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Metallurgical Plant and Technology

G 25074

ISSN 0935-7254


April 2013

Maintenance: Chelpipe values life-cycle partnership – a forward-looking service philosophy

Tap into cost-effective,

Right at the core: the metallurgical process chain //

Growth-centered structures //

Our plants and machinery, electrics, automation, and individualized service packages offer you the entire metallurgical process chain from a single source – starting from the ore to the ďŹ nished steel and nonferrous product.

SMS Siemag, working together with Paul Wurth, as well as SMS Meer, cover the complete spectrum of technology in the metallurgical process chain. Plus, with our acquisition of Elexis AG, we are switched on to the growth dynamic of connected industries.

exible solutions. From the ore to the ďŹ nished product.

Developments with you in mind // Spanning generations, our corporate culture under the roof of the SMS group has always relied on clear goals and structures. On the foundation of responsibility, innovation and customer dedication our growth has been driven.

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Nano mills and other technological trends “Nano mill technology” is probably the most spectacular headline in this issue of MPT International. This term does not mean that the production plants are of a microscopic scale. It rather expresses that classical mini mills have grown into sizes which have given rise to mill concepts that have scaled down the size of production units not just by one dimension – as the micro mill – but actually by two dimensions. The authors are presenting a plant concept that allows profitable operation already from a production capacity of 100,000 t/year. In addition to the supply of a regional market, this concept takes very much into account environmental aspects. Environmental protection – or putting it more appropriately, sustainable development – has become a key element of corporate development. This is the more true the closer the interrelationship between the company and the environment is. We all know how intense this interrelationship is in the steel industry. In corporate decision making it is therefore no longer sufficient to consider environmental compatibility as a side issue. Not only companies striving for leadership have made sustainability a central element of their corporate mission. Hence, it is not surprising that the topics of environmental compatibility and sustainability of production are becoming increasingly prominent in the media – including our journal. An example in this issue is the article featuring a project implemented by the Finnish steelmaker Ruukki, which involved the conversion of the blast furnace from sinter to pellet feedstock. It can be taken for granted that this project has a meticulously calculated technological basis. However, the article also shows that, apart from the technological benefits, the drastically reduced environmental impact was another important reason for Ruukki to introduce the new process. There are more articles in this issue of MPT International featuring aspects of sustainability and environmental protection in the steel industry. Several articles deal with heat recovery in EAF meltshops. Obviously, this is a much discussed issue, which we also featured in the February issue of our journal. What all these examples illustrate is that meanwhile value creation chains are increasingly being assessed and measured by their sustainability value.

Dipl.-Ing. Arnt Hannewald

MPT International 2/2013



Volume 36

No. 2 – April 2013

 6QRKECNVJGOGU 80 P. Tesè, C. Häusler, V. Tatzedinov Chelpipe values life-cycle partnership – a forward-looking service philosophy Plant owners have been increasingly demanding service and maintenance of the plant throughout its entire life cycle, utilizing the specific knowledge of the original equipment manufacturer (OEM) in order to safeguard “overall equipment effectiveness” and thus competitiveness on a permanent basis. At the same time, with innovation cycles becoming ever shorter, there is a need to maintain the technology at the latest state of the art by means of updates and upgrades.


 %QORCP[RTQƂNG 38 Optimization programme and change in leadership culture at ThyssenKrupp ThyssenKrupp has initiated a corporate programme of transition that creates a new leadership model for the whole group. The Steel Europe business area shall undergo an optimization programme.

Ironmaking Editorial A. Hannewald

115 Nano mills and other technological trends

Columns 110 International industry news 110 Advertisers‘ index 198 Technical innovations 105 Cartoon 106 Literature service 108 In the next issue 108 Imprint

44 Finnish Ruukki has drastically reduced environmental impact at the Raahe works The changeover to pellets as feedstock for ironmaking and the related closure of the sinter plant together with more efficient dedusting technology at the blast furnaces have resulted in a significant decrease in emissions.

 5VGGNOCMKPI C. Born, R. Granderath

50 2QVGPVKCNCPFFKHƂEWNVKGUQH heat recovery in steel plants In EAF steelmaking the off-gas provides the biggest potential for heat recovery. Depending on the temperature at the lower end of the off-gas duct and the control of dilution air, a big share of this energy content can be recovered. Contradictory to widespread opinion, steam buffering is not an issue here. In almost any case, it is possible to avoid the need for superheated steam and it is economically more favourable to generate power.

62 First Conarc EAF with heat recovery system for China The Chinese steel manufacturer Taiyuan Iron & Steel has ordered an X-Melt Conarc furnace unit with energy recovery system for a new long product mill in Taiyuan, North China. It will contribute to low CO2 emissions and energy costs.

48 Tata Steel restarts Port Talbot blast furnace The restarting of its second blast furnace – the UK’s largest industrial engineering project last year – will improve Tata Steel’s operational flexibility and enable it to better serve customers in the UK and the rest of Europe.

3D scheme of a twin-shell Conarc plant

Metallurgical Plant and Technology  *GCVVTGCVOGPV 32 AISTech 2013 in Pittsburgh, Pennsylvania The Iron & Steel Technology Conference and Exposition will return to the David L. Lawrence Convention Center in Pittsburgh, Pennsylvania, USA on May 6 – 9, 2013.

36 Steeluniversity challenge world champions 2013 The World Steel Association announced the new champions of the 7th steeluniversity challenge.


64 Bucket-charging system automates scrap feeding in electric steel plants A new scrap charging system helps to optimize and fully automate crane movements during charging. Precisely repeatable movement patterns shorten charging cycles, reduce the need for maintenance and increase operational reliability, while substantially improving work safety.

86 In-line thermal treatment of heavy-duty rails The newly developed “Idrha+” technology enables manufacturing of rails with improved resistance to contact fatigue and wear. Chinese Baotou Iron & Steel will implement the world’s first application of this in-line dual-phase rail hardening technology for the production of heavy-duty rails.

 5  VGGNOCMKPIs Hot rolling T. Klein, U. Wilhelm

68 Nano mill technology – an extra-low capex solution for local steel supply In contrast to common mini mills or integrated steel works, the nano mill is the answer to satisfying regional demand by a cost-sensitive investment approach. The concept is based on plant layouts for standard production sizes of up to 300,000 t/year of long products.

 3WCNKV[CUUWTCPEG 88 Straightness measurement system monitors bar and pipe steel production With laser measuring technology, the straightness of pipes and bars can be measured contactlessly. The Straightcheck system can help pipe and bar manufacturers to avoid time consuming manual measurement.

66 New secondary metallurgy complex goes into operation at Saarstahl The main components of the new facilities are two twin-ladle furnaces and a vacuum degassing plant. Temperature adjustment of the heats now takes place in the casting ladles, no longer in the converters, thus removing a major burden from the converters. In this project, particular emphasis was placed on environmental protection measures.

The outer facade has been covered with a double-shell insulation layer

 5VTKRRTQEGUUKPI  /CKPVGPCPEG 76 Extend component and equipment life – a safe approach to maximizing productivity Steel producing companies are constantly looking at ways of improving mill productivity. However, while increasing productivity is important, employee safety is paramount. Advanced lubrications can help operators to tackle the conundrum of increasing productivity while helping to reduce the potential hazards facing its engineers.

J.-J. Hardy, B. Grenier, S. Özer, M. Baras

90 $GPGƂVUQHWUKPIF[PCOKE air knives in a continuous galvanizing line The new continuous hot-dip galvanizing line at Borçelik was equipped with a special wiping system for zinc coatings, called dynamic air knife system. This technology enables accurately controlled homogeneity of the zinc coating thickness across the width.

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International industry news


The Americas Brazil

TenarisConfab orders tube processing equipment. Confab S.A. has ordered a mechanical expander with a newly developed straightener from SMS Meer, for its Pindamonhangaba tube mill near SĂŁo Paulo. The AGTÂŽ (advanced geometry technology) system allows precise calibration and straightening of longitudinally welded pipes with large wall thicknesses on one single machine. Such pipes are required for offshore pipelines laid in deep sea waters. Commissioning is scheduled for the first half of 2013.

Weser is supplying all of the equipment needed to transport, store and handle the iron ore in the new stockyard. The equipment supply will consist of a complete belt conveyor system for a capacity of 12,000 t/h and with a total length of 13 km. This system will cover all the stages from receiving through to loading onto ships, complete with conveyors for the two stockyards. TAIM Weser will also supply four combined stacker-reclaimer machines with a stacking capacity of 10,000 t/h and a reclaiming capacity of 12,000 t/h. These machines will be installed in the two new iron ore storage yards.


Greer Steel expands service centre capabilities. Greer Steel has Brazil

Iron ore handling equipment for new port terminal. For the Super Porto Sudeste, a new port terminal for the export of iron ore being built in Sepetiba Bay in ItaguaĂ­, TAIM

expanded its Dover, Ohio, operation to include full service centre capabilities. The new addition to the facilities features a new overhead crane and full radiant floor humidity control to support retention of both intermediate processed product and finished goods.

Advertisersâ&#x20AC;&#x2122; index ABB AB


GLAMA Maschinenbau GmbH


ABP Induction Systems GmbH


Heinrich GrĂźnewald


Automazioni Industriali Capitano srl

GSB Group GmbH



Guild International Inc.


Badische Stahl-Engineering GmbH 71



MPT International 2/2013

Heppenstall Technology AG

Bähr-Thermoanalyse GmbH


BEDA-Oxygentechnik Armaturen GmbH


Boldrocchi srl


INTECO special melting technologies GmbH

Can-Eng Furnaces


Th. Jansen Armaturen GmbH

IMS Messsysteme GmbH

JP Steel Plantech Co.

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


Combilift Ltd Co


Corts Engineering GmbH & Co. KG


10,102 21,22 75 85 I.B.C.

Amandus Kahl GmbH & Co.KG




Kiro-Nathaus GmbH


Danieli S.P.A.


Deutsche Edelstahlwerke GmbH

Maschinenfabrik KĂśppern GmbH & Co.KG



3tn Industriesoftware


Koll Anlagenbau GmbH + Co. KG


Fives DMS


Fabris InC.


KSK Kuhlmann-SystemKĂźhltechnik GmbH


KĂźttner GmbH & Co. KG


F.I.M.I. Fabrica Impianti Macchine Industriali SpA


Fontaine Engineering und Maschinen GmbH

Lase Industrielle Lasertechnik GmbH



M.A.T. Malmedie Antriebstechnik GmbH


International industry news Moreover, this expansion incorporates a broader range of products available not only in the breadth of grades being offered, but also in width, gauge and coil sizes.


Charter Steel to implement planning and scheduling solution. Charter Steel has selected Quintiq’s Metal Scheduler to optimize production scheduling. The solution will streamline operations in metal processing by generating detailed, optimized schedules and order sequencing, even when planning just days or hours ahead.


ArcelorMittal USA signs pellet off-take agreement. ArcelorMittal USA has entered into a long-term iron ore pellet off-take agreement with Essar Steel Minnesota. The term of the agreement is ten years and the supply of pellets is expected to commence during the second half of Essar Steel

Minnesota’s fiscal year ending March 31, 2014. The company will supply 3.5 million t of standard and fluxed iron ore pellets annually to ArcelorMittal’s North American operations. Essar Steel Minnesota is presently constructing a 7.0 million t/year iron ore pellet plant at Nashwauk in Northern Minnesota. Its product portfolio will include standard, flux and DR grade pellets.


CSI orders tube welding line. California Steel Industries (CSI) has placed an order with SMS Meer for the delivery of a 24” HF tube welding line. The line will be primarily used to produce up to 400,000 t of line pipes according to API 5L. In addition to increased production capacity, the new line will enable CSI to expand its tube product range to 24” outside diameter and 24 m length. The line will be designed to produce pipes at a rate of 35 m/min. It will also feature the SMS Meer inline and offline quick-change system for the URD® stands. Another

Medenus-GasDruckregeltechnik GmbH


Siempelkamp Maschinen -und Anlagenbau GmbH & Co.KG

Messe Düsseldorf GmbH


SMS Concast AG




SMS Mevac GmbH




Stein Industrie-Anlagen


Oerlikon Leybold Vacuum


Stopinc AG


Pert srl


Tenova spa


Pfaff-silberblau Hebezeugfabrik GmbH & Co.


ThyssenKrupp Uhde Engineering Services GmbH

Pieper GmbH


TML Technik GmbH


Plakoma GmbH




TMT Tapping Measuring Technology



SMS Siemag AG




UELZENER Maschinen GmbH


QuinLogic GmbH


Uni E. Mangelmann GmbH


R&D Centre for Iron an Steel


VELCO GmbH Ges. f. Förder-, Spritz- und Silo-Anlagen mbH


Ventilatorenfabrik Oelde GmbH


Verlag Stahleisen GmbH


Quaker Chemical S.A.

REBS-Zentralschmiertechnik GmbH 87 REFRATECHNIK Steel GmbH RV Rheinbraun GmbH Saar-Metallwerke GmbH Sachtleben Chemie GmbH von Schaewen AG SGL CARBON GmbH Siemens VAI Metals Technologies GmbH

4 99,100 61 101 81 O.B.C. 35

Walzengießerei Coswig GmbH




Z & J Technologies GmbH


Zumbach Electronic AG

MPT International 2/2013



International industry news advantage is the travelling MF seam annealing system which enables areas of the pipe insufficiently annealed to be re-annealed during a line stop. The plant will be brought into service in 2014.


Republic Steel to implement production planning and scheduling solution. Republic Steel will implement Quintiq’s industry solutions for metals manufacturing, including modules for campaign planning, order promising, finite capacity planning, and inventory optimization as well as Quintiq’s scheduler solutions for detailed scheduling and sequencing optimization for melt/cast, hot rolling and finishing operations.

a contract for the supply of one new hSystem® automation system for thickness and flatness control from China Nonferrous Metals Processing Technology (CNPT). The system will be installed on a cold rolling mill that will be put in operation in Venezuela. The system will feature automatic gauge control (AGC), automatic flatness control (AFC), roll eccentricity compensation (REC), a flatness measurement system with 34 zones and coolant spray bars. A level-2 system for automatic pass schedule calculation, primary mill data management and process data acquisition and recording will also be supplied.

Asia Africa



Jiangsu Shenyuan orders wire rod outlet. Jiangsu Shenyuan Special


El Marakby Steel to build its ƂTUV '#( SMS Concast will supply

Cold mill to be equipped with VJKEMPGUU CPF ƃCVPGUU EQPVTQN an electric arc furnace to long steel prosystem. Fata Hunter recently received ducer El Marakby Steel in Giza. It will

be the first EAF operated by El Marakby Steel. With a capacity of 350,000 t/year, the new meltshop will broaden the steelmaker’s portfolio. It will be used to feed El Marakby’s rebar mill with 130 mm square billets. The rolling mill has a capacity of 240,000 t/year. Excess billet output will be sold to the open market. Scrap from the Unites States and Europe will be used in the new furnace. The charge may include up to 20% scrap substitutes. Commissioning of the new furnace is scheduled for the end of 2013.

Steel from Shenyuan, Jiangsu province, has awarded an order to SMS Meer for the supply of the wire rod outlet of a special steel rolling mill. The mill has an annual production capacity of more than

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TWMS/metals: The Technical Warehouse Management System for the Steel Industry


MPT International 2/2013

International industry news 180,000 t and rolls top-quality stainless steels and high-grade valve steels in diameters from 5.5 mm to 20 mm at a maximum production rate of 60 t/h and maximum speed of 70 m/s. The expansion of the mill to include bar steel in coils will cover a size range from 21 to 40 mm in diameter. The wire rod section will consist of compact CL stands in H/V arrangement. Installed downstream will be an eight-stand wire-rod finishing block, a pinch-roll unit and a loop-laying head as well as an LCC® loop cooling conveyor. Commissioning is scheduled for the fourth quarter of 2013.

al scope of the system will embrace order dressing, production planning and execution, quality management and stock yard management. This project will be managed by PSI together with the local partner Lanzhou Wanqiao Intelligent Science and Technology. During the implementation phase, PSI will be responsible for software licencing, delivery and customizing, consulting and training services, while Wanqiao will handle most of the on-site work such as analysis, data collection, tests and basic on-site customer support.

China China

Jisco to implement production management system. PSI China received an order for the implementation of the production management system PSImetals at Jisco TianFeng Stainless Company. PSImetals will cover the whole production process from steelmaking, hot rolling, cold rolling through to plate pickling. The function-

(W,KCP 9W*CPI VQ DWKNF PGY stainless rolling mill. FuJian WuHang Stainless Steel has placed an order with SMS Meer for the supply of the core technologies for the construction of a new stainless steel rolling mill. The mill will produce wire rod and bar in coils. The core facilities will include a threeroll PSM® (precision sizing mill) with hydraulic roll adjustment performed under

News in brief Outokumpu has announced the completion of the Inoxum transaction and thus the merger with the former ThyssenKrupp subsidiary. ThyssenKrupp Nirosta is now operating under the name Outokumpu Nirosta, and ThyssenKrupp VDM under the name Outokumpu VDM.

Bluescope Steel, Australia, has PCAMLjESPCBGRQAMJBPMJJGLE KCR?J coated and painted steel production. This change will reduce production levels at its Western Port facility. Lines and assets at Western Port will be kept open RMNPMTGBCkCVG@GJGRW?LB?JJMU for additional throughput when demand improves.

F.I.M.I. Fabbrica Impianti Macchine Industriali Spa

METAL STRIPS AND SHEETS CUTTING LINES Cut to length, Slitting and Recoiling Lines suitable for high productivity, flexibility and wide thickness range 0,2-25 mm.

Medium Gauge Slitting Line for Carbon Steel THYSSENKRUPP, Germany.

Dual Phase High Strength Steel Cut to Lenght Line suitable for plasma laser cutting quality - SSAB, Sweden.


F.I.M.I. - Fabbrica Impianti Macchine Industriali S.p.A. Via Dell’Industria 15 I-23897 Viganò (Lecco) - Italy Tel +39.03992141 - Fax +39.0399272090 -


International industry news load for finish-rolling all final sizes between 13 mm and 38 mm diameter from a single-pass family. Another core component is the wire rod finishing block with MEERdriveÂŽ technology. A key feature of this facility is that each stand is individually driven by a single motor. Wire rod diameters will range from 5 to 20 mm. The supply package is completed by a coil handling system with several coil transportation routes for superior martensitic, ferritic and austenitic grades. Commissioning is scheduled for the second quarter of 2013.


JSL places metal recovery contract. Harsco Corporation received


a new multi-year contract from Jindal Stainless Limited (JSL). The 15-year contract calls on Harsco to serve as an onsite resource recovery and material handling partner to JSLâ&#x20AC;&#x2122;s expanding stainless steel production operations in India. Harscoâ&#x20AC;&#x2122;s services are scheduled to begin in the second half of 2013 and will include specialized process technologies for recovering metal from stainless steel production by-products.

Pfaff-silberblau supplies individual components as well as complete solutions for lifting systems in the steel industry.



,59 5VGGN RNCEGU PGY OKNN UGTvices contract. Harsco has received a

q)FBWZEVUZTDSFXKBDLTGPSMPBETGSPN 100 t to 200 t q4QFDJBMTDSFXKBDLTGPSTQFDJBM solutions q4QFDJBMTDSFXKBDLTGPSSFQPTJUJPOJOH tundishes q$PNQMFUFQPUMJGUJOHTZTUFNTGPS coating lines q%FWFMPQNFOUBOENBOVGBDUVSFPG complete lifting systems, including structural steel, control system, commissioning and service



MPT International 2/2013

new multi-year contract from JSW Steel for resource recovery and slag management services at JSW Steelâ&#x20AC;&#x2122;s Vijayanagar plant in Karnataka. Work is scheduled to begin in the second half of 2013. Harsco is already providing various industrial services at Vijayanagar and at JSW Steelâ&#x20AC;&#x2122;s associate company, JSW Ispat Steelâ&#x20AC;&#x2122;s Dolvi plant in Maharashtra.

The new blast furnace will have a working volume of 2,251 m3 and a hot metal capacity of up to 2 million t/year. The scope of supply of Paul Wurth includes the complete basic engineering and partial detail engineering, as well as the supply of key components for the BF top charging system, the BF proper, hot blast stoves, wet gas cleaning plant and INBAÂŽ slag granulation system. The furnace will be equipped with the BFXpertâ&#x201E;˘ level-2 blast furnace control system. Start-up is scheduled for April 2015. For the new sinter plant Paul Wurthâ&#x20AC;&#x2122;s contractual scope of supply comprises all key components including the mixing and nodulizing equipment, the sinter strand, key elements of the cooler as well as the complete control and automation systems of all plant units. The sinter plant will be designed for a nominal capacity of 2,400,000 t/year of sinter to be used to feed Gunungâ&#x20AC;&#x2122;s new future blast furnace. Commissioning is slated to be completed in 2015. For the new cokemaking plant of the stamp charging type Paul Wurth will provide the engineering and key items for a new coke oven battery consisting of 66 ovens with an oven height of 5.5 m and a coke production capacity of 755,000 t/year. Also the coal tower, the coke quenching tower, the coke wharf and the complete gas treatment plant as well as key items of the coke oven machines, comprising two sets of stamping/charging/pushing machines, one coke transfer car and one charging gas transfer system, will be supplied by Paul Wurth. The first coke is expected to be pushed in December 2015.

