MPT International 3/2015 (Jun)

Metallurgical Plant and Technology G 25074

ISSN 0935-7254

Tyasa, Mexico, deployed a new V[RG '#( HQT VJG Æ&#x201A;TUV VKOG GXGT

June 2015

METEC & 2nd ESTAD: European Steel Technology and Application Days

MEERdrive®: NEW STANDARD IN WIRE ROD PRODUCTION www.sms-ecoplants.com

ecoplants Visit us at

METEC 2015

Hall 5, Booth E22 GIFA/THERMPROCESS 2015

Hall 10, Booth H41 June 16 - 20, Düsseldorf, Germany

With MEERdrive®, SMS Meer has developed a new drive technology that redefines the standards in wire rod production. The basic idea is to replace the wear-prone, maintenance-intensive gearboxes of wire rod blocks with intelligent individual drives for each stand. These allow the rolling process to be made far more flexible and the defined metallurgical properties of the finished product to be precisely achieved. The energy consumption is significantly reduced and roll ring management greatly simplified. That is why MEERdrive® has been awarded the ecoplants mark – the sign of an ecologically and economically advantageous solution from SMS Meer.

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www.sms-meer.com

Maximum productivity

EDITORIAL

‹‹‹

METEC & 2nd ESTAD are awaiting you There are only a few weeks to go until the 9th International Metallurgical Trade Fair with Congresses – METEC 2015 – and the 11th International Trade Fair and Symposium for Thermo Process Technology – THERMPROCESS 2015 – will open their doors in Düsseldorf, Germany. The 2nd European Steel Technology and Application Days (ESTAD) 2015 will run in parallel with the trade fairs. With these mega events coming close, information on the fairs, the exhibits and the accompanying congresses is being given a major final update in this issue of MPT International. Many exhibitors are announcing here what will be on display. The technical articles relate perfectly to the scope of these outstanding trade fairs. With a view to the significance of these industry events, our show issue provides an enlarged range of topics and articles on latest developments in the iron and steel industry, spanning virtually the complete process chain and spotlighting issues of topical relevance for the industry. Within this wide spectrum, some topics deserve special attention and are featured by different authors from different angles. All in all five articles focus on recent developments in steelmaking technology, including its automation and quality control. Since steelmaking constantly strives for what is called low conversion costs, plant makers have developed various measures for energy savings. Four years ago – actually in the runup to METEC 2011 – we reported about a completely newly developed solution for preheating the scrap before being charged to an EAF. The so-called EAF Quantum was designed to achieve considerable energy and cost savings in conjunction with short tap-to-tap times of less than 33 minutes. Now we follow up with a report about the first EAF Quantum that has been implemented at Mexican steel producer Talleres y Aceros S.A. de C.V. (Tyasa). The 1.2 million t/year meltshop has meanwhile commenced permanent operation. In the article it is reported that this new type of furnace cuts the specific conversion costs of liquid steel production by around 20 per cent.

Dipl.-Ing. Arnt Hannewald

The second topic that I would like to draw special attention to is thin slab technology. In recent years engineers and business people have reflected on what may be the optimum plant configuration for a defined annual production capacity of 1 or 2 or 3 million t. Now we have learned new figures from China – the land of giant steel production. Rizhao Steel is building a new casting-rolling complex comprising five thin slab plants designed for a total annual production capacity of 11 million t of thin hot strip. Actually, these are just a few examples of the multiplicity of topics awaiting the visitors to the METEC and THERMPROCESS trade fairs – certainly this year’s most important meeting point for the steel industry.

MPT International 3 / 2015

››› CONTENTS

International industry news 28

World Steel Association short range outlook 2015 – 2016

AK Steel to build world-class research and innovation center

Aumund expands after sales service network by new centre in Brazil

Interview 34

Coverphoto: The Bright World of Metals: GIFA – METEC – THERMPROCESS – NEWCAST, Düsseldorf, Germany, 16 – 20 June 2015

Strained global markets present technology providers with ever new challenges MPT International interviewed Dr. Christian Bartelsvon Varnbüler, chairman of the German Metallurgical Plants and Rolling Mills Association and president of the Küttner Group

Messe Düsseldorf GmbH, Düsseldorf, Germany Contact: www.tbwom.com

Events

Cokemaking

METEC 2015 is focusing on sustainable metallurgy

Preview of exhibitors

METEC and 2nd ESTAD – European Steel Technology and Application Days

New quenching bucket for the Schwelgern coke plant The made-to-measure heavy plate construction was replaced for the first time

Ironmaking 76

New coal-injection technology installed at Salzgitter Flachstahl At two blast furnaces PCI will substitute oil as a reducing agent

Steelmaking 78

First EAF Quantum commences permanent operation

84 ' ZVGPUKQP QH C UVCKPNGUU UVGGN TGƂPKPI complex by a twin-tank VOD unit

Mexican steelmaker Tyasa deployed the new type EAF for first time ever

Intelligent transformers help reduce transformation costs in EAF meltshops

A 150 t VOD unit was added to increase the production flexibility

A smart and tailor-made transformer was developed in order to reduce energy losses, improve efficiency and achieve a short-term return on investment

Mechanical vacuum pump systems to cut operating costs and reduce emissions In many works, the vacuum needed for degassing processes is still generated using steam jet systems

Robots shall manipulate probes at the BOF The advantages that will accrue are higher sublance availability and – most of all – greater safety at work

MPT International 3 / 2015

136

102

Quality assurance

Continuous casting

102 Optimizing ancillary processes in continuous casting

Fully automated laboratory system accelerates sample processing and process control The analysis is now faster, more precise and can be better reproduced

AMT CCM Package has been developed as a complete solution of harmonized integrated systems

106 Cross-company cooperation to expand slab Ć&#x201A;PKUJKPI UGTXKEGU ThyssenKrupp MillServices & Systems is expanding finishing services on site of HKM MPT International 3 / 2015

108

106

Hot rolling 108 The evolution of thin-slab casting and rolling plant technology Danieli has progressively developed over the years a new generation of thin slab casting and rolling layout

118 Rizhao Steel counts on ESP thin slab technology for high-quality production The Chinese steel producer is now focusing on the highly attractive local and export markets for high-quality, thin-gauge strip products

122 Rolling process optimization by means of RTQƂNG OGCUWTGOGPV DGVYGGP VJG RCUUGU A portable device for measuring hot rolled profiles between the passes significantly shortens the set-up time

126 Safety couplings in rolling mills Safety couplings increase the service lives of universal shafts, while reducing costs

Cold rolling

Strip processing

130 Production of high-quality steel strip for automotive application

132 New process increases pickling speed and reduces length of pickling lines

Each individual plant of the whole cold strip mill is linked to an integrated automation system at a Chinese steel works

Spray modules allow the removal of scale much more effectively than conventional turbulence pickling

136 Batch annealing plant with fully automatic crane operation

Environmental protection 148 A transparent venturi scrubber for testing performance improvement strategies A full scale test rig helps to better understand the physical phenomena inside the throat section of venturi scrubbers

The world’s most modern, highest capacity and at the same time most energy efficient batch annealing plant saves 1.5 GWh of energy every year

142 Strip guiding technology in furnace atmospheres using ultra-wideband radar technology Detection of strip position is the absolute crucial element for all strip guiding solutions

156 End track-out and dust problems Wheel washing systems together with water cannons can offer a complete solution for an escalating environmental problem

144 Automated coil handling at slitting lines The “Coil-Hover“ accelerates stowing of coils after slitting

146 Targeting steel surfaces The laser will be able to influence the properties of steel strip surfaces in an energy-efficient way

Columns 10

International industry news

METEC 2015 – preview of exhibitors

158 Technical innovations

168 In the next issue

165 Cartoon

168 Imprint

166 Literature service

122

Advertisers’ index ABB AB

IMS Messsysteme GmbH

AMB Srl

145

Andritz AG

147

INTECO special melting technologies GmbH

Associazione Italiana di Metallurgia

Aumund Fördertechnik GmbH

Automazioni Industriali Capitano srl Badische Stahl-Engineering GmbH BEDA-Oxygentechnik Armaturen GmbH Bloom Engineering (Europa) GmbH Dr. BRANDT GmbH Braun Maschinenfabrik Gesellschaft m.b.H. Can-Eng Furnaces

161 77 18, 41 64 163

19, 20 115

Jasper Ges. für Energiewirtschaft & Kybernetik mbH

KAMAG Transporttechnik GmbH & Co. KG

KELLER HCW

KettenWulf Betriebs GmbH

87, 88

Kiro-Nathaus GmbH

Friedrich Kocks GmbH & Co. KG

123

Maschinenfabrik Köppern GmbH & Co. KG

Kranunion GmbH

KSK Kuhlmann-SystemKühltechnik GmbH

160

Küttner GmbH & Co. KG

52 62

CMI INDUSTRY SA Metals

LAP GmbH

Combilift Ltd Co

Lechler GmbH

LogoTek GmbH

159

Josua CORTS Sohn CORTS Bearing Technology Dango & Dienenthal Maschinenbau GmbH Danieli S.P.A.

117 68 8, 9

EMG Automation GmbH

Fabris Inc.

LSR - Niederlassung der Rheinbraun Brennstoff GmbH Lubas Maschinen GmbH Maschinenfabrik G. Eirich GmbH & Co. KG Metal-Expo, JSC MIDREX Technologies, Inc,

101, 155

133 24 33 139 91

RHI AG

Konrad Rump Oberflächentechnik GmbH & Co. KG

Saar-Metallwerke GmbH

Sarclad Ltd

162

Schenck Process GmbH

Schubert & Salzer Control Systems GmbH

158

Schuh Anlagentechnik GmbH

135

SGL CARBON GmbH

Siempelkamp Maschinen -und Anlagenbau GmbH & Co. KG SKF Lubrication Systems Germany GmbH

SMS group

Spraying Systems Deutschland GmbH

Stangl Technik GmbH

STEIN INJECTION TECHNOLOGY GmbH

surcon GmbH

ThyssenKrupp Industrial Solutions AG

125

TML Technik GmbH

TMT Tapping Measuring Technology

Transformers & Rectifiers (India) Ltd.

143

Forni Industriali Bendotti Spa

131

framag Industrieanlagenbau GmbH

105

Getriebebau NORD GmbH & Co. KG DRIVESYSTEMS

Oerlikon Leybold Vacuum

GLAMA Maschinenbau GmbH

Pieper GmbH

Verlag Stahleisen GmbH

GSB Group GmbH

Plakoma GmbH

Vesuvius Group SA

POLYTEC GMBH

Walzengießerei Coswig GmbH

Guild International Inc. Hans Hennig GmbH hpl-Neugnadenfelder Maschinenfabrik GmbH Johannes Hübner - Fabrik elektr. Maschinen GmbH Hydrowatt AG IMI Z & J Germany

Morgardshammar AB

NCO spa

95 151

158

169

Quaker Chemical Corporation

129

R+W Antriebselemente GmbH

60 121 53, 54

REA Elektronik GmbH REDEX GmbH REFRATECHNIK Steel GmbH

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

Weerulin GmbH

Primetals Technologies Austria GmbH

141 83 27, 29

113

WOKO Magnet- und Anlagenbau GmbH PAUL WURTH S.A.

153, 157, 164 127 47 107 22 170

Zumbach Electronic AG

2M Foundry Srl

3tn Industriesoftware

MPT International 3 / 2015

Danieli Centro Met has developed super-flexible and high-productivity refining stations, to match high-quality and high-productivity market requirements for higher added-value products.

Four main references out of total 303 refining stations TOKYO STEEL JAPAN 300-t twin-tank double-cover VD/OB station, equipped with a 700 kg/h suction capacity 4-stage vacuum pump, steam ejectors + WRP for the production of up to 2.6 Mtpy of low and ultra-low carbon and Al-killed grades (API, HSLA, EDDQ).

Steelmaking plants

DONGBU STEEL KOREA Two 160-t twin LFs and one twin-tank double-cover VD/OB, 400 kg/h suction capacity 5-stage vacuum pump, full steam ejectors, to refine up to 2.6 Mtpy of ULC and HSLA grades for automotive and pipe applications.

Danieli Headquarters 33042 Buttrio (Udine) Italy Tel (39) 0432.1958111

www.danieli.com

DANIELI CENTRO MET CLEAN STEEL TECHNOLOGY FOR BOTH HIGH QUALITY AND PRODUCTIVITY > LF, VD, VOD stations up to 300 t > Full range of steel grades

MECHEL GROUP RUSSIA Complete secondary metallurgy station, 140-t twin LF and twin-tank single cover VOD, 110 kg/h suction capacity, dry mechanical vacuum pump with 5 parallel skids, to produce ULC, HSLA and stainless steel grades.

SSAB OXELÃ&#x2013;SUND SWEDEN Innovative LF-VD combined plant design (twin-tank on moveable cars plus one LF in line) to match the short cycle time/high productivity of the BOF process route, decreasing average crane utilization and allowing longer casting sequences.

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

MEET THE DANIELI TECHNOLOGY AT DANIELI LOUNGE HALLE 4 / G28

››› INTERNATIONAL INDUSTRY NEWS

Africa Algeria Algerian Qatari Steel to built integrated minimill. Algerian Qatari Steel (AQS) will build an integrated minimill with a capacity of 2 million t/ year of steel products. The mechanical equipment, automation systems and assistance will be provided by Danieli. The new steel complex will be composed of a 2.1 million t/year meltshop, featuring two 120 t electric arc and refining furnaces and two five-strand continuous casters for billets and three rolling mills – two bar rolling mills and one wire rod mill. Danieli will also supply all the auxiliary plants, including a water treatment plant with a capacity of 20,000 m3/h.

The Americas Argentina Acindar revamps rolling mill automation. AIC has successfully completed the revamp of the rolling mill automation at Acindar, part of ArcelorMittal, at Tren Bonelli in San Nicolas. The project involved the replacement of the existing mill control system with a new system based on ABB AC800 technology allowing the complete mill to be controlled by the same platform. Also included in the project scope was new technology for clutch-brake and start-stop shears based on Siemens Simotion controllers to guarantee highest cutting precision and new control for slide braking and moving of the rakes to improve discharging of the material and positioning on the rakes. Commissioning was successfully completed during a three-week shutdown.

be at ArcelorMittal Tubarão, using existing lab facilities in the Vitória unit, Espirito Santo. The investment also includes the purchase of equipment for process simulations, product characterization as well as analytical models to reinforce the currently existing scientific structure. Around 30 researchers and technicians will be hired in Brazil over the next two years. Others may also join from European or American research centres within the group on temporary assignments. The new research centre aims to meet the demands from both Long and Flat Carbon South America in product development, process development and customer services, and plans to focus on innovations for the automotive industry, mechanical engineering, energy, construction and household appliances industries.

Asia USA China Bilstein orders annealing furnaces. Tenova Core has been contracted by Bilstein Cold Rolled Steel LP for the design and supply of HPH (high performance hydrogen) belltype furnaces for installation at Bilstein’s Bowling Green, Kentucky facility. The furnaces will be used to anneal steel strip coils in a 100% hydrogen atmosphere. The project scope includes HPH heating hoods, annealing bases and jet cooling hoods as well as associated equipment and process control systems. The high-performance recirculation system ensures effective gas circulation and superior temperature uniformity. The proven annealing base design is optimized for obtaining the lowest dew point possible and can be used for annealing almost any grade of steel strip coil. Jet cooling requires no cooling water and ensures homogeneous cooling of all coils. Tenova LOI Thermprocess has worldwide supplied over 8,500 annealing bases for steel strip coils.

Brazil USA ArcelorMittal opens new R&D centre. ArcelorMittal plans to open its 12th global research and development centre this year. The new centre will MPT International 3 / 2015

panded their facilities’ inspection systems. They selected a comprehensive inspection system from ISRA Vision Parsytec for their Cleveland, OH facility in order to augment and load-balance surface inspection with their Twinsburg, OH facility. Three years ago, in 2012, an ISRA Vision Parsytec inspection system was installed at the Twinsburg Samuel Steel facility. Samuel Steel Pickling now ordered an identical, additional inspection system. At the same time, they also upgraded the Twinsburg system, bringing both facility inspection systems current to the latest technology. The scope of the project includes a two-sided Surface Master system with traversing sensors as well as an upgrade for the Twinsburg facility.

Samuel Steel Pickling orders pickle line inspection system. Samuel Steel Pickling recently ex-

Shougang Qian’An to employ new fine dust extraction technology. Shougang Qian’An Iron and Steel has placed an order with the SMS group to retrofit their steelworks with hydro-hybrid filter systems. The steelworks is located in the city of Qian’An in the northeast of the Hebei province. The modernization of the primary dedusting systems of the three BOF converters will include the installation of hydro-hybrid filter systems and their integration into the exhaust duct downstream of the existing wet scrubbers. Commissioning of the first unit is scheduled to take place before the end of this year. The scope of equipment to be supplied by SMS China covers the complete wet-type filter system, electrics and automation system as well as assembly. This concept minimizes the time required for the reconstruction work. With this Ecoplants technology, Shougang will be able to significantly reduce their dust emissions. This order from China is also the first to include the installation of a filter system newly developed by SMS. Thanks to the innovative solution of combining the existing wet scrubber and the electrostatic precipitators, clean gas dust contents down to 10 mg/Nm3 can be achieved. While

Offering the highest quality of service in the graphite electrode industry we provide personalized consultations to maximize the total value for our customers. We also manage individual partnership projects as ongoing support for your process improvement efforts. Mutually agreed projects, with defined targets and cost impacts, aim to reduce process variability using Six Sigma methodology. Please visit our website to learn more about the types of services we offer and how we can add value to your operation. See details under www.ge-competence.com

+ Visit us at METEC 2015 FG04-01 | Open-air exhibition ground

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››› INTERNATIONAL INDUSTRY NEWS

News in brief BGH Lippendorf, Germany, has processed the first heat in its new VAR furnace supplied by Inteco. The unit produces ingots with a diameter of 860 mm and a maximum weight of 11 t.

Evraz ZSMK, Russia, has issued the FAC to Paul Wurth for the new PCI plant. Two coal grinding and drying plants feed pulverized coal to the injection plants of all three blast furnaces of the Zapsib site.

Jindal Stainless Limited (JSL), India, has started onsite metal recovery from stainless steel slag co-products. The service is provided by Harsco within the framework of a multi-year contract.

the main dust load will be separated in the existing wet scrubber, removal of the fine dust, which has not taken place in the past, will from now on be handled by the new unit.

China Zenith Steel to revamp rod outlet. Zenith Steel (Changzhou Zhongtian Iron & Steel) in Changzhou, Jiangsu province, has signed a contract with Primetals Technologies to revamp a complete wire-rod outlet to improve the quality and range of its products. For increased cooling capacity, the wire-rod mill project will include upgrading the existing Morgan Stelmor conveyor with the first Optimesh system in China to ensure cooling uniformity for high carbon products in fast cooling mode. The revamped mill will operate at an increased speed of 110 m/s and will be able to roll rod ranging in diameter from 5.5 mm to 20 mm. The mill is expected to be commissioned in early 2016.

The Optimesh system controls the air distribution across the width of the Stelmor conveyor, ensuring uniform cooling of the rings for consistency of both mechanical properties and metallurgical structure. The contract’s scope of supply also includes a prefinishing mill, shear, Morgan Vee NoTwist mill, a Morgan intelligent pinch roll, laying head and water boxes. In addition, Primetals Technologies is providing an integrated solution with electric and automation upgrades for the mill.

China JISCO standardizes processes by production management system. Since late 2014, JISCO TianFeng Stainless has been using the production management system PSImetals to improve production of coils and sheets. As a result of the introduction of the system, all business operation flows at the Jiayuguan Gansu plant have been standardized, leading to full

! i s ift V a r o P a y Düsseld– 20.06.15 . 16.06 5 ll a H D26 Stand

MPT International 3 / 2015

INTERNATIONAL INDUSTRY NEWS control down to piece level, improved product quality as well as optimized inventory levels. Based on customer orders, PSImetals automatically generates production orders and production schedules from steel making, hot and cold rolling down to plate pickling. If required manual adjustments are supported by enhanced filter mechanisms. The main advantage of the new system is the full traceability of every single piece of material.

level-2 automation complete with technological packages as well as implementation and commissioning services. The 9 m vertical bending machine will be linked to Sha Gang’s rolling mill for direct hot charging. The delivery of equipment is scheduled for late 2015, casting of the first heat is planned for mid-2016.

