confident, but it is relevant to know that the steam sale is the more attractive portion for Feralpi. With a look at the full cost, the profit per t of steam is higher for the sold steam than for the steam going to the turbine.

Level 2 waste heat boiler As stated above, the first iRecoveryŽ level 2 waste heat boiler is currently being implemented. In addition to some general concerns about transferring waste heat boiler technology to the meltshop, some other issues are to be discussed. Fouling. The high dust load of the EAF off-gas is actually not ideal for tube bundle heat exchangers. Sticky dust may lead to heavy dust settlements. Tenova ReEnergy analyzed the dust of different EAFs. The ash melting point has been above 1,000°C in all cases so far. Because the inlet temperature of the level 2 is significantly lower, the dust will not stick to the tubes. Nevertheless, dust settlements may occur. To avoid this side effect, rappinggear boiler cleaning equipment is used. The technology is successfully used for waste incinerators. Dioxins. Between 500°C to 250°C offgas temperature, the so called DeNovo synthesis may occur: destroyed dioxins and furans can recombine if this temperature range is not crossed fast enough. The allowable time is not consistently specified in the literature, mainly 1.5 s are named acceptable [2]. In most steel plants, water quenching towers are used to pass the critical range, mainly with good results. In some plants additional active carbon injection is required; either because the off-gas already arrives at the quenching tower within the critical temperature range, or because dioxins were not burned completely. There is common understanding that the off-gases must

Steelmaking stay above 800°C for at least two seconds; EAFs with high dilution air usage often fail this condition. For these furnaces quenching does not hit the mark – it prevents recombination but does not destroy remaining dioxins and furans. iRecoveryÂŽ level 2 waste heat boilers are designed in such a way that the residence time is not longer than in the formerly used system. Fast quenching does not depend on water injection. If the residence time does not become longer, the main criteria is fulfilled. On the other hand, the flow speed of the off-gas must be low enough to take care of abrasion problems. Tenova ReEnergy boiler dimensions cover these conflicting targets. Again, thinking outside the box of the steel world helps: waste incinerators had been facing the same situation and reliable solutions have been found here.

Methods for oxygen reduction The importance of dilution air reduction has been discussed above. Theoretically, no oxygen content downstream

the cooled duct would be ideal; in fact a value of 6% O2 is required to guarantee complete CO combustion. Lower values may result in remaining CO bubbles through to the presence of oxygen. The basic concept is to reduce in the first step, as far as possible, dilution air entering at the fourth hole and other gaps in the duct to an amount below the target value of 6% O2. Then additional dilution air could be added in a controlled way. Three aspects must be realized to achieve this target: oxygen measurement, control loop and a closed duct. O2 measurement. A reliable and integrated oxygen measurement system is part of the EFSOP package from Tenova Goodfellow. There are different products for oxygen measurement on the market; the Tenova Goodfellow system has been approved to be usable in the EAF environment. Control loop. At an early point of the waste gas duct, a motor-driven flap for dilution air ingress is installed. The preferred position is at the inlet of the post-

combustion chamber to let post-combustion happen at the desired place. This flap is set by a control loop of the oxygen measurement. Closing the duct. A challenge not to be underestimated is making the EAF off-gas duct air leakage proof. First of all, a sliding snout is placed at the first section of the waste gas duct; this element slides towards the elbow element of the furnace roof and closes the gap between furnace and duct. Furthermore, expansion joints are installed between different sections of the offgas duct.

References: 9 ; %P?LBCP?RF 0

MPL ! L?JWQGQ MD NMRCLRG?J ?LB QNCAGDGA NPM@JCKQ MD FC?R PCAMTCPW GL QRCCJ NJ?LRQ '12CAF AMLDCPCLAC 'LBG?Lapolis, 2011 9 ; & +ĂˆRXGLE +CAF?LGQKCL BCP .!"" $ GJBSLE $MPQAFSLEQXCLRPSK )?PJQPSFC ?LB RFC JGRCP?RSPC L?KCB RFCPC . & 2?Wlor, D. Lenoir; Chloroaromatic formation in incineration processes. Science Total EnviPMLKCLR ( .CBCPQC -NRGKGX?RGML MD CLTGPMLKCLR ?LB PCJ?RCB CLCPEW SRGJGX?RGML GL QAP?N @?QCB QRCCJK?IGLE #SPMNC?L !MKmission technical steel research, 1997

INNOVATIVE SOLUTIONS FOR WATERHYDRAULICS Shut-Off Valves / Descaling Valves Accumulator Valves

Dr. Breit GmbH Carl-Zeiss-StraĂ&#x;e 25 42579 Heiligenhaus-Hetterscheidt Phone: 02056 5807-0 Fax: 02056 5807-99 e-mail: mailbox@dr-breit.de home: www.dr-breit.de

MPT International 1/2013

35

Continuous casting

Secondary cooling concepts to increase the GHƂEKGPE[ CPF ƃGZKDKNKV[ QH UNCD ECUVGTU Today’s challenges in the further technological development of continuous casters lie in the improvement of quality and the increase in A?N?AGRW 2M CLQSPC RFC kCVG@JC production of different steel EP?BCQ ?R T?PG?@JC A?QRGLE speeds and with a wide range of product dimensions, novel cooling concepts are needed. For secondary cooling, this means that for all cooling strategies an as large as NMQQG@JC AMLRPMJ P?LEC AMTCPGLE RFC UFMJC NPMBSAR KGV KSQR @C attained.

VCJ 5CWCP 5/5 5KGOCI #), Düsseldorf, Germany; Jürgen Frick, .GEJNGT )OD*, Metzingen, Germany Contact: www.sms-siemag.com # K?GJ VCJ 5CWCP QKQ QGCK?E AMK

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MPT International 1/2013

'ZVGPFGF FGXGNQROGPV DCUKU thanks to cooperation To specifically further develop technologies and plant concepts, the cooperation between customers, component suppliers and plant builders is a future-oriented approach. It allows the direct joint harmonization and the corresponding alignment of the relevant tasks and solutions. At the same time, the basis for the future industrial utilization of the development results achieved is defined. German companies Lechler and SMS Siemag have made joint developments and, as part of a cooperation between component supplier and plant designer/ constructor, worked out effective overall concepts. Lechler GmbH is a familyowned business located in Metzingen in Baden-Wuerttemberg. The company develops and produces spray nozzles from various types of materials for a wide application range and is one of the leading companies on the international market. SMS Siemag AG is part of SMS group. The plants, machines, services and processing knowledge are internationally used in the steel and non-ferrous metal industries for turnkey integrated plants as well as for extensions and modernizations. The cooperation of both companies allows for a broad technical variety and considers specific aspects for partial components. The result is an innovative spray nozzle technology for an extended control range and a reduction of energy input: X-Cast® EcoCooler. The starting point of a new development is the required technology and its boundary conditions. This results in concrete tasks for the required technology, i.e. design, process and automation. New cooling concepts have become necessary to ensure the flexible production of various types of steel grade groups with variable casting speeds and a wide setting range of the section size (product dimensions). For secondary cooling, this means that the widest possible control range for all cooling strategies covering the complete product range has to be achieved.

4GSWKTGOGPVU QP GPJCPEGF continuous casting technology A higher plant flexibility of continuous casters means variable casting speeds, infinitely variable section widths and cooling strategies adapted to these requirements for different types of steel grades and process operations. The controlled creation of temperature profiles during solidification, increased production and throughput without quality losses, specific composite casting and defined boundary conditions for the soft reduction process within the strand guiding system all require a comprehensive secondary cooling concept. Producers of flat-rolled products presently prescribe specific requirements for the cooling loops and cooling zones necessary for this. Thus, the range of produced steel grades and the variety of section widths are constantly increased. The possible extensibility of production flexibility therefore has to be taken into consideration when designing the plants and is evaluated by plant owners when analyzing bid specifications. The possible replacement of spray nozzles, easy maintenance as well as trouble-free operation with a long service life are also criteria laid down by plant owners. The consumption of energy and utilities also plays a significant role when selecting components and systems, since operating cost account for a large share in the overall consideration of investments. With air-mist cooling systems providing a significantly higher control range, plant owners have now started to retrofit air-mist cooling systems to existing plants or install air-mist cooling systems to their new plants right away. To meet the requirement for a wider control range of the individual secondary water zones, the dimensioning of control valves, pipework, cooling zones and spraying nozzles needs to be considered in the plant design. The spraying height to the casting strand here

Continuous casting each; zones 6 to 11 in two control loops each. Spraying zones 12 and 13 work in every casting situation over the maximum casting width. In order to ensure an optimum setting of secondary cooling, i.e. supply of water over the slab width, and to allow for a flexible adjustment to the various sections widths, control loops 3 to 11 are designed as separate control loops (figure 4). This way, a differentiated control or selective disconnection of the control loops is possible for an optimized cooling strategy where various types of steel grades are involved.

&GXGNQROGPV QH EQQNKPI OQFGNU

Figure 1. /GEJCPKUO QH JGCV FKUUKRCVKQP XKC VJG OQWNF CPF UVTCPF IWKFG U[UVGO

is defined as a constant parameter. Otherwise, this parameter becomes a further restriction and limits the control ratio.

Secondary cooling for EQPVKPWQWU UNCD ECUVGTU The quality of cast steel slabs depends to a large degree on the solidification process and thus on the cooling system. All heat from the slab surface is carried off by different types of heat dissipation mechanisms (figures 1 and 2). In the mould, the heat is removed through contact, radiation and convection. In the strand guide system, the heat resulting from the solidification process is mostly removed through the heat transfer during spray cooling and the roller contact. In this area, surge water, radiation and convection also contribute to the heat dissipation. Roller contact, radiation and convection are responsible for heat dissipation in the area of the strand support without spray cooling and downstream of the casting machine.