South Korea

Dongil Industries orders tworoll straightener. Dongil Industries Indonesia

Gunung places cokemaking, UKPVGTRNCPVCPF$(GSWKROGPV order. PT Gunung Raja Paksi (Gunung Steel Group) is currently expanding its production capacity to become one of the most comprehensive integrated steel mills in the region. In this context, Paul Wurth was awarded orders for a cokemaking plant, a sinter plant and for Gunungâ&#x20AC;&#x2122;s new blast furnace to be built at the site of Cibitung in Cikarang Barat, West Java province.

of Pohang has placed an order with SMS Meer to replace an existing straightener machine with a WRP 40 BF tworoll straightening machine. The new machine will enable the company to produce bright steel bars with a straightness better than 0.35 mm/m and with a surface roughness under 5 Îźm. The new straightener will be integrated into an existing KZ-RP IIIB/25 drawing line of the Schumag type built in 1989. Bright steel producer Dongil plans to relocate the drawing line to a newly acquired plant in the port city of Pohang where

International industry news it will be modernized thereafter. The height-adjustable WRP 40 BF two-roll straighteners are specially designed for use in high-speed drawings lines. The machine for Dongil will be designed for bar diameters from 6 to 40 mm and straightening forces of up to 220 kN. Commissioning of the new straightening machine is scheduled to take place in April 2013.

South Korea


CSC to install new surface inspection systems. China Steel Corporation (CSC) decided in favour of surface inspection technology from Isra Vision Parsytec to be used on its continuous annealing line No. 2 in Kaohsiung. The advantages of the new system include reliable defect detection, as well as detection of the smallest longitudinal defects, thanks to highresolution cameras and the combination of two lighting technologies.


*[WPFCK 5VGGN QTFGTU XCEWWO degassing installation. MTAG Technology has been contracted by Hyundai Steel to design and supply a 70 t turnkey vacuum degassing system with a four-stage dry pumping configuration for its Incheon works. MTAG Technology offers the complete plant with engineering, implementation of the layout, feasibility studies, functional analysis, process technology, automation, documentation, manufacturing, supply and erecting, training, commissioning and after sales service.

South Korea

2QUEQ 500% VQ DWKNF PGY 5#( Ferronickel producer Posco SNNC has contracted SMS Siemag for the delivery of a submerged arc furnace with six electrodes to be installed in Gwangyang to increase annual production capacity from 30,000 to 54,000 t of nickel. Commissioning is scheduled for the end of 2014. The power rating of the rectangular-shaped FeNi smelter will be 140 MVA at a total nominal power input of 100 MW. To implement these performance values, furnace dimensions of 40 m x 15 m are required. SMS Siemag’s scope of supply comprises all engineering and supervisory services, the delivery of the furnace and the X-Pact® electrical and automation systems. The electrode columns have been developed by SMS Siemag especially for rectangular FeNi furnaces. Posco SNNC (Société du Nickel de Nouvelle-Calédonie et Corée Pty. Ltd.) is a joint venture between Posco and the mining company SMSP (Société Minière du Sud Pacifique S.A.), which is based in New Caledonia. From there, the nickel ore is shipped to the Gwangyang plant, where it is converted to ferronickel.


Europe Germany

TKS Europe to modernize converter cooling stacks. In early 2012, Oschatz had received an order from ThyssenKrupp Steel Europe for the modernization of the cooling system for converter 1 at the steel works in Duisburg-Bruckhausen. Now ThyssenKrupp placed a new order with Oschatz, covering the modernization of the second converter cooling stack. Oschatz converter cooling stacks are based on the principle of evaporation cooling. The hot exhaust gases from the converter are cooled from 1,650°C to approx. 500 to 600°C. In this process the cooling stack produces up to 240 t/h of steam, which can either be used as process steam or fed into the district heating system. Reconstruction in Bruckhausen has already started. The stack components are manufactured at the Oschatz plant in Turkey.

laser-optical measurement with thicknessCONTROL

SPEED & LENGTH optical sensor with ASCOspeed


*GKPTKEJ )GKUUNGT QTFGTU straightening equipment. Heinrich Geissler, a company of the GMH group, has ordered a two-roll straightener for bright steel from SMS Meer. The machine will be 7 m high and weigh 280 t. Heinrich Geissler will use the new machine to straighten round steel bars with diameters up to 250 mm. The machine will be able to apply a straightening force of 8,000 kN. It will be supplied by SMS Meer together with the comMPT International 2/2013

17 MICRO-EPSILON | 94496 Ortenburg / Germany Tel. +49 85 42/168-0 |

International industry news

News in brief Nippon Steel and Sumitomo Metal, Japan, completed construction of a new gas holder at the Kashima Steel Works, replacing the one damaged by the earthquake in March 2011. This completes the restoration of all Kashima production facilities damaged by the earthquake.

Aluminium Chue Chin Hua, Thailand, F?QQGELCBRFCjL?J?AACNR?LACACPRGjA?RCDMP? FGEFLML reversible aluminium cold rolling mill supplied by Fata Hunter.

Salzgitter Flachstahl, Germany, will equip one converter with new jJRCPRCAFLMJMEWDPMK1+1#JCV  The installation work will take place during the summer of 2013.

Tata Steel, Netherlands, has grantCB1+11GCK?ERFCjL?J?AACNR?LAC for the modernization of coiler No. 3 in its IJmuiden hot strip mill.

Ohio Star Forge, USA, has successfully started up a roller hearth continuous mesh belt normalizing furnace. The equipment was supplied by Can-Eng Furnaces.

U. S. Steel, USA, has commissioned the C battery at its Clairton plant.

plete finishing equipment. Commissioning is scheduled for June 2013.

plant and one for capturing and cleaning the gases from the sintering process.

Netherlands Poland

Tata Steel starts up research facility. Tata Steel Europe has started up a facility to develop crash-resistant steels. The 2.3 million euros investment at the company’s IJmuiden site combines the characteristics of commercial industrial lines alongside special research features and incorporates a hot press forming line. Tata Steel is also developing zinc-coated boron steels, which offer superior corrosion resistance compared to other boron steel grades. In June 2012 the company launched its first zinc-coated steel product under the trade name HQ1500 ZnX®.

Eurometal to build aluminium rolling mill. Fata Hunter recently received a contract for the supply of a 2-m-wide aluminium cold rolling mill and a tension levelling line to Eurometal SA, Stalowa Wola. The equipment will be installed at a greenfield plant located in the new Kleszczów industrial park. The mill will feature state-of-the-art controls that allow it to roll a wide variety of products from foil stock to can body. The tension leveling line will include an innovative cleaning section that minimizes the use of chemicals. Fata Hunter and Eurometal plan to further expand the plant in the future.


Tata Steel brings forward bag ƂNVGT KPUVCNNCVKQP Tata Steel is to


complete the installation of the new bag filter facility in IJmuiden’s sinter plant by the end of this year, more than a year ahead of the original completion date in 2015. Tata Steel expects the facility to reduce emissions of fine particles, heavy metals and dioxins from the sintering process by at least 75%. The new facility will contain 45,000 m² of bag filters. It consists of two parts, one for dedusting the sinter

#DKPUM 'NGEVTKE 5VGGN 9QTMU VQ upgrade rebar mill. Abinsk Electric Steel Works has placed an order with SMS Meer to upgrade its highspeed rebar rolling mill. With two new roughing stands, Abinsk will be able to roll larger square billets. So far, Abinsk has fed its rolling mill with 130 mm square billets purchased from other suppliers. The two new roughing stands from SMS Meer will extend the

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MPT International 2/2013

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International industry news range to 150 mm square billets which will be produced in Abinsk’s own new steel plant. The rolling mill was supplied and commissioned by SMS Meer in 2011. It operates with a rolling speed of 40 m/s and reaches a monthly production of 47,000 t. Commissioning of the new stands is scheduled for April 2013.


Ruspolymet to build new vacuum melting and pouring plant. Special steel manufacturer Ruspolymet placed an order with Inteco for the engineering and supply of a 3.5 t multichamber vacuum induction melting and pouring (VIMP®) plant. The plant will feature separated chambers for melting, casting, material charging and tundish charging. The melting and casting chambers will be of diagonally split design with moveable parts. The casting chamber will be equipped with a turntable for casting one to six ingots with diameters from 190 mm to approx. 600 mm and a maximum total mould height of 2,700 mm by top pouring remelting electrodes. It is also possible to cast forging ingots by bottom pouring. Start of construction will be in spring 2014.


LKAB to install new gas cleaning system on pellet plant. Outotec

will design and supply on a turnkey basis a gas cleaning plant for an existing iron ore pellet plant of LKAB in Malmberget. The pellet plant was originally built by Outotec in 2006. The new gas cleaning plant will bring sulphur dioxide, fluorides, chlorides and dust contents in the off-gases further down to levels that will meet the European Union’s new, stricter environmental regulations which will be in place from 2016. Outotec’s turnkey delivery will include basic and detail engineering of the gas cleaning plant, supply of ducts, absorber, bag filter and wastegas fan, construction and installation as well as operator training and commissioning services. The plant is scheduled to be commissioned in 2014.

Companies Mechel disposes its Romanian steel assets. Mechel has signed a series of agreements for the disposal of its Romanian steel assets Ductil Steel Mechel, Campia Turzii S.A., Mechel Targoviste S.A., Mechel East Europe Metallurgical Division SRL and Laminorul S.A. to a privately held Romanian group, Romania’s Invest Nikarom SRL. While production at these steelmaking facilities had been temporarily suspended around the end of 2012, all necessary measures were undertaken to retain the affected facilities’ opera-

News in brief Andec, Ecuador, has completed the installation and commissioning of a Consteel® system supplied by Tenova Core.

Salzgitter Flachstahl, Germany, is to use the new “Mould Screen” software from S&B Industrial Minerals for modeling the behaviour MDRFCkSVjJKGLRFCAMLRGLSMSQ casting mould.

UMC Metals, Thailand, has completed the construction of the FGEF CDjAGCLAW#AM?PATM furnace. The EcoarcTM project for UMC Metals had been entrusted to JP Steel Plantech by the Japanese New Energy and Industrial Technology Development Organization (NEDO). According to information released by UMC and JP Steel Plantech, the furnace has achieved QGELGjA?LRCLCPEW?LB!-2 savings BSPGLEGRQjPQRKMLRFQMDMNCP?tion.

Forgiatura A. Vienna, Italy, has QGELCBRFCjL?J?AACNR?LACACPRGjA?RCDMP?L#10NJ?LR@SGJR@W Inteco. The plant can remelt ESR ingots of up to 250 t weight and with a max. diameter of 2,600 mm.

MPT International 2/2013


International industry news tional capability and to conduct maintenance works in an orderly manner.

ArcelorMittal Liege to permanently close further assets. In October 2011, ArcelorMittal Liege had announced its intention to permanently idle its liquid phase operations due to structural over-capacity in Northern Europe. It was envisaged that in the future Liege would focus on its downstream activities, operating five core lines and seven flexible lines. Since then, the economic outlook has further deteriorated. As a result there is insufficient demand to support the running of these facilities. Despite the closure of the blast furnaces, the Liege facility reported an EBIT loss of more than 200 million euros for the nine first months of 2012 and no improvement is foreseen in 2013. The company is therefore proposing that in order to respond to these structural market changes and further adapt to the reality of demand in Europe, the following six flexible lines need to be closed: the hot strip mill in Chertal, one

of the two cold rolling lines in Tilleur, hot-dip galvanizing lines 4 and 5 in Flémalle, and electrogalvanizing lines HP3 and 4 in Marchin. The organic coating line 2 in Ramet will be maintained only as a repairing line for the Combiline products. Additionally, the company is proposing that the coke plant, which is no longer viable due to the excess supply of coke in Europe, will also be permanently closed.

JV to participate in sale process of Inoxum plant. Aperam, Arvedi (Ilta Inox) and Marcegaglia have signed a memorandum of understanding to create an Italian joint venture aimed at participating in the sale process of stainless steel producer Acciai Speciali Terni S.p.A, currently being divested by Outokumpu Oyj. Under the terms of the MoU, Aperam would be majority shareholder and operator of the joint venture, while Arvedi and Marcegaglia would each have equal minority shareholdings. The consortium’s combined experience and resources would be drawn upon to improve the competi-

Personalities Gerhard Cromme steps down at ThyssenKrupp as well as its shareholders – I want Dr. Gerhard Cromme (70) has stepped to support a renewal regarding the down as chairman of the supervisory supervisory board. Over the last 200 board of ThyssenKrupp AG effective March 31, 2013. Concuryears the company rently he has requested has always successfully the Alfried Krupp von overcome several critiBohlen und Halbach Founcal situations and I am dation to revoke his deleconvinced it will be gation into the supervisory the same this time. I board of ThyssenKrupp AG will remain strongly atalso effective March 31, tached to the company and its employees.” 2013. (The foundation is Dr. Heinrich Hiesinger, the largest shareholder of CEO of ThyssenKrupp the ThyssenKrupp AG and AG, commented: “The largely controls the board executive board as of the company.) Gerhard well as our employees Cromme also steps down Gerhard Cromme have acknowledged as vice chairman of the the decision by Gerboard of trustees and as hard Cromme with respect and wish a member of the Alfried Krupp von to thank him for his longstanding Bohlen und Halbach Foundation. Afservice. He has distinctly shaped the ter having served in different leadership roles at Krupp and the respeclandscape of the German steel industive successor companies for more try. The mergers of Krupp and Hoesch than 27 years he states: “With this in 1992 and later with Thyssen 1999 are results of his forward-looking inistep – after 12 years as chairman of RG?RGTCQ ?LB F?TC AMLRPG@SRCB QGELGjthe supervisory board of Thyssencantly to the required restructuring of Krupp AG and acting in responsibility the steel industry.” towards the company, its employees


MPT International 2/2013


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International industry news tiveness and profitability of the Italian mill in the European market for flat stainless steel products.

Eurofer comments on vote to amend ETS. Eurofer is disappointed by the vote of the European Parliament’s Committee for Environment, Public Health and Food Safety (ENVI) to pave the way for withholding CO2 emissions allowances from the European carbon market. ENVI voted in favour of a proposal by the European Commission to amend the Emissions Trading Scheme (ETS) in a way that would make it legal to modify the rules for auctioning allowances. This is a precondition for the actual backloading plan, the aim of which is to withdraw 900 million emissions allowances from the market. The parliament’s Industry, Research and Energy Committee (ITRE) rejected this last January. The proposal still has to be voted on by the plenary of the European Parliament. Eurofer emphasizes that the proposal is an attempt to manipulate carbon prices through political intervention. If accepted by the European Parliament, it will inevitably lead to additional cost increases, especially for energyintensive sectors like the steel industry. These increases occur in the EU only and will further weaken international competitiveness of the industry.

ArcelorMittal to sell interest in Mines Canada. ArcelorMittal has entered into an agreement pursuant to which ArcelorMittal’s wholly owned subsidiary ArcelorMittal Mines Canada (AMMC) and a consortium led by Posco and China Steel Corporation (CSC) will enter into a joint venture partnership that will own ArcelorMittal’s Labrador Trough iron ore mining and infrastructure assets. The consortium will acquire a 15% interest in the joint venture, with AMMC and its affiliates retaining an 85% interest. As part of the transaction, Posco and CSC will enter into long-term iron ore offtake agreements proportionate to their joint venture interests.

Outokumpu and Outotec enter into legal dispute over invention rights. Outokumpu and Outotec have entered into a legal dispute

over invention rights related to a ferrochrome production method. Outokumpu’s position is that Outokumpu has made the invention and has filed the patent applications related to this invention regarding the production of ferrochrome nickel. Outotec is alleging to have rights to the invention and has submitted an application for summons at the District Court of Helsinki. According to Outokumpu, these allegations are unfounded.

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4*+ VQ CESWKTG +PFKCP 1TKGPV Refractories. A wholly-owned affiliate of RHI AG signed a share purchase agreement to acquire 43.6% of the share capital of Orient Refractories Ltd. (ORL). ORL is an Indian producer of special refractories and monolithics. As a consequence of this transaction, and based on the Securities and Exchange Board of India Regulations, RHI’s wholly-owned affiliate, acting in concert together with RHI AG, is making an open offer to the public shareholders for up to an additional 26% of the shares of ORL.

,8 HQT CWVQOQVKXG ƃCV UVGGN products in Indonesia. Nippon Steel & Sumitomo Metal Corporation and PT Krakatau Steel have agreed to conduct a detailed study to jointly launch a business for the manufacture and sales of automotive flat steel products in Indonesia. The two companies have also agreed to establish a joint venture company to acquire the right to use a piece of land in the Krakatau Industrial Estate Cilegon, which is located adjacent to the manufacturing base of PTKS. Through the JV, the companies intend to meet the demand for high-grade automotive flat steel products mainly from Japanese automakers that have developed their business in Indonesia as well as to contribute to the further development of the Indonesian automotive industry.

SMS Meer acquires Girard Associates. SMS Meer has acquired the US engineering company Girard Associates, Strongsville, Ohio, which specializes in controls, hydraulics and robotic systems in the North American forging industry. For over 50 years, Girard has been SMS Meer’s partner in the AmeriMPT International 2/2013


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can market. Robert Bolin will remain president and CEO of Girard.

#+56 HQWPFCVKQP ETGCVGU ,WPKQT (CEWNV[ Award. The Association for Iron & Steel Technology (AIST) foundation has created the AIST Foundation Junior Faculty Award to increase the number of younger engineering professors with a vested interest in the iron and steel industry. This award is open to all technical engineering disciplines and will provide funding to encourage the junior faculty members to become better informed about the steel industry, encourage students to pursue careers in the iron and steel industry, provide seed money for steel-related research projects, and develop relationships between university and industry personnel. Complete details on the AIST Foundation Junior Faculty Award and the proposal process can be found at under scholarships and grants.

Eurofer market outlook. Since late 2012, several economic indicators such as the EU economic sentiment indicator and PMI output indices are improving. Eurofer’s economic and steel market outlook for the first quarter of 2013 nevertheless signals that for the time being the EU steel market looks set to remain fragile. Activity in the steel using sectors is expected to register a further decline in 2013 due to the continuation of difficult operating conditions in the EU, particularly in construction and automotive. A mild rebound is on the cards for 2014, in line with the expected economic recovery in the EU. As far as the EU steel market is concerned, the late 2012 rise in bookings confirms the likelihood of a “technical restocking” scenario in the first quarter of 2013. Imports are seen remaining at a reduced level, but will not drop any further. Apparent steel consumption will fall again slightly in 2013, before probably improving in 2014.

Simufact Engineering founds subsidiary in India. Software company Simufact Engineering has founded an Indian subsidiary: Simufact India Private Limited in the city of Bangalore. Dr. Gabriel Mc Bainhas been appointed as director of Simufact India. With its software solutions, Simufact primarily aims at metalworking and processing companies. The software simulates forming, welding and mechanical joining processes.

Severstal plans major investments for 2013. OAO Severstal plans to invest US$ 1.3 billion in 2013 to support its growth and long-term competitive strategy. Planned investment at each division is as follows: Severstal Russian Steel US$ 704 million, Severstal Resources US$ 525 million and Severstal North America US$ 107 million, including US$ 60 million invested in the maintenance programme.

International industry news Outotec acquires Scanalyse. Outotec has signed an agreement to acquire Scanalyse Holdings Pty Ltd, an Australian-based software technology company with operations in Australia, Brazil, Chile, and the United States. Scanalyse provides services in process equipment condition and performance monitoring. The acquisition strengthens Outotec’s specialized maintenance services, supporting life cycle solutions and Outotec’s strategy to grow the services business.

CRU present steelmaking cost outlook. A recent paper by business analysis and consultancy group CRU sets out the impact of CO2 charging on the cost structure of the EU steel industry, quantifies the effect on profitability and identifies the reductions in production volume that are likely to occur under different CO2 price scenarios. With the EU Emissions Trading Scheme entered into its 3rd phase on January 1, 2013, steel companies now have to purchase a proportion of the CO2 credits required to maintain production. According to a consultant in steel costs at CRU, there are few available options for steelmakers to mitigate the mounting threat of CO2 costs, and it is believed that the industry, in its current form, will be rendered non-viable. Some restructuring, equivalent to the closure of up to four integrated steelmaking operations, will become necessary as CO2 prices rise. This view is beginning to be recognized more widely, and steelmakers will be asking whether the ‘Action Plan for the European Steel Industry’, currently being drafted by the European Commission and scheduled for release by June 2013, will provide realistic solutions to this looming crisis.

“ Our production processes involve handling CO gases containing sulphur, hydrochloric acid, chlorine and fluorine – an aggressive mixture which has until now resulted in severe corrosion to fans. Venti Oelde has solved this problem for us. With corrosion-resistant alloys for impeller and shaft as well as gas-tight shaftseals. The benefits for us: long service life, high availability and great operational safety.”

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CD International Enterprises expands ore distribution business. CDII Minerals has begun delivery of 10,000 t of iron ore produced in Ecuador to a major Chinese trading company. CDII Minerals purchased the iron ore through a subsidiary of a local Ecuadorean mining operation, and upon successful completion of this shipment CDII Minerals expects to complete negotiations for an ongoing distribution arrangement with the Chinese trading company to ship iron ore from Ecuador into China on a monthly basis. CDII Minerals is a subsidiary of CD International Enterprises, a US-based company that produces, sources and distributes industrial commodities in China and the Americas and provides business and financial corporate consulting services.