Japan China Jiangsu Sha Gang to build bloom caster. Inteco will engineer and supply a new five-strand bloom caster for Jiangsu Sha Gang. The new caster will be designed for a bloom size of 300 mm x 400 mm. It will process engineering steels, spring steels and bearing steels as well as highestquality tire cord grades. Inteco will be responsible for the complete engineering and supply of key mechanical components, electrics, level-1 and

Nippon Steel & Sumitomo orders conveyor for hot sinter. Nippon Steel & Sumitomo is rebuilding its existing sintering plant, integrating at the end of the plant a high-performance system for conveying sintering material 600°C hot at a rate of 1,480 t/h. The pan conveyor for the transport of the hot sintering material will be supplied by Aumund Fördertechnik. The capacity of the new conveyor will be about three times the standard capacity of European plants. For the sintering plant of Nippon Steel & Sumitomo Metal, Aumund developed

DER

ANTRIEB

Q Reliable Q Versatile Q Global

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News in brief ArcelorMittal, Germany, has renewed a seal gas compressor in the reduction plant at its Hamburg site. Since installation of the new compressor, CO2 emissions of energy production in the power plant have been reduced by around 1,700 t. Numerous ongoing investments, including a new analyzer container in the steel plant, a new charging crane and an additional wire rod warehouse, will be completed in 2015. Puyang Steel, China, has successfully put into operation a continuous caster supplied by the SMS group. The caster produces medium-sized slabs. Aceros DM, Mexico, issued the FAC to AIC Automazioni Industriali Capitanio for the new MV drive system of the ten-stand wire rod line at the rolling mill in San Luis de Potosi.

NORD DRIVESYSTEMS: Q Worldwide available Q Subsidiaries in 36 countries Q Agents in 52 countries

www.nord.com/locator Headquarters: Getriebebau NORD GmbH & Co. KG Fon +49 (0) 4532 / 289 - 0 info@nord.com Member of the NORD DRIVESYSTEMS Group The

Gear Unit

The

Motor

The

Drive Electronic

Q Strong bearings Q High corrosion protection

Q High efficiency Q Global standards

Q Compact design Q Easy implementation

Q High power density

Q All operating conditions

Q Scalable functionalities

››› INTERNATIONAL INDUSTRY NEWS

a conveying system with a pan width of 3 m and special reinforcements for protection against wear caused by the extremely abrasive sinter material. Delivery has been planned for the end of 2015.

Europe Belgium ArcelorMittal Gent to upgrade hot-wide-strip mill. ArcelorMittal has awarded the SMS group the order to upgrade the seven-stand hot-widestrip mill in Gent. The order comprises the installation of new finishing stands F1 and F2 as well as modifications to stands F3 and F4. Additionally, the SMS group will support ArcelorMittal in optimizing the rolling process for its third-generation UHSS and AHSS grades. The installation work will take place in two steps during two short mill shutdowns. During

the first phase, which is scheduled for the end of 2015, stands F3 and F4 will receive new hydraulic screwdown systems, new oil film bearings and additional components that will provide for an increase in rolling forces. The main project phase in December 2016 will see the installation of the new rolling stands F1 and F2. The two new rolling stands will be pre-assembled and tested in the SMS workshop in Hilchenbach. On-site erection in Gent will then take place during running production alongside the rolling mill. During the subsequent mill shutdown, the existing stands F1 and F2 will be disassembled and the new, pre-assembled stands will be shifted into the finishing mill in place of the old ones.

Bremen. New modern moulds will be installed to increase the performance of the continuous casting plant and lead to qualitative benefits.

Germany ArcelorMittal to convert continuous casting line. In Duisburg, ArcelorMittal will convert the continuous casting line to a symmetric format, in order to align the system to the demands of the future and to enhance flexibility for further product segments. This investment will increase the site’s competitiveness, leading to higher flexibility and products for new segments in the automotive market.

Germany ArcelorMittal to invest in continuous casting plant. ArcelorMittal will remodel two strands of the continuous casting plant at its steel mill in

Germany ArcelorMittal to launch major investment. At the Eisenhütten-

w.s p

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Metec 2015: Hall 5 - Booth G02 |

Te l : 0 0 4 9 - ( 0 ) 4 0 - 7 6 6 0 0 1 - 0

INTERNATIONAL INDUSTRY NEWS stadt site, ArcelorMittal plans a major investment covering a performance improvement of the pulverized coal injection system at blast furnace 5A, the preparation of repairs at the same blast furnace and the installation of a new indoor crane in the hot rolling mill. Also the modernization concept at galvanizing line 1 will be continued with a new preheating furnace.

Germany BGH Lippendorf starts up new VAR furnace. At the end of February, special steel producer BGH Lippendorf processed the first heat in the new VAR furnace supplied by Inteco. The contract for this plant had been signed in 2014. Installation of the equiment had commenced in November of the same year. The furnace produces ingots with a diameter of 860 mm and a maximum weight of 11 t. BGH Lippendorf also operates VIM, ESR and Pressure ESR equipment from Inteco.

Italy Arvedi orders electric arc furnace. Acciaieria Arvedi has ordered an EAF Quantum from Primetals Technologies. This new type of electric arc furnace, to be installed in the Cremona steel works, will reduce specific conversion costs of electric steel production and have an annual production capacity of up to 1.57 million t of crude steel. The order also includes a complete dedusting system for primary, secondary and auxiliary emission sources with a heat recovery system to reuse the thermal power from the furnace offgas to produce steam for the pickling lines. The furnace will have a tapping weight of 125 (±10) t and replace an existing, conventional 120 t EAF. It combines proven elements of shaft furnace technology with a new scrap charging process, an efficient preheating system, a new tilting concept for the lower vessel, and an optimized tapping system, enabling tap-to-tap times of between 36 and 40 minutes. The new EAF Quantum is expected to increase yearly production

‹‹‹

by 20% – from 1.1 to 1.35 million t/year – without changing the tapping weight or the power input. The scope of supply also includes three combined burner systems for refining, a Lomas gas analysis system to optimize process control, and a LiquiRob robot system for sample taking and temperature measurements. The new equipment is scheduled to go on stream in the summer of 2016.

The Netherlands Tata Steel to install new hot sinter conveyor. Tata Steel has ordered another hot sinter conveyor from Aumund for installation at a third sintering plant. The by now third hot sinter pan-type conveyor for Tata will feature a pan width of 2,400 mm and a line length of 13.5 m. Its conveying capacity will be 250 t/h of 500 – 1,000°C hot sinter. The delivery is planned for September 2015. Transport will be in a fully assembled state by truck, markedly reducing the usual time required for mounting and alignment.

››› INTERNATIONAL INDUSTRY NEWS Russia MMK launches desktop virtualization project. MMK has completed a pilot project aimed at creating a desktop visualization system and switching users from regular personal computers to thin-clients in cooperation with the company CROC. Thin-clients are specialized client devices with a significantly simplified hardware configuration compared to a traditional computer. Since all application tasks, documents and files are stored on servers, connection only takes a few minutes. Desktop virtualization involves computer technologies and infrastructure that make it possible to transfer all PC functions, such as the application calculations, storage of corporate and personal data, Windows settings and desktops, to a server’s virtual space. The new system delivers a substantial cut in costs for workplace administration. MMK’s project was implemented at sheet mill No. 11, since it needs to be implemented on a significant scale in order to deliver the desired results. A feasibility assessment of desktop virtualization technologies will be carried out following the completion of this pilot project.

Russia

We agglomerate your valuable dusts and fines

In the metallurgical industry we briquette e. g. steel mill residues, sponge iron (hot and cold), chrome ore, nickel powder, copper concentrate, and other ﬁnes. Briquettes are used for feeding shaft furnaces, BOFs, RHFs, EAFs, and other reduction or melting units.

NLMK to boost productivity of ore beneficiation. NLMK has begun implementation of high-pressure grinding rolls in its iron ore beneficiation plant at the Stoilensky mine. High-pressure grinding rolls are being installed to complement the existing cone crushers and ball grinders. The use of these rolls reduces consumption of electric energy, water and other materials in the beneficiation and increases the fineness of crushed ore. During the first stage of the Stoilensky modernization project, four high pressure grinding rolls will be installed at beneficiation plant sections 1 and 4. Modernization of section 1 will be completed in 2015, with modernization of section 4 scheduled for completion in the first quarter of 2016. After completion of stage one, the company will review possible implementation of similar equipment at the remaining sections 2 and 3. This technology, coupled with other capacity upgrade projects and operational efficiency initiatives, will boost Stoilensky’s iron ore concentrate production from the current 15 million t/year to 17.2 million t/year by 2017.

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MPT International 3 / 2015

NLMK to increase use of secondary energy sources. NLMK has started hot testing of a new top-pressure recovery turbine (TRT) facility at its Lipetsk production site. Another turbine is under construction in parallel, with launch scheduled for 2016. TRT units are used to generate energy through the channeling of excess blast furnace gas pressure. To date, blast

furnace gas was directed to the heat power plant and the recovery cogeneration plant for energy generation, but the potential of excess blast furnace gas pressure had not been harnessed. The total design capacity of the two turbines forming the TRT complex is 28 MW. The TRT facility will receive gas from blast furnaces No. 6 and 7. The project will increase the plantâ&#x20AC;&#x2122;s energy self-sufficiency from 54% to 56%, reducing the amount of energy that must be purchased for the plant by 200 million kWh/year.

Russia MMK to increase budget for environmental initiatives. MMK plans to implement 72 initiatives within its approved 2015 Environmental Programme, covering all production plants and MMK group entities. This includes renovation work on the sulphur collecting units at the sintering plant, renovating the coke gas chilling cycle at block No. 1 of the coke-chemical production facility. A major sum will be allocated to decreasing water consumption, decreasing pollution discharge into water facilities, improving industrial waste utilization and fostering re-cultivation of affected land.

Turkey Tosyali Toyo orders tinning line. Tosyali Toyo Steel, the Turkish-Japanese joint venture between Tosyali Holding and Toyo Kohan, has awarded the SMS group the contract for the supply of an electrolytic tinning line based on the soluble tin anode technology. This line will be a key element of the new steel mill for the production of packing materials to be constructed in Osmaniye. From late 2016, 255,000 t/year of high-quality tinplate will be used as packing materials for foodstuffs or aerosols. The line will be supplied inclusive of the mechanical equipment, process technology and electrical and automation systems. Ancillary units such as the evaporation unit and anode casting equipment will also be provided by the SMS group. In the entry section of the line, a side trimming shear with scrap baller will be integrated. Prior to tinning, the strip will be prepared in a cleaning, tension levelling and pickling section. The tin coating section itself will contain one preconditioning cell and six electroplating cells. A separate anode caster will cast the anodes without tin losses and at a steady temperature. The fully automated casting process produces perfectly shaped, high-purity tin anodes from the anode remnants and tin ingots.

Turkey Tezcan orders continuous pickling line with acid regeneration plant. Tezcan has placed an order with the SMS group for the supply of a continuous pickling line. Tezcan will install the line at its Kartepe loca-

tion near Izmir to improve the economy of its hot strip pickling operations and achieve an increase in output. Tezcan ordered the continuous pickling line and the turbulence pickling process complete with a acid regeneration plant. Starting at the end of 2015, the line will pickle a yearly throughput of 1.3 million t of hot strip, as a preparatory treatment for the downstream cold rolling and coating processes. Most of the material will be used in the construction industry as galvanized and/or colour-coated cold strip. The pickling acid will be directly processed in the supplied fluidized-bed-type acid regeneration plant. The plant will have a capacity to regenerate 7,500 l/h of hydrochloric acid, enough to cover the lineâ&#x20AC;&#x2122;s complete turnover of pickling liquor.

Companies ArcelorMittal and CLN form joint venture. ArcelorMittal Distribution Solutions Italia (AMDSI) and CLN group have formed the joint venture company ArcelorMittal CLN Distribuzione Italia, combining the assets and activities of both companies in the flat carbon steel service centre business in Italy. ArcelorMittal CLN Distribuzione Italia will offer a complete and innovative range of flat carbon steel products including hot rolled, cold rolled and coated steels from its 15 sites throughout Italy.

Worldsteel advocates holistic approach to water policies. The World Steel Association (worldsteel) has published a position paper on water. Even though the steel industry uses large quantities of water, very little water is actually consumed. Around 90% of water used in the steel industry is cleaned, cooled and returned to source. Most of the loss is due to evaporation. Water returned to rivers and other sources is often cleaner than when extracted. The paper explains why a holistic and balanced approach is required for water policies and what should be taken into consideration to achieve the optimal use of water resources in the steel industry. It highlights the need for a local approach and a tailor-made regulatory framework. Water management policies suited to local conditions will help the steel industry to reduce its water footprint and improve its resource efficiency.

ThyssenKrupp to sell VDM group. ThyssenKrupp is selling the VDM group to Lindsay Goldberg, represented in Europe by Lindsay Goldberg Vogel, DĂźsseldorf. On completion of the transaction, ThyssenKrupp will achieve a positive effect on net financial debt and pension obligations. As part of the necessary refinancing measures at Outokumpu, all shares in VDM and AST were transferred to ThyssenKrupp at the end of February 2014. Comprehensive new business plans have been developed for VDM and AST over the

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past few months. ThyssenKrupp always emphasized that it did not intend to retain the two companies in the group in the medium to long term. The VDM Metals group offers a comprehensive range of nickel alloys, titanium and titanium alloys, special stainless steels, zirconium and cobalt-based alloys.

Regional steel trade groups object to China’s new steel policy. Eight national and regional trade associations representing steel interests in Europe, North and South America, including AISI, Eurofer and Alacero, have joined together in expressing concern to the Chinese government’s recently revised “Steel Adjustment Policy” on manufacturing and trade. In formal comments filed with the government of China, the associations jointly said that China’s steel overcapacity is not meaningfully addressed, enabling continued government control and financial assistance over China’s steel industry. It is also criticized that the policy continues to allow the Chinese government to intervene in the development of the steel industry. The only way to make meaningful and permanent reductions in excess steel capacity is to remove government support and subsidies from the industry and allow basic market forces to determine industry outcomes, the comments stated.

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REA JET continues to expand in Poland. In response to the positive business in recent years, REA JET, the Polish subsidiary of REA Elektronik, has moved into a larger company building. At the new base south of Poznan, a team of 14 employees will take care of the local market.The new office building offers plenty of square metres with enough room for further expansion, responding to growing demand for industrial coding and marking solutions in Poland.

PTI renamed to Inteco PTI. Since the beginning of 2013, PTI has been a member of the Inteco group. Within the Inteco group, PTI’s core competences lie within the area of high technological appliances in particular chemical energy systems for electric arc furnaces with the aim to increase efficiency, productivity and safety. Since the beginning of 2015, the products have been sold under the name of Inteco PTI and the company logo has been adapted to match with the Inteco corporate design. Inteco PTI’s European office, located in Prague, Czech Republic, and formerly called PTI Europe s.r.o. also became a member of Inteco with the acquisition of PTI US.

2014 world stainless steel production. The International Stainless Steel Forum (ISSF) has released figures for the full year 2014 showing that stainless steel melt shop production increased by 8.3% year-on-year to

Cold rolling Strip processing Chemical processes Thermal processes Mechanical equipment Automation Extractive metallurgy www.cmigroupe.com DESIGN | ENGINEERING | COMMISSIONING | TECHNICAL ASSISTANCE & TRAINING | AFTER-SALES

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş INTERNATIONAL INDUSTRY NEWS

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41.7 million t. Production increased in all regions except for Central and Eastern Europe. The production figures for the regions are as follows: Western Europe/Africa 7.5 million t; Central/Eastern Europe 277,000 t; the Americas 2.8 million t; Asia (without China) 9.3 million t and China 21.7 million t.

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Beta LaserMike expands customer support facilities. Beta LaserMike has combined its Beta LaserMike products and NDC Technologies customer service resources. This includes moving the technical support activities from the Marlow, UK office to the larger NDC Technologies facility in Maldon, UK. In conjunction with this expansion, the repair facilities have been combined in a dedicated, state-of-theart service centre in Derbyshire, UK for all Beta LaserMike equipment depot repairs. This expansion enhances customer support in Europe by offering a complete customer care technical staff and leading-edge diagnostic systems, while providing a single point of contact for all Beta LaserMike product needs.

Inteco buys intellectual property rights from Fuchs. Inteco has acquired all patents and further intellectual property rights of the companies Fuchs Technology GmbH, Fuchs Engineering GmbH and Fuchs Products GmbH. The patents and rights pertain to a range of innovative products and technologies for electric arc furnaces and ladle furnaces. These products and technologies will, as of completion of the purchase agreement, be marketed by Inteco.

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MPT International 3 / 2015

Changes to ownership structure of NLMK Belgium Holdings. NLMK and Belgian SOGEPA (Societe Wallonne de Gestion et de Participations S.A.) have signed an agreement providing for the increase of SOGEPAâ&#x20AC;&#x2122;s stake in NLMK Belgium Holdings (NBH) and the joint management of NBHâ&#x20AC;&#x2122;s businesses. NBH comprises the production companies and service centres of the NLMK Europe Strip Division (NLMK La LouviĂ¨re, NLMK Strasbourg, NLMK

Coating, NLMK Jemappes Steel Centre, NLMK Manage Steel Centre and NLMK Profil Batiment), and two NLMK Europe Plate production companies (NLMK Verona and NLMK Clabecq). Under the agreement, SOGEPAâ&#x20AC;&#x2122;s interest in NBH will increase from 20.5% to 49%. NLMK and SOGEPA have also agreed on a new stage of operational improvement programmes, targeting a return to profitability for the main NBH production companies, as well as the optimization of the structure of the entityâ&#x20AC;&#x2122;s auxiliary strip production companies.

Organizational changes at NSSMC. Nippon Steel and Sumitomo Metal Corporation (NSSMC) has established a Coke-making Technology division as part of its Ironmaking Technology division. This decision was based on the necessity to plan and study measures against coke fires, including the fire caused at the Nagoya Works last year, and measures to refresh coke furnaces across the company. Additionally, an Energy Management division will be established in the Kashima, Kimitsu and Oita works in response to the power failures and emission of black smoke experienced at the Nagoya Works.

Schmolz + Bickenbach sells specific distribution activities. Schmolz + Bickenbach is going to sell distribution units in Germany, Belgium, the Netherlands and Austria to special steel distributor Jacquet Metal Service. The affected distribution units belong to the Sales & Services division, in line with a diverging business model and focussing on selling third party products. The tool steel division will stay with Schmolz + Bickenbach.

Tata Steel completes transformation of Steelpark. Tata Steel has completed a series of investments at its Steelpark site at Wednesfield, in the West Midlands, England. The startup of a further multi-strand blanking line has completed the expansion of Steelparkâ&#x20AC;&#x2122;s new light gauge service centre, which operates cut-to-length, blanking and slitting lines processing

hot rolled, cold rolled and galvanized steel coils. Last year saw the opening of the UK’s largest plate profiling centre. The automotive service centre at Steelpark has also received substantial investment with the commissioning of new and upgraded tailor welded and press blanking lines. The new light gauge centre has been formed by the installation of a dedicated decoiler and three multi-strand blanking lines that process steel sheet supplied in coil from Tata Steel plants in Wales. Together with the adjacent slitting centre that has been operating out of Steelpark for many years, the new light gauge centre has an overall throughput capability of 500,000 t/year.

ThyssenKrupp reorganizes materials services operations in Germany. ThyssenKrupp has reorganized its materials services operations in Germany: The activities of ThyssenKrupp MetalServ GmbH, ThyssenKrupp Stahlkontor GmbH and ThyssenKrupp Schulte GmbH have been legally combined under the roof of the new ThyssenKrupp Schulte GmbH. With immediate effect all business activities of the previously separate companies will operate under the name ThyssenKrupp Schulte GmbH. This organizational realignment has reduced the number of individual companies, while expanding the product portfolio, the nationwide network, and the range of supply-chain and system-component solutions.