#TTCPIGOGPV QH EQPVTQN loops The secondary cooling concept shown in figure 3 includes 13 spraying zones. The spraying ring is supplied from a single-medium cooling system by spraying zone 1 and the two narrow sides by spraying zone 2. Spraying zones 3 to 5 are distributed over the casting width in three control loops with air-mist cooling

Figure 2. *GCV FKUUKRCVKQP OGEJCPKUO KP secondary cooling

To optimally design the solidification of the hot strand, cooling models are used in process automation to calculate the required cooling water flow rates and to thus preset the setpoints for the necessary spray water volume in a differentiated manner. In recent years, mainly proportional cooling water models and strand-age related dynamic models were used for process automation. The increased demand for the quality of slab surfaces and internal quality, optimization of the flow rate as well as the introduction of dynamic soft reduction led to the development of cooling models with a much wider functional scope. Dynamic solidification control DSC® as developed by SMS Siemag is a well-tried and powerful level 2 process model for secondary cooling. The specific and dynamic adaptation to the casting events results in an optimal temperature curve for cooling of the strand surface at varying casting speeds and steel grades, thus producing constant quality characteristics during casting. Based on the incoming process parameters, the DSC® implements the heat transfer and solidification processes that are relevant for casting as a physically closed model. The principal element of the DSC® model is the dynamic three-dimensional calculation of the strand temperature and solidification length, taking into account the mould geometry, arrangement of rollers and strand dimensions. The boundary conditions are derived from the allocation of the cooling zones, spraying water flow rates as well as from the water and ambient temperatures. The temperature calculaMPT International 1/2013

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Continuous casting transfer coefficient. This is used for a defined calculation of strand cooling and the determination of the temperature profile in the individual sections of the strand guiding system. This data is used for a visualization of the temperature gradient (surface and internal temperature) and thus for forecasting and/or controlling the solidification behaviour. The importance of the heat transfer coefficient (HTC) will increase in future. SMS Siemag determines the relationship between water spray density and cooling effect in single-medium and air-mist cooling by using the results of comprehensive measurements. There are plans to use the variable heat transfer coefficients thus determined in the model computations (for simulation) and process models (for plant automation) as a next development step in the model development.

Design and functional RTKPEKRNG QH CP CKT OKUV PQ\\NG

Figure 3. 'ZCORNG QH VJG FKUVTKDWVKQP QH EQQNKPI YCVGT \QPGU

Figure 4. Width-dependent cooling water setting

tion takes into account the current process data such as casting speed and casting temperature. The calculations are based on material-specific data from the comprehensive and extendable material database. Finally, the shell thick38

MPT International 1/2013

ness and solidification length are calculated based on the strand temperature distribution. An important parameter in the calculation of the cooling water setpoints in the secondary cooling model is the heat

The effective operating window of the nozzles, also referred to as control range, must be selected in such a way that the cooling intensity can be controlled in a flexible way in accordance with the significantly changing operating conditions in terms of casting speed and age of the strand. The control range of nozzles is usually referred to as the water volume flow that arises between the minimum and maximum usable water pressure. Singlemedium nozzles whose cooling intensity and/or water volume flow can only be controlled by the water pressure, have only a very limited control range of approx. 1:3.2 in the pressure range of 1 to 10 bar. However, secondary cooling systems of modern continuous slab casters require nozzle control ranges of at least 1:10 and more. Air-mist nozzles have become indispensable for secondary cooling, since the wide control ranges can only be achieved by using a second compressible atomizing medium, i.e. compressed air, which is capable of attaining these wide control ranges. The nozzles are internally mixing air-mist nozzles whose connection block also includes the mixing chamber for the secondary cooling water and the atomizing air. Here, a preatomization takes place before the fluid mixture flows through the extension pipe to the nozzle tip which forms the

Continuous casting actual spray jet and effects the final atomization. Thanks to the constant internal widths and the fluid mixture in the nozzle as well as the compressibility of the compressed air, sufficient internal backpressure is produced over the complete control range at any time. This backpressure upstream the nozzle tip provides the water drops with the necessary kinetic energy during the final atomization and ensures a good shape of the air-mist spray jet even in case the water pressures are lower than 1 bar. Since the cooling intensity (HTC) in air-mist nozzles can be additionally influenced by the air pressure, it is also possible to control the air pressure in addition to the water volume flow. This way, a further control element to influence the HTC is available. This also depends on the respective water/air ratio that is stated in l/min for water in proportion to m³/h (s.t.p.) for compressed air. An increased consumption of compressed air occurs when conventional air-mist nozzles are operated in the lower control range at water pressures below 1 bar and very slow casting speeds. The functional principle of Lechler’s slab cooler was developed to significantly reduce the air consumption and thus energy cost, for example in cooling systems that are operated at a constant air pressure. The slab cooler is also the ideal solution in cases where the air volume is limited by a preset capacity of the compressors. Compared with conventional air-mist nozzles, the principle of the water inlet flow to the mixing chamber has been reversed. The water is admitted into the mixing chamber axially, while the compressed air is added tangentially. As the water also exits axially in the direction of the nozzle tip, less compressed air is needed to provide the water/air mixture with the kinetic energy that is necessary for effective cooling.

0Q\\NG FGXGNQROGPVU The development of two nozzles with similar objectives was initiated in the context of the cooperation of SMS Siemag and Lechler. The basis of one development project was the optimization of the slab cooler nozzle with the aim of increasing the control range of the cooling intensity (HTC control range) whilst not making changes to the control range of the water volume flow. The second pro-

ject concerned a significant extension of the control range of an air-mist nozzle with integrated control valve to maintain the quality of the spray jet over the complete control range. 1RVKOK\CVKQP QH UNCD EQQNGT Today’s commonly employed design of the cooling-fluid piping at the rear end of the seg-

Analyzing the high-speed photographs (figure 5) made it possible to allocate a particular frequency to the plug flow, which was confirmed by acoustic measurements and by a measurement of the drop size. It was then possible to specifically define the task of optimizing the spraying properties with regard to pulsation damping and a further reduction

Figure 5. *KIJ URGGF RJQVQ QH RNWI ĆƒQY KP VJG PQ\\NG RKRG YKVJ C JKIJGT YCVGT density at the centre of the photo

Figure 6. *KIJ URGGF RJQVQITCRJ QH C JQOQIGPK\GF HQCO ĆƒQY KP VJG PQ\\NG pipe

ment usually results in approx. 1,000 mm long nozzle pipes between the connection block and the nozzle tip. Depending on the operating state and thus on the preset water/air ratio, different flow conditions arise inside the pipe. According to J.S. Chin and A.H. Lefebvre, one differentiates between a bubble flow, plug flow and foam flow. It was possible to experimentally demonstrate the different flow types in the laboratory by attaching a nozzle with a transparent acrylic glass section to a pipe and by recording the flow conditions by means of high-speed photography. This allowed an in-depth analysis of the low-frequency pulsation of the air-mist nozzle, especially in cases of low water volume flow rates. As the long pipe with a constant internal diameter provides a relatively large reservoir for the water/air mixture, it is especially in case of low water volume flow rates that, due to the compressible compressed air, an interval-like plug flow can arise that leads to the pulsation of the air-mist nozzle at the nozzle tip. This pulsation gives the impression of an uncontrollable interruption of the spray jet, which should be prevented.

of the air consumption. This resulted in an optimized coordination of all internal nozzle diameters and the additional installation of so-called frequency interrupters that can homogenize the pipe flow over the complete control range. The high-speed photographs also proved that a beneficial and almost pulsationfree foam flow could be ensured during any kind of operating states (figure 6). Comprehensive test series were performed on a group of six nozzles arranged in three rows, spraying horizontally and vertically upward and vertically downward. The volumetric flow rate and the pressure measurement for the complete control range were documented for all positions and the sprayjet formation assessed. The optimized nozzle proved its efficiency in all operating conditions prevailing in continuous casting. Afterwards, measurements were conducted with the original slab cooler nozzle in order to determine the HTC characteristics in direct comparison. Owing to the improved flow conditions, the amount of consumed air could be reduced by 20%. At the same time, the optimized nozzle achieves an MPT International 1/2013

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Continuous casting

Figure 7. +ORNGOGPVGF RTQLGEV PQ\\NG YKVJ TGFWEGF CKT EQPUWORVKQP

approx. 15% higher HTC at maximum water pressure without using more water (figure 7). The results prove that it is the HTC control range covered by one nozzle that determines the cooling result and not alone the control range of the water volume flow of a nozzle and consequently the density of water admission. In this specific case, the optimized nozzle could cover a wider range of casting speeds and, in the lower control range, the air consumption could even be reduced by 20%. One segment was completely equipped with the optimized nozzles and installed for a field trial in a continuous slab caster at Salzgitter Flachstahl. In this specific case, the amount of the consumed air could be reduced by 2 m続/h (s.t.p.) per nozzle. In the case of a two-strand continuous slab caster, in which a total of approx. 1,000 air-mist nozzles are installed,

this results in annual savings of approx. 5 million m続 (s.t.p.) of compressed air. Thus, the operating cost could be reduced by approx. 95,000 euros per year (basis: 0.02 euros per m続 s.t.p.). Further operating results are expected shortly. The product designation of SMS Siemag, i.e. X-Cast速 EcoCooler, thus also reflects the efficiency achieved through a reduced energy input. #FLWUVKPI XCNXG While the slab cooler nozzle aims at optimizing existing continuous casters, the newly developed nozzle with adjusting valve is intended for installation in new plants. With good controllability and acceptable jet formation, the control range remains restricted to approx. 1:15 (minimum to maximum water volume flow rate), regardless of whether the air-mist nozzle is designed for operation with