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Personalities 0GY UGETGVCT[ IGPGTCN QH +55( The International Stainless Steel Forum (ISSF) has appointed John Rowe as secretary general and member of its exMPT International 2/2013


Ventilatorenfabrik Oelde GmbH P.O. Box 37 09 D-59286 Oelde Phone: + 49 25 22 75 - 0 Fax: + 49 25 22 75 - 2 50

International industry news ecutive board. He is replacing Pascal Payet-Gaspard, who stepped down at the end of 2012. John Rowe was formerly CEO of the ThyssenKrupp group, as well as vice chairman of the Shanghai Association of Enterprises with Foreign Investment.

Rad-Con appoints marketing and sales director. Wynn H. Kearns has joined Rad-Con as director of marketing and sales. Based in the companyâ&#x20AC;&#x2122;s Cleveland office, he will lead ferrous and non-ferrous H2SHCâ&#x201E;˘ bell annealling furnace projects. Prior to joining Rad-Con, Kearns was responsible for NAFTA business development for CMI EFCO in Salem, OH.

New management team at ThyssenKrupp Steel Europe. ThyssenKrupp Steel

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Europe AG has a new management team. The executive board now comprises Dr. Herbert Eichelkraut (responsible for metallurgy), Dr. Heribert Fischer (rolling and coating), Andreas Goss (finance), Andreas Goss Thilo Lutz (sales) and Thomas Schlenz (human resources). Andreas Goss has also taken on the role of executive board spokesman. The position of executive board chairman, held by Edwin Eichler until December 31, 2012, will not be filled.

2CWN 9WTVJ %'1 LQKPU OCPCIKPI DQCTF QH SMS Siemag. Marc Solvi, CEO of Paul Wurth S.A., has been appointed to the managing board of SMS Siemag AG with effect from January 1, 2013. The takeover of the majority share of 59.1% in Paul Wurth by SMS Holding GmbH was finalized on December 17, 2012. Marc Solvi will continue to be in charge of the management of Paul Wurth. Furthermore, he will work with Dr. Guido Kleinschmidt, a member of the managing board of SMS Siemag AG, to coordinate the cooperation between Paul Wurth and SMS Siemag.

powder, copper concentrate, and other ďŹ nes. Briquettes are used for feeding shaft furnaces, BOFs, RHFs, EAFs, and other reduction or melting units.

*WOCP TGUQWTEGU GZGEWVKXG QH #- 5VGGN retires. Lawrence F. Zizzo, vice president, human resources, of AK Steel retired effective March 31, 2013. Lawrence F. Zizzo served in the steel industry for 35 years, joining AK Steel in 2004.

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MPT International 2/2013

States Steel Corporation has named Burt Caldwell general manager, sales, for its North American flat-rolled sales team based in Chicago. Caldwell will replace Michael Meyers, who is retiring after more than 38 years of service with the company. In his new position,

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International industry news Caldwell will assume responsibility for the sales activities for U.S. Steel’s service centre, pipe and tube converter, agricultural and industrial equipment customers.

Ruukki appoints senior vice president. Sami Ärilä has been appointed senior vice president, human resources, and a member of the corporate executive board of Rautaruukki Corporation. Sami Ärilä has been working for Ruukki for approximately five years, most recently as vice president, human resources management.

Changes on Quaker Chemical’s board of directors. Dr. Edwin J. Delattre has decided to retire as a director following nearly 30 years of service on the board of directors of Quaker Chemical Corporation. Effective immediately, Mark A. Douglas has been newly appointed to the board.

1WVWMWORWoU %(1 FGEKFGU VQ NGCXG JKU position. Outokumpu’s chief financial officer Esa Lager has informed the company of his intention to leave his current position by the end of 2013 for personal reasons. Esa Lager has committed to continue in the CFO position until year end to support the on-going company transformation and to ensure successful transition for his successor.

0GY %'1 QH $*2 $KNNKVQP Marius Kloppers will retire as chief executive officer and a director of BHP Billiton on May 10, 2013. Andrew MacKenzie will succeed him and join the board on that date. Marius Kloppers will retire from the group on October 1, 2013.

ArcelorMittal appoints new head of human resources. ArcelorMittal has appointed Henri Blaffart as executive vice president and head of human resources. He replaces Willie Smit, who leaves the company to pursue other opportunities. Henri Blaffart will also become a member of the company’s management committee. Previously, he was chief executive officer of ArcelorMittal Lorraine in France.

U. S. Steel names new plant manager QH (CKTƂGNF 6WDWNCT 1RGTCVKQPU Patrick J. Mullarkey has been named plant manager – Fairfield Tubular Operations, part of United States Steel Tubular Products, located near Birmingham, Alabama. Mullarkey succeeds Dennis Quirk who has retired following 36 years of service. MPT International 2/2013


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International industry news Obituary of Ralph Ridder, managing FKTGEVQT $59 Ralph Ridder, managing director

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

of Badische Stahlwerke passed away last February at the age of 54. During his career of more than 25 years with the Badische group, he acquired a great reputation. His managing philosophy will be carried forward within the group.

The International Tube and Pipe Trade Fair in Russia

Outokumpu appoints senior vice president. Olli-Matti Saksi has been appointed as senior vice president – sales, business area stainless coil EMEA. Saksi has over 20 years of experience within global steel and aluminium companies such as ArcelorMittal and Rautaruukki.


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

26 – 28 June 2013 Ranchi, India Organizers: SAIL

ARCS13. This international conference on “Advances in Refractories and Clean Steelmaking” will cover a wide range of topics and aspects related to the current state and prospects of refractory and steelmaking technology.

4 – 6 September 2013 NanNing, Guangxi, China Organizers: Metallurgical Council of China Council for the Promotion of International Trade

Coking technology and coke market congress. The 11th edition of the China international coking technology and coke market congress will focus on communication and exchanges on technological advances, trade order, investment cooperation and policies in the coke industry.

6 – 8 November 2013 Incheon, South Korea Organizers: Metal Network Korea Company

25 – 28 June 2013 Krasnaya Presnya Moscow, Russia

in conjunction with:


Thermo-Process Expo and Metal + Metallurgy Expo. These concurrently held expositions will cover heat-treatment technology and refractories, furnace and finishing equipment, and equipment for metallurgical processes, the iron, steel and foundry industries as well as casting and forging technology, respectively. MPT International 2/2013


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AISTech 2013 in Pittsburgh, Pennsylvania AISTech 2013 – the Iron & Steel Technology Conference and Exposition - will return to the David L. Lawrence Convention Center in Pittsburgh, Pennsylvania, USA on May 6 – 9, 2013. AISTech 2013 will feature international technologies from the world over, allowing steel producers to compete in today’s global market. The Town Hall Forum and the President’s Award Breakfast are the two most exciting events planned for AISTech 2013. Key industry leaders will be featured, including a keynote presentation by Richard J. Harshman, chairman, president and CEO of Allegheny Technologies, Inc. (ATI).

Association for Iron and Steel Technology (AIST), Warrendale, PA, USA Contact: E-mail:


MPT International 2/2013

Figure 1. Downtown Pittsburgh and the Three Rivers City skyline

AISTech 2013 – the Iron & Steel Technology Conference and Exposition – will incorporate North America’s biggest steel event of the year. More than 10,000 attendees are expected to attend this global event, which will feature technologies from the world over, allowing steel producers to compete in today’s global market. At the conferences more than 400 technical presentations will provide a very comprehensive technical program for the steel industry. In the exhibition hall about 420 exhibitors will display their products and services. Two plant tours will be held in conjunction with AISTech 2013. The U.S. Steel Corp. Mon Valley Works and Timken Co. Faircrest Plant will host the respective tours. As a preliminary, AIST Foundation Golf Classic 2013 has been arranged for Sunday, 5 May, in two sessions, in the morning and in the afternoon respectively, to be held at Chartiers Country Club what is known as a “shot maker’s course”. As in the years before, the Golf Classic has already been sold out early before the event. Marathon alert. The Pittsburgh Marathon will be held on Sunday, 5 May 2013, the day before the formal opening of AISTech 2013. As the marathon can attract upwards of 50,000 people to the city, there may occur a risk for logistical problems that day.

Iron and steel technology exposition The AISTech 2013 exposition is an opportunity to meet face-to-face with the individuals who specify, design, deliver and commission plants and facilities associated with the production and processing of iron and steel. The exhibition will feature more than 420 U.S. and international companies for an unrivaled display of steel technology. Due to increased demand, organizers of AISTech 2013 have expanded the exposition floor to accommodate the growing number of exhibitors for the 2013 show. The exposition will be available for all attendees to explore.

Conference schedule The three day technical program will kick off at 8 a.m. on 6 May with the Howe Memorial Lecture and the International Alliance Lecture, followed by 400+ technical presentations, the President’s Award Breakfast on 7 May and the Town Hall Forum on 8 May. The 2013 Howe Memorial lecturer will be Dr. Veena Sahajwalla, Scientia Professor, associate dean and director at the Centre for Sustainable Materials Research & Technology, University of New South Wales, Australia. Her lecture will describe the opportunities available to iron and steelmakers to utilize waste streams – ranging from polymeric mate-

Events rials to agricultural wastes – as raw materials. The AIST International Alliance Lecture was established in 2008 to provide AISTech conference attendees with an improved awareness of global and regional steel industry developments. Each year, a representative from the various industry trade groups, institutes and professional societies located around the world will be invited to deliver this lecture. The 2013 AIST International Alliance lecturer is Ugˇur Dalbeler, CEO of Çolakoglu Metalurji and deputy chairman of the Turkish Iron and Steel Producers Association. His lecture is entitled “The remarkable growth of the Turkish steel industry”.

Once again, a major highlight of the event will be the Town Hall Forum, which will be held on Wednesday morning, 8 May, at the Convention Center. The Town Hall Forum provides an inside view into today’s business climate from the people who know: a panel of respected leaders from some of the steel industry’s bestregarded companies. The Town Hall Forum’s moderated discussion format gives attendees a deeper understanding of the factors that help determine the direction of not just an individual company, but also the greater steel industry. Those in attendance will have the opportunity to submit questions to the panelists.

Sunday, May 5 Golf Classic 2013 morning session

8 a.m. (start) noon – 4 p.m.

Student plant tour

Golf Classic 2013 afternoon session 1 p.m. (start)

Monday, May 6 8 – 8:45 a.m.

Howe Memorial Lecture AIST International

8:45 – 9:30 a.m.

Alliance Lecture Technical sessions

9:30 a.m. – 5 p.m.

Exhibit hall open

9:30 a.m. – 6 p.m.

Student contests

9:30 – 11:30 a.m.

University/industry round table noon – 1:45 p.m. AIST welcome reception

5 – 6 p.m.

Steel to students reception

6 – 8 p.m.

Tuesday, May 7 8 – 9:45 a.m.

President´s Award Breakfast

9:30 – 11:30 a.m.

ASM materials camp Technical sessions

10 a.m. – 5 p.m.

Exhibit hall open

9:30 a.m. – 6 p.m. 5 – 6 p.m.

AIST welcome reception

President’s Award Breakfast and Town Hall Forum The AIST president, Kent D. Peaslee, will host the President’s Award Breakfast on Tuesday, 7 May, in the Spirit of Pittsburgh Ballroom in the Convention Center. The breakfast program will consist of the presentation of several prestigious association-level awards, including AIST’s Steelmaker of the Year. Richard J. Harshman, chairman, president and CEO of Allegheny Technologies, Inc. (ATI) will address a keynote entitled “Specialty metals: creating value through relentless innovation in a dynamic, global industry”.


MPT International 2/2013

Student activities Students in all disciplines of engineering with a technical interest in the iron and steel industry can benefit from attending this major international conference and exposition. Attending AISTech will procure an introduction to the steel industry and show the advanced technology in modern steelmaking. Attendance will provide opportunities for networking with steel industry leaders and a look at what is needed for a future career in steel. The student schedule includes a plant tour to AK Steel Butler works, an undergraduate student project pres-

Wednesday, May 8 Town Hall Forum

8:30 – 11:30 a.m.

Technical sessions

2 – 5 p.m.

Exhibit hall open

11:30 a.m. – 3 p.m.

Thursday, May 9 Plant tours

7:30 a.m. (depart.)

(This schedule may be subject to change.)

Table 1. Schedule of events

entation contest, and a graduate student poster contest. At the “Steel to Students Reception” students from various universities meet for a brief orientation and reception with representatives from a number of steel companies.


“Others are trying. We are producing. In endless mode.” Giovanni Arvedi, owner of Acciaieria Arvedi SpA and inventor of the Arvedi ESP process. Successful plant operations since start-up in 2009 – implemented with Siemens VAI.

While others are still talking about production in the continuous mode, we are far ahead. Arvedi ESP has been commercially producing hot-rolled strip in real endless mode since 2009. This is possible thanks to the seamless linking of the casting and rolling processes, backed by a full array of patented technological packages and automation systems. But how has Arvedi ESP been setting new benchmarks with this revolutionary technology? The facts: lower investment costs by up to 30% due to extremely compact line length (180 m), hot-rolled strip thicknesses down to 0.8 mm, steel yields in excess of 98%, energy savings of up to 45%, and the production of

highly advanced steel grades (e.g., API x70 pipe grades, multi-phase steels). The result: 25% lower operating costs for the production of thin and ultra-thin hot-rolled strip. Endless production means the world’s most efficient production line for high-quality, hot-rolled strip. Highly competitive production and a wide product mix allows producers to diversify into new market segments. To flexibly respond to changing requirements. To meet tomorrow’s demands with new steel grades. Experts from Arvedi and Siemens VAI will support you to meet your business challenges. Be the leader in the field – with Arvedi ESP.

Answers for industry.

International industry news

Steeluniversity challenge world champions 2013 The World Steel Association announced the new world champions of the 7th steeluniversity challenge. A team from Tata Steel in India won in the category for young steel industry employees, and a team from University of Ljubljana in Slovenia won in the student category.


The grand finals of the â&#x20AC;&#x153;7th Virtual Steelmaking Challenge 07â&#x20AC;? took place in Brussels on 19 February 2013 with the regional champions from the first round competing for the top prize. The task was to refine an order of construction steel grade, which is used in earthmoving equipment. The contestants had two-and-a-half hours to produce the requested steel at minimum cost. The lowest cost achieved at the world championship was $23.13 per tonne. At the end of the highly charged and intense contest, the team consisting of Manjunathan Mohan and Chandra Prakash Sankar from Tata Steel Ltd. India had the best result in the â&#x20AC;&#x2DC;Industryâ&#x20AC;&#x2122; category. In the â&#x20AC;&#x2DC;Studentâ&#x20AC;&#x2122; category the best result was submitted by the team consisting of AndraĹž BradeĹĄko and AnĹžeTekavcË&#x2021;icË&#x2021; of University of Ljubljana, Slovenia. The two teams were declared World Champion in their respective categories. The World Champions in the industry and student categories were awarded trophies, cash prizes and certificates by Alexey Mordashov, chairman of worldsteel and general director, Severstal JSC. The regional champions received certificates. The contest was watched by the steel industry leaders with great interest. Alexey Mordashov, who presented the trophies and certificates, said: â&#x20AC;&#x153;I am delighted to meet â&#x20AC;&#x2DC;the next generation of Bessemersâ&#x20AC;&#x2122; here today. The future of the steel industry lies in the areas of innovation and high-technology development,

which will be driven forward by the winners today. The steel industry offers great career opportunities for those who wish to help society to meet its future sustainability challenges.â&#x20AC;? Dr Edwin Basson, director general of worldsteel, said: â&#x20AC;&#x153;Steeluniversity provides sophisticated e-learning materials covering steel applications, processing, ferrous metallurgy, sustainability and safety. Over the last 10 years more than 23,000 registered users have benefited from this comprehensive collection of elearning resources. In the successful first round in November 2012, 1,148 talented entrants from 30 countries worldwide competed for the title of regional champion within 5 geographic areas. This is an impressive increase of 76% compared with last yearâ&#x20AC;&#x2122;s event.â&#x20AC;? Manjunathan Mohan and Chandra Prakash Sankar, the champions in the industry category, said: â&#x20AC;&#x153;The challenge not only taught us â&#x20AC;&#x2DC;flexibilityâ&#x20AC;&#x2122; in devising strategies but also gave us a great opportunity to meet many industry experts and share our knowledge. We think the modules of steeluniversity are very helpful especially for students and young engineers in the steel industry.â&#x20AC;? AndraĹž BradeĹĄko and AnĹže TekavcË&#x2021;icË&#x2021;, the student champions, said: â&#x20AC;&#x153;Team work and practice are the two key elements for our achievement at the challenge today. We are very proud of being the global champions of this exciting and remarkable challenge.â&#x20AC;?

Word Steel Association, Brussels, Belgium Contact: E-mail:


MPT International 2/2013

Figure 1. Champions of the 7th steeluniversity challenge 2013

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MPT International 2/2013

In the first quarter of the 2012/2013 fiscal year (October 1 – December 31, 2012) ThyssenKrupp’s orders from continuing operations amounted to 9.6 billion euros, level with the prior year despite the divestments. The capital goods businesses reported 14% growth yearon-year. The business areas Plant Technology and Elevator Technology each achieved record orders: While plant orders more than doubled, elevator orders were up by a strong 10%. However, weak demand and low prices weighed on the Materials business area. The group’s sales were 8% lower at 8.8 billion euros. While the capital goods businesses (Plant Technology and in particular the Elevators business area) reported significant growth, sales of industrial components and materials declined on account of divestments and conditions on the market. All business areas posted positive adjusted EBIT. Adjusted group’s EBIT from continuing operations came to 229 million euros in the first quarter of the current fiscal year, compared with 372 million euros in the prior-year quarter. The earnings target for the first quarter 2012/2013 – adjusted EBIT from continuing operations of around 200 million euros – was achieved in full. Earnings after tax attributable to ThyssenKrupp’s shareholders came to 29 million euros. Free cash flow from continuing operations, i.e. the sum of operating cash flows and cash flows from investing activities, amounted to 736 million euros, an improvement of around 2.1 billion euros against the year-earlier quarter reflecting the group’s efforts to optimize the structure of its cash flow profile. Free cash flow for the full group improved by around 2.4 billion euros year-on-year to 361 million euros. The costs of discontinued operations were comfortably offset by cash inflows from the successful closing of the stainless steel transaction. As a result, ThyssenKrupp also made progress with reducing its net financial debt. At December 31, 2012 this was 600 million euros lower quarter-on-quarter at 5,205 million euros (September 30, 2012: 5,800 million euros). With avail-

able liquidity of altogether 7.4 billion euros and a balanced maturity structure, ThyssenKrupp is solidly financed. Dr. Heinrich Hiesinger, executive board chairman of ThyssenKrupp AG: “We are well on track to achieve our operating targets for the full year. However, we cannot be satisfied with the group’s current earning power. The ‘Strategic Way Forward’ optimization programme is aimed at significantly improving the group’s value potential, and we will continue to work vigorously towards this goal. All the group’s businesses must contribute to this.”

2GTHQTOCPEGQHVJGDWUKPGUU CTGCU At %QORQPGPVU6GEJPQNQI[ the disposals of the previous fiscal year in connection with the strategic development programme resulted in a structurally lower volume of business in the first quarter 2012/2013. Order intake was 26% down from the prior-year quarter at 1.3 billion euros, sales were 23% lower at 1.3 billion euros. Excluding the disposals, order intake was 9% and sales 6% lower. At 42 million euros adjusted EBIT was down from the prior-year quarter (103 million euros). This reflected the absence of Waupaca’s operating profit, the slowdown in the Western European market for car and heavy truck components, and the ramp-up of the new plants in China and India. Added to this was continued weak demand in the wind energy and infrastructure sectors. 'NGXCVQT 6GEJPQNQI[ achieved double-digit growth rates in the first quarter 2012/2013, with order intake of 1.6 billion euros (up 10%) and sales of 1.5 billion euros (up 14%). Adjusted EBIT came to 169 million euros (prior year: 142 million euros). This improvement resulted from both increased sales and positive effects from the restructuring measures initiated in the last fiscal year. The business area continued its growth track with the closing of the takeover of AMCO Elevator, USA, on December 31, 2012.

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2NCPV 6GEJPQNQI[ performed particularly well in chemical plant construction. In the first three months new orders were won with a total value of 1.8 billion euros, double the prior-year figure. Sales were 6% higher than a year earlier at 1.0 billion euros. Adjusted EBIT at 110 million euros fell short of the high prior-year level (125 million euros) due to billing technicalities. /CTKPG5[UVGOU continued to profit from increased demand for frigates and submarines. Order intake in the reporting period came to 178 million euros, and sales to 305 million euros. At 30 million euros adjusted EBIT was level with the prior-year quarter minus the civil shipbuilding operations, which were included a year ago and have since been sold. Effective January 1, 2013 Plant Technology was combined with the Marine Systems business area to form the new Industrial Solutions business area. /CVGTKCNU 5GTXKEGU With the exception of North America, business was marked by declining demand and global price and margin pressure. Sales were 10% lower at 2.8 billion euros. Excluding the Xervon group contained in the 40

MPT International 2/2013

prior-year figures, sales fell by 7%. The materials and logistics business for the aerospace industry performed well. Despite the significant slide in sales, adjusted EBIT was level with the year-earlier period at 40 million euros thanks to cost reduction measures, particularly in logistics and administration. 5VGGN'WTQRG Low shipments and declining prices continued to weigh on business at Steel Europe. Sales in the first three months came to 2.3 billion euros. Adjusted EBIT fell to 30 million euros (prior year: 102 million euros) as a result of the persistent weakness of the European market and a year-on-year decrease in selling prices. The groupwide improvement programme impact was once again only able to partly offset the negative cost and margin effects.