Combilift to invest in new manufacturing facility. Combilift is building a new manufacturing facility. This expansion will enable Combilift to proceed with its plan to double its turnover over the next five years. The company has recently purchased 40 hectares of industrial zoned land to build the new 40,000 square metre, greenfield manufacturing site. This will include a dedicated research and development building and adjoining administrational offices and will be more than double the size of both of the company’s present manufacturing facilities. Combilift is known for its wide range of multi-directional

forklifts, articulated forklifts and other innovative material handling solutions designed to handle large containers and over-sized loads.

ThyssenKrupp Metallurgical Products signs offtake agreement for rare earth elements. ThyssenKrupp Metallurgical Products has signed an offtake agreement with the mining company Rainbow Rare Earths Limited. Under the ten-year agreement, the company undertakes to market 5,000 t of rare earth concentrate and downstream products such as neodymium oxide, praseodymium oxide and lanthanum oxide per year. Rare earth elements are used for example in batteries, magnets and LED screens. This offtake agreement makes ThyssenKrupp Metallurgical Products the exclusive sales partner to Rainbow Rare Earths, which is engaged in the exploration and development of rare earth deposits in Burundi, East Africa.

Look through walls with us! ThyssenKrupp signs up to framework agreement on labour standards. ThyssenKrupp AG, the ThyssenKrupp group works council, the German metalworkers union IG Metall, and the union federation IndustriALL Global Union entered into an international framework agreement (IFA) on global minimum labour standards in the ThyssenKrupp group. As well as recognizing the ILO’s core labour standards and the universal declaration of human rights, the IFA incorporates principles on good health and safety practices, career and personnel development opportunities, the right to fair pay, and the prohibition of child and forced labour and all forms of discrimination. The company has agreed a point of contact for reporting suspected infringements.

Personalities

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Learn more in our ESTAD presentation on June 17, 2015 at 11:40! Visit us at our booth G20 in hall 4!

Board chairman of Schmolz + Bickenbach re-elected. The general meeting of Schmolz + Bickenbach re-elected as board members Edwin Eichler, as chairman, Michael Büchter,

info@emg-automation.com • www.emg-automation.com

››› INTERNATIONAL INDUSTRY NEWS

Marco Musetti, Dr. Heinz Schumacher, Dr. Oliver Thum and Hans Ziegler. Johan van de Steen was elected as a new member of the board of directors.

Change at Outokumpu Coil Americas. Michael Wallis, the head of Outokumpu’s Coil Americas, has decided to leave the company. Jose Ramon Salas, currently head of Outokumpu Mexico, has been appointed as the interim head of the business area Coil Americas.

New strategy chief for ThyssenKrupp. Dr. Peter Feldhaus is taking over as head of strategy, markets and development at ThyssenKrupp. He succeeds Premal Desai, who became chief financial officer of ThyssenKrupp’s steel business on 1 January, 2015. Premal Desai is currently

Dr. Peter Feldhaus

combining his duties as head of ThyssenKrupp’s strategy unit with his new role. As director of the global management consulting firm McKinsey & Company, Peter Feldhaus has gained wide experience over many years in the energy and resource industries. Peter Feldhaus has been advising ThyssenKrupp on various projects. He has been involved in various corporate programmes, including

the ThyssenKrupp Steel Europe optimization programme currently ongoing.

New CEO Industrial at Schaeffler. Dr. Stefan Spindler has been appointed as member of Schaeffler’s board of managing directors. He is successor to Robert Schullan, CEO of the Industrial division, who left the Schaeffler group at his own request to pursue new career opportunities.

Management changes at BSE. Badische Stahl-Engineering (BSE) and Johannes Greinacher have mutually agreed to terminate the working agreement. Johannes Greinacher most recently has been managing director of BSE. He will leave the company to accept new challenges outside Badische group. Torsten Rummler will take over the duties of Johannes Greinacher.

New board chairman at Deutsche Edelstahlwerke. Oliver Bell is the new chairman of the management board of Deutsche Edelstahlwerke. Oliver Bell will also be responsible for the sales department. Most recently, he was executive vice president of Norsk Hydro ASA and, as a member of the management board, headed the rolled products division. Oliver Bell succeeds Dr. Martin Löwendick.

New managing director of Schade Lagertechnik. Dr. Chris-

toph Seifert is the new technical managing director of Schade Lagertechnik. He is responsible for engineering, project management and purchasing. Together with KarlHeinz Fiegenbaum (responsible for sales and finance), the new managing director forms the management of Schade Lagertechnik, manufacturers of equipment for bulk material stockyards and blending beds and part of the Aumund group.

Deputy chairman of BlueScope Steel retires. Ron McNeilly, deputy chairman of BlueScope Steel, has retired. Ron McNeilly was a foundation board member of BlueScope. His retirement is a further step in the board’s previously announced renewal programme.

2015 AIST steelmaker of the year. Mario Longhi, president and chief executive officer United States Steel Corporation, was named “Steelmaker of the Year” at AISTech 2015. This award is presented annually by AIST to recognize notable leaders for their impact on the steel industry. Mario Longhi joined U.S. Steel in July 2012 to serve as executive vice president and chief operating officer. He was appointed president and chief operating officer in June 2013, and was elected president and chief executive officer in September 2013.

New head of plate sales department. G.O. Carlson Inc., custom producer of specialty and stainless steels, has announced the retirement of Rick

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MPT International 3 / 2015

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Trudeau, vice president sales – plate. Trudeau provided G.O. Carlson with 39 years of service. Filling Trudeau’s position will be Craig C. Travaglini, representing the fourth generation to join the family-owned G.O. Carlson, Inc. business. Travaglini will be responsible for leading the plate department’s sales team.

New technical director at AIC North America. Roger Wallberg is the new technical director of AIC North America. Roger Wallberg will be the first contact for all the North American partners and be in charge of all the technical needs of the clients from the prebid discussions up to the after start-up service management, coordinating all the AIC resources available worldwide.

SSAB elects new board chairman. Chairman Sverker Martin-Löf and director Jan Johansson have resigned from the board of SSAB. Bengt Kjell was elected as a new director and as the new chairman of the board.

Management change at Schmidt + Clemens. Thomas Hellige has decided to leave his management position at Schmidt + Clemens for reasons of advancing age. Thomas Hellige will remain available to the company until a successor has been selected to take over his position as chief sales officer.

Events ›

8 – 10 September 2015 Beijing, China Organizers: Beijing Hiven Exhibition www.hwexpo.com

CIMIE 2015. The 11th Metallurgy Expo will cover the full range of metallurgical processes and technologies for iron and steel as well as non-ferrous metals. Equipment and services for all stages of the process chain, including testing equipment and auto-

mation, materials application, refractories and environmental aspects will be presented. CIMIE 2015 will be held concurrently with CIFE 2015, the 11th Foundry Expo.

›

3 – 5 November 2015 Leoben, Austria Organizers: Asmet www.mppe.org

MPPE 2015. The international conference on Materials, Processing and Product Engineering will cover aspects as wide ranging as materials synthesis and processing, development and characterization of materials, dimensioning of components, integration of materials and their processing, behaviour of materials and components during service. Specific topics to be featured are new materials, multi-scale modelling, production chain modelling, new manufacturing processes and new tool solutions.

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

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MPT International 3 / 2015

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››› INTERNATIONAL INDUSTRY NEWS

World Steel Association short range outlook 2015 – 2016 worldsteel forecasts that global apparent steel use will increase by 0.5% to 1,544 million t in 2015 following growth of 0.6% in 2014. In 2016, it is forecast that world steel demand will grow further by 1.4% and will reach 1,565 million t. On the occasion of their spring meeting in April in London, worldsteel Economics Committee provided the new short range outlook. The prospects for the steel industry suggest slow growth for global steel demand. Commenting on the outlook, Hans Jürgen Kerkhoff, chairman of the worldsteel Economics Committee said, “We are releasing a restrained growth outlook for the global steel industry mainly due to the deceleration in China. The outlook also reflects the influence of major structural adjustments in most economies, particularly owing to limited investment growth post 2008. As these changes take effect, the steel industry will experience a slower pace of growth, it will focus on operational efficiencies and on the value that steel products generate for customers and society.” “While we continue to face some downside risks coming from some parts of Europe – geopolitical instability, international capital flow volatility and the economic slowdown in China – the impact of these risks has come down. We have also started to see some encouraging developments. We hear increasingly positive news from developed economies, especially signs of firming recovery momentum in the Eurozone. In the developing and emerging world, we see increased optimism about India and growth in steel use in some MENA and ASEAN countries. While these developments will not be enough to counterbalance the deceleration of China, we expect to see gradually improving growth prospects beyond 2016,” Kerkhoff concluded. An interesting factor which has become increasingly apparent is that in some developing economies

Word Steel Association (wordsteel), Brussels, Belgium Contact: www.worldsteel.org E-mail: info@worldsteel.org

MPT International 3 / 2015

the steel markets are beginning to exhibThe developed world showed it the characteristics of mature markets. growth in steel demand of 6.2% in 2014 The sharp decline in oil prices influ- on the back of strong US fundamentals enced the forecast, though its impact and a firming EU recovery. However, varies between countries. On the one growth in the developed world is set to hand, it has a negative impact on steel moderate in 2015 due partly to the high demand for infrastructure investments base effect, but also less favourable steel financed from oil revenues; on the oth- market environments in the US, Japan er hand it helps business sectors and and South Korea. The recovery in the consumers in oil importing countries, EU, although becoming regionally thus creating better growth prospects. broader based, is still constrained by Further relaxation of monetary poli- weak investment activity and high uncy by the Central Banks is possible in employment. Steel demand in the decountries with high inflation, which may strengthCountry 2014 2015 (f) 2016 (f) en the recovery of underlying real steel use. It may China 710.8 707.2 703.7 lead to reduced demand United States 106.9 106.5 107.2 for steel in some economies in the short term, but India 75.3 80.0 85.8 should support economic Japan 67.5 65.9 66.6 growth and demand for steel in the medium term. South Korea 55.4 56.9 58.0 In China steel deRussia 43.1 40.2 39.6 mand in 2014 saw negative growth for the first Germany 39.2 39.8 40.7 time since 1995 due to Turkey 30.7 31.7 32.0 the government’s rebalBrazil 24.6 22.7 23.4 ancing efforts that had a major impact on the real Mexico 22.5 23.1 24.0 estate market. This situation is likely to remain un- Apparent steel use of the top 10 steel using countries changed in the short term (million t; f: forecast) and Chinese steel use will continue to record negative growth of veloped economies will grow by 0.2% -0.5% in both 2015 and 2016. In the in 2015 and by 1.8% in 2016. The developing economies (exmedium term no strong rebound is expected. Some uncertainty remains cluding China) posted low growth regarding the impact of government of 2.3% in 2014, in particular because measures aimed at stabilizing the de- of the continued deterioration in the celerating economy. The rebalancing Brazilian and Russian steel markets. of the Chinese economy is inevitable Growth momentum in the developas China enters its next stage of devel- ing economies is expected to remain opment, but it will take time. In the generally weak in 2015, however, posishort term, it has global consequences tive growth is expected in some econofor the steel industry in terms of trade mies such as India, Indonesia, Vietnam flows and possible intensification of and Egypt, where steel markets are still trade frictions, resulting from signifi- developing. Steel demand is expected cant increases in steel imports in many to grow by 4.0% in 2016 after growing economies during 2014. by 2.4% in 2015.

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AK Steel to build world-class research and innovation center The North American steel manufacturer AK Steel has selected Middletown, Ohio/USA, for its new US$ 36 million research and innovation center. The new facility will be home to the company’s approximately 75 researchers, scientists and engineers. AK Steel, one of the world leaders in the production of flat-rolled carbon, stainless and electrical steel products, will build a new steel research and innovation center providing advanced technical support to customers, as well as developing new and improved steel products for a number of markets. The company has selected Middletown, Ohio/USA, as the site for its US$ 36 million investment. Set to break ground in the late spring or early summer of 2015, the research and innovation center will be a signature corporate presence within Middletown’s thriving Renaissance district. Anchoring the district’s research and technology campus, the center will be built on a highly visible site, with frontage along Interstate 75, one of the most travelled roads in the US interstate system. The 11,150 square meter facility will be constructed on a 6 hectares site. It will replace the company’s existing research facili-

AK Steel, West Chester, Ohio, USA Contact: www.aksteel.com

MPT International 3 / 2015

ty that is located at another site in Middletown. “Construction of this new research and innovation center underscores AK Steel’s strong commitment to the future of steelmaking in America and to our company’s continued industry leadership as a technological innovator in the steel business,” said James L. Wainscott, chairman, president and CEO of AK Steel. “Our talented researchers, scientists and engineers are already working to develop innovative products as next-generation advanced high strength steels to help automotive customers design lighter, more fuel-efficient vehicles that maintain superior strength and safety performance, as well as high efficiency electrical steels that will help the nation’s electricity grid become more energy-efficient, and new stainless steels that offer superior corrosion resistance for a wide variety of applications. The new research and innovation center will enhance our capabilities to bring these products to the marketplace,” James L. Wainscott added. The new facility is subject to final state and local government approvals. It will be home to the company’s approx-

imately 75 researchers, scientists and engineers who will perform research, applications engineering, product development, and customer technical services. The facility will also house pilot lines that simulate the company’s steel manufacturing operations, ranging from melting and casting, to hot and cold rolling, to final finishing. The pilot lines are used for research, enhancing existing products, problem-solving in production, and experimentation for new and improved products.

Changes in executive leadership In conjunction with the announcement of the newly built research and innovation center, the company also announced two changes in executive leadership, effective immediately: Eric S. Petersen, 46, has been appointed to the newly-created position of vice president, research and innovation. He will have responsibility for the customer technical services, product development and applications engineering, research and innovation, and research planning functions. His successor at his previous function as

INTERNATIONAL INDUSTRY NEWS vice president sales and customer service is Scott M. Lauschke, 45. He joins AK Steel from his previous position as vice president and general manager of AFGlobal Corporation and spent 15 years at The Timken Company in a variety of leadership roles. Scott M. Lauschke will have responsibility for leading the sales and customer service organization, including carbon and specialty steel sales, as well as inside sales, customer service and inventory planning, products, sales planning and coordination, and AK Steel International activities.

Developments by AK Steel Rendering of AK Steel’s new research and innovation center to be built in Middletown, Ohio

In 1910, AK Steel’s predecessor company, Armco, Inc., established the first facility in the steel industry devoted

‹‹‹

entirely to research. The products and processes developed by the company throughout its history include pioneering the world’s first continuous hot rolling sheet mill in the 1920’s. Its research also led to the development of various types of electrical steels used in power transmission and distribution equipment. The company introduced specific types of aluminized stainless steels to the automotive exhaust market in the 1990’s. In recent years, AK Steel launched ULTRALUME®, an advanced high strength steel designed to improve safety and light weighting of structural components in vehicles, and CHROMESHIELD® 22, a new nickel-free stainless steel with enhanced benefits and stable pricing for customers in the automotive and food service markets.

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››› INTERNATIONAL INDUSTRY NEWS

Aumund expands after sales service network by new centre in Brazil In order to expand its service network for customers in South America, Aumund has established a new service centre with integrated warehouse in central Brazil. In addition to the warehouses in Rheinberg/Germany, Atlanta/USA and Hong Kong, the company now operates four service centres worldwide.

Part of a pan conveyor

By establishing the new service centre with integrated warehouse in Ipatinga, Minas Gerais, central Brazil, Aumund has enlarged its availableness for customers. The producer of transport and storage solutions for demanding bulk materials is further completing its worldwide service network so far consisting of warehouses in Rheinberg/Germany, Atlanta/ USA and Hong Kong. Aumund services are now available to customers in South America with special focus on markets in Brazil, Argentina, Bolivia, Paraguay, Uruguay and Chile. The new facility is destined for providing a broad range of services to the cement and mining and minerals in-

Aumund Holding B.V., Venlo, The Netherlands Contact: www.aumund.com E-mail: marketing@aumund-holding.nl

MPT International 3 / 2015

Aumund Brazil warehouse and new service centre in Ipatinga

dustry. One of the major goals will be to guarantee availability and operation of customer equipment and preventing failures through maintenance. This includes monitoring, conversions and field service activities, such as inspection, erection, start-up, both for conversion tasks and spare parts. All inspectors are trained to carry out PREMAS® inspections. The Premas concept has been developed by Aumund to provide its customers efficient preventive maintenance services. It is based on the four pillar-strategy of regular inspections, the training of operators and maintenance personnel, consulting and guaranty extension. Besides keeping spare parts on stock, manufacturing pan conveyors and assembling chains, the new service centre will service and repair all kinds of components and equipment for the Aumund Group, including Schade Lagertechnik GmbH and Samson Materials Handling Ltd.

Amongst others, Aumund offers solutions for the iron, steel and aluminium production as well as foundries. The company has been present in Brazil with its subsidiary in São Paulo since 1975. It develops conveying solutions especially for the cement, steel and smelting industry sectors, power generation, minerals and fertilisers as well as for ports and handling terminals. 10% of all equipment supplied by Aumund worldwide are installed in South America. Aumund Brazil employs a total staff of 30 persons. Ten specialized technicians are constantly in direct contact with the customers by visits and onsite support activities. They provide spare parts management, coordinate delivery times and further logistics, perform inspections and supervisions, assemble equipment, and offer recommendations for conversions and improvement of existing equipment.

››› INTERVIEW

Strained global markets present technology providers with ever new challenges MPT International interviewed Dr. Christian Bartels-von Varnbüler, chairman of the Metallurgical Plants and Rolling Mills Association within the German Engineering Association (VDMA) and president of the Küttner Group, based in Essen, Germany. The group, privately owned and managed by its owners, is specialized in plant engineering for the metallurgical industry. In the interview, he shares his views on chances and risks of international competition and on current technological and market trends in the runup to the METEC trade fair. What characterizes the manufac› turers of metallurgical and rolling mill equipment organized in your association? German and Austrian manufacturers of metallurgical and rolling mill equipment have acquired a leading market position in the global competitive landscape. Our USP (unique selling proposition) is technological leadership, in other words, high-tech as a trademark. It requires incessant efforts to defend this top position against strong competition, especially from Italy, Japan and nowadays also from South Korea.

What is it that makes metallurgi› cal and rolling mill equipment a high-tech product? Whether a product deserves the name high technology will be decided by the customer – whether he succeeds in the market thanks to our equipment. Everything starts with the development of technologically sophisticated solutions tailored to a specific project. This must be followed by

Metallurgical Plants and Rolling Mills Association within the German Engineering Association (VDMA), Frankfurt, Germany Contact: www.vdma.org E-Mail: ines.polak@vdma.org

MPT International 3 / 2015

a perfectly organized implementation phase to ensure that the plant can start up according to schedule. Our customer, the operator of the plant, can rest assured that he can start producing as scheduled in order to make money with his newly purchased plant.

this give your companies a › Does competitive edge? When tendering for large-scale projects, plant engineering companies find themselves exposed to an enormous price pressure and squeeze on margins. At first glance, bargain offers seem to provide cost advantages of 20% or more. However, only the look

companies pursuing this add› Can ed value strategy succeed in today’s heavily contested markets? We can only win the competition against companies in the low-price segment if we offer technologically and economically convincing solutions in which the operators trust.

this mean that this is also no › Does option for customers who have a limited investment budget and are willing to take higher risks? Low-budget projects are always risky. They put the confidence of quality-conscious investors at stake. One

»High-tech is our trademark, „low tech“ equipment is no alternative« at the total cost of ownership reveals that the alleged savings on Capex may later on be eaten up by higher operative costs. In other words: The better, though initially more expensive, technology provides the plant operator a number of significant benefits, such as lower operating costs and longer lifetimes of the plants. Metallurgical plants and rolling mills are long-life assets. Therefore the operating costs, or operating profit, determine the total cost of ownership. In my opinion, “low tech” equipment is no alternative.

cannot cater to both market segments at the same time. As long as the market demands best solutions, in terms of both technology and economic efficiency, we need no strategy for the lowprice segment.

to safeguard one’s › Isownit possible market share by expanding the service offer? Yes, indeed. Via services, plant suppliers maintain active customer relations over the entire lifecycle of the

INTERVIEW

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»Whether a product deserves the name high technology will be decided by the customer« plant. The service provider is always in direct contact with the plant operator. Of course, large groups usually have corporate compliance in place – especially in the area of procurement. Never theless, the service provider boasts a highly valuable information edge. Moreover, services are a not-to-be-underestimated source of revenues. Considering the revenues from the sale of equipment in combination with related services may result in attractive projects, which simply due to the synergy of plant engineering and service turn out to be a win-win situation for all parties involved.