Figure 8. (WPEVKQPCN RTKPEKRNG QH VJG PGY PQ\\NG YKVJ CFLWUVKPI XCNXG

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MPT International 1/2013

constant or variable air pressure. Especially in the lower control range, if only very limited water volume flow rates have to be set for very slow casting speeds, the quality of fluid distribution over the strand widths here requires higher tolerance levels for conventional air-mist nozzles. In particular, the influence of the compressible compressed air is at these operating points responsible for large spraying-angle constrictions. In this development, special attention was paid to the extension of the control range: optimal utilization of air pressure and/or amount of air at a very uniform formation of the spray jet. This, however, cannot be achieved with conventional air pressure control. Thus, an adjusting valve has been provided for this new development, which, depending on the casting speed, opens or closes an additional water orifice plate. Different orifice-plate diameters can thus be combined to optimally adjust the minimum and maximum water volume flow rates of the orifice plates to the requirements. According to the requirement book, there is no need for an additional control loop for operating the many nozzle valves of a cooling zone. The atomizing air lent itself for use as control medium for the valve, since direct air control is already state of the art in engineering. Figure 8 shows the functional principle of the new nozzle with adjusting valve. To ensure a clear-cut piston position in each case, there are only two control states. At an air pressure of 2 bar, the piston is in the top position at which only one water orifice plate is opened. Thus, the nozzle can only be operated at a maximum atomizing air pressure of 2 bar up to the maximum water pressure. The maximum water volume flow rate results from the water pressure and the diameter of water orifice plate No. 1. To operate the nozzle in the upper control range, the atomizing air pressure has to be raised to 4 bar. The piston of the valve then moves against the spring force to the bottom position, thus additionally opening water orifice plate No. 2. This results in the diameters of both orifice plates now being available to increase the cooling water volume flow rate. Since the orifice-plate diameter has remained constant on the air side, but the air pressure has been increased from 2 to 4 bar, there is a higher air volume available for optimized spraying and a uniform spray formation. The dashed line in figure 9 shows the increase of the water volume flow rate versus

Continuous casting higher HTC in the upper control range compared with a conventional air-mist nozzle. The characteristics of fluid distribution remain constant over the complete control range.

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the water pressure at a constant air pressure of 2 bar. Here, at 7 bar, a maximum water volume flow rate of 11.2 l/min arises. When now increasing the air pressure to 4 bar, the maximum water volume flow rate may also be increased to 15.7 l/min again at 7 bar (continuous line). This corresponds to an increase by 40%. Assuming a minimum water volume flow rate of 0.75

l/min at 0.5 bar water and 2 bar air pressure, the control ratio rises from 1:15 (at constant air pressure) to 1:21. Attributable to the higher pressure of the atomizing air, the water droplets are given a higher droplet speed at the exit of the nozzle tip. The drop speed thus increased leads to a significantly higher cooling capacity of the nozzle and/or a

Thanks to the joint and intensive cooperation of SMS Siemag and Lechler, new products to increase the efficiency and flexibility in the area of secondary cooling of continuous casters have been achieved. The implementation of the technological objectives leads to an additional energy optimization and thus to a reduction of operating cost in defined work areas of air-mist nozzles. The control range of secondary cooling systems is extended by means of continuously increasing demands of plant owners with regard to production, flexibility and reproducibility of high steel grades and is achieved by the new developments. With regard to the development of a nozzle with adjusting valve, the next steps will comprise tests on nozzles in a cooling zone (group of nozzles) as well as field tests in a production plant.

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Multi Zone Cooling and with this an optimal adjustment of the cooling medium to new requirements The integrated control circuit guarantees an exact cooling amount for high quality Valve control can be adapted to customers requirements Simple integration of valve control via Profi Bus Compact, individual spray bar design according to customers requirements

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MPT International 1/2013

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Figure 1. B.S.R.M. rolling mill for high-strength deformed bars

High-strength rebar production in the new rolling plant at B.S.R.M. in Bangladesh A so-called “market-sized” rolling mill plant has been designed for low/medium-scale output capacity tailored to the QNCAGjA BCK?LB MD ? PCEGML?J market, featuring the most advanced technologies for lowcost production of commercial steel long products. B.S.R.M. put particular emphasis on the high-strength rebar production processes.

Sunil Kumar Das, B.S.R.M. Group, Chittagong, Bangladesh; Enzo Francescatto, Andrea Taurino, Danieli Morgårdshammar; Antonello Mestroni, Danieli Automation, Buttrio, Italy Contact: www.danieli.com E-mail: info@danieli.com

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Production of high-strength rebars and other deformed-type long products for concrete reinforcement (such as ribbed wire rod and ribbed bar in coils), is a key issue for countries where the construction of buildings and infrastructures is growing. An increasing demand for high-strength rebars and other deformed-type long products for the concrete reinforcement is particularly felt in those countries or geographical areas with important seismic activity and the consequent high risk of earthquakes. The ideal answer to these manufacturing needs is the “market-sized” rolling mill plant, a flexible and cost-effective production unit for commercial steel grade long products having a relatively low or medium-scale output capacity, specifically tailored to particular regional supply requirements, both in terms of quantity and quality of the product to be supplied. The “marketsized” rolling mill will be fitted with the latest technologies for on-line production of water-quenched and self-tempered deformed long products at low production cost (through the Danieli

QTB, QTR, QTS processes, for example). The typical basic arrangement for such a plant foresees a rolling mill for production of high-strength deformed bars in straight bundles. The unit, designed for granting maximum operation efficiency and production flexibility, can be designed for easy completion at a later stage with the installation of additional production outlets for wire rod and bar-in-coils according to the market demand and/or customer requirements.

Plant description and highlights In 2006, B.S.R.M. Group of Companies selected Danieli Morgårdshammar as supplier of its new 300,000 t/year rebar mill to be installed as an expansion and modernization of the existing steel making and hot rolling facilities in Chittagong, Bangladesh. The new rolling mill (figure 1), which started rolling its first bars in early March 2008, introduced the latest long product hotrolling technologies for the first time in

Figure 2. The 4-strand slitting unit

Bangladesh, making this plant the most advanced and highly productive rolling mill in the whole area. The state-of-the-art bar mill (fed by a 75 t/hour pusher-type reheating furnace, not supplied by Danieli) is basically composed of: - 18 SHS stands, - QTB on-line rebar quenching & selftempering system, - automatic cooling bed and finishing facilities for straight bar production. Its original design uses a sq. 130 mm billets as starting material in 6 m and 12 m lengths in commercial steel grades. The mill is designed to produce 8 to 38 mm dia. quenched and self-tempered deformed bars for reinforced concrete (up to 40 mm dia. following a recent upgrade), at rates of up to 75 t/hour. The Danieli supply also included a complete water treatment plant for the new rolling mill. Electricals, automation system and process control for the rolling mill and auxiliary plants are from Danieli Automation. Hot run of the new plant started on March 4, 2008 (some days ahead to schedule) with the first rebars successfully rolled and delivered onto the cooling bed. In 2009 two additional H and V stands were added to the roughing mill to process the sq. 160 mm billets, and furnace capacity was increased to 90 t/hour to satisfy the new rolling conditions.

Multi-stand rolling. The mill is entirely made up of the latest generation Danieli heavy-duty SHS housinglesstype rolling stands, arranged in H and V sequence for twist-free rolling at the roughing and intermediate/pre-finishing area. The last portion of the finishing mill, arranged in H-H sequence, is specifically designed for the slit rolling process for production of smaller size deformed bars. Slitting. The multi-strand slitting system (figure 2), installed at the finishing mill, grants high output rates that enable reaching the full reheating furnace nominal capacity even with the smallest rebar size range. This system is a combination of special roll pass design and designated guide equipment to shape and longitudinally separate the incoming rolled stock into two, three or four individual strands, which are then simultaneously rolled down to the final rebar size at the finishing mill stands. The mill is designed for slit rolling on 4, 3 and 2 strands for the production of 8 mm, 10 mm, 12 mm and 16 mm dia. rebars at speeds of up to 12.5 m/s. Finishing. A multi-strand QTB line (figure 3) is provided at the finishing stand delivery side, for on-line rebar quenching and self-tempering. This will be a significant technological step for-

ward for B.S.R.M. that will make possible production of on-line treated highstrength/weldable rebars for the first time in Bangladesh. Outlet. The straight bar production outlet includes a dividing shear for multiple-length bars at the cooling bed entry, a 66-m-long automatic walking beam type cooling bed with associated feeding and delivery devices, bar cutto-length system with stationary cold shear, automatic bundling, weighing and collecting facilities.