+PQZWOVTCPUCEVKQP EQORNGVGFUCNGQH5VGGN #OGTKECUQPVTCEM ThyssenKrupp made further important progress with its strategic development programme in the first quarter 2012/2013. The combination of Inoxum, the former Stainless Global busi-

ness area, and the Finnish stainless steel manufacturer Outokumpu was successfully completed on December 28, 2012 and contributed to a reduction in net financial debt. The sale of Steel Americas is proceeding to plan. Since November 2012, a selection of potential buyers have had the opportunity to analyze the plants in Brazil and the USA in a due diligence process and submit binding purchase offers. ThyssenKrupp is confident of finding a new way forward for both plants before the end of this fiscal year. The proceeds from the sale will significantly reduce net financial debt.

1RVKOK\CVKQPRTQITCOOGCV 5VGGN'WTQRGDWUKPGUUCTGC Under the corporate programme impact, a cumulative EBIT effect of 2 billion euros is to be generated from performance measures in this and the next two fiscal years. In this context, the Steel Europe business area has developed a package of measures to sustainably improve profitability and competitiveness. Far-reaching structural adjustments and operational improvements are urgently needed to permit the continued run-

%QORCP[RTQĆ&#x201A;NG ning of the core units in the hot end operations and the hot rolling lines. As well as advantages in purchasing, this includes efficiency improvements in the production and administration processes. In addition, the company is looking into the closure, relocation or sale of business units and facilities. These measures relate to: - coil coating line No. 1 in DuisburgBeeckerwerth, - one of the two electrolytic coating lines at the Dortmund plant, - the cold-rolling and coating plant in Neuwied, - the grain-oriented electrical steel products of ThyssenKrupp Electrical Steel, and - the hot-dip galvanizing line of ThyssenKrupp Galmed in Spain. The optimization programme aims to achieve a savings volume of around 500 million euros by the 2014/2015 fiscal year and includes the socially responsible reduction of the workforce by more than 2,000 employees. This will also affect the administration at the Duisburg headquarters. As a result of possible disposals, the number of employees could be reduced by a further 1,800. (December 31, 2012: around 27,600 employees) With this optimization programme, the Steel Europe business area will make an important contribution to the corporate programme impact and to improving the performance of the group as a whole. Heinrich Hiesinger commented: â&#x20AC;&#x153;With its optimization programme, Steel Europe has taken an initial forceful step towards improving its position in a difficult competitive environment and achieving the required profitability and capital efficiency.â&#x20AC;? ThyssenKrupp Steel Europeâ&#x20AC;&#x2122;s technical and logistical capabilities are to be optimized so as to expand its market share in specific product groups and specific sectors. For this

a particular focus will be on innovation, customer orientation, and high-performance logistics.

%JCPIGUKPNGCFGTUJKROQFGN CPFNGCFGTUJKREWNVWTG To strengthen the performance of the group and enhance its corporate culture, a new leadership model is being created. A matrix organizational structure is being introduced to optimize the way business units, functions and regions work together. With the reorganization of the executive board effective January 1, 2013, structural changes have already been implemented. According to their function the business area management board members now report directly to the chief executive officer, the chief financial officer, or the chief human resources officer of ThyssenKrupp AG. At February 1, 2013 the previous corporate functions were reduced and reorganized. In the future each corporate function will bear global responsibility for standards and processes. The business areas will have central functions analogous with the structure at group level to optimize cooperation between the group and business areas. In the coming months all further structures and processes will be planned in detail, also to include the regions. The group plans to begin working in this new structure from October 2013. Effective March 31, Gerhard Cromme (70) has stepped down as chairman of the supervisory board of ThyssenKrupp AG. He also steps down as vice chairman of the board of trustees and as a member of the Alfried Krupp von Bohlen und Halbach foundation. Having served in different leadership roles at Krupp and the respective successor companies for









more than 27 years, Cromme has distinctly shaped the landscape of the German steel industry. Ulrich Lehner was elected to become the new chairman of the supervisory board of ThyssenKrupp AG. Lehner, who has been a member of the supervisory board of ThyssenKrupp AG since 2008, has already announced to restructure the supervisory board parallel to the strategic way forward of the group and that corporate governance and compliance will become core areas for the future work of the supervisory board.

1WVNQQM Heinrich Hiesinger resumes: â&#x20AC;&#x153;As a group we want to be able to respond much faster and more flexibly to changing market conditions in the future so as to profit more from the dynamic developments in the worldâ&#x20AC;&#x2122;s growth regions.â&#x20AC;? Based on the assumption of stagnation for the most parts in the core markets of the more cyclical materials and components businesses, where in the current economic environment visibility does not extend much beyond a quarter, ThyssenKrupp expects the groupâ&#x20AC;&#x2122;s sales from continuing operations to remain at the prior-year level of around 40 billion euros in fiscal year 2012/2013, provided there are no major dislocations on the raw materials markets. Sales lost due to portfolio measures, in particular at Steel Europe and Components Technology, should be largely offset by organic growth in the capital goods businesses. Assuming that the slower activity on the materials markets at the beginning of the new fiscal year compared with the prior year continues but does not progressively worsen, adjusted EBIT from the groupâ&#x20AC;&#x2122;s continuing operations should be around 1 billion euros.

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Figure 1. Panorama view at the Ruukki Raahe works, Finland

Finnish Ruukki has drastically reduced environmental impact at the Raahe works The changeover to pellets as feedstock for ironmaking and the related closure of the sinter plant together with KMPCCDjAGCLRBCBSQRGLE technology at the blast furnaces F?TCPCQSJRCBGL?QGELGjA?LR decrease in emissions at Ruukki’s Raahe works. All in all, the changes of processes and technologies reduced particulate emissions last year in line with targets. Ruukki Metals has started developing new grades of iron pellets to further GKNPMTCRFCMTCP?JJCDjAGCLAW of the ironmaking process.

Ruukki Metals Oy, Raahe, Finland Contact: E-mail:


MPT International 2/2013

Process changes and replacement of dust removal devices reduced particulate emissions at Ruukki’s Raahe works significantly last year in line with targets to result in an emissions reduction of over 80% compared to 2011. The decrease in emissions was especially attributable to: - the changeover to pellets as feedstock, - the related closure of the sinter plant and - replacement of the dust removal devices in the blast furnaces at the steel mill. In addition, the closed cooling water circulation system in blast furnace slag granulation has considerably reduced the discharge of suspended solids into the sea. “Regular emissions measurements indicate the fall we sought in particulate emissions in all measurement results,” reports Pirjo Lerssi, environmental manager at the Raahe works. Particulate emissions at the works have decreased by almost 84% since 2011. Modernization of the dust removal devices in the blast furnaces reduced their particulate emissions by 68% compared to previous years. Switching over to the use of iron pellets has reduced the processing of dispersoids. This in turn has resulted in a decrease of 16% in fugitive dust emissions. Dust contains heavy metal particles, which decrease as dust decreases. Emissions of sulphur dioxide into the air were just a quarter of what they were in 2011. In practice, hydrogen sulphide emissions have

also been practically eliminated. Likewise, carbon dioxide emissions have decreased by around a further 10%. “Everyone at the works is delighted that our efforts for the good of the environment and the works environs have had such a notable impact,” Pirjo Lerssi adds. Ruukki has been actively working to reduce emissions at the steel mill by investing in environmental technology and by improving production processes. Ruukki’s steel production has already ranked higher than the European average in terms of carbon dioxide efficiency. In addition, both blast furnaces at the works have for years ranked among the most energy efficient in Europe. Ruukki continues to work on eco-efficiency at the Raahe steel mill. Work is currently under way on a dust removal system at the steel plant to collect fugitive dust emissions. The system is expected to reduce fugitive dust emissions and to further improve the air quality in the environs of the works.

Studying new grades of pellets together with partner from Russia Ruukki Metals has initiated cooperation with Russian PJSC Karelsky Okatysh, a fully-owned subsidiary of the Severstal Group, to develop new grades of iron pellets. New grades of pellets developed by Karelsky Okatysh are

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Ironmaking to be tested in the laboratory at Ruukki’s Raahe works in Finland. Tests will also be conducted at the University of Oulu in the laboratory of process metallurgy, which can simulate blast furnace conditions. “Ruukki will provide a testing laboratory environment meeting international standards in the project and Karelsky Okatysh will manufacture different

grades of pellets for us to test. This development project is the interest of both Karelsky Okatysh, who are developing the pellet grades, and us, as users of iron ore pellets,” says Erkki Pisilä, director for the development of hot metal production and operations control at Ruukki’s Raahe works. Ruukki sources most of the pellets from Sweden. In spring last year, Ruuk-

ki signed a three-year contract for supplies of coking coal and iron pellets with Severstal Resources, a division of the Severstal Group. The goal is to reduce dependency on distant coking coal, to spread purchases of raw materials, and to improve the overall efficiency of the steel-making process, where development of the blast furnace charge material is an important factor.

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MPT International 2/2013



Tata Steel restarts Port Talbot blast furnace Tata Steel has restarted its second blast furnace at the Port Talbot steelworks in the UK following the completion of a £185 million (approx. US$ 275 million) rebuilding project. The restarting of blast furnace No. 4 – the UK’s largest industrial engineering project last year – will improve Tata 1RCCJQMNCP?RGML?JkCVG@GJGRW and enable it to better serve customers in the UK and the rest of Europe.

This QR links to a BBC video clip on YouTube about the Port Talbot blast furnace rebuild:

Tata Steel Europe Ltd., London, UK Contact: E-mail:

With the main steelmaking operations in UK and Netherlands, Tata Steel comprises Europe’s second largest steel producer. At the Tata Steel Port Talbot works in Wales (UK), blast furnace No. 4 was decommissioned in July 2012 before being completely rebuilt, incorporating the latest technology to improve energy efficiency, environmental performance, safety standards and capacity. The requirements of Tata Steel’s customers were central to the rebuild project. The furnace has enhanced health, safety and environmental care facilities, making it a worldwide standard-setter as one of the most efficient in the world. The state-of-the-art new furnace is more efficient and will allow Tata Steel to continue to meet the demanding requirements of UK and European manufacturing industries. Production has now started and the molten iron from the furnace will be converted into high-quality steel for a wide range of customer sectors, including construction, automotive, lifting and excavating, domestic appliances and packaging. Karl Köhler, CEO of Tata Steel’s European operations, said: “This rebuild has been a flagship investment, part of our strategy for long-term competitiveness in UK, EU and worldwide markets. The efficiency and sustain-

Figure 1. Rouha Hussaina lighting the rebuilt blast furnace


MPT International 2/2013

ability of the new furnace will also make a major contribution to our efforts to create an ‘all-weather’ company in Europe. We have been able to take advantage of a period of low steel demand to carry out this major engineering project and we are still operating today in an intensely challenging commercial environment. Restarting the furnace will help us improve our delivery performance which will enable us to better serve our customers, but we will continue to manage our output at levels appropriate to market conditions.” The rebuilt blast furnace was lit by Rouha Hussaina (figure 1) who joined Tata Steel in 2007 as a mechanical engineer from Bath University. Originally from Hyderabad in India, she now lives in Cardiff, and has been seconded as a furnace top project engineer on the rebuild. Rouha said: “To be asked to light the furnace is such an honour, especially when all around me were people with so many years’ experience, but it’s something I’ll never forget. My family are extremely proud of me.” Further energy and environmental benefits will be gained from the recently-completed £55 million (approx. US$ 85 million) energy-from-heat scheme at Port Talbot’s steelplant which will save 10 MW of energy – enough to power 20,000 homes. Michael Leahy, general secretary of the community trade union and chair of the UK trade unions’ steel committee, said: “The project’s completion is a source of great pride and hope for the future of steelmaking in the UK. The blast furnace project created many jobs for local contracting firms, providing a real boost to the South Wales economy at a difficult time. Longer term, the rebuilt furnace marks the start of a new era of sustainable steelmaking in the UK.” The start-up of the new furnace has enabled Tata Steel to restart its second hot strip mill in South Wales. In anticipation of the furnace restart, the Llanwern hot strip mill resumed production in December 2012. The restarts give the company greater operational flexibility and enable it to better serve its customers.

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2QVGPVKCNCPFFKHĆ&#x201A;EWNVKGUQHJGCVTGEQXGT[KPUVGGN RNCPVU In EAF steelmaking the off-gas provides the biggest potential for heat recovery. Depending on the temperature at the lower end of the off-gas duct and the control of dilution air, a big share of this energy content can be recovered. Depending on technology and contradictory to widespread opinion, steam buffering is not an issue here. In almost any case, it is possible to avoid the need for superheated steam and it is economically more favourable to generate power.

'PGTI[RQVGPVKCNQHQHHICU Talking about heat recovery in the EAF steel plant means talking about heat recovery from the EAF off-gas. (KIWTG  shows the energy balance of a typical 150 t stainless steel producing EAF [1]; the energy losses in the off-gas are the biggest losses by far. Heat recovery from cooling water is an interesting option especially for Consteel furnaces with their reduced mechanical stress for the shell and roof, but in this article the focus will be the EAF off-gas. When the EAF heat recovery potential is in the off-gas, the first questions are of course: How much energy is in the off-gas? How do you evaluate figures like the example given above? The answer is: Typically not by measuring. Experience shows that hardly any steel plant has a reliable system in place for measuring off-gas temperatures (at least not at the fourth hole), and not many steel plants have a measurement system for the off-gas flow. The simple formula â&#x20AC;&#x153;energy content = temperature x flowâ&#x20AC;? is simply not applicable. In some cases it may be possible to reverse calculate the off-gas energy by different indicators: If the flow rate and temperature difference (Delta T) of

the cooling water of the off-gas duct is measured, as well as the water consumption of a quencher and the off-gas temperature at the bag house inlet, this takes you rather close to the amount of energy contained in the off-gas at the fourth hole. But firstly this is not very precise and secondly not even this method is always applicable. Quite a few cooling systems have no system in place to measure how much cooling water goes to the shell, roof or duct. It was simply not necessary in the past, so why should it have been installed? The off-gas energy content has become interesting since increasing energy prices have created awareness of energy efficiency. Searching for reliable conclusions, Tenova engineers developed a different way: the off-gas energy content is to be determined from the energy input via a mass and energy balance. Whereas data about the off-gas is hardly available, most steel plants have very exact data about what is fed into the EAF. Based on the mathematical models of Tenova Goodfellow, developed for EFSOP and iEAF, the process engineers of Tenova Re Energy developed a sophisticated mass and energy balance that allows very exact conclusions to be drawn

Carsten Born, Ralf Granderath, 6GPQXC 4G 'PGTI[)OD*, DĂźsseldorf, Germany Contact: E-mail:


MPT International 2/2013


QUINTOLUBRIC® 888-68 FIRST APPROVED FIRE-RESISTANT POLYOL ESTER-BASED HYDRAULIC FLUID BY STEEL INSTITUTE (VDEh) The Fluid Power world is changing. Safety and Environmental demands are becoming more severe. This means that leakages are reduced to a minimum and endurance of the hydraulic fluid is challenged to the max. To combine Safety through fire-resistance, Environment protection through biodegradability and Effectiveness through extended service life without jeopardizing the performances of your hydraulic unit, you need Quaker. We’ve been the leading supplier for fire-resistant polyol ester-based hydraulic fluids for more then 50 years. We are in use at the biggest names in heavy industry. No surprise Quaker is the first company meeting the severe requirements (SEB 181 224) set by the Steel Institute (VDEh). At the heart of the heavy industry, you’ll find QUINTOLUBRIC® 888. It’s what’s inside that counts. |

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Steelmaking as to the off-gas energy content of different EAFs and even of different melts of the respective EAFs. The results were compared with measurements and reverse calculations â&#x20AC;&#x201C; as far as available. The results fit very well. These results allow classifying EAFs into off-gas energy content categories by size and operation scheme. 6CDNGU CPF show typical energy outputs in kWh per ton of liquid steel for different EAFs grouped by size and operation scheme. 6CDNG shows values calculated for numerous EAFs between 80 â&#x20AC;&#x201C; 120 t tapping weight. 6CDNG shows the corresponding values for EAFs between 121 â&#x20AC;&#x201C; 160 t tapping weight; it is easy to see that the bigger furnaces have a small, nearly negligible advantage in terms of specific energy consumption. Much bigger influence has the mode of operation. EAFs that consume predominantly electrical energy have a significantly smaller specific energy consumption, DRI feeding (85% DRI, 15% scrap) significantly increases the specific energy consumption. However, this is only a technical value. Since the relative prices of the different types of energy are not given in these tables, at lower operation costs specific energy consumption can still be higher. The answer to the question as to the heat recovery potential of EAFs is that most top-charged and scrap-fed EAFs have 180 â&#x20AC;&#x201C; 220 kWh/tls energy content in the off-gas.





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MPT International 2/2013

chemical energy


5VCIGQTUVCIGQHJGCV TGEQXGT[VGEJPQNQI[! To determine how much of the content as described above can be decoupled in a heat recovery system, heat recovery technology may be shortly regarded in general. Heat recovery for industrial furnaces â&#x20AC;&#x201C; independent of the furnace type â&#x20AC;&#x201C; in the first place means steam production. Especially for the EAFs a milestone was set in 2009 when Tenova implemented heat recovery for



chemical energy

the EAF of GeorgsmarienhĂźtte GmbH in Germany, with the new iRecovery technology [2]. Compared to conventional cold water cooling an iRecovery off-gas duct is a tube-tube construction with the same look and the same working principle. The main difference is the pressure and temperature level inside; while cold water cooling typically uses 20 â&#x20AC;&#x201C; 40°C, an iRecovery system works with water of approx. 180 â&#x20AC;&#x201C; 250°C towards the ducting and decouples the




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Steelmaking off-gas energy through the process of evaporation. iRecovery off-gas ducts (also called iRecovery stage 1) work with radiation heat transfer which is efficient down to approx. 600°C. Below this temperature, heat transfer by convection becomes more effective. In other words, a waste heat boiler must be used to recover the energy between approx. 600°C and a filter inlet temperature of 180 â&#x20AC;&#x201C; 250°C (also called iRecovery stage 2). Due to the extremely high dust load of EAF off-gas, the design of the waste heat boiler must be planned very carefully; solutions for similar situations can be found at waste incinerators. (KIWTG gives a schematic illustration of the two stages of EAF heat recovery.

A main difference between the cooled duct and the waste heat boiler is that energy decoupling is of utmost importance â&#x20AC;&#x201C; either by iRecovery or a cold water cooling â&#x20AC;&#x201C; where the waste heat boiler is optional; since off-gas temperatures below 600°C do not damage mild steel, it is not only possible to use waste heat boilers to recover energy but also trombone coolers or quenching. A significant parameter for the heat recovery potential is, of course, the offgas temperature at the iRecovery system outlet. It is important to keep in mind that the replacement of a cold water cooled duct is a must, but the potential for heat recovery is increased with an iRecovery waste heat boiler.


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usable without dilution air control (450°C)





usable without dilution air control (430°C)





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at the 4th hole


usable without dilution air control (600°C)








usable without dilution air control (450°C)





usable without dilution air control (430°C)





usable without dilution air control (315°C)








MPT International 2/2013

4GFWEVKQPQHFKNWVKQPCKT Most EAFs today suck in a large amount of dilution air at the fourth hole; in many cases this is not so well controlled or measured. In the past this was perfectly logical; the only purpose of a cooling system was to reach the acceptable inlet temperature for the bag house as simply and fast as possible; mixing in dilution air is an effective way to reach this. This resulted in a relatively high volume flow at the bag house, what was acceptable since otherwise the technological effort was reduced. However, when talking about heat recovery potential, the reduction of dilution air is a central issue. The logic is as easy as it was in the past, just the other way round. Dilution air is sucked in at ambient temperature, e.g. 10°C. It leaves the iRecovery system at around 200°C, in other words the energy content between 10°C and 200°C for the given amount of dilution air is wasted. If an amount of 80,000 mÂł/h (s.t.p.) off-gas (burned natural gas) at 1,500°C is sent through an iRecovery system where it cools down to 250°C, approx. 7 MW of energy remain in the off-gas. If the same amount of off-gas is mixed with 100,000 mÂł/h (s.t.p.) of dilution air to 700°C before entering the iRecovery system, approx. 15.5 MW of energy remain in the off-gas at 250°C, the systemâ&#x20AC;&#x2122;s efficiency is reduced by about 22%. (KIWTG illustrates the combined influence of outlet temperature and dilution air control, here expressed as controlled oxygen content. Dilution air cannot be reduced to zero since it is required for post-combustion. The efficiency (de-

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coupled energy by iRecovery – energy content at the fourth hole) in this case is 55%. This is already an example with controlled oxygen content; in reality it can easily be worse. The exit temperature after duct 3 (last cooled duct) is 476°C. (KIWTG  shows the same parameters but with dilution air reduced to an amount of 6% after combustion. The value of 6% is a good and safe compromise that guarantees a complete combustion under all circumstances but still a good efficiency for the iRecovery system. The system reaches an efficiency of 75% with an exit temperature after duct 3 of 432°C. (KIWTG indicates the difference when additional convection-type heat transfer surfaces are built into draft 4 (PCC 4). In this case the convection heat transfer surfaces are placed behind the cooled duct due to space restrictions. The additional heat transfer surface is integrated in the post-combustion chamber (PCC), achieving an outlet temperature of 317°C. Basically with a complete iRecovery stage 2, the outlet temperature can be reduced even lower, but already with this value the efficiency is at 81%.