Is customer retention via the ser› vice business a unilateral advantage for the plant supplier? In the service business, performance is the key criterion for both sides. Only good performance satisfies both business partners. As a matter of fact, the plant builder should know his plant better than anybody else. This information edge is the plant builder’s advantage over third-party service providers, from which also the plant operator benefits.

this mean a long-term ob› Doesn’t ligation and great dependence on one supplier for the plant operator? Not at all. Service contracts are not a guarantee for follow-up orders. However, via a service contract and the close customer relation, the plant supplier will stay updated about any need for investment at the customer’s facilities or in a certain region. Customers usually appreciate this kind of competent advice. And should there eventually be a tendering procedure for a follow-up project, the plant builder will in any case have to compete against other participating companies.

European plant engineering › Are companies with a service offer in a particularly favourable position?

these are negative factors for international transactions involving medium-term investments because they make it impossible for our customers to predict the market situation, even for the next three or four years. Steel demand and production are only growing in Asia. We are currently in a phase in which steel companies are reluctant to invest and plant engineering companies have to cope with low margins.

The European plant engineering companies are successfully positioned in the international service business. Today, some of the large, internationally active plant builders are already generating some 20% of their sales in the service business. Sales generated from services are much less cyclical than the supply of new plants or the revamping business. Especially, in years of sluggish economic activ»European plant engineering ity the service business is companies are well positioned in very important for the plant building sector. the international service business«

are the biggest challenges › How is the market for metallur› What for companies active in the plant gical and rolling mill equipment building sector? International trade is presently being influenced by numerous conflicts and crises, which may have concrete effects on concrete deals. The conflicts and crises I’m referring to are, for example, the heating-up East-West conflict, tensions in the MENA region and the recent collapse of the oil price. All

going to develop? The market for metallurgical plants is characterized by uncertainty because the demand is not growing. This year, manufacturers of metallurgical and rolling mill equipment have been reporting an order intake slightly above last year’s figure for the same period. However, the order inMPT International 3 / 2015

››› INTERVIEW

take generally remains at a very low level. The industry stays clearly behind the boom years 2007 and 2008. This has been leading to continued consolidation.

nies with highly innovative product portfolios. The corporate culture often stems from similar roots and traditions are alike. This is a good basis for collaboration.

there be just a few metallur- › What is the role of standards and › Will gical equipment suppliers left in specifications? the future? Consolidation does not only happen by mergers & acquisitions. Companies – except for the big full-liners – have been forming alliances to improve their positions in the global market. These companies have established networks, in which they join their forces to facilitate the access to customers and markets. By consolidating their various activities, they create a new variety of coordinated offers – to the benefit of the customers.

these alliances provide more › Do risks or more opportunities? Such an alliance may in certain cases be the only possibility to stand up to the preponderance of the big full-liners in the plant engineering market. The key to success is to come up with a

»Alliances facilitate the access to customers and markets« benefit for the plant operator. In such a joint approach, the cooperating partners optimize their solutions to best suit the operator’s requirements. Thus, also the operator will benefit from this strategy. The result is a true win-winwin situation. By the way, particularly for highly specialized companies from Germany and Austria the prospects are good. There are many family-owned compa-

The rules stipulated in today’s national and international standards are of a rather broad nature. Often, company standards – specified by the steel producers and above all by the steel users – are much stricter, especially as far as safety is concerned. Generally, standards are very important. On the one hand, the plant operators can be sure that the production equipment and eventually the products they will make with this equipment comply with the defined standards and specifications. The plant manufacturers have an advantage over plant suppliers from regions with weaker standards.

concepts like “big data, data › Will mining and analysis” change the steel industry? Metallurgical and rolling mill equipment provide huge amounts of data which today can be evaluated in great detail by modern computers and control systems. Networks of plants, computers and systems open up additional opportunities. However, “data mining and analysis” are not an end unto themselves. The challenge rather is to increase the efficiency of production by means of these tools. However, there is still a long way to go. We are just at the beginning of this route. In several committees, we have been working on coordinated projects. And we are curious about the progress we will be seeing.

Which will be the dominating › trends at METEC, THERMPROCESS and GIFA this year?

Currently, there is not such thing as singular development which may revolutionize our production plants. An Does each region regulate the important issue is the sustainability of market according to its own production. Environmentally friendly standards? technologies and the careful use of resources – of both raw materials and enerStandards and guidelines influence gy – are central topics. This aspect will be plant engineering worldwide, because gaining in importance, especially against many customers look for the best avail- the background that approximately 50% able technology, as this technology of the global steel output is produced in will provide them with the better mar- China, where there is certainly still much ket opportunities. High standards not potential for optimization. On the other only justify an appropriate price of a hand, we have been observing that plant plant. Participating in the market for suppliers and operators are more and metallurgical equipment would sim- more interlinking their business processply be impossible without ensuring es. The plant engineering sector will have compliance with tight tolerances and to cope increasingly with this type of enhigh safety standards. Here suppliers trepreneurial challenges. Plant engineerbased in the EU have clear advantages ing companies will also have to respond because plants to EU standards are al- to the growing demand for solutions that ways internationally marketable. This affect the financial and service aspects of in turn means a competitive edge for investment projects. our customers in other regions – in India, South Africa or other countries – who manufacture their products with Dr. Bartels-von Varnbüler, thank you very much for this interview. our plants.

›

MPT International

the leading technical journal for the global iron and steel industry METEC Düsseldorf, Germany, 16 – 20 June 2015 Come and meet the MPT staff at METEC, hall 5, booth 5 / C30 www.MPT-International.com

MPT International 3 / 2015

INTERVIEW

‹‹‹

Metallurgical Plants and Rolling Mills Association within the German Engineering Association VDMA Sales moving upwards from low 2014 level The upwards trend in the sales generated by suppliers of metallurgical and rolling mill equipment, which had been noticeable as early as in the second half of 2013, eventually manifested itself in the 2014 annual accounts by a 22% increase. That we have a calculated two-digit sales plus in our industry is due to the low level of sales generated in 2013. However, in Germany, the 2014 yearly average production was approx. seven percent lower than in 2013 when – like in 2011 and 2012 – the two-billion mark had been exceeded. This may be an indication that the expectations for 2015 will be more moderate, last but not least against the background of the decrease in order intake in 2014 (minus ten percent). In 2014, the exports by German manufacturers of metallurgical and rolling mill equipment totalled 791 million euros, a year-on-year increase of almost four percent. China remained the No. 1 export destination, although the exports continued to decrease (by 14%). Supplies to Russia exceeded previous year’s figures by almost 40%. This was possible due to the existing order backlog. Exports to the USA continued its upwards trend, with a year-on-year increase by seven percent (120 million euros). The supplies to India by German manufacturers were more than halved (68% less than in 2013). Customers within the EU purchased seven percent less machinery and plants than in 2013 (184 million euros). The challenges due to the market situation continue to exist. The uncertainties and the different market situation resulting from the sanctions imposed on Russia contribute

to the negative order intake trend and will have repercussions on this year’s sales volumes. China will continue to expand its exports of metallurgical plants. Adding to this is the fact that the worldwide potential for largescale projects will remain low. Howev-

er, the positive trend in exports to the USA, Mexico and certain countries in Southeast Asia, which was observed in 2014, may be an indicator for additional potentials in these markets. Contact: www.vdma.org

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METEC 2015 is focusing on sustainable metallurgy GIFA, METEC, THERMPROCESS and NEWCAST – the four trade fairs will be held in Düsseldorf, Germany from 16 to 20 June. Numerous innovations are expected to be on display. More than 2,100 exhibitors will show their products and services. GIFA, METEC, THERMPROCESS and NEWCAST – the four trade fairs will report record figures when they are held in Düsseldorf from 16 to 20 June. For the first time in the almost 60-year history of the event, the trade fairs will be exceeding 2,000 exhibitors: a total of 2,124 have registered. The stand space booked has increased substantially

The Bright World of Metals Messe Düsseldorf, Germany 16 – 20 June 2015 Find more information on the Internet: www.metec.de · www.thermprocess.de www.gifa.de · www.newcast.de

MPT International 3 / 2015

too: 86,253 square metres have been reserved this year in halls 3 to 17 of the exhibition site in Düsseldorf. This means that “The Bright World of Metals” is one of the leading international capital goods trade fair events. The list of countries participating is truly global. Apart from Germany, which is being represented by 736 companies in total, Italian, British and French manufacturers as well as from overseas Chinese, Indian and US American companies all play a particularly prominent role on the world market and at the four trade fairs. The event is focussing on the minimization of resource input and energy efficiency as central issues to an even larger extent this year than was the case four years ago. Whereas only a few compa-

nies concentrated on sustainability last time, this subject is a priority for many of the European companies in 2015. This is of course attributable – among other things – to the presence of such energy-intensive industries as foundries and ferrous/non-ferrous metal manufacturing. New developments and key technologies that help to maximize efficiency levels and reduce CO2 emissions and thus contribute actively to climate protection are being presented.

ecoMetals campaign: focus on sustainability, minimization of resource consumption and GPGTI[ GHƂEKGPE[ Only one feature of the “Bright World of Metals” for the second time,

EVENTS

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More than 500 exhibitors from 35 different countries have registered for METEC 2015

but already an impressive success: the ecoMetals campaign organized by Messe Düsseldorf. In 2015, a total of 22 companies will be participating in the ecoMetals campaign with the motto “efficient process solutions”. Companies have been allowed to take part that adopt a progressive and innovative approach to the issue and make optimized energy controlling a priority. They are also expected to save energy or make efficient use of materials and resources in their production operations, while demonstrating climate friendliness in taking advantage of renewable energy sources. Project director Friedrich-Georg Kehrer: “Modern resource minimization and energy efficiency technologies play an important role in investment decision-making by industrial customers. So companies that perform particularly well in these areas will definitely attract plenty of visitors at the four trade fairs too.” In co-operation with the associations Steel Institute VDEh and Bundesverband der Deutschen Gießerei -Industrie (BDG), Messe Düsseldorf is organizing guided highlight tours of the ecoMetals exhibitors for visitors, that will be available in both German and English. Registration for them is possible on the websites in the ecoMetals section. Professionals who are interested should make sure they obtain their admission tickets to the “Bright World of Metals” from the websites in advance and print them out at home before they leave for the trade fairs.

Four trade fairs together join their focus on metallurgical technologies Although GIFA, METEC, THERMPROCESS and NEWCAST are independent trade fairs, each of which aims to serve its own individual markets, it is only together that they present a comprehensive picture of “The Bright World of Metals”. The major plant manufacturers give METEC its distinctive character. Suppliers of plant and equipment for iron-

making, steelmaking and non-ferrous metal production, for casting and pouring molten steel and for rolling mills and forming/forging plants have a particularly impressive presence at METEC, which has been performing successfully in Düsseldorf for 35 years now. METEC is setting a new record this year, with 512 exhibitors from 35 countries and 21,581 square metres of stand space. METEC is one of the most prominent global trade fairs with its large proportion of international participants and is the undisputed leader in its industry. METEC boasts the European Steel Technology and Application Days (ESTAD), which focus on raw materials, fireproofing, coking, blast furnaces and iron and steel making. The European Metallurgical Conference (EMC) will be the communication forum for non-ferrous metallurgy experts, which covers the entire light metal field, and the trade conference Pb Zn 2015. At the Lead & Zinc Symposium, everything revolves around extractive metallurgy and processing concepts. Heat is what counts at THERMPROCESS; industrial furnaces, industrial heat treatment plants and thermal processes are the main areas covered by the exhibits. THERMPROCESS is the second-oldest trade fair in “The Bright World of Metals” (after GIFA) and has been part of the Messe Düsseldorf portfolio for forty years now. It continues to be a success, with 306 exhibitors and 10,331 square metres of stand space this year. At THERMPROCESS, experts hold discussions about technical innovations relating to heat treatment and modern energy engineering plant concepts in the context of the THERMPROCESS Symposium. The symposium is organized by the VDMA thermprocess technology trade association. The emphasis at the FOGI Special Show organized by Forschungsgemeinschaft Industrieofenbau e.V. (FOGI) is on the heating, smelting and pouring of metals, heating technology as well as the heat and surface treatment of metal, ceramics and glass.

GIFA – the 13th International Foundry Trade Fair with Technical Forum – can report impressive statistics for 2015, with a record number of 898 companies from 46 different countries and 47,457 square metres of stand space in halls 10 to 13 and 15 to 17 on the exhibition site in Düsseldorf. With the Technical Forum and GIFA Conference, GIFA is not only a technological forum and event for placing orders but also a high-quality lecture and conference venue. GIFA reflects the entire market, with a complete range of foundry machines and equipment, die-casting machines and melting operations. NEWCAST – the 4th International Trade Fair for Castings – is another successful concept: launched in 2003 as the latest addition to “The Bright World of Metals”, it immediately attracted a global response from both exhibitors and visitors. There has been steady growth since then and now NEWCAST has considerably more companies from overseas, particularly Asia, among the 408 exhibitors with their 6,884 square metres of stand space in halls 13 and 14. In addition to the practical presentation of castings in the exhibition halls, NEWCAST will also be a rich source of research information. The NEWCAST Forum, for example, MPT International 3 / 2015

››› EVENTS

where the emphasis is on direct interaction with industry experts, will be giving an interesting insight into the technical and scientific progress that has been made in foundry engineering. The most innovative and creative castings from the industry will be presented with the NEWCAST Award too. Project director Friedrich-Georg Kehrer is delighted about the positive development of the four trade fairs: “These four established and successful trade fairs are both a significant image factor and an important economic factor for the city. With a total of 2,124 ex-

fore they leave for the trade fairs. The cost advantages are obvious. In addition to this, the online ticket can already be used for free travel to Messe Düsseldorf on buses and trains in the Rhine-Ruhr public transport system (VRR).

Metsearch – the new sector portal for the metal-working industries A comprehensive and complete product and company database across the various metal-working sec-

The “Bright World of Metals” has positive news to report

ways up-to-date, Metsearch is an international sector portal in German and English which covers the complete metal-working industry market. The user accesses a comprehensive data-base containing products, companies, sector and company news. It is also possible to search for trade fairs where specific companies are exhibiting or presenting special products. In this connection the GIFA, METEC, THERMPROCESS, NEWCAST, wire, Tube and Valve World Expo trade fairs have been taken into account.

The ecoMetals campaign focuses on energy GHƂEKGPE[ CPF VJG OKPKOK\CVKQP QH TGUQWTEG KPRWV

hibitors, more than 15,000 people who will be working on the stands here and the roughly 80,000 visitors who are expected, Düsseldorf can look forward to one of the absolute highlights of the trade fair year.” Professionals who are interested should make sure they obtain their admission tickets from the websites in advance and print them out at home beMPT International 3 / 2015

tors is offered by the new sector portal www.metsearch.net. News with background information on the industrial sectors of the national and international trade fairs covering the areas of foundry technology, metallurgy, cast products, thermal process technology, industrial fittings, pipes/tubes along with wire and cable round off the range of services. Al-

Quite irrespective of whether the search is specifically for exhibitors, countries or products, the structure of the database enables the user to conduct a quick search and navigate directly to concentrated information. Changing monthly highlights with different key themes round off the portal’s diversity for every industrial sector.

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Control pulpit in a rolling mill

Innovation and dialogue Present with two trade fair stands At METEC 2015, the SMS group will be presenting itself as a systems supplier. Being one of the leading suppliers of metallurgical systems solutions for the steel and NF metals industry, the SMS group will participate with two trade fair stands covering a total floor space of around 1,500 square metres. On the METEC stand in hall 5 and the GIFA/THERMPROCESS stand in hall 10, visitors will get first-hand information about the entire technology and service portfolio of the SMS group.

Technology experienced live On the METEC stand, the visitors will have the opportunity to experience live the solutions offered by the SMS group, for example, by physically operating a control pulpit and actively controlling the rolling process in a heavy-plate mill stand. The process will be shown at the Data Analysis and Vision Desk – called DAVID. Based on this form of virtual process representation, it is possible to evaluate process-relevant data and discuss the obtained information with other experts during running production.

Coping with the challenges of the future The central topic of this year’s METEC will be “Growth Engine Metallurgy – MPT International 3 / 2015

Designing the Future Efficiently and in an Eco-friendly Way”, underscoring two of the main challenges facing the plant and mechanical engineering sector in the global competitive environment: efficiency and sustainability. The companies of the SMS group put great emphasis on innovative technologies and a continuous dialogue with their customers. To this end, the SMS group’s design engineers also collaborate with external scientists. This facilitates the development of groundbreaking solutions that possess great potential for the future. One example is a concept developed in collaboration with the Technical University of Clausthal and Salzgitter Flachstahl GmbH: the Belt Casting Technology (BCT®), a horizontal strip casting process. This process uses much less energy and raw materials than other steel casting processes and the capital investment in a BCT® plant is only about one third of that otherwise required. For this innovation, the team of researchers was put forward for “Deutsche Zukunftspreis 2014”, one of the most important German science awards. The SMS group will also present the USP® plant (Universal Strip Production), a further develop-

ment of the CSP® thin slab casting and rolling technology. These are only two examples of the portfolio of SMS group technologies, which the METEC visitor will be able to experience. Another important issue is the growing digitization of economic and manufacturing processes. This development presents the entire metallurgical sector with major new challenges. Also in this field, the companies of the SMS group have already developed various pioneering solutions and are inviting the trade fair visitors to discuss – on the basis of practical examples – where metallurgical technology will be heading in the future.

Technical papers Additionally, experts of the SMS group will be presenting new developments and successful reference projects from the last few years at ESTAD 2015 (European Steel Technology and Application Days) in around 60 technical papers. The conference will provide participants a forum to obtain indepth information on latest developments in the field of metallurgy.

SMS group Hall 5, stand E22 (METEC) · Hall 10, stand H41 (GIFA/THERMPROCESS) · www.sms-group.com/metec/ SMS group app with push news function

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Every project is preceded by a requirements analysis to identify the equipment required, the necessary engineering services and the work required for installation and commissioning. The resulting action plan often produces innovative new solutions.

We are looking forward to seeing you! METEC 2015 16 – 20 June 2015 in Düsseldorf Hall 05 Booth 5G22

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş PREVIEW OF EXHIBITORS

Ironmaking and steelmaking Conveyors for hot materials transport Aumund will present conveying equipment for different types of hot materials transport. For hot sinter, Aumund has a vast range of different types of pans and plates for transporting hot and abrasive bulk materials. Temperature, precise material dosage, and the proportion of lumps and chunks have to be considered. The conveyors transport hot sinter with temperatures up to 1,000Â°C. Capacities from 200 t/h

Pan conveyor

up to 1,480 t/h have been realized. Hot Fe-pellet transport: The capabilities of existing facilities can hardly keep up with the increased demand in capacities. The pellet cooler is often followed by rubber belt conveyors to handle the cooled pellets. After a capacity increase, the temperature of the pellets at the cooler exit rises remarkably. Aumund metallic pan conveyors are installed from the early beginning or as a main part of a conversion. After the pellets have been cooled down, the remaining distance can be bridged over with rubber belts. Transport of hot DRI and EAF hot charging: Hot transport systems of Aumundâ&#x20AC;&#x2122;s latest design require significantly less nitrogen compared to earlier designs. The strength of chains has increased from 1,200 to 3,000 kN. The current third generation of rollers, which can resist the high temperature in a metallurgical surrounding, is life lubricated.