Highlights of the project B.S.R.M. Steels has increased its capacity over the past few years and is now in a position to make 600,000 t/year with continuous technological input and support from Danieli. Mr. Aameir Alihussain, managing director of B.S.R.M., said: “It was challenging both financially as well as technologically when we envisioned the 300,000 tons per year rolling mill to be set up in Chittagong, Bangladesh. With excellent team work from both Danieli as well as our side, we were able to commission the plant successfully in time and then later kept on improving our efficiencies to increase our production.� Today, the rolling plant produces over 50,000 tons per MPT International 1/2013

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Hot rolling month. “In August 2012, we achieved a mill efficiency of 94.55%, 0.08% cobble and a yield of 97.16%,” he continued. “We are proud of our association with Danieli as well as our own team, as we have reached figures which are amongst the best in the world.”

t/hour productivity, 88.21% efficiency, 0.08% cobbles, 97.46% yield and lowest power consumption of 68.33kWh/t. On April 3, 2012 the mill ran non-stop without any interruptions with an average billet to billet gap of 2 seconds for 11 hours continuously while rolling 3 x 12 mm.

Figure 3. The 4-strand QTB unit

Figure 4. CCT diagram of QTB process

In June 2011, with the nominal capacity reaching 75 t/h (originally supplied with a capacity of 60 t/h), various records in the production programme at the Chittagong facilities were reached. 4 x 10 mm were successfully rolled during five days. A record production of 1,965 t was achieved, with more than 87 t/hour productivity, 94% mill efficiency while rolling 4 x 10 mm rebar. In July 2011, monthly production reached 50,000 t. Another milestone was reached in 2012. The best performance so far was in January 2012 with a net production of 54,740 t with a monthly average of 85.21 44

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During the year 2012, the mill produced 580,000 t – despite 560 hours loss due to shortage of power – with mill utilization at 89.6%, productivity at 83.4%, yield at 97.38% and power at 73.74 kWh/t. The December performance was so far the best, reaching 57,000 t in this last month of 2012.

Manufacturing technology QTB process. The QTB on-line surface quenching and self-tempering process enables production of de-

formed bars with high yield strength, good weldability and ductility and better homogeneity, starting from low-cost starting material (low carbon steel) instead of micro-alloy or low-alloy steels or, in some cases, with a minimized portion of the same, in relation to the most suitable chemical composition. The QTB system means high product quality with final technological characteristics equal or even better than the ones obtained by low-alloy/micro-alloy steels, i.e.: - high yield strength values (550 MPa and higher), - sufficient ductility (Agt 10% and higher), - good weldability with carbon equivalent of 0.40% or less, - lower production cost, in steel making or in billet purchasing, due to lower amount of alloying elements: approximately up to 18% and 8% cost saving if compared with micro-alloy or lowalloy steels, respectively. In addition, just one single chemical composition of low carbon steel is used to cover the production of a wide range of rebars, according to International Standard requirements (carbon 0.18 – 0.24%; manganese 0.60 – 0.80%; silicon 0.15 – 0.30%). The QTB process involves three stages (figure 4): - 1st: quenching in a water box after the finishing stand, - 2nd: tempering after quenching when bar is exposed to air, - 3rd: final cooling on the cooling bed. The bar surface quenching temperatures are down to 250 – 300°C, resulting in tempering temperatures of 550 – 600°C on the cooling bed. The product properties depend on the volume fraction of martensite, the properties of the tempered martensite, and those of the ferritic-pearlitic core. The volume fraction of martensite depends on the degree of quenching and on the temperature at the start of martensite transformation. The martensite properties depend on the steel composition and on the tempering temperature, the properties at the core, and on the cooling rate in the second and third stages. The properties are therefore controlled by the tempering temperature, through an adequate control of the cooling stage. In the QTS process, by adding a secondary cooling section, it is possible to obtain mixed structures.

Hot rolling

Figure 5. Rolling mill main pulpit

The QTB line is basically made up of a water box of suitable length (depending on the product size and rolling speed), located immediately after the finishing roll stand and before the dividing shear at the cooling bed entry side. The water box can be of single and/or multiple line design, depending on the rolling mill production process (e.g.: multi-strand slit rolling) and is provided with side-shifting for correct and easy alignment with the pass line, depending on the product size being rolled. QTR and QTS processes. The QTR process follows the same basic concepts as the QTB, but is dedicated to production of deformed wire rod in coils. A typical QTR line is made up of a series of water boxes located between the highspeed wire rod finishing block and the loop laying head. The water boxes are equipped with pinch rolls at the delivery side for avoiding vibrations of the rolled stock. Their use in cascade sequence on each bar head and on the whole bar length grants perfect tension on the rolled stock, resulting in uniform cooling throughout the product length and section. Based on the same technological concepts as the QTB and QTR systems, the QTS process is a fully integrated part of the production lines for rebarin-coils. Like in the afore-mentioned correspondent processes, the QTS line is also made up of a set of water boxes located between the mill’s finishing stand and the rebar spooling units. 46

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Electrics and automation. Danieli Automation supplied the whole electrical equipment from the medium voltage distribution to the main DC and auxiliary motors. Basic automation provided is based on the DMC2000 solution for the control of long product rolling mills. It includes a process control system, operator workstations and equipment control system, everything fitted with documentation and services for installation and start-up. In the design, all automation units and instrumentation are integrated with one another through a local area network to meet plant production and process requirements. The architecture of the rolling mill process control automation system is based on client-server structure, with a single system database assuring consistency of the data used to calculate the equipment set-up. Operator workstations, based on personal computer hardware, support the operator’s decisions displaying the necessary information about process and equipment status (figure 5). The equipment control automation system is based on distributed architecture of PLC units, with the single unit being dedicated to control single machines or groups of them, simplifying handling and maintenance and making troubleshooting easier. Hot metal detectors and loop scanners and the fast data acquisition system for maintenance complete the system. The performances of the mill are achieved thanks to:

- proven design, - proper rating of electrical equipment, - good integration between best market equipment, - process know-how in long products, reflected in high-performance application software, - special tools and sensors specifically designed for rolling mills.

Conclusions Now, after four years of operation, the plant has consolidated its position in the local market and is expected to enter the export market thanks to good performances and excellent, unparalleled operative results. “I am very proud of Danieli that they have given us equipment that can do all the jobs we have expected from it,” stated Ali Hussain Akberali, chairman B.S.R.M. Group. “In this less developed country, a company has achieved what many others in the highly developed world are not able to achieve.” Today, the availability of technologically advanced production processes makes lower cost production of rebars and other high-strength deformedtype long products possible. The “market-sized” rolling mill, specifically tailored to particular regional production requirements, can be the right choice to fulfil the growing demand for concrete reinforcement steel for the building construction industry, particularly in geographical areas with high seismic activity.

From concept to design – we manufacture steel and rolling mill technology: Superb design consists not only of a bold plan but also of simple and reliable solutions. We offer the possibility of realizing your conceptions by developing and implementing individual and flexible solutions. A great idea!

GmbH · Hütten- und Walzwerktechnik Bahnhofstraße 101 · D-66809 Nalbach-Körprich Fon +49 6838 8608-02 · Fax +49 6838 8608-61 info@plakoma.de · www.plakoma.de

www.larascraft.de

Individual solutions – without limits

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Second generation of Bi-Support rolling stands Today’s long steel products market with ever smaller NPMjR K?PEGLQ ?LB QRPMLECP competition requires the use of rolling mills with minimized operational cost and the capability of assuring ? jL?J NPMBSAR MD TCPW high quality. Starting from these considerations, Pert has developed the second generation of its Bi-Support rolling stands.

Massimiliano Zuccato, Matteo Tomba, Andrea Fontanini, Nicola Tomba, Pert srl, Tavagnacco, UD, Italy Contact: www.pertengineering.com E-mail: info@pertengineering.com

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MPT International 1/2013

For various years, the first generation of Pert Bi-Support rolling stands has been working successfully in many steel production plants worldwide. Pert, which is committed to continuously improving and further developing its equipment and plants, is now offering a new generation of its Bi-Support rolling stands (figure 1). The innovative features of these new Bi-Support stands are based on the enhanced concept of the rolling stands that have become a milestone in rolling technology for long products. While maintaining the benefits of the first generation, the new BiSupport rolling stands provide the following innovative advantages: - absence of spindles, chocks and onboard piping, - use of rings instead of rolls (less groove wear per t of production), - smaller dimension for easier handling, - high stiffness, - 85% less spare parts, - increased working life of bearings (min. 50,000 h),

- ring gap regulation starting from 5 μm, - horizontal and vertical stands of the same design and fully interchangeable, - mono-groove (roughing mill) and multi-groove (intermediate and finishing mill) design, - roll gap regulation with eccentric system, - easy maintenance. All in all, the second-generation BiSupport stands provide the possibility of improving the quality of the final product, cutting changeover times and downtimes for maintenance, reducing civil works and spare parts cost.

+ORTQXGOGPV QH ƂPCN RTQFWEV quality It is commonly known that in housingless stands the rolling load is concentrated on the tie rods, subjecting the adjusting screws to mechanical stress. This results in roll wear and mechanical yielding.

Hot rolling – Automation

Figure 2. Pert Bi-Support stand under rolling load (P = 1,850 kN)

The Bi-Support stands, however, feature higher stiffness and better load distribution into the housing (figure 2), reducing mechanical yielding (deflection). As a consequence, dimensionally stable products can be manufactured reliably within the standard tolerances or even better. The Bi-Support stands are designed to provide a force transmitting surface that is five times bigger than in housingless stands. Hence, housing elongation under load variation is reduced down to one fifth compared to common housingless stands. Further, BiSupport stands have a stress path of approximately half the length of common housingless stands; hence, also the elongations are reduced proportionately. Constraints are designed very near to the rolling load, so the rigidity of the stand is high and, consequently, the deflection of the ring-holding shaft is small. In comparison with common housingless stands, flexion is reduced to one third. Compared to a cantilever stand, it is halved. Considering the above mentioned facts, the rigidity of the Bi-Support stands is approximately three times higher than that of the other types of rolling stands currently available on the market. This guarantees a very high quality to the final product.