5WOOCT[QHVGEJPKECN RQVGPVKCNHQTJGCVTGEQXGT[ As explained above, three main factors determine the heat recovery potential of an EAF: - the operation scheme, which determines the overall energy content of the off-gas, - the targeted off-gas temperature behind the iRecovery system, - the control of dilution air. 56

MPT International 2/2013

The EAF size obviously influences the total energy content in the off-gas. However, its contribution to the respective values per t of liquid steel is quite low. The results are given in separate tables for an EAF with a tapping weight of 100 t and for an EAF with a tapping weight of 150 t VCDNGUCPF .

&KUEQPVKPWQWUUVGCOUWRRN[ HTQOCDCVEJOQFGHWTPCEG Possibilities and challenges of finding the right steam demand have already been discussed earlier [3]. Still two main issues must be mentioned for the discussion to follow: - Most heat sinks for steam require a continuous steam supply. - This is especially valid when power generation is part of the steam use concept. It is sometimes put forward that this requirement makes power generation from an EAF impossible, at least without an additional burner for the poweroff time of the furnace [4]. This is not the case. To bridge the power-off time, there is a set of tools to homogenize the steam output from a batch-mode furnace. 5NKFKPIRTGUUWTG During the power-on time of the EAF the pressure rises with the effect that a part of the absorbed energy heats the water that would evaporate at the lower temperature. During the power-off time the pressure will sink leading to evaporation although no new energy is brought into the system. The lower end of the pressure sliding range is determined by the steam demand, i.e.

when steam of 14 bar is required, the pressure slide will be set to 15 – 30 bar. 4WVJ DWHHGTU can be integrated into the system. Ruth buffers are big pressure vessels that store energy in hot water which is released as steam when the pressure drops; in other words, they provide additional storing capacity when the sliding pressure is used. Also the steam drum can and should be designed bigger than necessary for the same steam production with a continuously working furnace [5]. 9CVGTVGORGTCVWTG The typical feed water temperature for boiler systems is 105°C. In an iRecovery system the temperature can vary between 105°C and e.g. 180°C; during the peaks of the power-on time energy is used to heat the feed water, thus leading to less energy required for evaporating the feed water in the steam drum during lower energy output of the EAF. With these instruments the power-off time can easily be bridged, even with a 100% flat steam output. Experience shows that the buffering capacity of an iRecovery system should be bigger than the planned power-off time since the start of a melt is always a critical point, where various problems may delay the process for a couple of minutes. As a matter of course, for each specific project it must be carefully checked what the consequences of an interruption to the steam supply are, which backup steam supply is available and which triggering time for the start of the backup is required etc. For example, a five minutes interruption to the en-

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Buffering capacity, t





ergy supply is less critical for a district heating plant than for an air separation plant. 6CDNG gives the required amount of buffering for three exemplary EAFs. None of the described recommended capacities would be a problem to realize.

5CVWTCVGFXUUWRGTJGCVGF UVGCO As explained above, buffering steam for a continuous steam supply is common practice, however with one reservation. It is not a problem to buffer steam, but it is not possible to buffer superheated steam. Steam cannot be superheated in the presence of liquid water, and the sliding pressure method binds the offgas energy in the water that will be released as steam in a low energy phase. So there is always water present. First a difference must be made between “slightly” superheated steam and “seriously” superheated steam. Some processes require steam which is e.g. 5°C above the steam saturation curve. This requirement typically has nothing to do with energy content but it is to make sure the steam is definitely dry steam. A

typical example is a steam piping where steam is transported over a distance of some hundred metres, without allowing any condensing to occur during this passage. This “slightly” superheated steam can even be generated from buffered steam – although this was considered impossible before. This is demonstrated by the following example: If the requirement is steam of 187°C at 10 bar (where saturated steam at 10 bar has 184°C) the lower point of the sliding pressure is set to 13 bar (which correlates to a boiling point of 195°C). When steam is released now, this would be typically done at 13 bar and 195°C. In the example, it is however released at 10 bar, with the result of 3°C superheated steam. But this is not the typical case for power generation using a steam turbine. A steam turbine may require steam of e.g. 50 bar and 450 – 500°C, where the temperature of saturated steam at 50 bar is 264°C. In this scenario it remains true that superheated steam cannot be buffered. Possible strategies to solve this issue are: - use of an external superheater during power-off time, - avoiding the need for superheated steam.



MPT International 2/2013

'ZVGTPCN UWRGTJGCVGT There are two possibilities of external superheating: - using another heat source on the plant, e.g. a walking beam furnace which operates continuously for superheating, - using a burner in the heat recovery system. The first option, i.e. to use another furnace as heat source, is feasible – and recommendable – if various prerequisites are fulfilled: The other heat source must provide off-gas at a sufficient temperature level; with off-gas of 400°C, it is impossible to superheat steam to 500°C. Furthermore, the other heat source should always be available when the EAF is operating; sometimes problems may result from different shutdown times for maintenance, and dependencies between the different processes may be created. The EAF and the other heat source are placed within a sensible distance from each other. The basic idea of this option is simple and convincing. However, the realization is unfortunately often not that easy. The second option, the use of a burner in the heat recovery system, is always possible, but not recommendable. Technically it is not a challenge at all: The burner can be placed in the duct before the heat transfer surface that is designed as superheater. The burner is switched on when the furnace goes into the power-off mode or into phases producing low temperature off-gas. The problem is the economics. Superheating steam for typical needs of a steam turbine uses up approx. 12 – 15% of the energy of the saturated steam. As a rule of thumb, 3 MW of natural gas are needed to superheat 20 MW steam. But this does not mean that a 3 MW natural gas burner is sufficient.



THE Tapping Technology TMT â&#x20AC;&#x201C; Tapping Measuring Technology Sàrl 32%R[//X[HPERXUJÂ&#x2021;UXHGC$OVDFH//X[HPERXUJ 3KRQHÂ&#x2021;)D[Â&#x2021;(0DLOFRQWDFW#WPWFRP 0DQDJLQJ'LUHFWRUV'LSO,QJ$UQR'LHQHQWKDOÂ&#x2021;'LSO,QJ&ODXGH%RGHYLQJÂ&#x2021;9LNPZ[YH[PVU5V)  



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Steelmaking Assuming the burner produces offgas of approx. 1,200°C, only the portion down to approx. 550 – 600°C can be used for superheating; in other words approx. 50% of the natural gas energy is still in the 600°C off-gas after superheating. This will cause additional evaporation during power-off. The positive effect is that the need for steam buffering is reduced. Additionally, the question is how efficiently the burner will work if installed in a duct for a much bigger volume flow. Eventually, for a 20 MW heat recovery system a burner of 6 – 8 MW will be required. According to different studies by the authors, this burner would not only have to be switched on during power-off but also during other phases of relatively cold off-gas during a melt. Hence, the burner would be working during approx. 25% of the furnace operation time. And here is the problem. Assuming an electrical efficiency of 30%, the output would be 0.3 x 20 MW = 6.6 MW electrical energy. In other words, for almost 25% of the time you would put in the same amount of primary energy as you would gain in electrical energy. This would drastically affect the amortization of the whole project. #XQKFKPIUWRGTJGCVGFUVGCO The alternative is to generate electrical energy without the need of superheated steam. This does not mean running a steam turbine that uses saturated steam, because these machines have a very poor efficiency of approx. 10%. There is an alternative called ORC (organic rankine cycle) turbine. These machines have become proven standard in biomass or waste incinerator power stations. They offer a range of advantages if used in industrial waste heat recovery projects. The main advantage is that the turbine cycle is a closed loop using an organic work fluid. The steam’s heat is fed in over a simple heat exchanger. This is the reason why the question of superheating does not need to be discussed here. Apart from steam you can also use hot water or e.g. thermal oil to feed energy into the turbine cycle. Additional advantages of this technology are: - fully automated start-stop system, - only little training of the staff is required, - very low maintenance effort, - very good partial load factor (relevant when power generation follows a varying demand for process steam with changing steam supply for the turbine), - robust system. 60

MPT International 2/2013

These advantages add up to a significantly lower total cost of ownership compared to a steam turbine. Additionally the system design for iRecovery is easier and therefore investment costs are lower. The disadvantage is the lower electrical efficiency. ORC will not reach more than 20 – 25%. Still, after various comparative calculations by the authors the overall profitability of an ORC system is better for projects with a potential of up to approx. 50 MW thermal energy – where the avoidance of superheated steam is an important factor.

dized as such, for example as in the case of wind energy. This is a very sensitive issue as regulations may be different in different countries. Sometimes, if it is not possible to qualify for subsidization of the produced energy, it still may be possible to receive subsidies for the investment. Without any of these subsidizing options, amortization periods of 6 – 12 years must be calculated, depending on the local energy price. Even if this does not seem very attractive from a steel plant operator’s perspective, energy providers may be interested.

%QPENWUKQP 'EQPQOKECNRQVGPVKCNsC SWGUVKQPQHVKOKPI The issue of return on investment for an iRecovery project depends on three aspects: - Does the cooling system need a revamping anyway or would an investment be merely made for the sake of heat recovery? - Is there demand for process steam/ heating energy or is power generation the only option (the case of process steam/heating energy usually provides better payback)? - What are the energy prices in the respective plant location? Generally speaking, an iRecovery project is always easy to realize when only the cost difference to conventional cold water cooling needs to be justified. iRecovery brings additional costs of max. 20 – 25% compared to the required sum for cold water cooling, because of the higher-grade equipment and additional components like a steam drum or steam buffers. In case of power generation, a rule of thumb is that the turbine doubles the costs. An exact payback calculation must be done on a case-by-case base, but as a general rule the following can be assumed. In a scenario of a necessary revamp/new furnace, iRecovery will always provide a sensible payback time. With steam demand, it is excellent, with power generation acceptable. A switch from an existing and working cold water cooling system is sometimes difficult from an economical point of view. The higher the percentage of process steam demand compared to the complete steam production is, the better the amortization becomes. Power generation is feasible if the produced power is considered as “green energy” and subsi-

A standard top-charged EAF has approximately 180 – 220 kWh/tls off-gas energy content, with the off-gas being the central element for heat recovery. Depending on the temperature at the low end and the control of dilution air, between 50 – 85% of this energy content can be recovered. Contrary to the widespread opinion, heat recovery from a batch-mode furnace is feasible with the Tenova iRecovery steam buffering technology. Nevertheless, superheated steam is an issue. But, as the discussion showed, in almost all cases it is possible to avoid the need for superheated steam and go for the economically more favourable option of generating power with an ORC turbine instead of using external burners for superheating. The right point in time to plan an iRecovery system is always when there is a high demand for process steam. Otherwise iRecovery should be taken into consideration when an existing cooling system needs revamping or a new furnace is being planned.

4GHGTGPEGU [1] D. Zuliani, V. Scipolo, J. Maiolo: Opportunities for Increasing Productivity and Lowering Operating Costs while Reducing GHG Emissions in Steelmaking. AISTech Conference, Pittsburgh, 2010. [2] H. Schliephake, F. Memoli, J. Simmons, R. Granderath, C. Born: Heat recovery for the EAF of Georgsmarienhütte. AISTech Conference, Pittsburgh, 2010. [3] C. Born, R. Granderath: The Challenge of Heat Recovery in Integrated Steel Plants. AISTech Conference, Indianapolis, 2011. [4] R. Seki, M. Yamazaki, Y. Sato: Hybrid way EAF off-gas heat recovery. AISTech Conference, Indianapolis, 2011. [5] W.-D. Streinmann, M. Eck: Buffer storage for direct steam generation. Available online at, 2005

Technological Innovations for iron, steel, ferro alloy and non-ferrous metal manufacturers

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First Conarc EAF with heat recovery system for China The Chinese steel manufacturer Taiyuan Iron & Steel has ordered an X-Melt Conarc furnace unit with energy recovery system for a new long product mill in Taiyuan, North China. The energy recovery system will provide MSRQR?LBGLECLCPEWCDjAGCLAW of the steelworks and especially contributes to low CO2 emissions and energy costs.

Figure 1. 3D scheme of a twin-shell Conarc plant

SMS Siemag AG, D端sseldorf, Germany Contact: E-mail:


MPT International 2/2013

Chinese Taiyuan Iron & Steel group will build the first Conarc-type meltshop in China. The company has ordered an 80 t CONARC速 plant with two furnace shells. SMS Siemag was contracted for engineering, manufacturing of core components as well as supervision of erection and commissioning. The entire plant will be equipped with an XPact速 electrical and automation system (including level 2). Furthermore, SMS Siemag will supply the electrode arms, the SIS burner and injector systems (figure 1) as well as the engineering and core components for the oxygen blowing top lance. The CONARC速 furnace unit is part of a complete special steelworks project for which the Chinese steel producer contracted SMS. In the scope of this project, SMS Concast will additionally supply two twin-ladle furnaces and a three-strand jumbo continuous caster for round blooms with a diameter of between 390 and 800 mm. The continuous caster will be equipped with electromagnetic mould, strand and final stirrers, strand heating and dynamic soft reduction systems to achieve top quality blooms. Amongst others, these blooms will be used for the production

of wheels for high-speed trains. In addition to high quality, the new investment will allow Taiyuan Iron & Steel to achieve significantly improved material utilization and reduced transformation costs compared to the old plant. Commissioning of the plants is scheduled for March 2014. Developed by SMS Siemag, 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. In the two furnace shells, the blowing lance and electrodes are used in turns. This makes it possible to process steel scrap, crude iron and direct-reduced iron ore (DRI) in various mixing ratios. The flexibility thus obtained allows the steelmaker to dynamically react to fluctuating market prices for energy and charge materials. Furthermore, it is possible to flexibly switch between the operating modes of the burner and injector systems. Thus, the amount of electrical energy required is significantly reduced. The technological equipment includes a blowing lance, oxygen and carbon injectors, the materials management and the gas cleaning system.

Steelmaking Energy recovery. The off-gas from the EAF is led through a boiler system that on the one hand provides for the required cooling of the gas and on the other hand uses a major portion of the thermal energy for the generation of steam which can be put to further use in the steelworks. A newly developed two-stage boiler system is used for heat recovery. In the first stage, the off-gas is led through a swivel-type elbow, a post-combustion chamber and a hot-gas line and cooled down to approx. 600°C. These components have been designed as

pressure parts (pressurized components) for steam generation. In the second stage, the off-gas is cooled down to 200°C in a vertical pass boiler especially developed for this type of application. In the two boiler units, up to 60 t of steam can be generated per hour. Thanks to this concept of heat recovery for steam generation, a significant contribution can be made to sustainably improve the energy efficiency of the steelworks. The energy recovery system effects a reduction of CO2 emissions by approx. 25,000 t/year.

Figure 2. SIS burner and injector module

New bucket-charging system automates scrap feeding in electric steel plants Simetal EAF Chargeopt helps to optimize and fully automate crane movements during 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 successfully in use at Riva SAMâ&#x20AC;&#x2122;s electric steel plant in Neuves Maisons, France, since June 2012.

Siemens AG, Industry Sector â&#x20AC;&#x201C; Metals Technologies, Linz, Austria Contact: E-mail:


MPT International 2/2013

A charging control and visualization system was integrated into the existing meltshop control interface at the Riva steelworks in Neuves Maisons, France. Siemens supplied the mechanical and electrical equipment as well as the basic automation system. Simetal EAF Chargeopt offers a number of advantages compared to manual crane operation. Irrespective of their size, shape or position on a transfer car, scrap buckets are located and picked up precisely by the crane. The movement of the crane to the doghouse, the coupling of the auxiliary crane and the charging of the scrap into the electric arc furnace automatically follow an optimal, reproducible path. This saves time, prevents damage to the equipment and reduces hazards for personnel. Additionally, crane and doghouse movements are synchronized optimally, resulting in poweroff-times of less than 1.5 minutes for charging. This increases EAF plant productivity. The automatic scrap charging system installed at the Riva Neuves Maisons steelworks includes a laser-based solution specially designed to pinpoint the position of the scrap buckets. Radio sensors determine the crane position in the X and Y directions while high-precision encoders report the Z position of the crane hook. These data are transferred via an industrial WLAN to a programm-

able logic controller where they are compared with the ideal pathway templates stored in the controller, which then initiates the necessary crane movements. The measuring and data transmission systems are designed for use under rough ambient conditions, which boosts the availability of the entire system. Riva Neuves-Maisons works produces wire and reinforcing steels and is part of the SAM division of Riva. The meltshop comprises an electric arc furnace with a tapping weight of 150 t and a ladle furnace. Billets cast on a six-strand continuous casting machine pass to a rolling mill for further processing. Riva was the first steel producer in the world to use a LiquiRob at an electric arc furnace. It automatically takes samples from the EAF and performs measurements. This Siemens LiquiRob robot system has been in use in Neuves Maisons since March 2010.

Conclusion The steel plant operator now commands a fully integrated automation system for scrap handling from the scrap yard to the electric arc furnace. Operations are controlled solely by the shift manager from the control room. The time for return on investment is less than one year.

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New secondary metallurgy complex goes into operation at Saarstahl Saarstahl, German producer of wire rod, bar and forged products, invested a total of 150 million euros in building ?LCUQRCCJPCjLGLEAMKNJCV  The main components of the new facilities are two twinladle furnaces and a vacuum BCE?QQGLENJ?LR 2CKNCP?RSPC adjustment of the heats now takes place in the casting ladles, no longer in the converters, thus removing a major burden DPMKRFCAMLTCPRCPQ 'LRFGQ project, particular emphasis was placed on environmental NPMRCARGMLKC?QSPCQ 

Saarstahl AG, Völklingen, Germany !MLR?AR UUU Q??PQR?FJ AMK # K?GJ Q??PQR?FJQ??PQR?FJ AMK

The Saarstahl group, with its headquarters in Völklingen, Germany, specializes in the manufacture of wire rod, bar steel and forged products in exacting qualities. After two and a half years of planning and building, the new secondary metallurgy facilities went into operation smoothly and according to schedule on 28 January 2013. Commenting on the 150 million euros investment, the chairman of the board, Dr. Karlheinz Blessing, said: “This is a further milestone in our strategy of growing in the premium segment on an international scale.” With this investment, Saarstahl is more than doubling its capacity in the field of high-quality steels, while extending its product range and improving its product quality. With the new facilities, Saarstahl can offer more types of steels and, above all, steels with higher alloying contents to cater to the demand of the automotive industry. The new secondary metallurgy facilities are accommodated in a bay directly linked with the steelmaking plant. The facilities mainly consist of the following units: - two twin-ladle furnaces (figure 1), - the vacuum degassing plant, - an injection unit,

- a central alloying plant with 34 bunkers, - a water supply system, and - a central dust removal system. A decisive innovation for Saarstahl is the implementation of ladle furnace technology. It allows targeted heating of the steel melts in the pouring ladle instead of, as hitherto, in the converters. As a result the converters have been relieved from a major burden.

Remarkable building project The preparatory measures such as demolition or relocation of existing buildings and allocation of areas started in September 2010. The actual hall construction began in May 2011. In its final stage, the building is now 60 metres high (the chimney is even 70 metres high), 88 metres long and 48 metres wide (figure 2). In spite of the confined building site, the closeness of roads and the complexity of the installation activities, production in the adjacent steelmaking plant was running smoothly throughout the construction project.

Environmental protection measures

Figure 1. Ladle furnace in the new secondary metallurgy complex


MPT International 2/2013

Figure 2. The outer facade has been covered with a two-shell insulation layer

Saarstahl placed utmost emphasis on effective environmental protection measures. The central dust removal system was designed for a maximum extraction quantity of 600,000 m³/h. It remains below the current dust emissions limit by more than 75 percent. In order to reduce noise, the complete outer facade has been covered by a two-shell, 140-mm-thick insulation layer. Roof openings, cooling towers and the chimney are equipped with sound absorbers. Steam, which occurs as a by-product in the converter process, is used as energy source for the vacuum degassing facility. A highlight in terms of energy efficiency is a newly installed turbine driven by the return water from the cooling towers. Through this solution, part of the electrical energy consumed is recovered.

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Figure 1. Danieli Lynxs shredder

Nano mill technology – an extra-low capex solution for local steel supply The nano mill concept has been developed as a competitive solution for local steel production supplying a regional market. In contrast to common mini mills or integrated steel works, the nano mill is the answer to satisfying regional demand by a cost-sensitive investment approach. The nano mill concept is based on plant layouts for standard production sizes of up to 300,000 t/year of long products.