AUMUND FĂśrdertechnik GmbH Hall 4, stand F18 (METEC) www.aumund.com

Electromagnetic stirrers and other products for continuous casting plants Ergolines produces a whole range of products for the continuous casting of steel. Products include EMS systems, sensors, electric machines and sophis-

Electromagnetic stirrer

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MPT International 3 / 2015

PREVIEW OF EXHIBITORS ticated automatic process control devices, all designed to achieve the highest standards in steel quality. Alongside stirrers, the product range includes mould level control sensors, powder thickness control and feeding systems, mould oscillation checkers, ladle-to-tundish slag carry-over detection sensors, breakout prediction systems, and others. Ergolines boasts valuable relationships with leading engineering companies and steel producers worldwide, including Primetals, ArcelorMittal, Inteco, Riva Group, Ovako, Ferriere Nord, GMH, Feralpi Group and Severstal.

ture in two dimensions. This provides much more information than systems making spot-type measurements. The system consists of several interlinked transmitter and receiver units of iden-

Ergolines Lab s.r.l.

For the temperature measurement, the

Hall 4, stand E28 (METEC)

eight transmitter and receiver units

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create a virtual plane between the burden and the chute

Temperature distribution measurement of top gas in blast furnaces IMI Z&J will present a new 2D gas temperature measuring system t-matriX for blast furnaces. The system measures the distribution of the top gas tempera-

tical design, distributed along the circumference of the blast furnace. As they are installed outside the furnace chamber, they are accessible at any time. t-matriX uses the principle of acoustic pyrometry, i.e. the principle that the speed of sound in a gas chang-

‹‹‹

es as a function of temperature. The system measures the time it takes for an acoustic signal to propagate between the transmitter and receiver units. From the individual, integral sound propagation times, the tomographic software of the system calculates the temperature distribution in the measurement plane. This technique no longer measures the top gas temperature at certain spots, as used to be common practice in the past, but in two dimensions across the entire furnace chamber. The system not only measures and calculates the temperature distribution. It is also designed to automatically determine hot spots. Blast furnace operators using this system in combination with IMI Z&J’s solution p-matriX – a system providing a three-dimensional image of the burden geometry – will benefit from highly valuable information about the processes going on inside the blast furnace. IMI Z&J Germany – Z&J Technologies GmbH Hall 4, stand E17 (METEC) www.imi-critical.com

The next dimension in surface inspection

Fully automatic classifying slab inspection system: • Detects cracks and other defects on the slab surface

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Düs Germany 15 6.20 16. – 20.0

surcon GmbH Dieselstraße 52 42579 Heiligenhaus Germany

phone: + 49 (0) 2056 975-300 fax: + 49 (0) 2056 975-301 info@surcon-gmbh.de www.surcon-gmbh.de

MPT International 3 / 2015

››› PREVIEW OF EXHIBITORS

Vibrating machines and systems Jöst is globally known for innovation and constant developments of vibrating machines and systems for the steel industry. The company presents an overview of its products for primary and secondary metallurgy. The products range from machines and systems for conveying raw materials, screening, storage and dosing of different products up to the different furnace melting processes like EAF, RH, VD or LF. Jöst GmbH + Co. KG Hall 3, stand F33 (METEC) www.joest.com

dle-based HM pretreatment technologies. This process can be integrated into the production sequence of nearly all plant concepts and layouts. Production of clean steel requires removal of all undesired impurities especially sulphur and phosphorous. While sulphur is already often removed from the hot metal, desiliconization and dephosphorization are traditionally carried out in the BOF. As the BOF process is often already optimized to its limits, additional incoming silicon or phosphorous loads can only be handled at the expense of reduced productivity and increased production costs. Benefits can be gained by introducing selected hot metal

New approaches to sulphur and phosphorous removal Küttner presents solutions and concepts to cope with today’s challenges regarding sulphur, silicon, and phosphorous removal. A special process compensates a main part of the temperature losses often associated as a main drawback of the la-

“Drive-through” hot metal pretreatment station

pretreatment steps before charging the hot metal into the BOF converter. Many already existing stations for hot metal desulphurization are suitable to be used also for desiliconization and dephosphorization. Thus, extending desulphurization stations to most flexible pretreatment stations is often just a short step. Küttner GmbH & Co. KG Hall 4, stand C28 (METEC) www.kuettner.com

Water-cooled elements Lebronze Alloys Germany/Hundt & Weber is specialized in the production of water-cooled cooling components for blast furnace processes, steelmaking and primary and secondary metallurgy. The company will present new and trendsetting concepts, for example optimization of cooling elements by a cast-in coil system. To meet the requirements of this solution, Lebronze Alloys Germany/Hundt & Weber developed a new casting and handling system. The patented system is traded

Shorten search times and cut your costs… Efﬁcient warehouse management

www.vip-kommunikation.de

Visit us in Düsseldorf June 16 - 20, 2015 Hall 3, Booth No. E35

MPT International 3 / 2015

TWMS/metals visualizes and controls transportation and warehouse processes in real time, from continuous casting to loading of the finished long or flat products. The benefits are optimum use of warehouse space, short handling times, efficient deployment of personnel and means of transportation, low operating costs.

TWMS/metals: The Technical Warehouse Management System for the Steel Industry www.3tn.de

PREVIEW OF EXHIBITORS mechanical stress, are characterized by high reliability and long service lives. Lebronze Alloys Germany GmbH – Hundt & Weber Hall 5, stand F11 (METEC) www.hundtundweber.de

Precision spray nozzles and nozzle systems

Water-cooled element for runner system

under the brand TNC™. Besides cast-in copper coil systems (Cu DHP EN 12449) also coils made of Monel 400 are commonly used. Advanced monitoring systems (e.g. simulated solidification, CFD analysis, infrared testing) have been integrated into the entire quality process. Also water-cooled cooling components for blast furnaces and steelmaking will be presented. These components, which are subjected to extreme thermal and

Lechler, manufacturer of precision spray nozzles and nozzle systems for the metallurgical industry, presents two new nozzle innovations for secondary cooling in billet and bloom casting. The new air mist nozzle Billetcooler Flex® is characterized

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by its very constant spray angle over the entire turn-down ratio. In addition to that the liquid distribution can be set dynamically according to the strand format by controlling the water and air pressures. Thanks to these innovative features this new nozzle offers greater flexibility in the process since the local heat extraction can be specifically increased or reduced. This means an additional actuator for optimal cooling is now available. Lechler was also innovative in secondary cooling with water-only nozzles. The new full cone nozzle series 490 with extraordinarily large free cross sections features true non-clogging characteristics. Reduced nozzle clogging means higher operation safety, improved product quality due to more uniform cooling and reduced maintenance costs. Lechler also engineers solutions for processes such as high-pressure descaling in hot rolling and forging, roll cooling in hot and cold rolling, and pickling lines. Lechler GmbH

Water nozzle (left) and air mist nozzle

Hall 4, stand F 23 (METEC)

(right)

www.lechler.com

Please visi

t us!

2015

16.06.2015 20.06.2015

hall 3, booth E 20

››› PREVIEW OF EXHIBITORS

Spare parts and consumables MSITech is a supplier of spare parts and consumables for the iron and steel industry. The company has an in-house manufacturing facility for thermocouples, oxygen sensors and samplers. MSITech will have on display thermocouples for instant temperature measurements, single-dip temperature and oxygen probes, samplers for O2/C/Al analyses and immersion sampling probes for metallurgical analyses.

nologies experts by calling up technical presentations on touchscreen PCs distributed around the booth. The ESTAD conference will feature 65 technical presentations by Primetals Technologies – that is more than ten percent of all contributions at the ESTAD. Primetals Technologies, Limited Hall 4, stand E10 (METEC) www.primetals.com/en/METEC2015

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Thermocouples /5+6GEJ #UKC 2CEKƂE 26' .6& Hall 3, stand F04 (METEC) www.msimetal.net

First presentation of joint portfolio

Visit us at the MET EC on our Booth C37 in Ha ll 4

[Vision becomes reality with transporters from SCHEUERLE & KAMAG

Slag Pot Transporters in a platform or U-Frame design, Slab and Coil Transporters, Industrial Lift Transporters with cabin on top or under QMBUGPSN r XF PGGFS FGæDJFOU TQFDJBM vehicles for metallurgical applications. Innovative technology developed from decades of experience is behind our names. Reliability and functionality are the features that our vehicles offer.

www.scheuerle.com www.kamag.com

Primetals Technologies will be presenting itself for the first time at METEC this year. The joint venture of Siemens, Mitsubishi Heavy Industries and Partners was established in January 2015. At a booth covering around 800 square metres, the company is displaying its comprehensive technology, product and service portfolio for every step in the iron and steel production value chain as well as the latest rolling solutions for nonferrous metals. The booth is characterized by interactive elements. Large wall screens feature a map of the world which visitors can touch to learn more about Primetals Technologies’ reference projects around the globe. A number of “Innovation Corners” will provide extensive information on technological highlights that include the EAF Quantum electric arc furnace that first went into operation at Tyasa in Mexico in 2014; the ESP line with references in Acciaieria Arvedi, Italy and the Rizhao Steel Group, China; the portfolio of solutions across the various process steps in the production of AHSS (advanced high-strength steel) grades. Visitors can delve more deeply into specific topics with Primetals TechMPT International 3 / 2015

Saarmetall, and its subsidiary Solocuivre, display the whole gamut of water cooled copper fittings for the metallurgical industries, including latest developments. The main groups of fittings are copper fittings for blast furnaces and cupola furnaces (tuyeres, tuyere coolers, cooling elements), copper fittings for electric arc furnaces (contact clamps, cooling elements), copper fittings for submerged arc furnaces and smelters for the production of ferroalloys and non-ferrous metals (contact clamps, pressure rings, cooling elements, tap holes) as well as lance tips and sub-lance tips for BOF converters and lance tips for special applications. Also on display are copper moulds for continuous casting (mould tubes, mould plates) and copper cruci-

Copper products for metallurgical plants

bles for re-melting furnaces (VAR, ESR). Saarmetall and Solocuivre cover the whole range of copper and copper alloy forgings and fabricated structures. Most of the products are supplied in the finish machined condition, ready for immediate installation. Saar-Metallwerke GmbH Hall 4, stand C20 (METEC) www.saarmetall.de

Oxygen lance tips for LD converters Soudobeam presents a new generation of oxygen lance tips, called Sou-

dotip®. These lance tips have been developed to improve steelmaking efficiency through optimized blowing with permanent coherent oxygen jets. They feature a new dedicated design which achieves savings as a result of a reduction of iron in slags, less oxygen dissolved, extended lifetime, reduced skulling and low refractory wear. Soudobeam SA Hall 3, stand A38 (METEC) www.soudobeam.be

Oxygen lance tip

Clean lance technology for eliminating converter lance skulling Tallman will show its special SD lances (also known as PCD lances) which include a secondary oxygen distributor designed to reduce the frequency of, and in some cases, completely eliminate lance skulls (jams). Lance jams occur to a greater or lesser extent at all steel plants. Lance skulls are a safety issue especially when lances are removed from the converter and during deskulling operations. The use of SD lances has been proven to increase the lance life, reducing maintenance costs, improving safety, and increasing productivity. Standard lances can be easily retrofitted. The SD lances are designed so that there is no change to lance blowing height, total oxygen flow rate or total oxygen consumed. There is no increase in refractory wear or reduction in CO recovered. SD lances can also be designed to control converter cone and mouth build-up. Tallman offers custom-engineered BOF lance tips, supersonic carbon and lime injector technology for EAF steelmakers

Precise, Reliable, Repeatable

Too Hot to Handle? No Problem with Polytec

Lime dosing and injection system The range of products displayed by Stein Injection Technology also includes lime dosing and injection systems. Burned lime is injected for metallurgical reasons and dolomite lime for the adjustment of MgO in the slag. To avoid that too much of the mentioned material is charged, exact measurements and dosing are required. Stein injection systems achieve savings up to 10% in comparison to conventional methods of lime charging. Precise lime injection by means of equipment developed by Stein reduces overall lime consumption and refractory lining wear. The reduced gunning/fettling effort will result in shorter repair times and less heat losses. The possibility of charging lime in smaller quantities when and where it is needed has substantially improved the metallurgical melting conditions and reduced heat times. Stein Injection Technology GmbH Hall 4, stand F09 (METEC) www.sit-gmbh.net

Come and see us on 16th - 20th June 2015 at METEC Dusseldorf, Hall 3, Booth 3D33

Skull-eliminating lance

and calorized tuyeres and coolers for blast furnaces. Tallman Bronze Hall 3, stand E36 (METEC) www.tallman-bronze.com

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

6TCPUHQTOGTU CPF TGEVKƂGTU Transformer & Rectifier (India) Ltd. is a transformer manufacturer with a track record of more than 9,000 transformers. The diversified product

Learn more: www.velocimeter.us

››› PREVIEW OF EXHIBITORS

range comprises power transformers up to 1,000 MVA, 1,200 kV class, distribution transformers of rating 315 kVA and more, furnace transformers up to 120 kA, rectifier transformers up to 160 kA, reactors up to 765 kV class and other special-duty transformers. The state-of-the-art manufacturing facilities with modern testing laboratory perform all routine and type tests for transformer ratings up to 1,000 MVA, 1,200 kV class. One of the test laboratories has been accredited by the National Accreditation Board for testing and calibration laboratories (NABL).

Transformer production

6TCPUHQTOGTU 4GEVKƂGTU +PFKC .VF Hall 3, stand F24 (METEC) www.transformerindia.com

Injection systems Velco will show its Unidos injection system used in electric steel plants for the injection of carbon for the foaming slag process as well as for the addition of lime and the injection of different additives for the metallurgical process. Nowadays, with regard to ecological and economical aspects, it is also used to blow-in filter dust. Unidos is also a sophisticated system used in blast furnace operations, where carbon powder, iron ore, filter dust, rutilite, ilmenite and even plastic shredded material are fed into the furnace. A further field of application is ladle metallurgy. Here, Velco’s machine system is used among others for the carburization or desulphurization process. In the non-iron industry it is utilized to inject salts, alloys or carbon dust. For materials that flow poorly and agglomerate easily, Velco offers the Unidos-R model which is equipped with a special

agitator in the chamber substructure. For coarser bulk materials or material with higher humidity, Velco offers its machine type EKS with mechanical dosing system. All machine types can be provided as multiple dosing devices with several, parallel outlets.

Injection plant

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Systems for separation of dust and water from quenching steam built to our own patents with residue guarantee as per TA Luft

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mail@kiro-nathaus.de www.kiro-nathaus.de

PREVIEW OF EXHIBITORS

Velco Gesellschaft für Förder-, Spritz- & Silo-Anlagen mbH Hall 5, stand D26 (METEC) www.velco.de

control panel, local operation panel and valve. The milliwave beam transmitted from the antenna scans from the centre to the edge of the furnace. The scanned positions and the distance to the mate-

.CPEGNGUU DNCUV HWTPCEG RTQƂNG meter The MWS-BF-2P milli-scanner lanceless blast furnace profile meter presented by Wadeco is an FM-CW radar-type milliwave range finder. Developed for profile measurements of charging materials (coke or iron ore), the system consists of a range finder, enclosure, local

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rial are calculated and converted to the profile measurement and the output and profile are displayed on a personal computer. By using this profile information, the charging profile of the material can always be controlled in real-time so as to keep an optimal concave shape. Greater charging control results in more stable gas flow in the blast furnace, facilitating coke conservation and increasing the longevity of the furnace. Wadeco Co., Ltd. Hall 3, stand A55 (METEC)

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www.wadeco.co.jp

Rolling and processing technology Rolling mill simulator Achenbach Buschhütten supplies complex production plants for non-ferrous metal rolling and slitting products. The company focuses its exhibits on the Optiroll® rolling mill automation system. Visitors are invited to operate a

new rolling mill simulator, which consists of three screens and one control desk with various operating elements. One can select the coil to be rolled and ‘bring it into the machine’. All parameters belonging to this coil like alloy, target thickness, strip width etc.

A powerful new formula for improved reliability

are transferred to the presetting screen. In order to secure an optimum rolling process, further technological parameters are automatically added and the coil is rolled with all functions of the Optiroll® system. Alternatively, visitors may choose all settings manually

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MPT International 3 / 2015

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş PREVIEW OF EXHIBITORS without leaving any sticky material on the surface. The surface will be softer and the appearance of the rolled steel be improved. Other Emuref products include anti-sticking products for slag pots, steel ladle lips, reheating covers, etc., which avoid stickiness of the slag or steel, increasing the availability of the equipment. Emuref S.A. Hall 3, F06 (METEC) www.emuref.com

Universal foil rolling mill for 2,170-mmwide aluminium foil

and compete with other â&#x20AC;&#x2DC;operatorsâ&#x20AC;&#x2122; in the contest: â&#x20AC;&#x153;Who rolls the best strip?â&#x20AC;? Achenbach BuschhĂźtten GmbH & Co. KG Hall 4, stand C25 (METEC) www.achenbach.de

*KIJ Ć&#x192;WZ OCIPGVKE KPFWEVKQP technology Fives has developed a new generation of reheating furnace inductors providing reduced operational costs and minimized NOx emissions. The new highflux magnetic induction technology,

Products reducing scale formation and decarburization depth Emuref will present its Stopoxy coating product applied before reheating processes for reducing the decarburization depth. During reheating, it will create a protective shield around the product. Emuref will also display its Descalizer product, a coating applied before the reheating process, to significantly reduce scale formation. During reheating, it will create a protective shield around the product in the descaler. The coating is easily removed

Celes Celine, with high-intensity magnetic fields is generated by multilayer coiling. The power is injected into the product up to 4 to 6 MW/m2. This technology has been developed for long and flat products and is mainly used for continuous casting lines before roughing mills or finishing mill stands, at reheating furnaces or in thermal profile correction machinery at rolling lines. The technology eliminates the temperature difference between head and tail of the billet and reduces skid marks. Due to lower operating temperature of the furnace, the technology reduces maintenance costs, metal loss, production costs, NOx emissions and electricity costs. Celes Celine has a very compact footprint so it can be easily integrated into existing lines. The equipment generates virtually no magnetic field in the environment close to the inductor, which has emissions ratings consistently below European standards. Fives Celes S.A. Hall 9, stand E58 (THERMPROCESS) ZZZ Ć&#x201A;YHVJURXS FRP

Bright annealing furnace with tubular heating elements FK Industrieofen + Schutzgastechnik will show the latest in heat treatment technologies, special inert gas generators for DRI technologies as well as technologies for generating inert gas. Among the exhibits will be a bright annealing furnace with tubular heating

Reheated billet

Water-cooled components for the steel industry

rs at exhibito 015! We are ldorf 2 e s s u D METEC 3A02 , Booth 3 0 ll a H

Electric arc furnaces Ladle refining stands Converters Waste-gas cooling systems Cooled equipment We are able to design and supply the complete set of equipment. The modernisation of existing EAF and converter plants can be done by us as well as planning and manufacturing complete new exhaust gas cooling systems. We are also your partner in finding functional solutions in detail design. Contact us for our competence.

MPT International 3 / 2015

Kuhlmann-System-KĂźhltechnik GmbH D - 45721 Haltern am See . An der Ziegelei 11 Phone: +49(0)2364/10 53 9-0 . Fax: +49(0)2364/10 53 9-16 E-mail: info@k-s-k.de . Web: www.k-s-k.de

Engineering ns GREAT Solutio

Professional Blast Furnace Equipment No-Bell Top The new compact charger ensures the simple exchange of a furnace-top double bell for a No-Bell Top system. The usual modiďŹ cation of the steel construction of the blast furnace necessary for such changes is no longer required, meaning no further modiďŹ cations at the skip-or belt feeder system. This is due to the space-saving concept consisting of material storage, material control valves and gas shut-off valves. The combination of low investment costs and increased productivity ensures shortest repayment.

In terms of technology this is the extension of the blast furnace operating capacity as well as a decrease of the reduction agent consumption due to a systematic distribution of material. The structural arrangement and the kinematics of the chute minimise the loads on the gearbox. The material is distributed on the complete surface by the independent movement of the upper- and lower chute. This concept ensures a failure- and maintenance free operation of the charger.

Valves for the Iron and Steel Industry Our current modern products for the Iron and Steel Industry are known world-wide for their extensive and trouble-free operation.