Reduced downtimes of the plant for changeover and maintenance Changing the stands involves approximately ten minutes from motor

stop to restart, including changing the ring-holding shaft. When a complete stand is available as a spare, changeover time goes down to approximately 2.5 minutes. Such reduced changing times are possible thanks to the reason that the second-generation BiSupport stand does not have a container or piping on board, as typical of the housingless stand. Unlocking, lifting, replacement and re-locking of the rolling unit are fully automated, in both horizontal and vertical configuration.

Savings on buildings, cranes and civil works Major efforts have been dedicated to containing the total stand size and reducing the stand height in the vertical configuration. As an example, the BiSupport 650 vertical stand, being part of a roughing mill, has a height of just 4.3 m, against the average height of 7 to 8 m of common housingless stands. There are several advantages due to the smaller stand dimensions. The rolling mill bay can be built less high, so the structure can be smaller and lighter. Thanks to the reduced height of the second-generation Bi-Support stand, the runways of the cranes are at a height of just 7.50 m. The crane capacity is only 60% of that required by a standard mill. All in all, civil works for the roughing, intermediate and finishing mills are reduced by 60%. For plants on ground level, the building can be made of prefabricated concrete; this option allows the initial investment to be reduced and

construction of the production site to be speeded up.

Low spare part cost The new Bi-Support stands have no moving machined parts directly in contact with water or scale, as e. g. the tie rods in common housingless stands. All moving parts are positioned on the shoulder and protected by adequate gaskets. The Bi-Support stands do not need any operator intervention in the rolling line, as with cantilever stands where the ring changes are to be performed in the working area of the plant. These changing operations are very difficult to perform with the risk of damaging the stand shafts. The Bi-Support stand consists of only half the number of components in comparison with a common housingless stand. This allows the number of spare parts to be drastically reduced and, last but not least, also the stand weight. In the Bi-Support stand the rolling rings are assembled on a heat-treated shaft made of alloyed steel (figure 3). This avoids any cracking due to overloading during rolling. Furthermore, when grooves have reached their end of life and there is no possibility of re-machining, only the worn rolling ring will be replaced, as the steel shaft on which the rings are installed can be re-used. In housingless stands the whole roll must be replaced. The Bi-Support stand bearings have an increased working life, which is 2.5 MPT International 1/2013

49

Figure 3. Typical shaft and ring assembly

times longer (min. 50,000 h) than in common housingless stands. The reason for this is the fact that in the housingless stand the rolling load is always fixed at the external ring of the bearing. The second generation of Bi-Support stands has been designed and

developed with the objective to avoid the use of cardanic spindles. Instead of cardanic spindles, gear couplings have been installed, which, under appropriate working conditions, are not subject to wear. Therefore there is no need to replace them or keep any spare parts. The lubrication system of Bi-Support stands is very simple, like a lubrication system of a normal gear box. Bi-Support stands do not need a special skimming device for separating water from oil, such as cantilever stands.

Conclusion

Figure 4. Pert Bi-Support stand

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MPT International 1/2013

The new Bi-Support stands (figure 4) have been designed for use in rolling mills that produce rebars, rounds and sections in SBQ (special quality bar) steel grade, wire rod as well as light and medium sections. They are also suitable for special steel plants. Bi-Support stands can be supplied in different

configurations: horizontal, vertical or convertible, mono-groove (roughing mill) or multi-groove (intermediate and finishing mill). Each component group of the stands (basement, gear box and stand proper) is tested in the assembled condition in the Pert workshops to be “ready to roll� when shipped. The use of second-generation BiSupport stands results in multiple technological and economic advantages. Net savings on the initial investment result from the reduced expenditure on building and civil works. The small quantity of spare parts offers additional savings on production cost. Plant productivity increases thanks to the short changeover times and minimized downtimes for maintenance. The dimensional quality of the final products is very high. In general, the plant can be more efficiently operated, needing little maintenance and low manpower. Finally, also the costs of remachining are minimized.

Trendsetting technologies for cold-rolling mills E10001-M1-Z42-V1-7600

SIROLL pickling lines and tandem cold-rolling mills Metals Technologies

Meeting today’s quality requirements in rolling means producing the highest strip quality on a consistent basis. To achieve this, highly sophisticated mill actuators, measurement systems and control modules are indispensable. As one of the world’s leading suppliers of pickling line and tandem cold mills, Siemens VAI offers the latest technological solutions to keep your cold-rolling mill on the forefront of technology. This extends from the engineering and supply of full turnkey mill installations to the installation of equipment, modernization packages and mechatronic systems. This includes, for example, a fully automatic pickling liquor analysis model (SIROLL FAPLAC®) to ensure a highly efficient and environmentally friendly pickling process, the SIROLL SmartCrown® roll contour for

precise fulfillment of the specified strip flatness and profile requirements, SIROLL SIAS strip surface inspection, coil eccentricity compensation and the SIROLL Off-Gauge Optimizer The technological, mechanical and process automation experience of Siemens VAI in the design and supply of 6-high and 4-high mill stands means that you have a powerful partner to meet the unique requirements of your rolling mill. Benefit from our more than 80 years of experience and expertise in rolling technology. A full range of products and services are available from a life-cycle partner for new investments, mill upgrades and plant extensions. Profit from experience

www.siemens-vai.com

Figure 1. Finishing train of the new hot strip mill at Dragon Steel

Advanced automation system for Dragon Steel’s new hot strip mill Dragon Steel Corporation, a subsidiary of China Steel Corporation, commissioned a new hot strip mill at their EPCCLjCJB QRCCJ D?AGJGRW GL Taichung, Taiwan. The new mill is capable to produce about 3 million t/year of a broad variety of high quality steel strip, including low carbon, API, IF, HSLA, BH, electric, and stainless grades.

TMEIC®, formed from the merger of the industrial systems divisions of Toshiba and Mitsubishi-Electric, provided the drive equipment and automation system for the new hot strip mill at Dragon Steel, Taichung, Taiwan. For this very large system integration project, TMEIC responsibilities included writing the custom control and supervisory software, conducting the factory system test, supervising installation of the motors, drives and controls, and performing system commissioning. TMEIC also provided customer training and plant service support.

Hot strip mill layout

TMEIC Corp., Roanoke, VA, USA Contact: www.TMEIC.com E-mail: metals@tmeic.com

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MPT International 1/2013

This new hot rolling mill (figure 1) was designed to produce strip up to 1,880 mm wide with a final thickness down to 1.2 mm. The plant comprises a twostand reversing roughing mill with vertical edgers and a seven-stand finishing train with two downcoilers (figure 2).

Slabs are provided by three reheating furnaces. The main data of the mill are summarized at table 1. The large 10 MW (13,400 hp) synchronous motors on the finishing mill are controlled by powerful variable frequency drives, used to start the motors and vary the speed up to a maximum of 620 rpm. The speeds of the seven drives are controlled and coordinated by the master controller so that the desired strip speed is obtained and correct tension is maintained between stands. In the rolling process, precise control of strip tension, speed, gap, roll force, and temperature is required to produce the strip. To ensure a perfectly shaped (flat) product, the work rolls are bent and moved horizontally by electro-hydraulic actuators, as directed by the controllers. Strip width Final strip thickness

max. 1,880 mm 1.2 – 25.4 mm

Max. exit speed

20 m/s

Overall length of the mill

443 m

Table 1. Main technical data of the plant

Hot rolling

Figure 2. Diagram of the mill, metal slabs enter at right, coils are delivered at left

Accurate X-ray gages located at the finishing mill exit measure the thickness and profile across the width of the strip. After exiting the mill onto the run out table, laminar water streams cool the strip at the exact rate to produce the enhanced material strength and elongation properties required. As the strip moves down the table, temperature control is critical. At the end of the table the strip enters the coiler where it is coiled for shipment.

Hot strip mill control system The control system includes the following important characteristics: - open architecture, - scalability and ease of expansion, - simple control network communication, - unified Level 1 and Level 2 HMI, - structured software products and distributed computing, - global signals and data structures definition, - tools for process and equipment data analysis, - ease of system maintenance. The hierarchical automation system, developed over 50 years of steel rolling mill experience, provides advanced control allowing higher mill speeds and improved product quality. The open control architecture is based on standard controllers, computers, software, and communication interfaces, allowing easy system expansion. The Level 2 supervisory control computer uses physics-based computer process models, which supply references (setpoints) to and are tightly integrated with the Level 1 controllers. The speed of all the motors is coordinated by the controllers, which communicate with the drives over a fiber optic I/O network. To illustrate the size of the automation project, the figures of control I/O units and major components are summarized as following: - 4,000 digital control inputs and outputs,

Figure 3. Results of eccentricity control

- 800 analogue control inputs and outputs, - 560 variable speed AC motors, - 18 high-power, medium voltage variable frequency AC drives (up to 13,400 HP each), comprising in total 100 MW power. Level 1 provides direct control of the process actuators of all kinds: electrical, hydraulic and pneumatic. The drives to control electrical motors are included in this level of control, and the regulating, sequencing and equipment protection functions. Level 1 control is performed by the Toshiba nv controller™. This is Toshiba’s latest industrial controller with unsurpassed execution speed, capable of performing Boolean functions in 20 nanoseconds and word instructions in 100 nanoseconds, allowing superior machine and process control. The nv controller™ is a multitasking controller capable of executing the high priority task, a special programme requiring high-speed, at a 0.5 msec rate. Communication with the I/O modules is over a fault-tolerant fiber optic ring running at the rate of 100 Mb/s, allowing the controller to rapidly access I/O data down to a 0.1 millisecond rate.