Thomas Klein, Uwe Wilhelm, Danieli Centro Met Swiss GmbH, Rheinfelden (Aargau), Switzerland Contact: E-mail:


MPT International 2/2013

Investments in a new steelmaking plant are always driven by the same key factors, i.e. the market for finished products, capital expenditure (capex), operational expenditure (opex), availability of raw materials and electrical power, plant location, environmental issues, skilled manpower, etc. Considering these aspects, the classical mini mill concepts alone no longer match the changing demands of the industry. Especially for the emerging markets, these concepts were simply oversized. Looking at the needs of developing regions around the globe, it clearly turns out that there are locations with a distinct local demand for long products but with certain constraints, such as restricted power supply, limited investment potential, etc. Against this background, Danieli developed the nano mill concept to be able to flexibly meet the specific requirements of such markets.

A plant concept strictly focusing on regional niches The nano mill is a plant concept that focuses on the region, i.e. regional resources and regional market demands. The nano mill exploits the available scrap or iron ore resources. The available raw materials are converted into finished products demanded by the local market in a highly efficient process – and involving extremely short transport routes. The plant concept of the nano mill is based on plant layouts for standard production sizes. The following sizes – reflected in the nomenclature – are available for billets or rolled products: - NANO100 for 100,000 t/year, - NANO150 for 150,000 t/year, - NANO200 for 200,000 t/year, - NANO250 for 250,000 t/year, - NANO300 for 300,000 t/year. For these standard sizes the nano mill concept provides site solutions and business planning to enable fast decision-

Figure 2. High-powered coreless induction furnace during pouring

making and to save capex already at a very early stage.

Process routes Four different process routes are feasible. The EAF based nano mill comprises: - scrap yard, - electric arc furnace (EAF), - alloying unit, - ladle furnace, - continuous billet casting machine (one or two strands), - rolling mill. The induction furnace based nano mill comprises: - scrap yard, shredder and shear, - induction furnace, - oxygen bottom stirring stand, - de-slagging stand, - ladle furnace, - continuous billet casting machine (one or two strands), - rolling mill. The mini blast furnace based nano mill comprises: 70

MPT International 2/2013


charcoal and iron ore storage, mini blast furnace, hot metal treatment stand, basic oxygen furnace (converter), ladle furnace, continuous billet casting machine (one or two strands), - rolling mill.

The mini BF and EAF based nano mill comprises: - charcoal and iron ore supply, - scrap yard - mini blast furnace, - hot metal treatment stand, - electric arc furnace, - ladle furnace, - continuous billet casting machine (one or two strands), - rolling mill. If a mini blast furnace is used, there is also the option to produce pig iron. Independent of the process routes, the nano mill should be equipped with an off-gas cleaning and fume treatment plant. Other auxiliary equipment comprises material handling systems, cranes, water treatment plant, laboratories, meltshop auxiliaries etc.

Main technologies of the nano mill process chain Scrap preparation. The use of a shredder has been proven to be the most efficient method to guarantee optimum scrap size and shape and a high scrap yield for the feeding of the meltshop. The shredder ensures operational and cost efficiency, high yield of the melting process, high productivity and good control of the metallurgical analysis. Besides the shredder machines, other scrap preparation systems, e.g. scrap shears and pre-shredders, are used to cover all scrap preparation and logistical activities (figure 1). Primary melting facility. The nano mill concept provides two primary melting options: the EAF and the induction furnace. The Danieli nano EAF has been specially developed for the nano mill. It is available in two sizes covering the tapping weight ranges of 5 – 15 t (NANO²) and 15 – 35 t (NANO³) respectively (table 1). They are available in full or half-platform design and with eccentric bottom tapping (EBT) or spout tapping. The nano EAF can be designed as

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Steelmaking AC or DC type, depending on individual requirements. A special Nano-Robox door lance for carbon and oxygen injection via the slag door has been developed to complete the system. Alternatively, a complete injection system can be installed including burners, supersonic oxygen lances, and carbon and lime injectors, as required.

induction furnaces with four crucibles (two in operation and two in the relining/sintering mode – figure 3). The arrangement of the induction furnaces within the plant is very important for the overall plant logistics and the development of the overall layout of the nano mill. Fume exhaust during charging and tapping is via a special suction

Figure 3. Two induction furnaces equipped with special suction hoods



Heat size, t









Diameter, m









Electrical power, MW









Productivity, t/h









Tap-to-tap time, min









Tapping system Chemical packages Charge buckets Hot heel


Spout and EBT

Door lance

Door lance and modules



max. 15% of tapping weight

max. 15% of tapping weight

Table 1. Nano mill EAF sizes and technical data

As an alternative primary melting system, the induction furnace technology can be applied to nano mills, especially in the case of limited availability of electrical power and if production is limited to commodity steel grades like rebars. Generally, a medium-frequency coreless induction furnace with a tapping weight of 5 to 35 t is used, requiring 3 to 18 MW of converter power (figure 2). Scrap feeding is semiautomatic by means of charging cars loaded by crane. Depending on the intended production, induction furnaces are either arranged as one induction furnace with two crucibles, with one crucible being used for the melting process, while the second one is being relined/sintered, or the arrangement is extended to two 72

MPT International 2/2013

hood which reduces the overall off-gas treatment volumes to a minimum. Even if no electrical power is available from the public network, the power for the induction furnace can be produced by compact Diesel generators which are grouped to small units to cover the dirty bus bar (induction furnace, ladle furnace), clean bus bar (auxiliary equipment and rolling mill) and the shredder plant. The mini blast furnace is a very flexible and competitive plant for hot metal production in the range from 65,000 to 300,000 t/year. It is highly flexible allowing burdening of 100% lump ore as well as any blend of lump ore, sinter and pellets. It can be designed to use charcoal (environmental friendly) or

coke as a reducer. A mini blast furnace is the ideal solution for a nano mill at locations where iron ore and charcoal or coke are available but the capacity of the electricity network is insufficient for the operation of an EAF or induction furnace. After tapping the hot metal from the mini blast furnace, it is transferred to a BOF or EAF. Both basic and foundry steel can be produced. The mini blast furnace has the following advantages: - low specific investment, - flexibility in burden preparation and composition, - low impact on the electricity network, - easy operation and maintenance, - proven technology. A secondary metallurgy treatment facility is a must in a modern nano mill. It comprises a small ladle furnace (LF) which guarantees attainment of the required chemical composition of the melt and acts as a liquid steel buffer between the upstream primary melting system and the downstream production facilities. In case an induction furnace is used as primary melting unit, an oxygen blowing stand (OBS) will be provided upstream the ladle for decarburization and dephosphorization. After the dephosphorization process, the oxidized slag is removed at the deslagging stand or on the tiltable ladle car by intensive stirring. If necessary, the ladle slag is raked off to ensure that clear metal is transferred to the ladle furnace station. Billet caster. After the secondary metallurgical treatment of the heat, the ladle is transferred to a conventional 1-strand or 2-strand continuous casting machine with 7 m radius. The billet sizes produced here are in the range of 100 mm x 100 mm to 160 mm x 160 mm in lengths of 4 to 12 m. This dimensional range provides the flexibility needed to fulfil the requirements of the market. Proven equipment is implemented such as: - ladle turret for high operational safety, - delta-shape tundish design, - flying nozzle change system, - flying tundish technology, - mould electro-magnetic stirrers. Rolling mill. The NANO100 and NANO150 sized mills (see above) are equipped with a semi-continuous roll-


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MPT International 2/2013


Steelmaking ing mill (reversing stands). The bigger NANO200, NANO250 and NANO300 mills include a roughing stand and a continuously operating rolling mill. The rolling mill configuration ensures highest flexibility to satisfy the demand for rebar and for the production of wire rod or light sections (figure 4). Rebar dimensions to be produced depend on the individual

However, re-heating the billets from ambient to rolling temperature is only an option in case of emergency. Auxiliary facilities needed for the continuous operation of the plant are provided for in the nano mill concept. Such facilities are designed and specified according to the specific regional requirements.

Figure 4. Finishing mill

requirements and cover the full finished product range between 8 and 40 mm dia. Besides the classical type of reheating furnace (gas or oil fired pusher or walking beam type), it is possible to implement an induction heater. Thus, constant and correct temperature over the billet length as required for the rolling operation can be achieved. The induction heater requires a fully synchronized casting and rolling process.

A fume treatment plant ensures environmental compliance with the usual European and international standards. The charging of clean scrap prepared by the shredder plant and/or use of the induction furnace technology make for a small carbon footprint. In case of using charcoal as a reducer in the mini blast furnace, hot metal is produced with a neutral carbon footprint. A water treatment plant ensures the correct re-cooling of the pro-

cess water used in the different process steps. Other auxiliary equipment is defined according to the process needs.

Conclusions The nano mill concept has been developed to supply steel to a regional market within a 300-km radius. Within this region scrap is collected, transported over short distances to the mill where it is processed into finished products for the construction industry. The general benefits of the nanomill concept can be summarized as following: - local suppliers, - local customers, - local raw materials, - reduced capex, - reduced opex, - reduced inventory costs, - compact mill design, - low freight costs, - minimized buildings and civil works, - highly preassembled equipment. Around the globe, this concept can assist the development of regions in which no one had ever before thought of building a steel making plant. With a nano mill, this can now become very feasible. A nano mill will draw other businesses and industries to settle around the steel works. To implement a nano-size mill, the know-how and capabilities of a full-line plant supplier like Danieli are of utmost benefit as they reduce the number of interfaces during the project execution, leading to a fast and successful start and ramp-up of production. The success of the nano mill concept has been already confirmed by recent orders received from customers in Africa, Asia and Middle East.

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MPT International 2/2013

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Extend component and equipment life – a safe approach to maximizing productivity To meet ever-increasing demand, steel producing companies are constantly looking at ways of improving mill productivity, which often results in machines running at faster speeds. However, while increasing productivity is important, employee safety is paramount. Faster running speeds cannot be allowed to compromise safety, and it is in this area that advanced lubrications can help operators to tackle the conundrum of increasing productivity while helping to reduce the potential hazards facing its engineers.

ExxonMobil Fuels and Lubricants, Moscow, Russia Contact: E-mail:


MPT International 2/2013

Advancements in lubricant technology, especially when it comes to fully-synthetic based products, have seen significant breakthroughs in regards to extending equipment life, oil drain intervals and improving the energy efficiency of equipment. For example, Mobil SHC series of fully synthetic lubricants can last up to six times longer than conventional mineral based oils, with upper operating temperature limits that can typically reach 50°C (90°F) higher than conventional mineral oils. This high temperature performance is particularly important for operators seeking to increase the speed of their machinery; as a side effect of this is often an increase in operating temperature, and the lubricants in use still need to offer sufficient protection. The Mobil SHC range of synthetic lubricants has been engineered to help reduce maintenance shutdowns, and by reducing scheduled and unscheduled maintenance the associated safety risks that engineers face when undertaking the work are eliminated, which is especially challenging in a steel mill. Unlike conventional mineral oils, Mobil SHC range can offer significant productivity and sustainability improvements by extending equipment life and oil drain intervals. The latest addition to the Mobil SHC brand of high-performance synthetic lubricants, Mobil SHC 600 series for gear, circulating and bearing oils are expertly formulated to improve safety, productivity and sustainability performance compared to conventional mineral oils. Featuring advanced syntheticbased fluids and a proprietary additive system, the oils can deliver a service life of up to six times longer than competitive mineral oils. Another product breakthrough which enables equipment to operate efficiently at high temperatures is the high performance grease, Mobil SHC Polyrex. It provides a combination of extreme low and high temperature performance alongside balanced wear performance, outstanding load carrying capabilities and rust protection. Using advanced Polyu-

rea thickener technology to provide lubrication performance even at high temperatures of up to 170°C, this grease can resist oxidation and loss of structural stability at the highest of temperatures, allowing re-lubrication intervals to be extended while maintaining equipment protection. Its excellent corrosion inhibition properties provide the necessary protection for equipment operating in wet, humid environments and applications where water wash downs are frequent.

Proven performance in the steel industry In recent times, ExxonMobil’s high performance range of industrial oil and greases have helped a number of steel companies around the world to increase the productivity and safety of their operations by increasing oil drain intervals and reducing component wear, as well as scheduled and unscheduled downtime: For example, an Egyptian steel mill achieved an extended bearing life by 300%. When a scrap charging crane in the meltshop was suffering from short re-greasing intervals, due to a mineral oil being unable to withstand the high temperatures during the furnace charging phase, the result was repeated bearing replacements every two months and a subsequent increase in maintenance activity and costs. ExxonMobil technical experts identified that a switch to high performance Mobilith SHC 460 synthetic grease would help to extend re-greasing intervals thanks to the synthetic lubricant’s extreme temperature capabilities, which provide better component protection at high temperatures. By taking advantage of such recommendation the plant maintenance team soon saw the related bearing replacement intervals extend to six months. The extended regreasing intervals and reduced bearing replacements resulted in cost savings of up to US$ 199,000 over the course of a year.


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Maintenance Several Russian steel mills have successfully increased overall productivity and reliability of operations due to change to high-performance lubrication solutions. Better component protection and performance under extreme conditions resulted in reduced downtime, extended re-greasing intervals and lower grease consumption. Over the past few years ExxonMobil has developed a proven track record in helping Russian steel mills increase their productivity. One example saw a leading Russian steel company benefit from improved performance whilst lowering grease consumption in its hot rolling mill. The manufacturer was experiencing significant water washout of a conventional mineral competitor grease from the roller bearing cages of the work rolls 2000. Grease coking, as an effect of high temperature exposure, had also been observed. Deposits began to form and corrosion would attack the bearings due to lack of protection by the lubricant. ExxonMobil field engineers recommended trialling Mobilgrease XHP 461 for six months on a set of bearings due its resistance to water washout, excellent rust and corrosion protection and good thermal stability. After monitoring both the grease and the roller bearings over a six months period, the results showed that the grease had resisted significant amounts of water and demonstrated outstanding adhesive abilities. As a result, the bearings were consistently lubricated and protected which helped to prevent machinery stoppages. The lifespan of the bearings was improved as no corrosion, deposits or coking was found. In addition, re-greasing intervals were extended, resulting in an overall decrease in grease consumption. Consequently, the customer decided to convert the rest of the roll bearings in the mill 2000 to Mobilgrease XHP 461. In another case, the steel mill in question was struggling to overcome

Figure 1. Mobil SHC gear series’ high viscosity index and low traction EQGHƂEKGPVEQODKPGVQ RTQXKFGCUKIPKƂECPV reduction in energy consumption in many gearboxes


MPT International 2/2013

the poor water separation and emulsion formation that was the result of a competitor mineral oil unable to perform under difficult operating conditions. Consequently, from 2002 to 2005 the steel mill was obliged to change 182 oil-film bearings due to sever rusting and failure. Following consultation with ExxonMobil field engineers, which included thorough inspection of the lubrication system and analysis of the equipment features, the recommendation was made to switch the oil-film bearing lubricant to Mobil Vacuoline 133. Designed specifically to withstand heavy water contamination through outstanding water separation ability, Mobil Vacuoline 133 also offered good resistance to thermal degradation and oxidation providing excellent protective capabilities against rust and corrosion, making it well suited to the unique operating conditions of the steel mill. Since 2005 the steel manufacturer has used Mobil Vacuoline 133 to lubricate the bearings of a SKET 350 small-section and medium-section mill with the result that no bearings were found to be suffering from rust or damage and the first bearing replaced

in only November 2006. Improved component reliability was calculated to have saved the company replacing 120 oil-film bearings over a period of two years, and with the average price of bearings approx. US$ 1,620 this culminated in an estimated saving of up to US$ 194,400.

Conclusion The above mentioned proofs of performances relate solely to the experiences of single customers. Actual results can vary depending upon the type of equipment used and its maintenance, operating conditions and environment, and any prior lubricant used. However, with global demand for steel production expected to continue, there is a great opportunity for steel mill operators to take advantage of new and innovative ways of maximizing productivity without compromising safety. Understanding how high performance, expertly formulated lubricants can contribute to enhanced productivity and minimized downtime will help steel mill operators to gain a competitive edge in today’s marketplace.

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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. tSTEELMASTER SMR measures a complete proďŹ le 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. tUnique, fully contact-free transmission of both energy and signals by means of induction and encapsulated W-LAN grants

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Chelpipe values life-cycle partnership – a forward-looking service philosophy

Figure 1. Plant operator and advisor in the control room

Plant owners have been increasingly demanding service and maintenance of the plant throughout its entire life cycle, SRGJGXGLERFCQNCAGjAILMUJCBEC of the original equipment manufacturer (OEM) in order to safeguard “overall equipment effectiveness” and thus competitiveness on a permanent basis. At the same time, with innovation cycles becoming ever shorter, there is a need to maintain the technology at the latest state of the art by means of updates and upgrades.

Life-cycle management is a key factor in making total cost of ownership predictable. Realizing the importance, SMS Siemag – manufacturer of plant and machines for the metallurgical and rolling mills industry – has developed the respective service solutions and has made them available to plant operators via a worldwide service network. The plant manufacturer offers integrated service modules which can be individually adapted. Costs, quality and productivityrelated aspects of plant operation can be safeguarded at an optimized level over the entire life cycle. The aim is to achieve a life-cycle partnership between plant manufacturer and plant user (figure 1).

Selection criteria for a maintenance concept

Pino Tesè, Christoph Häusler, SMS Siemag AG, Düsseldorf; Valentin Tatzedinov, Chelpipe, !FCJW?@GLQI 0SQQG? Contact: E-mail:


MPT International 2/2013

The basis of the life-cycle partnership is provided by the maintenance concept. The first question to be asked is whether maintenance is worthwhile, and if so, the next question to be asked is to what extent it would be worthwhile. This is answered and illustrated in figure 2. Here, the empirical values of

SMS Siemag are plotted in a typical progression. In the case of a failure-induced maintenance strategy, following a steep run-up phase, irregular and unforeseeable productivity breakdowns will arise. In the case of a best-practice maintenance strategy, as favoured by SMS Siemag, the customer can expect to enjoy above-average availability and yield. A large variety of strategies are available for maintenance. Basically, three essential strategies can be assumed to be relevant for the metallurgical and rolling mills industry: - condition-dependent strategy, - time-dependent/preventive strategy, - failure-induced strategy. A decision can be made individually according to the best-practice method. As a rule, it comprises an efficient mix of the strategies. This approach considers both the criticality of the components and the cost-benefit ratio (figure 3). The aim is to attain the right balance, since the following can be stated in simple terms: Too little maintenance results in considerable malfunctions and costs, whereas an excessive amount of maintenance is no longer profitable when measured against the value added.


CORTS Engineering



Maintenance Life-cycle partnership for Pervouralsk New Pipe Plant To get an idea of how an integrated service concept appears in concrete, practical terms and how the modules used in the concept interact with one

cleanliness, organizational charts, management system, current stocks of plant and materials, maintenance methods, diagnosis systems, cooperation with spareparts and equipment suppliers, as well as expenditure on maintenance methods. SMS identified stock-keeping in the in-

Figure 2. Systematic maintenance management helps to increase plant performance

another, Pervouralsk New Pipe Plant, JSC, a company belonging to the leading Russian pipe manufacturer Chelpipe, is illustrated in the following as an example. In 2009, Chelpipe commissioned an electric arc furnace, secondary-metallurgical treatment facilities and casting machines, all plants provided by SMS Siemag. Together with the supply of the plants, Chelpipe also decided in favour of a comprehensive service package from SMS Siemag, which essentially comprises the following elements: - audits of the maintenance workshops, - technical assistance for the introduction of new methods and optimizations, - implementation of an integrated maintenance management system (IMMS®), - training sessions for employee qualification, - warehousing for spare-parts administration and local provision. Audits. At Chelpipe Pervouralsk works, audits were first carried out by expert groups from SMS Siemag in order to ascertain the status and optimization potential of the technical maintenance in the Chelpipe workshops. These assessments took account of factors such as 82

MPT International 2/2013

dividual workshops as the main areas of potential optimization. Each production department operated various stores for spare parts, tools and materials. Technical assistance. The task of the technical assistance service by SMS Siemag at Chelpipe was to implement the knowledge and experience gained from the audits in close cooperation with the customer, in other words to optimize the work sequences and to initiate and organize the maintenance processes. However, the work of the technical assistance service did not end here, since the provision of this assistance is really a continuous service within the scope of the life-cycle partnership. Thus, the SMS Siemag advisors support Chelpipe in the development of new products and in the introduction of new process steps required for this. Implementation of IMMS®. One of Chelpipe’s main tasks was to introduce the integrated maintenance management system (IMMS®). It is based on software that supports maintenance planning with intelligent tools. Sequences become linked and partly automated and thereby greatly simplified. The usual disadvantage of maintenance software

is that no consideration is given to specific plant data and plant processes. The IMMS®, however, integrates the plant and process data obtained and continuously incorporated into the system by SMS Siemag during decades of experience. Software and data together constitute a plant-specific, tailor-made package that forms a reliable basis for a clear and easily understood management. Each component to be serviced is clearly identified and coded to ensure purposefully targeted maintenance. An exhaustive database at Chelpipe allows easy service and maintenance and can be supplemented independently. This furthers the continuous process of improvement that is aimed at during the entire life cycle of the plants. The integrated maintenance management system fulfilled the conditions for continuous improvement of flexibility, efficiency and transparency in the professional management of spare parts and maintenance. Its utilization has already enabled a short-term increase in the plant availability of up to 20 percent at Chelpipe. Valentin Tatzedinov, director New Project Management at Chelpipe, confirms the benefits: “Our maintenance work has become much more transparent. We have created a more efficient structure for the organization of our technical maintenance and of our repair operations.” Besides the assistance in daily work, the integrated maintenance management system also provides long-term opportunities for significantly enhancing plant availability, reducing the maintenance costs and the tie-up of storage capital, and improving customer satisfaction. Training courses. Not only the technology but also the professional and personal qualifications of the staff form part of a life-cycle partnership. SMS Siemag first conducted a comprehensive assessment in order to ascertain the level of knowledge and the training requirements of the maintenance managers and specialist workers at Chelpipe. The focus was on the process know-how relating to maintenance, the technical knowledge regarding the installed plants, and the key qualifications (social, communicative and methodical competence) of the Chelpipe employees. The ascertained qualifications were then contrasted with the previously drawn-up set of job requirements. The trainers from SMS

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Your life. Our steel. Gear transmissions in wind turbines need to work in all weathers, whatever the wind force, and even offshore exposed to seawater. Deutsche Edelstahlwerke produces steels to meet these highly interdependent requirements. The surfaces of the gearing mechanism must exhibit an extreme level of wear resistance and fatigue strength, while the core needs to be exceptionally tough to cope with the sudden loads of

wind gusts. Rotor blades turn 20 times per minute, which is translated into 2000 rpm in the generator. A generator shaft will handle approximately 15 billion rotations. This enables clean, future-proof energy to be obtained from the wind on a sustainable, long-term basis.