Basic product range: Plants • Energy Recovery Turbines (TRT plants) • Flare Stack Systems • Control Systems (elec./hyd./pneu.) Measuring System for use inside Blast Furnaces • t-matriX: 2D - Gas Temperature Measurement System based on sound pyrometry. • p-matriX: 3D - Radar Based Measurement System to scan the entire dumping proﬁle Equipment • No-Bell Top Charging System • Lock Hopper Systems • Burners • Ignition Equipment • Tuyere Stocks - Energy saving design

p-matriX: 3D Radar Based Measurement

Valves for Stoves, Gas Systems, Blast Furnaces etc. • Hot Blast Valves • Back Draught Valves • Goggle Valves (Line Blinds) • Lever Valves (2, 3 or Push-Lever) • Butterﬂy Valves (Control and Eccentric Type) • Snort Valves • Bleeder Valves • Pressure Equalizing Valves • Septum Valves • Gas Safety Valves

t-matriX: 2D Gas Temperature Measurement

We make the largest valves in our industry

Contact IMI Z&J Germany Z&J Technologies GmbH Bahnstraße 52 D-52355 Düren, Germany

IMI Z&J Houston Zimmermann & Jansen Inc. 4525 Kennedy Commerce Drive Houston, TX 77038, USA

Tel: +49 2421 691 0 Email: imizandj.germany@imi-critical.com

Tel: +1 281 446 8000 Email: imizandj.usa@imi-critical.com

Website: www.imi-critical.com

IMI Z&J South Africa Zimmerman & Jansen S.A.(Pty.) Ltd. 11 Michelin Street P.O. Box 1335 Vanderbijlpark 1900 South Africa

IMI Z&J Shanghai Z&J High Temperature Equipment Co Ltd. No. 2 Workshop No. 819 Yinchuan Road Minhang Dist., Shanghai 201109 China

Tel: +27 16 986 0159 Email: imizandj.sa@imi-critical.com

Tel: +86 21 6490 7780 Email: imizandj.china@imi-critical.com

PREVIEW OF EXHIBITORS elements. These elements will be transported through heat resistant tubes made of special heat resistant steel. The annealing temperature is approximately 1,150°C. The tubes are filled with inert gas (N2 and/or H2). The inert

Laser welder for processing lines Ideal-Werk offers joining solutions based on butt welding, flash butt welding, shield arc welding and laser welding. The key factors to be observed include joining with weld seams that have no over-thickness, a joint withstanding all subsequent processes such as rolling and deep-drawing. The machines are used in inspection lines, slitting lines, galvanizing lines, organic or multilayer coating lines, pickling lines, continuous anneal-

Bright annealing furnace

gas remains in the tubes during the annealing process, because inlet and outlet of the tubes are closed with special elastic gaskets. The extreme low inert gas consumption of max. 0.1 Nm³/h guarantees excellent annealing results under highly economical conditions. Modern pneumatic tensioning devices installed on the automatic feeding device guarantee fast loading and even feeding and transport of the tubular heating elements into the furnace. The feeding speed is adjustable by means of a frequency converter. The standard furnaces have a through-put between 5 and 300 kg/h.

ing lines and rolling mills. New steel grades such as AHSS, Dual and TRIP steels pose great challenges to joining technologies. Integrating a laser welder into hot-dip galvanizing lines dispenses with the need of having to weld intermediate mild steel strips between the AHSS coils (zebra system). The Ideal concept takes care of this problem as not only the joining of the coil head to the tail is done by the laser but also the strip end preparation is done by laser cutting. This achieves an outstanding strip edge preparation for the complete steel grade range. Even different material mixes, various strip dimensions and eventually coatings can now be handled. In cases where space is confined, a 3D modelling tool ensures a small footprint of the equipment. Ideal-Werk C.+ E. Jungeblodt GmbH + Co. KG Hall 5, stand B04 (METEC) www.ideal-werk.com

Guides for long product rolling mills

FK Industrieofenbau + Schutzgastechnik GmbH Hall 9, stand B29 (THERMPROCESS) www.industrieofen-schutzgas.de

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Laser welding machine in operation

Morgårdshammar will have on display latest equipment and solutions for long rolling mills. A live demo will be given of the Smart Eye digital setting system developed for simple and precise calibration. Its user friendly interface makes it fast and easy to achieve precise settings for the roller guide and stand. It has a compact design

MPT International 3 / 2015

››› PREVIEW OF EXHIBITORS

and the screen projects a clear image of how to adjust the correct position. A new patented roller guide for intermediate and finishing mill stands has been engineered in new special alloy, saving approximately 40% of the usual guide weight. The new patented WEG exit guide can be adapted, with different rollers, to achieve several functions: as marker

ous analysis in hot rolling mills for rod and wire, optimizes the setup of the rolling mill, calculates process parameters, automatically generates pass design and creates roll and groove drawings. Its wide range of applications makes it a useful tool at all levels in the company. Morgårdshammar AB

Detail view of the universal shaft

Hall 5, stand A28 (METEC)

showing the internal bearing ring

www.morgardshammar.se

Heavy-duty universal joint shaft series

Exit guide with marking roller

for marking the bar, as edger for making the edging pass and saving one stand at the beginning of the slitting process, or for sizing, i.e. decreasing the ovality of finished round products of up to 16 mm. The WICON rolling simulation software provides continu-

Voith CH universal joint shafts with rotation diameters ranging from 590 to 1,460 mm are designed for transmitting the highest torques. While the rolling elements used to run directly on the journal cross, the CH series has a newly designed internal bearing ring with an integrated axial bearing. The axial bearing on roller bearings provides maximum deformation resistance and ensures a uniform load distribution. As a result, the weight forces of the universal joint shaft are handled reliably, even in the face of high lateral accelerations. The

new bearing unit excels with its ease of assembly. Replacing the bearings no longer requires replacing the entire journal cross assembly; even separate bearings can be replaced individually. This reduces life cycle costs by 20 – 30% and relieves operators from the high costs of acquisition and storage of the journal cross assemblies. There are no additional load-bearing screw connections in the bearing unit. Consequently, the design eliminates the possibility of screw connections becoming loose or fracturing due to elastic deformation. Voith Turbo GmbH & Co. KG Hall 05, stand C02 (METEC) www.voith.com

Automation and quality assurance Measuring transducers and electronic evaluation system Dr. Brandt develops and manufactures measuring systems and electronic evaluation equipment, which since the year 2000 has been based on digital signal processing. The new meas-

uring electronics DMM-65, in addition to numerous customer-inspired features, combines fast digital signals with the Profibus communication protocol. Both measuring transducers and evaluation electronics are completely manufactured in-house.

Dr. Brandt builds on strong experience in developing and manufacturing transducers of different shapes and for different purposes. The extensive scope of products comprises solutions for measurements in steelmaking and steel processing: strip tension, rolling

7+(50352&(66 +DOO %RRWK $ ȥ *,)$ +DOO %RRWK $

Measuring ranges from -30 to 3500 °C!

Precise non-contact temperature measurement is our passion. E MORE SE

info@keller-msr.de www.keller-msr.com F

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PREVIEW OF EXHIBITORS

Electronic board of the evaluation system

settings and values (e.g. line speed, furnace temperatures and steel grade) on the mechanical properties on a quantitative basis. At METEC, the numerous benefits of combining the new furnace mathematical model, the IMPOC device and the data analysis will be explained. Also presented at METEC will be the EMG hotCAM camera technology for position and camber measurement in hot mills.

force, pressure transducers, weighing e.g. for ladle turrets, billets, coils, scrap transfer cars, ladles in casting bays; crane weighers, force measuring, overload safeguards, torque measurement, wire rope testing devices and devices for special measurement applications upon request. Dr. Brandt GmbH

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EMG Automation GmbH Hall 4, stand G20 (METEC) www.emg-automation.com

Incremental encoder technology Johannes HĂźbner Giessen will display its FG(HJ) 2 incremental encoder for standard motors, auxiliary drives and secondary drives. The encoder for standard motors is available as a solid shaft construction (FG 2) or hollow shaft construction (FGHJ 2) for a variety of shaft diameters. Due to its large ball bearings with a high dynamic load rating the latter guarantees a long service life and high levels of availabili-

Operating principle of online measurements

Hall 3, stand E01 (METEC) www.dr-brandt-gmbh.de

Strip measuring systems The growing complexity of the process and the high quality requirements on continuous galvanizing lines have led to the introduction of a furnace mathematical model developed by Drever combined with EMG IMPOC, an online quality measuring device. EMG IMPOC is based on the magnetic remanence principle for non-destructive determination of the mechanical properties of ferromagnetic steel strips. For every four metres of strip, the furnace mathematical model monitors the process history along with the online determined mechanical properties. The analysis of this data obtained from several months of production enabled the observation and the explanation of the influence of different process

The detection of slab/strip position and width is crucial with respect to optimal positioning and movement of the processed strip between the rolling stands or on the run-out roller table. The system is used in hot rolling mills for online position measurement of the strip and for camber measurements. In finishing mills EMG hotCAM helps to avoid â&#x20AC;&#x153;cobblesâ&#x20AC;?. The latest generation of EMGâ&#x20AC;&#x2122;s technology portfolio for furnace solutions is based on the so called Vivaldi antenna technology. Vivaldi antennas are co-planar antennas with ultra-wide-band characteristics. With EMG-VivaldiÂŽ the current limitations of radar, capacitive or inductive sensor solutions for furnaces could be overcome. The sensor is located outside the furnace atmosphere and measures through the furnace wall in a certain wavelength region of the radar spectrum.

Solid shaft encoder and encoder with hybrid bearings

Visit us att hhall 3 booth F54

Ideas do not care where they come from. Because only when intelligence and precision, craftsmanship and design work together, an optimum concept can be developed with our know-how and perfectly in OLQH ZLWK \RXU VSHFLÂżF UHTXLUHPHQWV

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PRECISION IS REQUESTED

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››› PREVIEW OF EXHIBITORS

ty. Consisting of components made of technical ceramics, the hybrid bearings of the FGHJ 2 insulate the bearing assembly by interrupting possible shaft currents on the machines. The shaft made of stainless steel, a robust and thick-walled casing as well as speeds up to 7,000 rpm (solid shaft) and 6,000 rpm (hollow shaft) are further factors that ensure the high level of reliability of the encoder. In addition to the incremental output, this solution allows users to choose between several options to fit their needs. With its option S, Johannes Hübner Giessen offers the possibility to add an additional electronic overspeed switch to facilitate precise monitoring of speed at the machine. The FOC option contains an integrated transmitter to convert electrical signals to optical signals. This means the encoder is ideally prepared to provide interference-free signal transmissions via fibre optic cable. Featuring designed-in redundancy, the option AKK offers a dual pulse output with second scanning as well as double electronics.

Johannes Hübner Fabrik elektrischer Maschinen GmbH Hall 4, stand A33 (METEC) www.huebner-giessen.com

New controller generation Mesa Electronic introduces its new MCon family of controllers for almost every application. The MCon Carbo is the new C-level controller with three different control loops. This allows the customer to control the C-level, the furnace temperature and the oil bath temperature. The MCon Nitro manages the nitriding Kn and furnace tem-

Mesa Electronic GmbH Hall 9, stand C73 (THERMPROCESS) www.mesa-international.de

Dynamic thickness and width measurement of metal strips

Controller unit

BRAUN Innovations vations for Steel Technology at the cutting edge

perature. The MCon TP can control the dew point and temperature of an endothermic gas generator, and MCon Uni is a universal controller with which the customer can control up to three different process variables. All controllers are equipped with the latest technologies such as touch screen display, multiple analog inputs and outputs as well as a variety of connectivity and communication protocols. The C-level calculation in MCon Carbo can be done with one or with two sensors. An additional control circuit can be used to control the oil bath temperature.

The O-frame measurement system developed by Micro-Epsilon for the metal processing industry has been extended by a new high-precision width measurement feature. The system uses three laser profile scanners and therefore op-

23$$+2(, 6th IInternational nternattionall C Conference onfference

MODELLING and SIMULATION of METALLURGICAL PROCESSES in STEELMAKING

BARDOLINO, ITALY 23-25 SEPTEMBER 2015 www.aimnet.it/steelsim2015.htm

BRAUN high-performance abrasive cut-off machine

Bar end quality after cutting

Ground billet surfaces

BRAUN high-pressure grinding machines

• High-performance abrasive cut-off machines (up to 2000 mm cutting wheel diameter and above) • High-pressure grinding machines • Flexible and innovative solutions for fully-automated turn-key-facilities • Consulting engineering and life cycle service support

MASCHINENFABRIK

www. braun.at

A-4840 Vöcklabruck, Austria, Tel. +43(0)7672-72463, E-mail: office@braun.at

MPT International 3 / 2015

Modelling and Simulation of metallurgical processes cover an important role in optimizing technological processes, decreasing production costs, increasing steel quality and defining the correct design of metallurgical processes in order to improve their sustainability even from the environmental point of view. The fundamentals of metallurgical processes can be investigated through physical and numerical modelling following several numerical approaches. Traditional and new mathematical techniques applied by modern simulation facilities allow to achieve results that are useful to understand physical interaction and to design a profitable metallurgical process. The simulations technique can be applied to the different steps of the metallurgical production route: production and refining of liquid metals, solidification, plastic deformation, thermomechanical processes, thermal treatment, verification of structural reliability etc. Organised by ASSOCIAZIONE ITALIANA DI METALLURGIA

ORGANIZING SECRETARIAT AIM - ASSOCIAZIONE ITALIANA DI METALLURGIA P.le R. Morandi, 2 · 20121 Milano · Italy · tel. +39 02 76021132 · fax. +39 02 76020551 e-mail: aim@aimnet.it www.aimnet.it

PREVIEW OF EXHIBITORS erates independently of the material. The scanners provide measurement values for thickness and width of the strip. O-frame systems of the thicknessCONTROL 8201 series for thickness meas-

‹‹‹

edge. This is how slitting lines are able to measure and report on the thickness and width of the entire band of any single strip. As well as being independent of the material and alloy, another important advantage of laser line sensors is the stability of the measurements that can be gained from their high level of information density. Micro-Epsilon Messtechnik GmbH & Co. KG Hall 3, stand C40 (METEC)

Thickness measurement system

www.micro-epsilon.com

Thickness and width measurement of

New laser thickness gauge

metal strips

Nokra, specialists in high-precision measurement gauges for steel and aluminium production, will launch the next generation of its successful contactless laser thickness gauge family, alpha.ti 2.0. The latest system generation comes with the new laser series alpha.plus, which is even more accurate than its predecessors, with much higher repeatability and highest measurement rates for use in rolling mill control loops. Nokra’s contactless thickness gauges are optimized to work

urement of metal strips are tried and tested in practice. They operate using two scanners based on the principle of laser line triangulation. As an option, the thickness measurement system can now be equipped with a third laser scanner. The sensor can be moved autonomously and measures the position of the second edge and therefore the band width, while the upper thickness sensor measures the first band

even in harshest environments in cold or hot flat rolling processes, with optional active temperature control and interfaces to all common mill control systems. Nokra Optische Prüftechnik und Automations GmbH Hall 3, stand E45 (METEC) www.nokra.de

Infrared camera for temperatures of up to 1,800°C The optris® PI 1M thermal imaging camera is the latest innovation in the

INJECTION TECHNOLOGY GmbH

TECHNOLOGY WITHOUT

COMPROMISE

Pneumatic Conveying-, Dosing- and Injection-Systems • Customised and cost-optimised technical solutions and systems • Development of specific customised process technologies • Multipoint-Injection-Process (MPI ) for foamy slag practice • Top-Injection-Process (TIP ) at LF and ladle for carburising or Pat.

Pat.

alloying without refractory lance

• Desulphurisation technology for Steel & Pig Iron • Complete Service from design to start-up • Long lifetime = less maintenance = higher productivity

METEC 2015 Hall 4 Booth F09 STEIN INJECTION TECHNOLOGY GmbH Hagener Str. 20 - 24 D-58285 Gevelsberg Germany

Telefon: +49 / (0) 2332 / 75742-0 Telefax: +49 / (0) 2332 / 75742-40 E-Mail: stein@sit-gmbh.net Internet: www.sit-gmbh.net

i.e. flexible ceramic lined hose

MPT International 3 / 2015

››› PREVIEW OF EXHIBITORS

Optris camera range. In addition to the advantages of Optris infrared cameras, such as their compact size, USB interface and license-free software, the new PI 1M features a continuous temperature measurement range of 450°C to 1,800°C, a frame rate of up to 1 kHz and a choice of optical resolution/ frame rate modes. The continuous range means that it can be used without subdivisions, making the camera much more versatile. The highly dynamic CMOS detector allows a maximum optical resolution of 764 x 480 pixels at a frame rate of 32 Hz. The ultra-compact infrared camera can be switched to 382 x 288 pixels at 80 Hz or 27 Hz and 72 x 56 pixels at 1,000 Hz for fast processes. Optris GmbH Hall 9, stand B49 (METEC) www.optris.de

tem has been engineered to label products up to 1,000°C. It features an advanced vision system and no longer

tions of the machine and components, separating structure-borne sound from machine movement. This allows damage to be spotted and prevented early. The flip-flop screen FlexaClass SFX is designed for the efficient processing of high-value raw materials. Damp and fine-grain bulk materials can block or

Labelling of billets

requires the presence of operators in the handling area. The system consists of a heavy industrial container, insulated and conditioned by means of refrigerators with water or air exchangers. Both the robot and the label machine are inside the container. The label is positioned on the billet, fixed and welded in the envisioned point by a metal nail. Polytec srl Hall 4, stand D34 (METEC)

Condition monitoring system on the force exciter

stick to screen panels. FlexaClass exploits the flip-flop motion of a trampoline, accelerating the material to a high speed so it is easy to screen. The screen panel is stretched to allow it to clean itself.

www.polytecrobotics.com Schenck Process GmbH Hall 5, stand G22 (METEC)

Short-wave camera for temperatures up to 1,800°C

Fully automatic cell for billet labelling Polytec, supplier of robotics for the steel industry, presents its PolyTAG B L cell, which meets the increasing requirements placed on the traceability of products in the steelworks. The sys-

Condition monitoring system for screening machines and vibrating feeders

www.schenckprocess.com

To succeed in the current competitive environment, manufacturers have been placing constantly growing demands on technology providers. Schenck will be presenting its condition monitoring system CONiQ for screening machines and vibrating feeders. In line with the principle of predictive maintenance, the condition monitoring system continually measures the temperature and vibra-

Stamping of machine-readable data-matrix codes Stangl Technik presents its new data-matrix stamping machine for continuous casting and rolling mill products as well as its range of ink, paint and wire marking machines, deburrers and ladle shroud manipulators. The existing line of alpha-numerical stamping machines will be complemented by a new version

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PREVIEW OF EXHIBITORS cult weather and environmental conditions like dirt, dust, steam, smoke, vibrations and extreme temperatures. One highlight will be the new wireless system LPR®-1D24 which offers centimetre-precise distance measurement at long ranges up to 1,000 m and simultaneous wireless data transfer. This is a flexible, cost-effective sensor solutions for indoor and outdoor applications.

‹‹‹

FLEX your cooling. B I LLETCOOLE R

Symeo GmbH Hall 3, stand F47 (METEC) www.symeo.com

Stroboscopic inspection lights Stamping of data-matrix code

that is able to stamp machine-readable codes into hot and cold surfaces. The new machine is designed especially for uneven and scaly surfaces such as the torchcuts of continuous casting products. Stamping is possible at very high temperatures, requires no additional materials and the marked codes are extremely durable. This sets it apart from other marking techniques, e. g. paint markings or printed labels. The two-dimensional data-matrix code is camera-readable and an industry standard. Its built-in automatic error detection makes misreadings virtually impossible. Even partially damaged codes may remain legible due to built-in redundancies.