Performed by the controllers, Level 1 accepts discrete and continuous signals from the mill sensors, and generates output signals to control motor speed, gap, roll movement, strip tension, and a host of other machine functions. Some of the major functions performed include: - Automatic gage control (AGC) employs mass flow calculation, thickness measurement, feedforward, feedback, tension, and slip compensation. - Supplied by the mill builder, the automatic flatness control uses advanced data filtering, parabolic flatness control, tilt control, and shape maintenance. - Coordinated in-coil adjustments use measured and calculated values to maintain targets. - High-speed data acquisition and tracking allows faster and more accurate control action. - Eccentricity control dynamically reduces the effect of backup roll irregularities on thickness using fast Fourier series analysis (figure 3). - System diagnostic functions built into the engineering tools allow production delays to be quickly resolved. MPT International 1/2013

53

Hot rolling

Figure 4. Level 2 models provide setup and references for the Level 1 control

Level 2 sub-system consists of two basic parts: process execution and process data storage. The process algorithms execution (supervisory) computer includes process models and Level 2 support functions (models infrastructure) software. The process data storage computer includes process data bases and necessary communication interface software. This computer, also known as the data server, contains all-important data required for process automation and process analysis, and uses Oracle™. The databases include primary data input, process models tables, rolls’ data, rolling history, and data dictionary. Due to the importance of the data servers, the hardware is based on a high class PC server, which includes cluster configuration with redundant storage, providing a “no single point failure” feature. The trending and reporting station has the copy of the rolling history database (data transferred on manual request) for the customer’s engineers to perform data analysis, statistical correlations, customized reports etc. The purpose of such separate, off-line database is to have multiple connections to 54

MPT International 1/2013

this database, which will not affect the on-line performance of the data servers. The automation system provides superior hot mill control based on Level 2 functions, including data acquisition, mill setup, product tracking, and accurate process models. TMEIC’s Level 2 provides the mathematical process models and required software infrastructure for models to function. During mill operation, Level 2 supplies the Level 1 with references and receives process feedbacks for model updates and data collection. Typically, Level 2 does not include in-bar close loop control functions, except for finish temperature control and coiling temperature control models. The process models are adaptive mathematical models based on the fundamental physics of the rolling process, using advanced iterative techniques such as finite element analysis to compute physical effects such as heat transfer and plastic deformation. The models generate the optimum controller setpoints to ensure production of the highest quality product. The roll bite model includes the effects of plastic de-

formation, roll compression, friction, and elastic release. Some of the process models are listed below: - force, torque, and power models with the effects of tension, slip, and friction, - deformation resistance model with the material chemistry and work hardening effects on elongation, - friction models with coefficients to compensate for friction variations, - roll wear model with thermal and wear effects on roll diameter profile, - product-dependent transfer functions for better thickness, width, and temperature control, - roll bending and shifting (shape model supplied by the mill builder). In figure 4, all of TMEIC’s Level 2 models are listed at the top; not all of them are used on the Dragon Steel system, also the furnace control and models were not supplied by TMEIC. The models, shown in blue, provide the setup and references for the Level 1 controls shown in purple. HMI. Providing an interface between the process control and operators,

Hot rolling erators to see all sections of the mill (figure 5).

Conclusion

Figure 5. Part of the operator’s pulpit

the human machine interface (HMI) replaces traditional operator devices such as switches, pushbuttons, analog meters, etc. The PC-based HMIs process the operator’s entries and send data to Level 1 and 2; they also process data

from Level 1 and Level 2 and display on the terminals both as text and animated graphics. This mill employs just one long control pulpit, so a number of video screens are used, allowing the op-

The features of this control and automation system fully meet the criteria of modern control concepts and solutions. Highly configurable software applications and open and simple architecture have brought low cost ownership and maintenance. The application of advanced rolling process modeling and control schemes has resulted in high level performance, thus providing excellent product quality. Finally, the control system has proven to be extremely reliable. As Song-Mo Lai, Dragon’s assistant superintendent of the rolling mill department, comments, “Since the mill startup on April 2010, the TMEIC equipment including main motor, PLC, and drives are all running smoothly. We deeply appreciate the high stability and reliability of the TMEIC system, and the good cooperative relationship with the TMEIC project teams from the beginning.”

A NEW ERA IN HOT AND COLD STEEL MEASUREMENT

Revolutionary Rotational Measurement

Revolutionary laser rotation technology results in highly accurate measurement of dimensions down to 1/10th second cycle. STEELMASTER SMR systems from ZUMBACH: The solution for all lines including high speed with 2- & 3-roll blocks, also for short product lengths.

STEELMASTER SMR Direct link to the brochure (0.6 MB)

Video

SWISS PRIME MEASURING SINCE 1957

Finally the trouble-free answer to the industry demands for rolled steel. As quality requirements become ever stricter and raw material prices continue to rise, reducing waste is increasingly the key factor for economic viability. t STEELMASTER SMR measures a complete profile within 1/10 second. The system, with up to 3 synchronous rotating measuring heads can acquire up to 6000 measurements/second due to our innovative laser rotational measurement technology. t Unique, fully contact-free transmission of both energy and signals by means of induction and encapsulated W-LAN grants

virtually zero maintenance and wear-free operation. t ZUMBACH’s highly evolved software guarantees: – Continuous error detection – Immediate readjustment in case of shape deviations and rolling errors – Minimal waste STEELMASTER SMR - Most probably the best measurement solution currently available on the market for hot and cold rolled steel.

ZUMBACH Electronics sales@zumbach.ch I www.zumbach.com

Automation

Condition monitoring of plants and process analysis with a single system An adaptable condition monitoring system has been developed for different application scenarios and in variable sizes. From decentralized monitoring of individual physical machine NCPDMPK?LAC jESPCQ SN RM the central acquisition of all relevant data for a total production, this new condition monitoring system covers a variety of applications and can be used independently of the automation manufacturer. It A?L @C AMLjESPCB GLBGTGBS?JJW and connected to any conventional automation solution.

Dr. Ulrich Lettau, CEO, Iba AG, Fürth, Germany Contact: www.iba-ag.com E-mail: ulrich.lettau@iba-ag.com

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MPT International 1/2013

During the last few years, in manufacturing companies, monitoring of the machine condition has strongly grown in importance. Applying condition monitoring (CM) can help to develop condition-oriented maintenance plans and consequently lower significantly production costs. In contrast to preventive maintenance, worn parts are replaced only if there is measurable wear. This prevents faultless parts from being replaced. Compared to reactive maintenance, the decisive advantage lies in preventing machine stand stills caused by defective parts. With the increasing size of the production plants, there is also an increased effort for condition-oriented maintenance. Iba AG has developed the condition monitoring system named “ibaInSpectra” that does not only monitor condition data, but all machine data, process data, material data and quality data, independently of the manufacturer. This condition monitoring system is available in three different versions: - “ibaInSpectra compact” offers a costeffective and decentralized isolated solution. - The more powerful version “ibaInSpectra embedded” can be used for monitoring complex plants. It is especially made for machine groups and spectrum analysis for single machines. - “ibaInSpectra factory” offers the biggest savings potential. It monitors the whole machine park of a site along the whole production chain. Being a standardized condition monitoring solution for heterogeneous automation environments, the series offer open interfaces to PLC and HMI and the option of seamless integration of condition monitoring functionalities into the monitoring of the whole plant. Typical tasks are acquisition of process-induced vibrations (“chatter”) and defect-inducing frequencies of mechanical components like bearings and gears with the same system. The condition monitoring system can be used for monitoring both simple objects (e.g. fans, pumps) and complex monitoring solutions (e.g.

planetary gears, acoustic test benches). It can be simply integrated into database-based management systems to become a powerful analysis tool for the early detection of negative trends. It is technologically possible to integrate the condition monitoring system into the automation system of machines and plant. This may at first sight appear to be the more cost effective solution, but it often implies problems. For example, data processing needs a considerable amount of system resources. Withdrawing these resources from the automation system may have a negative effect on automation performance. Günter Spreitzhofer, responsible for consulting and applications at Iba AG, strongly recommends installing an autonomous condition monitoring system. It does not only relieve automation, but also makes it possible to implement all-encompassing solutions that cover the whole site, which is a great advantage. Here, the universal connectivity of the condition monitoring systems has proven to be helpful. Spreitzhofer adds: “If the automation system incorporates a condition monitoring system, this is usually a vendor-specific installation providing only partial information to the producer. In contrast to this, a separate condition monitoring system can be used independently of the automation system and the system generation.”

Conclusion An innovative condition monitoring system is available in variable sizes for different application scenarios. From decentralized monitoring of individual physical machine performance figures up to the central acquisition of all relevant data for a total production, the three versions of the condition monitoring system cover any field of application and can – due to their connectivity to any conventional automation solution – be used independently of the manufacturer. A unique property is the possibility to acquire and analyze process data simultaneously.

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CONFERENCE

ROLLING 2013 9th International ROLLING Conference & 6th European ROLLING Conference

Venice (Italy)

Organised by

Main sponsor

June 10-12, 2013 Exhibition organisers

The 9th International Rolling Conference and the 6th European Rolling Conference will be jointly organized by AIM, the Italian Society for Metallurgy. The Conference will cover all metals rolling topics and issues: at and long products rolling, hot and cold rolling and ferrous and non-ferrous rolling, products and processes, properties, quality and applications, design, control and management of mill assets.