Maintenance were then able to impart the know-how required for introducing the new maintenance concepts and processes in local training courses in keeping with the specific needs. Furthermore, a large number of educational and qualification courses are offered to the Chelpipe employees – as also to other companies – within the

Service portals professionally support the safe and comfortable communication between Chelpipe and SMS Siemag. It is a remote service by means of highly secure network connections, through which the SMS Siemag service experts have access to the automation systems at Chelpipe. They can thus implement process

Figure 3. Best-practice maintenance strategy in relation to the cost expenditure for decision-making processes

Figure 4. Spare-parts warehouse

framework of SMS Siemag’s TECademy. TECademy stands for technology academy incorporating the outbound seminar and training division of SMS Siemag. It offers steelmakers and rolling-mill owners worldwide efficient packages for professional training comprising the expert know-how of SMS Siemag. Engineers, plant technicians, plant owners and other specialists can draw upon expert support here so that they can recognize the potential of their plants and utilize it efficiently. 84

MPT International 2/2013

improvements or efficient elimination of faults. In the case of Chelpipe, the responsible portal is the Russian 24/7 service set-up of SMS Siemag in Chelyabinsk. This constitutes the service entry point for the Russian and CIS companies. With the aid of the local centres, optimum customer care and assistance to Chelpipe is assured because the SMS Siemag staff is not only familiar with the plant but can also communicate in the local language. A further bonus is the informationtechnology interlink, allowing rapid ex-

change of knowledge between the Siemag experts on specialist subjects also at a global level, thus reinforcing the capacities of the local service employees in finding solutions. The activities are supported by the main service centre in Germany. Spare-parts management. Within the scope of a service contract, Chelpipe has transferred operation of the local spare-parts store and the spare-parts management to SMS Siemag (figure 4). Here, SMS Siemag manages and stocks not only those spare parts made available by SMS Siemag but also the parts belonging to Chelpipe. The advantage for Chelpipe is that spare-parts storage is accurately, and therefore economically, coordinated with the requirements of the plants, thus enabling the spare and wear parts to be immediately available locally. In addition, Chelpipe does not require any personnel of its own and thus saves the expense of administration. 24/7 accessibility of the store is thus safeguarded.

Conclusion Chelpipe Pervouralsk New Pipe Plant is a prime example of the benefits available through the life-cycle partnership. This service offered by SMS Siemag is established on four pillars: - worldwide presence in the “metallurgical centres”, - experience and competence of operators and engineers and knowledgebased management tools, - comprehensive range of products aimed at catering successfully to the entire metallurgical process chain, with application of own solutions and know-how, - active support through R&D with a view to providing “added-value solutions”. Valentin Tatzedinov, director New Project Management at Chelpipe, is satisfied with the result: “What we want from out plant supplier is not only high quality and efficient technology but also a partnership that goes beyond the actual supply of the plant itself. Our supplier should stay with us during the entire life cycle of the plant and help us overcome the challenges relating to its successful operation. Such challenges would arise, for example, in the field of spare parts service, repairs, technical support and assistance in issues of technology.”

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Heat treatment

In-line thermal treatment of heavy-duty rails

Figure 1. 3D scheme of the dual-phase rail hardening line

The newly developed “Idrha+” technology enables manufacturing of rails with improved resistance to contact fatigue and wear. Chinese Baotou Iron & Steel will implement the world’s jPQR?NNJGA?RGMLMDRFGQGL JGLC BS?J NF?QCP?GJF?PBCLGLE technology for the production MDFC?TW BSRWP?GJQ 1GCKCLQU?Q awarded the order to expand one of the Baotou long product rolling mills in China.

Siemens AG, Industry Sector – Metals Tech nologies, Linz, Austria Contact: # K?GJ P?GLCP QAFSJXCQGCKCLQ AMK


MPT International 2/2013

Baotou Iron and Steel (Group) Co., Ltd. in Inner Mongolia province is one of only three locations in China where rails are produced. The company has awarded Siemens Metals Technologies an order for the supply of a new facility for the in-line thermal treatment of heavy-duty rails, to be installed in one of the two company’s long product rolling mills in Baotou, Inner Mongolia. This project will include the world’s first application of an advanced technology for rail hardening, which has been jointly developed by Siemens and the Italian technical centre, Centro Sviluppo Materiali S.p.A. (CSM). This “injector dual-phase rail hardening” system named Idrha+ enables rails to be produced with improved resistance to contact fatigue and wear. The new inline system will also be able to optimize the rail product performances according to the different grades of steel, which may be processed reliably and flexibly. Commissioning of the plant is scheduled for early 2014. The new rail hardening system (figure 1) will be installed in a rail rolling line which has an annual capacity of 400,000 t and rolls various sizes and shapes of rail, including asymmetric rails, in special steel grades with carbon contents ranging from 0.6 to 0.8%. The maximum hourly productivity is 150 t of rails up to 104 m in length. The design of the Idrha+ rail hardening system, the first commercial application of which will be at the Baotou rail rolling line, is based on thermo-me-

chanical and metallurgical process models, and validated by experimental trials in pilot plants. The final rail product performances are in accordance with the Chinese standards in terms of hardness, while the resistance to both contact fatigue and wear is improved. It also allows the simulation of various cooling strategies for different grades of rail steel prior to the start of production. This enables run-up times to be reduced, nominal capacity to be attained more quickly and relevant performance parameters to be fulfilled consistently and reliably. Within the project, Siemens is responsible for the entire process technology, and for engineering its own deliveries as well as the equipment to be provided by the Baotou Iron and Steel. The scope of delivery by Siemens includes the induction furnace, a highly flexible quenching line and closed-loop process automation. Siemens will also support installation and commissioning. The delivery scope also includes the joint development and definition of new rail steel grades with Baotou Iron and Steel, as well as assistance with grade certification for the international market. Siemens has already carried out two modernizations at the Baotou long-product rolling mill. A new shear and a new pinch roll were installed in 1999 and, in 2005, four new rolling stands and an optical alignment system were installed at the Baotou site. The temperature control system of this long-product rolling mill was also modernized.

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MPT International 2/2013


Quality assurance

Straightness measurement system monitors bar and pipe steel production Quality assurance directly after the straightening process is important in bar and pipe production. With laser measuring technology, the straightness of pipes and bars can now be measured contactlessly. The Straightcheck contactless measuring system provides pipe and bar manufacturers with unimaginable potential for online quality assurance avoiding time consuming manual measurement.

Pipe and bar steel manufacturers are always confronted with the same problem: does the straightened pipe or bar satisfy the customer’s demand for quality? Straightness is a significant criterion here. If straightness is not within the required tolerance, the bars or pipes cannot be sold on. The Straightcheck laser measurement system has been developed to solve this problem. It dispenses operators from performing time consuming and complex checks using a straight edge.

cal solution therefore was to use our sensors to measure the straightness. We obtain this information by means of synchronized real-time measurement. For this measurement to be executed online, all sensors must be fully synchronized when the scan is in progress. Our Straightcheck software decides immediately after the first straightening operation whether or not the product needs to be straightened again. This also makes integration into the manufacturing process much easier. In general, no changes to existing production lines are required.”

Also large products can be checked

Figure 1. The laser measurement system can determine the straightness of pipes and bar steel, even for lengths of up to 30 m

Synchronous real-time scanning during manufacturing

LAP GmbH, Lüneburg, Germany Contact: E-mail:


MPT International 2/2013

The measuring system developed by LAP can be directly integrated into the manufacturing process. Existing systems do not need to be adapted. “The Metis sensors in the Straightcheck system measure the straightness of steel products,” explains Frank Lohmann, who works in sales and distribution for the steel industry at LAP. “During the straightening process the pipe or bar rotates at approximately 400 revolutions per minute. The only logi-

The laser measuring system can determine the straightness of extremely long pipes and bar steel, even for lengths up to 30 m. To do so, the measuring range, i.e. the overall length of the products, is subdivided into segments one, two or three metres long each. These are then measured separately in order to determine the straightness of the individual segment of the workpiece. “The typical pipe or bar steel is about 80 mm in diameter or smaller, but diameters of up to 200 mm can be measured online using our standard solution,” Lohmann continues. Metis sensors operate according to the laser scan or “shadowing” principle (figure 1). A sensor consists of a transmitter and a receiver with the measuring field in between. The width of the shadow and/or distance between objects can be measured. In addition to the straightness of the pipe, the system also delivers detailed information on the diameter and ovality of the products being measured using the Metis laser micrometer and Straightcheck evaluation software. LAP also manufactures laser projection systems. They generate points of light, lines, crosses or outlines of any shape such as true-to-scale shapes generated from CAD files.

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$GPGƂVUQHWUKPIF[PCOKECKTMPKXGUKPC EQPVKPWQWUICNXCPK\KPINKPG The new continuous hot-dip galvanizing line CGL 3 at Borçelik was equipped with a special wiping system for zinc coatings, called dynamic air knife system (DAK®E). This technology enables accurately controlled homogeneity of the zinc coating thickness across the width.

Jean-Jacques Hardy, Benjamin Grenier, 5KGOGPU/GVCNU6GEJPQNQIKGU5#5, Savigneux, France; Sertaç Özer, Mahmut Baras, $QTÃGNKM, Gemlik, Bursa, Turkey Contact: E-mail:


MPT International 2/2013

Borçelik is a joint venture between ArcelorMittal and Borusan. Located on the Marmara sea coast, Borçelik is Turkey’s first private and its second-largest flat steel producer HKIWTG  . Facilities operated by Borçelik include - one continuous pickling line, - three continuous galvanizing lines, - three cold rolling mills, - two coil slitting lines, - 64 batch annealing furnaces (16 H2 bases and 48 HNx bases), - one electro-cleaning line, - one skin pass mill, and - one inspection line. The new continuous hot-dip galvanizing line CGL 3 is part of the 2006 investment programme which, in addition to other upgrades on site, was intended to increase plant capacity to 1.5 million t/year. Installation of the mechanical equipment for CGL 3 started in March 2008 and ended in October of the same year. The annual production of CGL 3 amounts to 350,000 t/year. The highly flexible line makes construction, appliances and automotive products. The main steel grades produced here are CQ,

DQ, DDQ, EDDQ, HSLA 240-260 and structural grades 220-360. The line is dedicated to zinc-based coatings (GI or Extragal®) with a thickness range from 50 to 350 g/m² (both sides). The main design parameters of CGL 3 are summarized in VCDNG. Borçelik contracted Siemens Metals Technology SAS (Siemens) as supplier of this CGL 3 line at the end 2007. Siemens’ supply scope comprised all mechanical, hydraulic and fluid equipment, horizontal non-oxidizing furnace, the complete electrical and automation package, plus supervision of erection and commissioning. Furthermore, Siemens optimized the line design to provide the best capital and operating costs for Production capacity

350,000 t/year

Thickness range

0.25 to 2 mm

Strip speed

max. 170 m/min

Width range

750 to 1,530 mm

Tensile strength

max. 500 MPa

Coil weight

max. 30 t

Coating gauge (both sides) 50 to 350 g/m²

6CDNGMain technical data of CGL 3










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the application HKIWTG . This included minimized civil work and easy operation plus provision for a cleaning section of innovative design to handle future, more exacting cleanliness requirements. Siemens also provided critical components and automation, as the double pay-off reel, the entry shears and flatteners, the welding section with mash lap welders, the horizontal entry looper, the horizontal annealing furnace, the zinc pot and associated equipment, the cooling tower with quench, the temper mill and tension leveller, the chromating section, the horizontal exit looper, the vertical and horizontal inspection station, the electrostatic oiler, the exit shear, the tension reel, all motors and drives on DC bus, PLCs, including HMI.

5VCVGQHVJGCTVCKTMPKHG VGEJPQNQI[ Siemens supplied an own air knife development, the SIROLL DAKÂŽ E HKIWTG  . The latest generation of this technology features improvements of the following details: - coating controller, - lip cleaning, - contactless baffle, - less weight, - improved visibility on strip, - easy access to the zinc bath level, - baffle autocentring system. 92

MPT International 2/2013

.KRICRRTQHKNG The key point of the wiping process is to reach a perfect coating (homogeneity and thickness). The design of the lip gap profile HKIWTG  is paramount for this. Commonly, the lip gap profile is set off-line. But thanks to several brushless motorized actuators installed on DAKÂŽE, this innovative device enables setting of a remote lip gap profile, which adapts in real time to strip gauges and coating set-points as well as to line operation behaviour. The lip gap profile can be varied from 0.1 to 2.5 mm across the nozzle. Thanks to the online adjustment of the lip gap profile, it is possible to adjust to the shape of the strip: narrow strip, cross bow or strip shifting. .KR ENGCPKPI Each air knife system comes with an automatic lip cleaning system in order to make sure that the lips are clean and jet lines on the strip are avoided. This lip cleaning system, installed on each side, can be used manually or automatically and activated at each strip weld stage. The cleaning tool is actuated by means of pneumatic cylinders. 2QUKVKQP QH CKT MPKXGU Position encoders allow the vertical and horizontal position of the air knives relative to the strip to be set highly accurately. For horizontal position setting, four brushless motors (two per air knife) actuate and locate each air knife in order to set the

nozzles in the right position. The vertical position, i.e. the height of the nozzles, is set by two brushless motors. $CHHNGU A baffle system is installed to reduce noise produced by disturbances of the wiping air flow and to ensure proper edge coating quality. Two solutions can be chosen to position the baffles relative to the strip: by roller contact or by a contactless tool. The contactless tool uses an infrared detector to detect the strip edge position. This reduces edge defects and is more effective for low thickness gauges. With this solution, the operator can adjust the distance between the strip edges and the baffle plates to ensure the best coating results for the strip edges. The design of the plate baffles has been improved in cooperation with Borçelik to further reduce edge defect. In addition, an autocentring system is installed on the baffle in order to keep the baffle aligned with the strip even if the strip position moves. #KT YKRKPI RTGUUWTG is measured by a sensor integrated into each air knife beam close to the nozzles. The average pressure is controlled via the blower speed. Each air knife features a control valve for fine pressure adjustment. +OOGTUGFTQNNU The three-roll guiding strategy comprises a sink roll, corrector roll and pass-line roll, which together

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control the strip position. This configuration makes for optimum control of the strip shape in front of the air knives. The corrector roll and the pass-line roll can be adjusted from the HMI to reduce strip cross-bow and to position the strip in the line axis.

%QPVTQN To control the wiping process, the following information is collected: coating gauge results for each strip side, coil weld position and the complete product

data information (PDI: strip thickness, strip width, line speed and zinc coating target, etc. ). The cold zinc coating gauge (X-ray), installed after the cooling tower (from 50 to 120 m after the air knives depending on line layout), continuously measures the coating thickness (longitudinal and transversal values). The measurements are collected by scanning the strip surface with two heads, one on each strip side. 6JGRTGUGVVKPIHWPEVKQP allows the air knives to be set up for the next coil according to the PDI from level 2. The air



MPT International 2/2013

pressure, horizontal position and lip gap profile will be set according to a mathematical coating model when a weld is detected at the entrance of the furnace. The presetting data will be shown on the HMI, giving the operator the opportunity to modify them. These values will be automatically applied when the weld is in front of the air knives. .QPIKVWFKPCN EQCVKPI EQPVTQN is a closed loop intended to achieve coating thickness specifications and minimize zinc coating thickness variation along the strip. This control adjusts the air pressure and the horizontal position for each air knife. The computer receives zinc coating information from the gauge and computes the deviation from the target value. Air pressure correction is calculated for each side in accordance with the set-point, and any required gain is computed by the model. If the pressure is saturated, corrections will be taken over by the horizontal position setting function. If pressures are different on both sides, the difference is compensated by the horizontal distance to avoid edge build-up. Due to the distance between the DAK® and the gauge, a Smith predictor is used to improve the response time of the loop.

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AISTech 2013, 6-9 May 2013, Pittsburgh, PA, USA, Booth #629 Oerlikon Leybold Vacuum GmbH Bonner Strasse 498 D-50968 Kรถln T +49 (0)221 347-0 F +49 (0)221 347-1250




(GGFHQTYCTF EQCVKPI EQPVTQN is an open loop control to minimize zinc coating weight variation along the strip when speed is decreasing or increasing. Indeed, as the distance to the cold coating gauge is long, the coating model calculates the estimated coating variation when the speed changes and requests a quick adjustment of air pressure and/ or horizontal distance to maintain the same zinc coating. 6TCPUXGTUCNEQCVKPIEQPVTQN is a closed loop intended to minimize zinc coating variation across the strip. It adjusts the lip gap profile of each air knife. This control is based on a multivariable strategy using 12 actuators and a matrix system for the computation. The computer receives zinc coating information from the gauge and computes the deviation for the positions in front of each actuator. Lip gap profile variation in accordance with the set point and gains are calculated by the model. Variations are balanced across the profile to maintain the average coating thickness. As for 96

MPT International 2/2013

longitudinal coating control, a Smith predictor is also used to shorten the response time of the loop. With this control strategy HKIWTG , the air knife parameters can be controlled online according to variations or deviations of operating and process conditions and to the coating scanning results.

+ORTGUUKXGQRGTCVKQPCN TGUWNVU Conventional air knives achieve zinc coatings on the strip that are within the coating specifications determined by the galvanizers. But the DAK®E device with its remote lip gap profile for transversal coating control can achieve even better coating results by e.g.: - tighter distribution of coating results around the target, - possible reduction and optimization of coating target, - possible reduction of air flow rates thanks to closing lip gap on edges,

leading to reduced scum production, - possible adaptation of lip gap opening to product mix. For economic reasons, the target is to have a minimum required coating thickness everywhere on the strip. Due to the process variations, the mean coating thickness is usually much higher than the set target HKIWTG . Thanks to the remote lip gap profile supplied by the DAK®E system, the coating dispersion across the strip can be reduced (from d1 to d2 in figure 6). Consequently the mean coating thickness can also be reduced. In addition, coating thickness is also more homogeneous along and across the strip thanks to the transversal coating control with less dispersion observed. After start-up of the CGL 3, numerous jet line issues were observed, leading to downgrading of products. Since the start-up, Borçelik has observed various points that could be improved on the line, as e.g. the right and efficient maintenance of the equipment, especially of key equipment as the air knives. So a maintenance strategy was developed by the Borçelik team. Operator skills were improved through dedicated training, and specific maintenance procedures were elaborated. As a result, over two years the product defects could be drastically decreased VCDNG . Since the start-up of the line, the Borçelik team has improved its knowledge of CGL 3 and the air knife system installed. From 2010 to 2012, production has stabilized with significant improvements in zinc coating targets and coating performance. In the same period, regulation loops and presetting have also been optimized according to the product mix (in terms of section, products and coating) and the specifics of the line. Operation examples for the period 2010 – 2012 are shown in VCDNG. Initially the mean coating weight measured was a few g/m² higher than the target value – assuming that the operators manually corrected the setting, probably for safety reasons regarding coating performance. Hence, it was possible to save zinc by reducing this misalignment through a better management of the preset values by the operators, as has been done on site. This reduction in zinc coating (mean value) by 0.7 g/m²/side in 2011 and another 0.49 g/m²/side in 2012 has led to better efficiency, as has the global reduction in zinc consump-

5VTKRRTQEGUUKPI tion by about 140 t (representing about 1.5 to 2% of annual zinc consumption â&#x20AC;&#x201C; depending on the product mix).

(WTVJGTRQVGPVKCNHQT GHĆ&#x201A;EKGPE[KORTQXGOGPV To make the benefits of the remote gap profile more visible, the air knife system was used in combination with the transversal coating control. For comparison, this control was stopped while setting up the lip gap parallel across the strip as done by conventional air knives. A mean improvement of about 2.1 g/m²/ side was observed during normal operation when using the DAKÂŽE air knives with transversal coating control. For several months, coating measurements were subjected to a global statistical analysis. The DAK was found to enable a tighter distribution of the coatings around the target than a conventional system. With the DAK, it would be possible to reduce the zinc coating target by up to 6%. But to be on the safe side and stay above the minimum target, Borçelik decided to reduce the zinc thickness target by 2%. This would already lead to interesting and significant zinc savings while complying with the specified coating thickness tolerance target. With these examples, the DAKÂŽE system has proven to achieve a decrease in the zinc coating thickness target. The further decrease by 2 g/m² as specified by Borçelik can lead to additional savings of about 120 t of zinc per year â&#x20AC;&#x201C; thanks to transversal coating control.