The products shown by Unilux include the EdgeTech and LED2000 series of strobe lights for two-surface inspection. EdgeTech uses strobe lights, cameras and video monitors to verify edge specifications on the pulpit

NEW

5 good reasons for a new secondary cooling system Pulpit and drive side camera views of strip edge plus status information of the coil being processed

Stangl Technik GmbH Hall 4, stand C27 (METEC) www.stangltechnik.com

Position, distance and anticollision measurements Symeo GmbH presents components and system solutions for reliable, continuous crane and vehicle positioning, distance measurement and anti-collision in the steel industry. The robust radio-based Symeo technology is especially designed for use under diffi-

Distance measurement devices

for billet and bloom continuous casting machines

and drive sides in real time after trimming, and enables knife trim adjustments to maintain specs. New controls include a camera auto re-adjust that maintains perfect focus as the strip wanders from side to side. Also new are 100% knife circumference views for knife crack detection, and a greater level of computer integration that captures and stores coil data with images. All performance and status information can be seen on the system’s control screen in real time. Unilux’s LED2000 series lights are gaining large-scale acceptance in mills because their softer, brighter, more even illumination offers better inspection of reflective surfaces. Various models of the LED2000 accommodate custom configurations for strip width, distance from the strip, mounting requirements, and ambient light in the area. LED’s also lower energy costs by

New steel types and formats call for new approaches to secondary cooling. Both cooling performance and water application must be precisely adjustable. With the Billetcooler FLEX®, we’ve developed a twin-ﬂuid nozzle offering exactly that – and much more. Stable spray angle over turndown ratio Flexible spray characteristics for every format and steel grade Non-clogging due to large cross sections Low air consumption HTC designed air mist nozzle

Visit us at METEC 2015, hall 5, stand F23

Lechler GmbH P. O. Box 13 23 72544 Metzingen, Germany Phone +49 7123 962-0 info@lechler.de

www.billetcooler-ﬂex.com MPT International 3 / 2015

THE ENTIRE WORLD OF IRON AND STEEL MAKING

two-thirds and eliminate lamp replacement, as well as reducing the entry cost for stroboscopic inspection. When not used for inspection, the LEDs can be used in simulated constant-on mode to serve as a work light. Unilux Europe GmbH Hall 3, stand D09 (METEC) www.unilux.com

Thickness measurement of cold strip Vollmer presents its new “VTLG” laser strip thickness measuring system. With a measuring accuracy of +/- 1 μm per millimetre strip thickness, it achieves the same

Coking & sintering technologies Material handling

Compact-design laser gauge

Iron making plants Steel making plants Rolling mill plants Recycling plants / Shaft furnaces Electric and process automation Heat and energy recovery Dedusting and gas cleaning

PROCESS DEVELOPMENT TECHNOLOGY TURNKEY RELOCATION UPGRADING REVAMPING OPERATOR MODELS NON FERROUS Küttner GmbH & Co. KG Essen/Germany info@kuettner.com www.kuettner.com METEC 2015 Stand 4C28

precision as the tactile and X-ray gauges. It is so compact and robust that it can be installed in the mill in the immediate vicinity of the roll gap. With an internal scanning rate of 50 kHz, the scalable analogue output provides the input signal for the high-speed thickness control within milliseconds. It offers different measuring ranges from 0.015 to 12.0 mm thickness. With an air gap of the C-frame of 125 or 285 mm, the sensors are positioned at a safe distance from the strip. The gauge is also suitable for use on processing lines, such as annealing lines, finishing lines, shear lines, etc. Vollmer compensates the thermal expansion of the C-frame by means of an intelligent temperature management system. This ensures that the measurement of the strip thickness in the mill, at the exit from a furnace line or on the annealing line is just as accurate as in an air conditioned laboratory. Air cleaning systems ensure reliable operation even under the rough environmental conditions in the mill. Friedrich Vollmer Feinmessgerätebau GmbH Hall 4, stand D18 (METEC) www.vollmergmbh.de

Shape measurement of long products Zumbach will exhibit equipment and solutions for precise measurement and monitoring of dimensions and shape/geometry of any bar, pipe or profile, hot and cold. With two sophisticated technologies Zumbach can always offer an optimal solution. Steelmaster is based on tangential laser scanning with ODAC® scanners and Profilemaster® is based on highly developed “light cut” vision technology. Different models are available, covering dimensions up to 600 mm. For cold application such as centreless grinding, peeling, tube welding, drawing, roll-

W E ing, straightening etc., Zumbach is offering sophisticated and well established solutions using the ODACÂŽ laser scanners and USYS processors for diameter measurement. Also the new Bendcheck system for the measurement and monitoring of bend (straightness) of bars, rods and pipes will be on display.

C O N V E Y

Q U A L I T Y

Hot Sinter Transport

Zumbach Electronic AG Hall 5, stand F22 (METEC) www.zumbach.com Measuring unit for products of up to 600 mm in diameter

Special equipment Electrical immersion heaters Atherm will present electrical immersion heaters and heating solutions dedicated to specific applications and challenges, such as the task to maintain the aluminium temperature during maintenance operation. In this case, the customer has 28 vault furnaces of 45 kW each. The

AUMUND Pan Conveyors s #APACITY UP TO T H s 0AN WIDTH UP TO MM s -ATERIAL TEMPERATURE UP TO Â˛# Mobile heater station

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furnaces must be maintained twice a month. Each time the furnace operator loses four hours of production time per furnace while reheating the aluminium from 630Â°C up to 665Â°C. Atherm proposed its â&#x20AC;&#x153;Heat Packâ&#x20AC;? mobile station of 12.5 kW heaters. It comprises a small control board on a trolley, piloting a single heater powered with up to 15 kW, and two different electric immersion heaters. Depending on the furnace size, a heater of 32 mm diameter with a heating length of 250 mm for 8 kW or a heater with a diameter of 55 mm with a heating length of 200 mm for 12.5 kW can be used. As a result, one hour of maintenance time is saved on each furnace, twice a month. This means a monthly average of additional 56 production hours.

s -INIMIZED HEAT LOSS s .O GENERATION OF lNES

Sintered and agglomerated Materials

Atherm S.A. Hall 10, stand A73 (THERMPROCESS) www.atherm.com

AUMUND Foerdertechnik GmbH 3AALHOFFER 3TR s 2HEINBERG s 'ERMANY METALLURGY AUMUND DE q WWW AUMUND COM

››› PREVIEW OF EXHIBITORS

Burner technology ESA Pyronics, specialized in the design of burners and combustion plants, presents two new burners added to its low NOx and fuel-saving family of burners: the REKO-SIK-SW flat flame self-recuperative burner and the REGE-NxT regenerative burner. The REKO-SIKSW burner follows the development of the standard REKO-SIK free-flame self-recuperative burner. According to a new flame tube design, it provides a flat flame during all operations. They

ature of 1,100°C. Ignition is provided via electrode and detection via UV scanner. The burners are suitable for heat treatment furnaces, furnaces with fiber insulation, ceramic furnaces, tunnel or car bottom furnaces. The REGE-NxT burners have been developed for all high energy consumption furnaces. They are regenerative gas burners for direct heating. In regenerative burners the heat exchange between flue gas and combustion air takes place via an alternate functioning of two burners in a fixed series of cycles. The burners are suitable for melting furnaces, forging furnaces, heat treatment furnaces, reheating furnaces and glass treatment furnaces. For ultra-low NOx applications, a flameless kit is available, also as a retrofit. ESA S.p.A. Hall 9, stand F49 (THERMPROCESS) www.esapyronics.com

Burner installation

are implemented with dual stage combustion to assure an NOx level below 200 mg/Nm3 with a furnace temper-

INNOVATIVE

new EVOLUTIONal cutting nozzle programme. These cutting nozzles minimize the cutting kerf of the complete range of cutting thickness

Example of a cutting nozzle

while improving cutting quality and increasing cutting speed. Also utility consumption (cutting oxygen, heating gas and oxygen) can be reduced. The nozzles are designed to cut carbon steel as well as stainless steel grades, for nominal cutting thicknesses up to 300 mm.

Cutting nozzles

Framag Industrieanlagenbau GmbH

The exhibits of Framag Industrieanlagenbau will include the

Hall 5, stand E20 (METEC) www.framag.com

ENERGY AND ENVIRONMENTAL SOLUTIONS

FLAMELESS REGENERATIVE AND RECUPERATIVE BURNERS RADIANT TUBE BURNERS

ULTRA LOW NOX

FLAT FLAME REGENERATIVE BURNERS

FLARES BLOOM ENGINEERING (EUROPA) GMBH Phone: +49(0)211 500 91-0 info@bloomeng.de www.bloomeng.de

MPT International 3 / 2015

Hall 9, Stand 9F22

PREVIEW OF EXHIBITORS Temperature-resistant and sealing products The Insulcon Group (Insulcon and Keramab) supplies high temperature resistant products with thermal-shock, chemical and wear resistance and/or high thermal insulation properties for industrial energy sav-

1600 P shapes (1,600Â°C), manufactured by vacuum forming high-performance refractory fibres, blended with specially selected organic and inorganic refractory binders; RefrexÂŽ heat shields, zone dividers, tube bellows up to 1,400Â°C; WearflexÂŽ tube seals, expansion joints and insulation covers. Also presented will be the range of hot spot repair and hot endoscopy inspection services.

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bulky loads between different production areas. This must take place quickly and safely. Italcarrelli will present a selection of its wide range of self-propelled platform transporters suitable for these applications with load capacities from 10 to 500 t and more. These machines can be supplied with onboard driver place, remote controlled or even fully automatic (AGV), with lifting system and bidirectional

Keramab will show its range of high temperature resistant textile products up to 1,260Â°C, such as twisted ropes, fibre ropes, braided and knitted packings, woven and knitted tapes, sleeves and cloths. Textile high temperatures resistant

Insulcon B.V.

products

Hall 9, stand D02 (THERMPROCESS) www.insulcon.com

ings. The products shown by the Insulcon Group include HT composite, a thin but strong, >1,350Â°C, extreme thermal-shock-resistant composite, composed of high temperature resistant ceramic endless fibers and matrices, based on metal oxides; Insulvax

www.keramab.com

Self-propelled platform transporters Metallurgical operations are characterized by the transport of heavy and

Transportation platform

or multidirectional steering systems. The innovative multidirectional driving system developed by Italcarrelli provides excellent control of direction, extremely precise movements,

THE SLAG TAURUS FROM KIROW, EXTREMLY ROBUST AND RELIABLE.

THE MULTI MOVER FROM KIROW, ULTIMATE FLEXIBILITY AND EFFICIENCY. WWW.KIROW.DE KIROW IS A MEMBER OF KRANUNION.

VISIT KIROW IN DĂ&#x153;SSELDORF/GERMANY AT METEC 2015, 16 - 20 JUNE 2015, BOOTH 5G19/HALL 5

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş PREVIEW OF EXHIBITORS

and reliably high stability of the load under any circumstances. The platforms can be supplied battery-powered or equipped with diesel or gas engines. These machines are supplied with wheels suitable for any type of flooring in order to operate both indoor and outdoor, and with axles compensation systems for rough flooring. Optional devices are also available including lights, ultrasound sensors to automatically slow down the truck in the presence of obstacles, special blocking equipment, sensors for the optical or inductive driving, etc. Italcarrelli can provide customizations and tailor made solutions in order to meet any customer requirements. Italcarrelli S.r.l. Hall 3, stand C10 (METEC) www.italcarrelli.eu

Low-maintenance and lub-free chain technology KettenWulf exhibits conveyor and drive engineering solutions, including innovations in the field of low-maintenance

introducing contaminating grease into the environment, both innovations not only contribute to a sustainable protection of the environment, but also provide high production efficiency. KettenWulf Betriebs GmbH Hall 4, stand B37 (METEC)

Chain with sealed joints

www.kettenwulf.com

and lubrication-free chain technology. Abrasive media like dust, ashes, ore, slag or gravel cause wear in the chain joint, which is the most common reason for an early failure of the chain. KettenWulfâ&#x20AC;&#x2122;s solutions feature a sealing system for the chain joint that is embedded by two anti-corrosion lids which serve two purposes; the first is that the sealing prevents dirt from entering the chain joint and the second makes sure that the lubricant cannot leak out. A special sealing system on the outboard support roller protects the bearings against damaging external influences so that the roller can be deemed lifetime lubricated without generating any additional maintenance efforts or extra costs. Due to the chain joint and roller using less energy, producing less waste and not

2TQEGUU URGEKĆ&#x201A;E QHH ICU treatment KĂźttner presents its Air Quench process for the treatment of off-gases arising from metallurgical processes. Such off-gases often comprise unburned hydrocarbons, acid components like SO2, HCl, HF and sticky dust particles. The

Principle of the off-gas treatment process

Customised 4-Way Handling www.combilift.com

ŕ Ž Space saving, safe and productive handling ŕ Ž Indoor/outdoor capabilites ŕ Ž Robust and versatile ŕ Ž Capacities from 1.5 â&#x20AC;&#x201C; 25 tonnes

GSB â&#x20AC;&#x201C; for secure Products

ŕ Ž Diesel / LPG /AC Electric Without Combilift

With Combilift

Combilift Ltd Gallinagh Co. Monaghan Ireland Tel: +353 47 80500 UK: 07870 976 758 E-mail: info@combilift.com

MPT International 3 / 2015

The GSB-GROUP GMBH is a reliable and flexible partner for refractory material (pre- and unshaped e.g. lances, dams, snorkels). Steel construction and wear technology (flexible, high abrasive resistant elbows).

GSB Group GmbH FlottmannstraĂ&#x;e 57 D-44807 Bochum Tel.: +49 (0)2 34 - 9 04 53-0 Fax: +49 (0)2 34 - 9 04 53-33 eMail: info@gsb-group.de Internet: www.gsb-group.de

PREVIEW OF EXHIBITORS Küttner Air Quench process can be subdivided into three stages: First, with primary air, a post-combustion is realized. In the second stage, the temperature is adjusted by the supply of secondary air in such a way that the acid components will be bonded by additives. By the supply of tertiary air, the off-gas and the sticky dust particles will be rapidly quenched. The technology is based on intensive and guided mixing of the off-gases with the supplied cooling air and the additives. The cleaning and maintenance effort is drastically reduced compared to conventional air cooling systems. Küttner GmbH & Co. KG

and gaseous burning material, hot gas generators, ladle heaters and boiler firing with all accompanying automation, installation, commissioning and after-sales services. LTP will present a series of industrial monoblock burners for ladle heaters and casting channel heating. In a cooperation with CIB Unigas S.p.A., the compact burners are distributed by LTP exclusively in Germany and are sold worldwide under the name of Loesche ThermoProzess. The burners equipped with high quality components are produced with capacities ranging from 160 kW up to 20 MW for industrial applications. Special features are the integrated combustion air fan and control system.

Hall 4, stand C28 (METEC) www. kuettner.com

Loesche ThermoProzess GmbH Hall 9, stand B 23 (THERMPROCESS) www.loesche-tp.de

Industrial burner technology Loesche ThermoProzess GmbH (LTP), subsidiary of Loesche GmbH, will present state-of-the-art burner systems. In addition to standard burners, the product portfolio of LTP includes mono and duo block burners for the industry as well as heating systems for solid, fluid

Gunning manipulators Velco will provide information about its range of gunning manipulators. The new MobiGUN manipulator is based on a diesel driven, robust four-wheel telescopic handler with hydraulic boom

‹‹‹

Gunning manipulator in operation

and electro-mechanic gunning head. Previously, it was only possible to repair a single unit as the gunning robot had to be fix installed near the furnace. MobiGUN can be used for all furnaces, as it is self-moving or transportable by crane. All it needs is a hose connection to the water and material supply. Once the MobiGUN is placed in front of the furnace to be repaired and the boom is positioned from the top, the operator leaves the cab and carries out the repair work by means of a radio remote control. The gunning head is turnable through 360° and can be lowered/lifted through 90°. Due to the dimension of the boom, all areas, even of very large

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş PREVIEW OF EXHIBITORS

furnaces, can be gunned. Hence, MobiGUN is a cost-saving allrounder. Velco Gesellschaft fĂźr FĂśrder-, Spritz- & Silo-Anlagen mbH Hall 5, stand D26 (METEC) www.velco.de

)CR Ć&#x192;QY DWTPGTU HQT JKIJ operating temperatures The range of gap-flow burners offered by WS Thermal Process Technology has been completed with a new burner, RekumatÂŽ CS. This burner can be operated at higher temperatures for direct and indirect heating. The combination of a thermally resistant ceramic recuperator and a highly efficient gap-

flow heat exchanger makes it possible to apply the gap-flow technology at a flue gas inlet temperature of 1,200Â°C. The new RekumatÂŽ CS saves energy compared to burners with ceramic recuperator. The high flue gas inlet temperature continuously decreases along the ceramic recuperator, falling below the maximum application temperature when it enters the gapflow heat exchanger. Compared to a conventional self-recuperative burner with ceramic heat exchanger, the new burner achieves higher efficiencies. With the flameless oxidation mode (FloxÂŽ) developed by WS, NOx levels of <100 ppm can be achieved. Also the range of regenerative burners RegematÂŽ has been extended. The new RegematÂŽ

400 is used in direct heating with max. 600 kW (boost mode). This highly efficient self-regenerative technology is suitable for operating temperatures up to 1,300Â°C. WS WĂ¤rmeprozesstechnik GmbH Hall 9, stand A76 (THERMPROCESS) ZZZ Ć&#x192;R[ FRP

)CR Ć&#x192;QY DWTPGT

Forging Manipulator

Furnace Charger

Heavy Load Robot

Please visit us at the

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METEC

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DÜSSELDORF, GERMANY 16 – 20 June 2015 Visit us:

HALL 5 / STAND D22

››› EVENTS

METEC & 2nd ESTAD – European Steel Technology and Application Days The 2nd European Steel Technology and Application Days (ESTAD) 2015 will run in parallel with the METEC trade fair. The Steel Institute VDEh and its partners offer visitors the perfect opportunity to reach their objectives. Only those who continue to develop their businesses remain competitive. The prerequisite for this development means being constantly informed about the latest and most sophisticated technological advances, exchanging ideas and initiating and expanding networks with clients, partners and suppliers. The 2nd European Steel Technology and Application Days (ESTAD) 2015 will run in parallel with the METEC trade fair. The Steel Institute VDEh and its partners offer visitors the perfect opportunity to reach their objectives. At this event, participants will acquire the latest information on new ideas and developments as well as on the state-of-the-art in metallurgical process technologies for iron and steel production, steel materials and steel application. The conference language will be English. The conference is organized in close cooperation with the Austrian Society for Metallurgy and Materials (ASMET), the Swedisch Steel Producers Association (Jernkontoret), Associazione Italiana di Metallurgia (AIM) and Fédération Française de l’Acier (FFA, this association will be merged soon into the alliance of mining, minerals and metals A3M). A scientific programme committee of international experts in all fields

Date: 15 – 19 June 2015 Venue: CCD Congress Center Düsseldorf, Germany Host: Steel Institute VDEh, Düsseldorf, Germany Organizer: TEMA Technologie Marketing AG, Aachen, Germany Contact: www.metec-estad2015.com Email: metec@tema.de

MPT International 3 / 2015

of ironmaking and steelmaking processes, steel materials and steel application reviewed the papers. Approximately 640 technical presentations in 135 technical sessions within three days from 16 to 18 June 2015 are given in the fields ▪ ironmaking, ▪ steelmaking, ▪ rolling, ▪ steel materials and their application, ▪ surface technologies, ▪ environmental and energy aspects to inform on and discuss the latest state-of-the-art steel technology.

Plant tours Conference participants are offered plant tours to eight plant locations in Germany and the Netherlands to take place directly after the conference. Information and explanations during the plant tours will be provided in English. Transportation to the various plants will be by bus from the Congress Center Düsseldorf CCD South. Plant tour No. 1 will visit the cokemaking site Prosper in Bottrop, Germany, a company of ArcelorMittal group. Started up in 1985/1989, the coke plant comprises three oven batteries with a combined annual production capacity of 2.0 million t of coke. Plant tour No. 2 will lead to the Schwelgern coke plant at the site of ThyssenKrupp Steel Europe in Duisburg, Germany. Started up in 2003, the coke plant comprises two oven batteries with a combined annual production capacity of 2.6 million t of coke.

Plant tour No. 3 will give a comprehensive overview of some major production sites of ThyssenKrupp Steel Europe in Duisburg, Germany. Included in the tour are production facilities as following: ▪ sinter plant Schwelgern 3 (modernized in 2002), ▪ blast furnace Schwelgern 2 (hearth diameter 14.9 m; relined in 2014), ▪ BOF steel plant Bruckhausen (two 380 t converter stands, modernized in 2014), ▪ slab caster Bruckhausen (two strands, max. width 2,600 mm), ▪ thin-slab casting plant and rolling plant (two casting strands, max. strip width 1,600 mm), ▪ hot strip mill Beeckerwerth 2. Plant tour No. 4 will visit Hüttenwerke Krupp Mannesmann, the most compact integrated iron and steel works in Duisburg, Germany. All production facilities are very closely located here, i.e. coke plant (new battery started 2014), sinter plant, blast furnace A (hearth diameter 10.3 m), BOF steel plant (annual production capacity 5.67 million t), continuous bloom caster No. 1 and No. 2 (six stands and five strands, respectively) and continuous slab caster No. 3 (two strands).