CONFERENCE CHAIRMAN Ing. Gianpietro Benedetti President of Danieli

Contributing sponsor

EXHIBITION Associazione Italiana di Metallurgia

JOIN ROLLING 2013 AND DO NOT MISS THIS UNIQUE OPPORTUNITY! Organising Secretariat Associazione Italiana di Metallurgia P.le R. Morandi, 2 ¡ 20121 Milan ¡ Italy ¡ Tel. +39 02 76021132 ¡ Fax +39 02 76020551 ¡ E-mail: aim@aimnet.it

www.aimnet.it/rolling2013.htm

ROLLING 2013 will feature an Exhibition, that will enable excellent exposure for company products, technologies, innovative solutions or services. For information on the Exhibition please contact: Siderweb Phone: 0302540006 Fax: 0302540041 E-mail: commerciale@siderweb.com

MPT International 3/2011

57

Technical innovations

Strip painting section in-line with a continuous galvanizing plant SURFACE TREATMENT The inline paint section (IPS) is a fully organic painting production unit for integration in continuous hot-dip galvanizing lines. A recently started up IPS is a complete (twocoat, two-bake) “on demand” paint production unit – exceptionally integrated and linked to a before ongoing galvanizing process. “On demand” paint production means coil geometry changes (width and/or thickness), colour and/or coating changes, but also proper paint operation during varying line speeds are possible without interrupting the ongoing galvanizing process. The production speed of the coating line is equivalent to the maximum processing speed of the

galvanizing line (180 m/min), with a production capacity of 80 t/h or up to 500,000 t/a of organic-painted galvanized steel coils. The coater provided by Globus Engineering consists of a pretreatment section, either for chem-coatings or passivation coatings, followed by two organic painting sections for two-sided primer coating and finish coating. A short drying and curing section incorporates NIR® technology from Adphos. Curing times of 5 s and less at a maximum speed of 180 m/min for a coating layer thickness of 25 μm have already been proven in successful production batches for several colours and for coatings from different manufacturers.

Painting section integrated in a continuous galvanizing line

The IPS is installed within a “cubic” tower of approx. 30 m x 30 m x 30 m, containing all process equipment, except the three-chamber recuperative thermal oxidizer (RTO), which is positioned on the ground floor next to the tow-

er. This type of inline paint section can also be horizontally integrated in the galvanizing lines.

Contact: E-mail:

www.adphos.de info@adphos.de

Forming presses for large-diameter pipe production PIPE MANUFACTURE For Oforming presses applied in large-diameter pipes manufacturing Siempelkamp has improved the control and tooling concepts. The incoming steel cannings are positioned in the press centre. Thus, independently of the length of the workpiece, the press force is introduced exactly into the plate. This results in better load distribution and, at the same time, lower mechanical load. Furthermore, Siempelkamp

optimized the proven tooling concept featuring exchangeable shells. The outline of the half-shells which was optimized by the finiteelement method evens out deformations by the tools in the transverse direction. Combined with the patented tool clamping which compensates the occurring forces in the longitudinal direction, Siempelkamp thus achieves the optimal pipe geometry for the subsequent production steps.

Contact: www.siempelkamp.com E-mail: ralf.griesche@siempelkamp.com O-forming press for large-diameter pipes

58

MPT International 1/2013

Technical innovations

Acid recycling technology SURFACE TREATMENT During the pickling, hydrochloric acid of 20 wt% must be constantly replaced because of the loss of acid strength due to the pickling reactions. If lowered to contents of less than 10 wt%, the pickling velocity slows down so much that the whole pickling liquor volume must be replaced by fresh acid. The spray roast regeneration technology from Astec Engineering GmbH provides a comprehensive solution for the regeneration of waste pickling liquor and rinse water in the steel industry. It combines high economical benefits with environmental aspects. When coming from the pickling line, the waste pickling liquor is first collected in storage tanks. This allows the regeneration plant to be operated independently of the pickling line. The thermal recycling process (pyrohydrolysis) is carried out in a gas-fired reactor. Here the waste pickling liquor is completely evaporated and the iron chloride is split up into iron (Fe) and chlorine (Cl). The produced iron oxide powder is transported out of the reactor through a rotary valve mounted on the lower end of the reactor. Above this, an oxide lump breaker is installed to break any existing lumps. The gases produced in the reactor, containing water vapour and hydrogen chloride, leave the reactor via the roast gas line. For the absorption of the hydrogen chloride gas and its transformation into hydrochloric acid, a sequence of two absorber columns is used. They are both fed with rinse water, absorbing the hydrogen chloride gas from the gas stream. The use of rinse water also means that no neutralization is required and that the acid dissolved in the rinse water is also returned to the process and reused. The regenerated acid leaving the absorber columns can be reused in the pickling process. To guarantee highest environmental standards, the Astec spray roast regeneration system uses a two-stage exhaust cleaning system. The Astec spray roast regeneration plants are equipped with the latest sensor and control systems, ensuring safe, reliable, efficient and comfortable operation of the plant.

Contact: www.astec-engineering.at E-mail: michael.mair@astec-engineering.at MPT International 1/2013

59

Technical innovations

Slag skimming machine for small ladles

Skimming machine with protection plate

STEELMAKING The basic purpose of a de-slagging machine is to remove the molten slag /skull from the surface of the molten mate-

rial in the ladle. This process assists in maintaining the purity of the molten product for further processing. In responding to the need

identified in small to medium size operations for a slag skimming machine to be utilized on small, cranehung ladles, Dango & Dienenthal developed the type SAM 7 skimming machine, the smallest model available in the company’s range so far. The machine is economical, reliable and safe to operate, and requires minimum skill. The design includes a wireless pendant which allows machine operation from a safe position whilst allowing clear view of the

skimming process. It is also possible to operate the machine via a fixed stand on the operating platform. The SAM 7 with a skimming force of 7 kN (horizontal) and 7.5 kN (vertical) is hydraulically operated and mounted on a fixed pedestal. Simultaneous swivelling, tilting and skimming stroke functions are possible as required by the operator to achieve the desired skimming result. The skimming stroke amounts to 4,000 mm, the maximum skimming speed is 1.0 m/s.

Contact: www.dango-dienenthal.com E-mail: contact@dango-dienenthal.de

Encoder solutions for large shaft diameters

Magnetic encoder system with split pulse wheel and scanning head

SPECIAL EQUIPMENT As an alternative to the standard optical scanning principle, which has to be protected in a closed housing with a bearing-supported shaft, the new magnetic encoders MAG(-G) 50‌1200 from Huebner can be installed without bearings or housing. The system is resistant to shocks and vibrations and transmits interference-free sig60

MPT International 1/2013

nals even under extreme conditions. It uses a stationary sensor that records magnetic field changes of a rotating pulse wheel with north-south poles. The alternating magnetic field produces a sinusoidal or rectangular voltage in this sensor. The magnetic scanning principle boasts additional benefits: it is resistant to soiling and provides for large radial and axial tolerances. Huebner magnetic encoders are wear-free and low-noise. The variant with a split pulse wheel is particularly well suited for retrofitting and upgrading as well as for applications without a free shaft end. Magnetic encoders from Huebner can be installed in highly confined spaces due to their very slim design. For shaft diameters between 16 mm and 1,000 mm, the system adapts flexibly to the specific set-up of the customer’s application. Various options for attaching the pulse wheel are available depending on the actual design conditions, including screw mounting and hot shrink fitting as well as mounting by means of clamping pieces, clamping plates or tolerance sleeves. The encoder systems can output various types of electrical signals, sinusoidal, incremental and absolute signals (SSI, EtherCat, other bus interfaces).

Contact: www.huebner-giessen.com E-mail: frank.tscherney@huebner-giessen.com

Technical innovations

Hydraulic AOD tilting system

After revamp vibrations have been dramatically reduced

fitted on the trunnion ring with a shaft and with a torque arm fixed to the foundation. The hydraulic drive enables rotation as well as holding the vessel in position during charging, tapping and de-slagging. A disc brake provides an additional possibility for mechanically locking the converter positions, typically during maintenance. Hydraulic pressure is generated in a power pack unit placed in an adjacent location. Contact: www.uht.se E-mail: per.vesterberg@uht.se

www.vip-kommunikation.de

STEELMAKING The AOD converter at UGITECH, France, was recently fitted with a hydraulic drive system that replaced the electromechanical solution with gearbox and electrical drive. The system was supplied by UHT. The new hydraulic tilt drive enables the capacity of the 57 t AOD vessel to be increased by 4 t per work shift. This increase is possible thanks to the fact that there are no longer any severe vibrations and shocks during processing which previously had made it necessary to operate a newly relined vessel with reduced blowing or limited tonnages in the first charges. Measurements by UGITECH have shown that vibrations have been dramatically reduced. Also control of the vessel rotation and tilting has improved, since the hydraulic motor provides rapid and direct response with full torque from zero speed. These features save additional operating time and minimize costly metal losses during de-slagging. In a hydraulic system, the oil serves as a built-in damper to vibrations and shocks. UHT has further improved this effect by applying an adjustable counter-balancing valve to the drive to reduce severe vibrations which typically occur during refining. Wear and maintenance are minimal since all moving parts of the hydraulic drive are always in contact with or embedded in oil. With the short delivery time of seven months from the date of the order, it was possible for UGITECH to schedule the revamp during the regular maintenance stop in summer 2012. The hydraulic drive solution comprises one hydraulic motor

‰

Accurate to the millimeter: H&K Industrieanlagen – Hightech & Know-how for planning, engineering, manufacturing and installation

Our ample range of equipment for cold and hot cutting works with highest precision. www.koch-hk.com

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Technical innovations

Optimized cooling tower design ENVIRONMENTAL PROTECTION A new series of cooling towers offering major environmental, safety and performance benefits in processes requiring efficient direct cooling is available from Outotec. These cooling towers offer increased cooling capacity as well as lower emissions to air. The most important change is that the air flows out of demisters horizontally, not vertically, as in conventional cooling towers. This allows for higher speed airflow in the demisters resulting in the ability to use more cooling air. In addition to the horizontal demister’s increased efficiency, the new technology’s careful nozzle placement ensures efficient droplet distribution and separation, reducing emissions to as low as 20% of traditional cooling tower designs. The new structure and high efficiency fans also improve cooling air flow distribution inside the tower. Furthermore, the inflow of the air can be adjusted dynamically so that the out-flowing solution temperature can be controlled.