Metallurgical Plant and Technology

A further potential improvement to the DAKÂŽE wiping system may be the addition of an on-line control system to optimize the target as a function of the standard transversal coating deviation. As a supplement, a distance sensor could be installed in order to continuously monitor the strip position and more quickly adjust the horizontal air knife position when the strip is swinging, in case of strip speed variations, adjustment of submerged rolls and product change, strip tension variation etc.

tance according to operation and process condition variations: strip shifting, strip cross-bow and strip section changes. The DAKŽE system is supplied with automatic lip cleaning, a contactless baffle including an autocentring device. Thanks to this new line, Borçelik can supply the best quality products to the markets in a very broad product mix. Furthermore, the close and friendly cooperation between Borçelik and Siemens allows continuous improvements of product quality while reducing operating costs.







2012 0.04%





2nd quality








5CXGF g/m²/side

6CDNGJet line improvement 2010 â&#x20AC;&#x201C; 2012

4GCNEQCVKPI g/m²/side

6CTIGV g/m²/side

&GNVC g/m²/side

May 2010




May 2011





June 2012





6CDNGImprovements in zinc coating targets from 2010 to 2012

%QPENWUKQPU The main objectives of DAKÂŽE are not only to save zinc within the coating thickness target by lip gap adjustment, but also to improve surface quality by an air cushion and to improve strip weldability through a more consistent distribution of the zinc coating thickness. DAKÂŽE equipment is able to control the on-line lip profile, air pressure and the strip/nozzle dis-

The DAKŽE air wiping system greatly contributes to these performance effects. It finally shows an excellent behaviour with an about 2% decrease in the zinc thickness target which achieves interesting and significant zinc savings, within the specified coating thickness tolerance target. A system as that installed at Borçelik CGL 3 enables better line performance at a rapid return on investment.

G 25074

ISSN 0935-7254


April 2013

Maintenance: Chelpipe values life-cycle partnership â&#x20AC;&#x201C; a forward-looking service philosophy

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MPT International 2/2013


Technical innovations

Start-up of atmosphere roller hearth reduction furnace IRONMAKING At North American Hoganas, Niagara Falls, New York, an atmosphere roller hearth reduction furnace supplied by Can-Eng Furnace was recently started up. The electrically heated unit has the capability of reducing iron oxide powder to sponge iron in a 100% hydrogen environment flowing at high capacity. In addition to the furnace, Can-Eng supplied an H2 recycle system, consisting of an energy efficient heat recovery unit, spray towers and auxiliary equipment for the purpose of decreasing the dewpoint of the process hydrogen atmosphere. A preheat furnace system was supplied to heat the recycled hydrogen to near process temperature. The continuous roller hearth furnace employs unique sealing arrangements on the charge and discharge openings as well as a special gasket system on all rollers. The system came complete with level 2 automation software from Can-Eng.

Outside view of the roller hearth reduction furnace

Problems with the Handling of Coke Breeze?

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New Sendzimir mill running at 1,200 m/min

The Solution: Pelleting.

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COLD ROLLING Chinese steelmaker Taiyuan Iron and Steel Co. recently commissioned a new cold rolling mill for stainless steel. The rolling mill was supplied by Fives DMS. With this project, Tisco intended to reach a production capacity of 133,000 t/year of 1,200 m/min. The 20-high Sendzimir mill supplied by Fives DMS for this project had been specially designed for cold rolling bright annealed stainless steel at a maximum strip width of 1,650 mm and for a minimum thickness of 0.20 mm. As mostly thin strip would be rolled on the mill, Fives DMS teams recommended a housing-type ZR21AB mill. Fives DMS installed its newly developed oil wiper system on the mill. This allows the coil to be wound perfectly straight with no damage or markings from the wiper on the strip surface. The new rolling mill at Taiyuan Iron and Steel reached a speed record of 1,200 m/min, without compromising on the coilâ&#x20AC;&#x2122;s flatness and surface quality.

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MPT International 2/2013

If you talk about environment and industries, say HOK . ®

And it‘s okay.

Rheinbraun Brennstoff GmbH D-50416 Köln Tel.: +49 221-480-25386

tuoba klat uoy fI tnemnorivne ,seirtsudni dna . KOH yas ®

And it‘s okay. HOK® . Activated lignite. Flue gas adsorbent and catalyst. First choice for gas cleaning in metallurgical processes. Substantial reduction of dioxins and furans e.g. in electric steel mills and sintering plants. Sometimes, a single, well-considered decision is all it takes: for the beneğt of your company, for the good of the environment.

The choice is HOK®. HOK® is OK.

Rheinbraun Brennstoff GmbH D-50416 Köln Tel.: +49 221-480-25386

Technical innovations

Start-up of dedusting plants at Shanghai Meishan ENVIRONMENTAL PROTECTION Two dedusting plants have recently been successfully started up at Shanghai Meishan Iron & Steel in Nanjing City, China. The two LT (Lurgi-Thyssen) plants supplied by GEA Bischoff are used for the dedusting of carbon monoxide laden industrial gas arising from the two 250 t converters of the new steel production lines 4 and 5 at Shanghai Meishan, which belongs to the Baosteel group. The GEA Bischoff LT process is characterized by very low energy demand and minimized residual dust concentrations. The extracted dry dust is rich in metallic iron which will be reused in the steelmaking process. GEA Bischoff’s order scope comprised the complete engineering including the plant automation, planning, supply of equipment and supervision of erection and commissioning. Each plant includes an evaporation cooler, a dry round-type electrostatic precipitator, an ID fan, a switch-over station, a flare stack and a gas cooler connected to a gas holder. The plants reduce the dust content to below 10 mg/m3 (stp). The incorporated gas recovery system reduces CO2 emissions by more than 250,000 t/year. The values measured in August

Second ULCOS HIsarna test campaign IRONMAKING The HIsarna pilot plant at Tata Steel in IJmuiden, Netherlands – an initiative of the ULCOS consortium of European steelmakers – underwent a second test campaign that ran for about six weeks, starting on October 4, 2012. The revolutionary element of the HIsarna ironmaking technology is the elimination of costly preparatory processes. Fine ore and coal can be fed straight into a HIsarna plant without prior processing. The technology is still at a very early stage, but if it can be successfully implemented, the new process could result in the gradual phasing out of the preparatory processes, reducing carbon emissions by 20% in ten to twenty years from now. The first HIsarna test campaign, in spring 2011, had proved that a plant using this technology can operate in practice, not merely in theory. The engineers succeeded in producing liquid iron. After several improvements to the technology’s processes, as well as to the plant itself, the key objective of the second test campaign was to achieve stable liquid iron production over a longer period of time. The results are still being evaluated. In addition, mining companies Rio Tinto and LKAB and several research institutes are working on HIsarna. The project has received financial support from the European Union and the Dutch Ministry of Economic Affairs.

Contact: E-mail:

Newly installed dedusting plant

2012 for the acceptance certificate were significantly below the guaranteed values. Contact: E-mail:

Problems with hot spots? You want to protect blast furnace hearth? Increase livetime of blast furnace? Reduce of hot spot? Durable, higher strength refractories? Decrease of cost?

2013 in the David L. Lawrence Meet the Sachtleben experts at the AIST 6 to 8 May 2013. Convention Center, Pittsburgh, USA, from

Great Solutions with Small Particles

Technical innovations


Fire-resistant, polyolester-based, FWBP?SJGAkSGB HYDRAULICS QuintolubricÂŽ 888-68, a polyolester-based fire-resistant hydraulic fluid (HFDU) developed by Quaker Chemical, successfully passed the new SEB 181224 specification of German Steel Institute (VDEh). The new SEB specifications issued in 2013 by the

Steel Instituteâ&#x20AC;&#x2122;s hydraulic fluids committee were developed to increase safety in steel mills.

Contact: E-mail:

Trolley system for scrap bucket transport

Trolley carrying a scrap bucket



MPT International 2/2013

STEELMAKING At Peiner Träger, a company of the Salzgitter Group, the scrap buckets weighing up to 140 t are transported by rail-bound trolleys from the scrap yard to the two electric arc furnaces. Peine had initially asked Vollert to build a new trolley that was identical to the transport systems already in use. Vollert, however, recommended a different approach that convinced the team at Peiner: an all-new concept that would incorporate a robust vehicle frame with a 1,000 l fuel tank acting as part of the load-bearing structure and a diesel engine that would swing outward to facilitate maintenance. The gear motors would also be accessible without having to remove the axles and wheels. With each dump of material, the equipment has to cope with loads of several tonnes. The most important aspect of the design was to achieve a solution that would be able to cope with the dusty and harsh environment in the long run. The new vehicle features sprung

wheels, a weighing device, and a collision-protection system that ensures short braking distances even under high-load conditions. The diesel-hydraulic drive can be operated in automatic or manual mode, and the on-board control system transmits all relevant data, such as weight and operating status, to the control centre via a WLAN connection. During the design phase, the load-bearing components were computed using the finite element method, which allows achievement of optimal load distribution and prediction of stresses and strains. Nevertheless, the trolley was subjected to a real-world, around-the-clock endurance test. Since its introduction in the summer of 2012, the new trolley has been transporting scrap to the electric arc furnaces non-stop, at an average availability better than 99 percent.


Technical innovations

!MLTCPRCPQSQNCLQGMLQWQRCKUGRFKGLGKSK space requirements STEELMAKING An especially robust converter suspension system, Simetal Conlink 2.0, with minimum space requirements has been newly developed by Siemens Metals Technologies. In the Simetal Conlink 2.0 design, the vessel is attached to the trunnion ring with four vertically and horizontally mounted connecting elements (links). Because of the link arrangement, the suspension is 100% statically determined in spite of the flexibility of the links. The system ensures uniform distribution of the load across all positions of the vessel. Each of the links is mounted underneath the trunnion ring, where they are within the protected zone. This simplifies assembly and increases service life. The patented positioning of the links is the result of development that optimizes uniform distribution and minimum space requirements during swivel movement of the converter. Eight links arranged in optimized positions connect the converter vessel to the trunnion ring. The patented H-shaped links allow simple installation â&#x20AC;&#x201C; onsite welding is not required. All vertical and horizontal links are identical, which shortens the manufacturing time and simplifies spare parts management. The Simetal Conlink 2.0 system is completely maintenance-free throughout its entire service life.

Converter vessel with suspension system

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Innovation in Quality Assurance For more information contact us at: +49 (2405) 47 999 40 Please visit us at AISTech 2013, booth 2534 MPT International 2/2013


Technical innovations

Rotating in-line dimension measurement

Rotating measuring unit for cold steel bar

MEASURING EQUIPMENT To make production processes as efficient as possible, modern in-line measurement devices are required not only to measure parameters such as diameter, ovality, width and height at very high speed but also to instantly detect shape deviations and rolling errors. Zumbach Electronics has developed a rotation-based laser scanning process that maps round and polygonal shapes up to 6,000 times per second. Static or oscillating devices can measure with great accuracy outer dimensions and

diagonals. But the level of precision achievable in manufacturing processes involving high rolling speeds and short lengths left much to be desired. The new Steelmaster SMR product generation now comes with an innovative and much faster rotational measurement system. The system is based on up to three fully synchronized high-tech laser measuring heads of the ODAC® series, which use an innovative rotational principle to measure outer dimensions, diagonals, diameters and cross-sections with 360o coverage. Each one

of the laser measuring head rotates at a speed of 100 rpm and maps the scanned products up to 2,000 times per second to create a precise product profile. In this way up to 600 profiles can be generated every minute. This allows manufacturers to significantly reduce scrap while maintaining stricter tolerances of ½ and ¼ DIN. Up to a diameter of approximately 135 mm and temperatures of up to 1,200°C, there are no longer any restrictions as to the shapes the system can cope with. The Steelmaster SMR software is very flexible, allowing data statistics, numerical and graphical displays as well as logs to be freely configured. Zumbach also developed a new method, EPM (enhanced profile measurement, patent pending), for geometries with irregular or asymmetric shape aberrations. In particular it is also able to capture and calculate polygonal shapes, which can occur in certain rolling processes or after subsequent peeling/grinding operations. For any shape it will measure at high ac-

curacy not only minimum, maximum and mean diameters but also the true outof-round deviation RONt as defined by ISO/TS 12181-1 as well as the inscribed circle MICI and the circumscribed circle MCCI. An optional module named FPS, especially for 3-roll blocks, calculates accurate values corresponding to the diameter values which would be found by manual 3-point micrometer screws. This module additionally calculates the “Touch” and “Gap” diameters which are essential for the initial roll setting. The dynamic regression analysis included in the software package means that twist and angle of twist no longer influence the measurement result. This results in lower scrap rates and ensures compliance with strict tolerances. The technology also performs regardless of position, vibration, material temperature and light intensity.

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International Conference on

Advances in Refractories and Clean Steel Making Theme: Challenges & Opportunities in Refractories and Clean Steel Making In Association With Organised by June 26-28, 2013, Ispat Bhawan, SAIL Ranchi, India

Media Partners

R & D Centre for Iron and Steel Centre for Engineering & Technology Ranchi - 834002, Jharkhand, India

Under Aegis Of Indian Ceramic Society Subarnarekha Chapter, Ranchi

Steel Authority of India Limited

MECON Limited Ranchi - 834002, Jharkhand, India

Indian Institute of Metals Ranchi Chapter

R&D Centre for Iron & Steel, the corporate research unit of Steel Authority of India Ltd.(SAIL), in association with Centre for Engineering & Technology (CET), SAIL and MECON Limited is organising an International Conference on “Advances in Refractories and Clean Steel Making (ARCS13)” during June 26 to 28, 2013 at Ispat Bhawan, Ranchi, Jharkhand, India. The theme of the Conference is “Challenges & Opportunities in Refractory and Clean Steel Making” If you are Steel Plant personnel/ Equipment Manufacturer/Technology Provider/ Researcher/Consultant/ associated with Steelmaking & Refractories you shouldn’t miss ARCS13 and the many networking and learning opportunities offered.

For more information on ARCS13 please visit 104

MPT International 2/2013

Technical innovations

!CLRP?JGXCB?BKGLGQRP?RGML?LBCT?JS?RGMLMD process data files can be found either by their name or by means of their properties. The individual departments of a company, such as production, quality assurance or maintenance, get an insight in all available data and have them filtered by individual criteria. The tool searches in the stored data for specific characteristics like e.g. production period, batch number, limit values that have been exceeded and further parameters in order to initialize process optimization. For this purpose, the measured data files can be opened by means of the ibaAnalyzer software one by one or as a group of files. The HMI can be configured freely and supports MS SQL-Server,

The HMI makes decentrally acquired data transparent

MS Access, Oracle and other ODBC-compatible databases. In a pilot project, not only savings on time have proved to be a major advantage. Also the network load could be noticeably reduced by the

ibaDatManager. The application has been available for broad use since the first quarter of 2013. Contact: E-mail:

© Utz Peter Greis, Düsseldorf

AUTOMATION Especially in complex production processes and automated plants, process and quality monitoring are based on numerous measured variables. For acquisition and recording of these measured variables, iba offers modular hard- and software components that can be combined and make the whole process more transparent. iba recently introduced the ibaDatManager, a userfriendly application for the centralized administration of measured data. With the ibaDatManager, it is possible for users to analyze the locally recorded data across processes and have always an eye on all relevant key figures. The

„Ladies and Gentlemen, not too long ago, some of these steel guys were still dreaming of a never-ending economic boom.”

MPT International 2/2013


Literature service

Acid regeneration 4 pages, English This brochure summarizes the activities and service range of Astec Engineering which specializes in acid regeneration plants for hydrochloric acids using spray roaster or fluidized bed systems. The company provides comprehensive solutions for the regeneration of waste pickle liquor and rinse water in the steel industry. Contact: E-mail:

Strip processing lines 30 pages, English, German A comprehensive brochure on technologies and solutions offered by BWG Bergwerk-Walzwerk-Maschinenbau in the field of strip processing lines. Detailed information is provided on levelling and degreasing lines, coil coating lines, heat treatment lines, side trimming lines as well as special equipment.

Contact: E-mail:

Electric actuators 34 pages, English, German A technical brochure outlining the range of electric actuators offered by Euba Antriebstechnik. It contains a general description of the main and auxiliary equipment, a survey of the product range complete with technical data and technical drawings for each model, lists and drawings of spare parts, wiring diagrams, etc. Contact: E-mail:

Roll cooling systems for rolling mills 2 pages, English, German A leaflet providing an overview of roll cooling systems offered by Evertz Hydrotechnik for hot and cold rolling mills. Concise information is provided on spray valves and spray valve systems, both directly and remotely operated. The descriptions are complemented by equipment photos. Contact: E-mail:

Refractory services 16 pages, English A brochure detailing refractory engineering activities and products supplied by the ikb/vhi group. The product range includes anchor systems, steel fibres, refractory and insulating materials as well as stud welding machines. The products are tailored to specific customer requirements. Contact:; 'OCKN QHĆ&#x201A;EG"KMDIODJEQOQHĆ&#x201A;EG"XJKIODJEQO


MPT International 2/2013

Literature service

Combustion imaging solutions 12 pages, English A brochure describing temperature and gas sensing instruments supplied by Lumasense Technologies. With the Lumasense combustion imaging solutions, operators get continuous imaging inside their furnaces. Features include image comparison, trending, offline report writing, HTML export for remote reviewing, etc. Contact: E-mail:

Flat product processing 4 pages, English, German Information about Nisterhammer Maschinenbau, supplier of machines, facilities and systems for the processing of flat products made of steel, aluminium and other non-ferrous metals. Services include the full range from engineering, supply of process equipment, site supervision and comprehensive after-sales service. Contact: E-mail:

Refractory bricks 6 pages, English A brochure featuring Refratechnik's CeramacÂŽ brick . This brick stands out due to its combination of a flexible carbon bond with a stable ceramic bond. The bond matrix is graphitized, which has a positive impact on the mechanical properties and the oxidation behaviour of the products. The bricks release no smoke or odours. Contact: E-mail:

Furnace systems for the steel and copper industries 48 pages, English, German A catalogue of shotblasting machines supplied by Rump. It contains descriptions, photos, technical drawings and technical data of overhead monorail, wire belt and rolling conveyor shotblasting machines, drum tumbler machines, airblast cabinets and shotblast machines for large-volume parts. Contact: E-mail:

Lifecycle solutions for plants 24 pages, English, German A brochure describing the modular technology services concept offered by ThyssenKrupp Uhde, enabling operators to identify any potential for optimizing their plants. The concept modules address the entire lifecycle of plants through basic, system, performance and consulting service modules. Contact: E-mail:

MPT International 2/2013


In the next issueâ&#x20AC;Ś Steelmaking High-quality hot strip production in India using CONARCÂŽ and CSPÂŽ technology In 2010 and 2011, Essar Steel India extended its production capacity at the Hazira steel works in the Indian federal state of Gujarat by five million t/year of crude steel and another 3.5 million t/year of hot rolled strip. The pertaining plant technology consists of two 200 t CONARCÂŽ furnaces, three twin-ladle furnaces and a CSPÂŽ plant. Whereas the latter started operating with two strands, it has meanwhile been extended to become the worldâ&#x20AC;&#x2122;s first three-strand CSPÂŽ plant. This article describes the plant technology and presents the most important operating results in the commissioning phase.

Hot rolling Modernization of the SBQ bar mill at GeorgsmarienhĂźtte, Germany GeorgsmarienhĂźtte GmbH has revamped and extended its 3-roll reducing & sizing block (RSB), originally commissioned in 2001. The mill revamping comprised among others the implementation of a size control system in connection with 3-roll stands adjustable under load. Thus the rolled tolerances and their reproducibility could be improved by means of automated optimization of process parameters for the rolled bars based on a real-time closedloop control system. Additionally, the existing reducing & sizing block has been extended from five to six stand positions. As a result the roughing and intermediate mill has to produce fewer input sizes for the RSB, increasing productivity. GeorgsmarienhĂźtte GmbH is the first rolling mill worldwide to use this trend-setting technology.

New ring locking/unlocking system for wire rod finishing blocks enables quick change-over Pert has developed a new locking system for rolling rings in finishing blocks of bar and wire rod mills. With this system, ring changing can be accomplished in less than one minute. Presently, without the system, ten minutes are required. Moreover, the effort involved in both ring manufacture and ring and groove changing is drastically reduced. The new system can be introduced without changing the mill configuration. Being installed on the existing block, its advantages can be immediately tapped. The system is adaptable to all types of finishing blocks as well as cantilever stands in intermediate or finishing mills.

This preview may be subject to change.

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MPT International 2/2013

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SERVICE MAKES THE DIFFERENCE Reducing electrode consumption, shorter tap-to-tap times and high arc stability enable an efficient melting process. Our graphite electrodes come with a comprehensive service package and various options to optimize your operations. Everything around the graphite electrode, and more.

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MPT International 2/2013 (Apr)