Contact: www.outotec.com E-mail: hydro@outotec.com

Cooling tower design with horizontal demisters

Mobile metals analyzer ANALYTICAL EQUIPMENT Equipped with an efficient plasma generator and a newly designed UV probe, the latest generation of Spectrotest mobile metal analyzers from Spectro Analytical Instruments is the perfect instrument for exact analyses, difficult to identify materials or large numbers of samples. Its fieldproven ICAL (intelligent calibration logic) logic system monitors the correct state of the measuring system independently of external influences, eliminating the need for time-consuming recalibration of the spectrometer. Instead, one single control sample is measured. The plasma generator requires less energy, making it possible to do hundreds of measurements with a single battery charge. In addition to improvements to the plasma generator, a new pluggable probe with integrated UV optics for special measurement applications has been designed. This probe can be used for both spark and arc excitation, making probe changing unnecessary. By incorporating a low-weight and robust transport trolley, the instrument’s weight has been cut by half. The Spectrotest metals analyzer is especially suited for the identification of low-alloy steels by the carbon content in the rapid arc excitation mode. Possible applications in the spark excitation mode include the analysis of carbon, phosphorous and sulphur as well as the identification of duplex steels by the nitrogen content.

Compact, mobile metals tester

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Contact: www.spectro.com E-mail: spectro.info@ametek.com

Technical innovations

Bulk material feeding equipment

Surface feeder extracting bulk materials directly from the truck

Contact: www.aumund.com E-mail: info@aumund.com

Š Utz Peter Greis, Dßsseldorf

MATERIAL HANDLING Being a member of the Aumund group since 2002, B&W Mechanical Handling is known for its range of Samson™ surface feeder equipment, mobile shiploaders and the mobile Stormajor™ radial boom stacker. The Samson™ surface feeder was specifically designed for root crops but soon to be diversified into the industrial sector handling aggregates, coal, clay and heavier minerals as the application range expanded. The inherent mobility proved a major bonus in the ports and marine terminals sector since by combining a Samson™ with a mobile loading boom any bulk material could be exported from any berth providing a flexible bulk export facility without dedicated port infrastructure. This concept has since been extended to ever larger machines able to load Panamax or even Capesize vessels at loading rates to 2,500 t/h. B&W have extended their product range with the addition of track mounted options for their existing products plus a new range of specialized mobile conveyors, link conveyors, stackers and shiploaders.

„Signore, this machine will produce metal sheets of precise thickness. Apart from this, in 500 years from now, it will be HQWPF VQ DG GZEGRVKQPCNN[ GEQ HTKGPFN[ CPF GPGTI[ GHƂEKGPV YJGP EQNF TQNNKPI UJGGV HQT JQTUGNGUU OQVQT FTKXGP EQCEJGU q

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Literature service

Vacuum systems and technologies for metallurgy and heat treatment 6 pages, English A brochure featuring vacuum equipment, systems and process services offered by ALD Vacuum Technologies for thermal and thermo chemical treatment of metals in solid and liquid form. Processes include primary melting, remelting, vacuum hardening and tempering, case hardening and sintering. Contact: www.ald-vt.de E-mail: info@ald-vt.de

Process measurement systems 4 pages, English A concise brochure setting out key features and benefits of control and measurement systems offered by Amepa, e. g. electromagnetic, thermographic and ultra slag detection, residual steel detection, surface roughness measurement and online oil film measurement. Contact: www.amepa.de E-mail: info@amepa.de

Furnace systems for the steel and copper industries 20 pages, English, German A comprehensive brochure by furnace specialists Andritz Maerz. Descriptions of equipment for the steel industry cover various types of continuous reheating furnaces, annealing furnaces and burner technology. Furnaces for the copper industry include reverberatory, shaft and hearth-shaft as well as drum-type furnaces.

Contact: www.andritz.com E-mail: welcome-maerz@andritz.com

Industrial and tensioning hydraulics 8 pages, English A brochure outlining the activities and services provided by AS Tech in the field of industrial and tensioning hydraulics. It addresses aspects such as axial bolting, torque bolting, pressure generators, accessories, special screws, special-purpose hydraulics and training. Contact: www.astech-hydraulik.com E-mail: info@astech-hydraulik.com

Special steel products 6 pages, English, German, French This brochure provides an overview of the range of special-steel products offered by Buderus Edelstahl. For example, open die forgings in the as-forged or machined condition, pre-machined and heat-treated tool steels and engineering steels, forged steel bar or rolled billets. Contact: www.buderus-steel.com E-mail: info@buderus-steel.com

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Literature service

Coke oven technology 24 pages, English An illustrative brochure on Paul Wurth cokemaking technology. It covers modern coke oven plants, coke oven batteries, bracing systems and heating wall stability, heating systems, coke oven doors, single-oven pressure control, coke oven gas treatment, automation and recent references. Contact: www.paulwurth.com E-mail: paulwurth@paulwurth.com

Refractory technology 8 pages, English A product brochure featuring the Nanobond technology, a range of refractory cements insensitive to rapid heating, developed by Refratechnik. Nanobond-based products are recommended for use in applications such as steel casting ladles, torpedo ladles, tundishes, BF runner systems and stacks, as well as in Al furnaces. Contact: www.refra.com E-mail: steel@refra.com

Tapping technology 8 pages, English This brochure outlines tapping technology for non-ferrous and ferro-alloy applications offered by TMT, a joint venture company combining the expertise of Dango & Dienenthal and Paul Wurth. Products offered include clay guns, taphole drills, rodding and cleaning devices, and modular construction kits. Contact: www.tmt.com E-mail: contact@tmt.com

High-pressure fans 10 pages, English A product brochure detailing the range of high-pressure fans offered by Ventilatorenfabrik Oelde. Presentation of the basic fan types, special features and detailed lists, including technical specifications and technical drawings of the various models available. Contact: www.venti-oelde.de E-mail: info@venti-oelde.de

Industrial cardan shafts 56 pages, English, German A catalogue of industrial cardan shafts offered by Welte. Each model version is presented by technical drawings as well as detailed technical specifications for normal and/or heavy-duty applications. A technical appendix provides additional information and assistance in choosing the most appropriate product. Contact: www.welte-group.com E-mail: info.neu-ulm@welte-group.com

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In the next issue‌ Steelmaking New bucket-charging system automates scrap feeding in electric steel plants A new automation tool helps to optimize and fully automate crane movements during EAF charging. Precisely repeatable movement patterns shorten charging cycles, reduce the need for maintenance and increase operational reliability while substantially improving work safety. This scrap charging system recently developed by Siemens has been used successfully in Riva SAM’s electric steel plant in Neuves Maisons, France, since June 2012.

First Conarc plant with energy recovery system to be built in China The Chinese steel manufacturer Taiyuan Iron & Steel has ordered an X-Melt Conarc furnace unit with energy recovery system. The meltshop will be part of a new long product mill for specialty steel products to be erected in Taiyuan, North China. The Conarc process combines the technological benefits of the electric arc furnace with those of the conventional converter blowing process in one production unit with two identical shells. The energy recovery system increases the steelworks’ energy efficiency and especially contributes to reducing CO2 emissions and energy costs.

Maintenance Extending component and equipment life – a safe approach to maximizing productivity Advancements in lubricant technology, especially when it comes to fully synthetic-based products, have made major contributions to extending equipment life and oil drain intervals and to improving the energy efficiency of equipment. High-temperature performance of lubricants is particularly important for operators aiming at increasing the speed of their machinery, because a side effect of this is often an increase in operating temperature. It is crucial that under these higher temperature conditions the lubricants still offer sufficient protection. Reducing scheduled and unscheduled maintenance means reducing the safety risks associated with the performance of maintenance work. Recently, high-performance industrial oils and greases have helped a number of steel companies around the world to increase productivity and safety of their operations by extending oil drain intervals, reducing component wear and decreasing scheduled and unscheduled downtime.

This preview may be subject to change.

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Passion for innovation!

...150 years!

We are strong in know-how, planning, engineering and service of our guide systems. Contact us.

Branch Office:

Phone: +46 240 668500 Fax: +46 240 668501 E-mail: mh@morgardshammar.se www.morgardshammar.se

Morgårdshammar AB Sales office Krefeld P.O. Box 101552 D- 47715 KREFELD, Germany Phone: +49 2151 81290 Fax: +49 2151 611795 E-mail: office@mh-guides.de

www.mh-guides.com

www.gk-mas.de

Morgårdshammar AB SE-777 82 SMEDJEBACKEN, Sweden

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