EVENTS Attending plant tour No. 5, participants will visit ArcelorMittal Bremen works, in particular the blast furnace No. 2 (hearth diameter 12.0 m), BOF steel plant (modernized in 2011, annual capacity 3.7 million t), hot strip mill (modernized in 2008, max. strip width 2,150 mm). Plant tour No. 6 will lead to Tata Steel IJmuiden, the Netherlands. The sinter plant (three strands), the blast furnaces No. 6 and No. 7 (hearth diameter 11.0 m and 13.83 m, respectively), BOF steel plant (modernized in 2003, annual capacity 7.2 million t), continuous slab casters No. 1, No. 2 and thin slab caster No. 3 are included in this tour. Plant tour No. 7 will visit the company DK Recycling und Roheisen located

also in Duisburg, Germany. The plant is specialized in processing residues from steel works to produce foundry pig iron and zinc. The tour stops comprise the sinter plant and the blast furnace (hearth diameter 5.5 m). Plant tour No. 8 will lead to Georgsmarienhütte GmbH, an EAF based steel works with an annual capacity of approx. 1 million t of long products. It operates a 140 t DC EAF, a continuous bloom caster and a medium section mill (modernized in 2012).

Get-together and evening event On Monday, 15 June the participants of the conference will have the oppor-

tunity to meet on the occasion of an evening reception. The opening event will be staged next to the conference rooms and registration office in the CCD South in Düsseldorf. There will also be entertainment and a finger buffet. Accompanying persons will be welcome, too. All conference participants will have the opportunity to participate in another evening event on Tuesday, 16 June 2015. The conference dinner will take place on the river boat MS RheinEnergie. This extraordinary location will offer a panorama view of Düsseldorf from the river Rhine. The boat will await the attendees within walking distance from the conference centre.

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››› COKEMAKING – SPECIAL EQUIPMENT

Two special cranes weighing a total of 700 tons placed the giant into position

New quenching bucket for the Schwelgern coke plant, Germany The coke bucket of the Schwelgern coke plant in Duisburg, Germany, was replaced for WKH ƂUVW WLPH $ PDGH WR PHDVXUH KHDY\ SODWH FRQVWUXFWLRQ ZDV EXLOW E\ KDQG When pots and pans wear out, they are replaced. It’s no different at the Schwelgern coke plant in Duisburg, Germany. The cokemaking facilities produce metallurgical coke mainly to fuel the various ironmaking sites here. There is no other place in Europe producing such a huge amount of hot metal every year. ThyssenKrupp Steel Europe, Duisburg, Germany Contact: www.thyssenkrupp-steel-europe.com E-mail: erik.walner@thyssenkrupp.com

MPT International 3 / 2015

“Our coke plant may be only eleven years old but one of the original coke buckets was completely worn out,” explains Michael Cremer, head of mechanical maintenance. “The buckets come under extreme stress every day, so their life is naturally limited.” A new bucket was therefore needed, as big as a house, as heavy as 15 elephants (75 tons with attachments) and consisting entirely of steel. The decommissioned bucket is now being scrapped and recycled. The giant buckets are exposed to extreme temperature fluctuations. Sev-

eral times a day they are filled with 55 tons of red-hot coke, transported to the quenching tower and quenched with around 100 cubic metres of water. This treatment stops the hot coke from burning and ensures it can be used as a reducing agent and energy source for hot metal production in the blast furnaces. The wet quenching is an excellent treatment of the coke; however, even the toughest material won’t last forever if exposed to such hot and humid atmosphere. Finally it wears out. Eventually the old bucket was no longer fit for purpose.

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››› COKEMAKING – SPECIAL EQUIPMENT

Coke bucket with attachments weighs 75 tons and is as big as a house Manufacturing the new bucket took around twelve weeks. The 65-t vessel was welded together by hand on site according to existing construc-

tion drawings: “Obviously you can’t buy buckets like these off the peg,” says Cremer. “The individual parts were prefabricated in a workshop and joined together by hand at the coke plant. We worked day and night to plans we developed jointly with a

consulting engineering firm and our sister company ThyssenKrupp Mill Services & Systems.” The team modified several areas of the original construction based on the experience gained over the past eleven years. For the first time, heavy plates of grade XAR500 – two centimetres of particularly tough high-quality structural steel made by ThyssenKrupp Steel Europe – were used as a wear lining inside the bucket. “Now the bucket is even more functional and may last longer,” says Cremer. Before the finished bucket was able to make its first journey on rails between the coke batteries and the quenching tower, there was still a lot of work to be done. The bucket had to be replaced during a two and a half week shutdown. It involved removing the old bucket from its car using two special cranes weighing a total 700 t, placing the new bucket on the car and reconnecting water, electrical and hydraulic systems. The operation was carried out successfully: “We were bang on schedule. Everything went smoothly and above all there were no accidents,” says Cremer. “The new bucket should keep us going for a long while.”

Harsh environment for machines The quenching bucket can hold 55 tons of red-hot coke. Several times a day it is filled with a hot load. The temperature of the coke when it falls into the bucket is approx. 1,000°C. 100 cubic metres of water is needed to quench one load of coke in the bucket. That’s the equivalent roughly of 400 bath tubs. The whole load is cooled down to 50°C within only 50 seconds. The Schwelgern coke plant produces 2.6 million tons of fuel a year for the blast furnaces in Duisburg. It is the most modern of its kind in Europe and boasts the world’s biggest ovens. Kokereibetriebsgesellschaft Schwelgern (KBS) currently employs around 300 people.

Manufacturing the new coke bucket took three months MPT International 3 / 2015

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New coal-injection technology installed at the blast furnaces of Salzgitter Flachstahl, Germany At two blast furnaces, injected pulverized coal will substitute oil as a reducing agent in order to save expenses, also for externally procured coke. German flat steel producer Salzgitter Flachstahl GmbH has invested in a new plant for its ironmaking facilities. The new pulverized coal-injection plant for its blast furnaces A and B recently commenced operation and has already contributed to reduced hot metal production costs. In the past, oil was used to cut the consumption of coke, which is the main reducing agent in the blast furnace process. Now oil injection has been replaced by the injection of pulverized coal. The blast furnaces of Salzgitter Flachstahl produce 4.3 million t/year of hot metal. It is planned to initially produce around 370,000 t of pulverized coal in the new coal processing facilities. This figure is planned to rise to 700,000 t/ year in the long term. The project will pay back soon and help to improve cost efficiency in ironmaking in the light of volatile and increasing oil prices. The Salzgitter Group invested some 78 million euros in the new facilities. The core of the project is the 70-meter-high coal grinding and drying tower in which the coal is pulverized. The major share of the steel sections for the coal grinding and drying plant was manufactured by long steel producer Peiner TrĂ¤ger GmbH, which belongs to the Salzgitter group. The coal for the pulverization process is transported to Salzgitter by train and ship via the Hansaport group sea port in Hamburg, Germany. For this purpose, new conveyor systems were installed at the works harbour. Construction commenced in January 2014 and the systems started operation as early as in spring 2015. Salzgitter Flachstahl GmbH, Salzgitter, Germany %QPVCEV YYY UCN\IKVVGT Ć&#x192;CEJUVCJN FG ' OCKN Ć&#x192;CEJUVCJN"UCN\IKVVGT CI EQO 70-m-high coal grinding and drying plant at Salzgitter Flachstahl MPT International 3 / 2015

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Quantum EAF from Primetals Technologies at TyasaÂ´s minimill meltshop in Ixtaczoquitlan, Mexico

First EAF Quantum commences permanent operation at Talleres y Aceros, Mexico 7KH 0H[LFDQ VWHHOPDNHU GHSOR\HG WKH QHZ ($) 4XDQWXP IXUQDFH IRU Ć&#x201A;UVW WLPH HYHU 7KH PHOWVKRS IHHGV D FRPELQHG FRQWLQXRXV FDVWHU WR SURGXFH ELOOHWV DQG SUHOLPLQDU\ VHFWLRQV Talleres y Aceros S.A. de C.V. (Tyasa), a Mexican steel producer, has issued Primetals Technologies with the final acceptance certificate for a new minimill meltshop in fall 2014. The plant was constructed on the Ixtaczoquitlan site, and has an annual capaciMPT International 3 / 2015

ty of 1.2 million metric tons of steel. An EAF Quantum electric arc furnace in the new steel works has been deployed worldwide for the first time. This new type of furnace cuts the specific conversion costs of electric steel production by around 20 percent. The project

also covered the secondary metallurgical facilities and a combined continuous caster that casts billets and preliminary sections, which are then used as the input material for the long-product rolling mill on the site. The new plant enables Tyasa not only to substantial-

Design scheme of the EAF Quantum

ly increase its production capacity but also to widen its range of products. For Tyasa’s new minimill meltshop in Ixtaczoquitlan, in the Mexican state of Veracruz, Primetals Technologies supplied a Quantum electric arc furnace with a tapping weight of 100 t, as well as secondary steelmaking facilities. These include a 100 t double ladle furnace and a 100 t double vacuum degassing plant with mechani-

cal pumps. The plant produces killed, low, medium and high-carbon grades of steel. A six-strand combined continuous caster casts the steel into billets with cross-sections ranging from 130 x 130 to 200 x 200 mm, as well as preliminary sections with dimensions of 300 x 200 x 80 mm, beam blanks and rounds on two lines.

Revolutionary furnace concept Primetals Technologies, Ltd., a joint venture of Siemens, Mitsubishi Heavy Industries and Partners; London, UK Contact: www.primetals.com E-mail: rainer.schulze@primetals.com

The key component of the minimill meltshop is the EAF Quantum electric arc furnace developed by Primetals Technologies. This combines proven elements of shaft furnace technology with new concepts as following: ▪ a new scrap charging process,

▪ an efficient preheating system, ▪ a new tilting concept for the lower shell, and ▪ an optimized tapping system, which togegether enable tap-to-tap times of 36 minutes to be achieved. The electricity consumption, at just 280 kilowatt-hours per metric ton, is considerably lower than that of a conventional electric arc furnace. Coupled with the lower consumption of electrodes and oxygen, this produces overall benefits of around 20 percent in the specific conversion costs. Overall CO2 emissions can also be reduced by up to 30 percent per metric ton of crude steel in comparison to conventional electric arc furnaces. A dry dedusting system has been installed to minimize the emissions of MPT International 3 / 2015

››› STEELMAKING

the steel works. It has an evaporation cooler, a quenching tower, an automated pulse-jet type filter-bag house, and an induced draught fan. The dedusting system cleans the off-gases from the electric arc and ladle furnaces, as well as from the material handling system. The system has a suction capacity of around one million standard cubic metres per hour, and reduces the dust content of the off-gases to less than ten milligrams per cubic metre. The project also included a dual-circuit water cooling system for the electric arc furnace, the secondary steelmaking facilities and the casting plant. Drinking, service and quenching water circuits have also been installed. A water treatment plant with mechanical and chemical stages helps to optimize all the water requirements of the steel works. The scope of supply from Primetals Technologies was rounded off by electrical and automation systems and components. These included the power distribution, the basic and process automation, as well as process models for the steel works and the continuous caster. Talleres y Aceros S.A. de C.V. was founded in 1985, and is privately owned. The company currently has two production sites, one in Ixtaczoquitlan near Orizaba in the State of Veracruz, the other in Mérida, the capital city of the Mexican State of Yucatán. Tyasa produced around 450,000 metric tons of billets per annum in the old steelplant, which are then further processed in its own rolling mill to make wire and bar steels, as well as building materials, such as rebars and nails. Total annual capacity for rolled products is around 700,000 metric tons.

References [1] Talleres y Aceros, Mexico, to build a complete, new type compact steel plant. MPT International (2012) 2, 50-51 [2] Abel, M., Dorndorf, M., Hein, M. Huber, H.: Highly productive electric steelmaking at extra low conversion costs.MPT International (2011) 3, 92-96

EAF Quantum combines very new technologies enabling tap-to-tap times of 36 minutes MPT International 3 / 2015

The new minimill of Tyasa is located in Ixtaczoquitlan near Orizaba in the State of Veracruz, Mexico

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››› STEELMAKING

Intelligent transformers help reduce transformation costs in EAF meltshops A smart and tailor-made transformer was developed in order to reduce energy losses, LPSURYH HIƂFLHQF\ DQG DFKLHYH D VKRUW WHUP UHWXUQ RQ LQYHVWPHQW 7KH LPSOHPHQWDWLRQ RI WKH 7(6 WUDQVIRUPHU Ŕ($) 60$57UDIRŕ LQ DQ ($) PHOWVKRS SURYLGHV UHPDUNDEOH VDYLQJV Protection device monitoring

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EAF SMARTrafo realizes a series of best practices and technological innovations

In modern steel plants, saving a few kWh/ton or cutting the melting time by a few minutes are no easy tasks, but constant goals. Any losses caused by the transformation process taking place at high power and current must not be underestimated in the investment and operating costs analysis. This is why investing in an EAF SMARTrafo provides long-term savings on energy consumption and maintenance costs, thanks to the longer life of the transformer as well. The EAF SMARTrafo is a tailor-made transformer properly dimensioned and

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MPT International 3 / 2015

designed to meet a steel plant’s functional requirements. It realizes a series of best practices and technological innovations developed by the TES R&D department. The EAF SMARTrafo optimizes consumption according to the real plant needs: it consumes only when necessary, energy is used more efficiently and maintenance services are reduced and simplified. The efficiency of the system has also been verified by the engineering department of the University of Brescia (Italy), which carried out a survey on the performance and the actual savings related to the transformer use. This academic involvement confirms TES’ strong commitment to most advanced technological research, and its preference of tailored quality solutions to standard solutions. This commitment makes a major contribution to the iron and steel industry’s con-

stant endeavour to improve production processes. If furnace transformers are designed without considering their production efficiency, the meltshops waste energy due to a lack of active controls. Such design solutions are no longer state of the art. TES provides many new options for improvement. An advanced cooling system helps to avoid useless and dangerous temperature excursions and energy consumption. The transformer can be dimensioned properly thanks to the simulation of its real use and its load curves. A monitoring system for the transformer and its main components is implemented in order to plan the maintenance intervals according to the actual use. Finally, easy and scheduled transformer maintenance results in a long lifetime of the system.

Extension of a stainless steel TGÆ&#x201A;PKPI EQORNGZ D[ C VYKP VCPM VOD unit )XMLDQ )X[LQ 6SHFLDO 6WHHO D Æ&#x192;DW VWHHO SURGXFHU ORFDWHG LQ PDLQODQG &KLQD KDV H[WHQGHG LWV VWHHOPDNLQJ FDSDFLWLHV ,Q D QHZ W 92' XQLW IURP 606 0HYDF ZDV DGGHG 7KH PDLQ UHDVRQ IRU WKLV H[WHQVLRQ ZDV WR LQFUHDVH WKH SURGXFWLRQ Æ&#x192;H[LELOLW\ IRU LWV YDULHW\ RI VWHHO JUDGHV HVSHFLDOO\ IRU JUDGHV ZKLFK UHTXLUH ORZ FDUERQ DQG QLWURJHQ FRQWHQWV Fujian Fuxin Special Steel (FFSS), a manufacturer of stainless steel flat products, was established in the framework of a greenfield project in mainland China. FFSS, a company of Formosa Plastics Corporation, is located in Zhangzhou, Fujian province. The liqMPT International 3 / 2015

uid steel production facilities of FFSS comprise plant equipment as follows: â&#x2013;ª electric arc furnace (EAF), â&#x2013;ª AOD-L converter (argon oxygen decarburization with lance), â&#x2013;ª ladle furnace (LF), â&#x2013;ª continuous casting machine (CCM).

The whole investment project is separated into two phases (I + II). The steelmaking shop is designed for a total production capacity of approx. 900,000 t/year in phase I. Capacity will be increased to 1,800,000 t/year in phase II by adding another EAF, AOD-L, LF and CCM.

STEELMAKING

‹‹‹

150 t VOD X-eed facility at Fuxin Fujian Special Steel

will be described below, and the solid phase made up of plants for reheating, hot rolling, pickling and annealing as well as re-coiling. The liquid phase starts with the storage area for raw materials like common and stainless scrap as well as several types of alloying materials. These raw materials are used to feed the EAF for being molten down, dephosphorized and heated up to produce a liquid steel melt which is then transferred to the AOD-L converter. The AOD-L converter with its huge reaction chamber has been suitably designed to execute process steps like decarburization, slag reduction, desulphurization and trimming of temperature and analysis. For most of the steel grades the final treatment is executed in the ladle furnace. Finally the slabs are cast on the single-strand caster. However, for some special grades a vacuum refining treatment in the new VOD unit is required after the AOD-L treatment. These grades are ferritic or austenitic grades with special requirements such as ultra-low contents of carbon and especially nitrogen. (The VOD process and its different treatment steps are described below in more detail.) It is planned to treat 35% of the total production at FFSS in the VOD plant. In phase I, construction work for the new steelmaking plant started in the middle of 2010. The new production line started operation in 2013. Like other sites in China, this plant also underlines the Chinese strategy which started in 2008 to consistently increase stainless steel production capacity in mainland China. This will be discussed below in more detail.

Production line at FFSS The actual production line at Fuxin consists of the liquid phase, which

Dieter Tembergen, Thomas Eichert, Rainer Teworte, SMS Mevac GmbH, Essen, Germany Contact: www.sms-mevac.com E-mail: communications@sms-group.com

VOD design To be able to follow the tap-to-tap time of the AOD-L converter, which is approximately 60 min, the VOD unit was designed as a twin-tank unit with two vacuum tanks located on the shop floor. They feature manual argon couplings connecting to high-temperature resistant hoses for supplying the ladle with bottom-stirring gas. Both tanks are connected to a vacuum pump system via a movable bend allowing to switch between the two tanks. As the required ladle freeboard of approx. 1,500 mm has to be considered for the VOD process, the heat size of this unit is limited to 150 t. The facility has two mobile vacuum covers (cover cars on a common rail track) with centrally positioned oxygen lances and equipment for semi-automatic sampling and temperature meas-

urement at atmospheric pressure. The covers are lifted and lowered hydraulically. Likewise mounted on the cover are vacuum locks for the feeding of bulk additives like ferro-alloys and slag formers also during vacuum treatment. On each cover, a two-track wire-feeding system is mounted for metallurgical wire feeding after the vacuum treatment. Beside the two vacuum covers there is a third movable atmospheric trimming cover which mainly serves for the addition of gaseous nitrogen via an immersion lance for steel grades with defined nitrogen contents.

Vacuum generation To generate the required vacuum pressure, the facility is equipped with a four-stage vacuum pump system consisting of three steam-ejector stages and four water ring pumps in the atmospheric stage. There are needle valves in the steam nozzles of ejectors 3A, 3B and B2. These are used for regulating the vacuum pressure in the range of 300-10 mbar and also for optimizing steam consumption at a steam pressure of approx. 10 bar at the TOP (take-over point). Steam consumption is approx. 21 t/h at low vacuum. The vacuum pump is rated for a suction capacity of 700 kg/h at a pressure of 0.67 mbar. For oxygen blowing for decarburization at low vacuum pressure, the system is also rated for a suction capacity of 2,500 kg/h at a pressure of 10 mbar. In the off-gas extracted by the pump, the contents of CO, CO2 and O2 are continuously measured by an analysis unit enabling the process control to be adapted to the current situation in each individual step. The dust arising together with the off-gas is to a very large extent already removed by a bag filter system before it enters the vacuum pump, after having lowered the off-gas temperature accordingly by an upstream gas cooler.

Worldwide trends in stainless steel production During the past 14 years, there has been a more or less continuous inMPT International 3 / 2015

››› STEELMAKING

The Duplex VOD plant is equipped with two tanks and two vacuum covers

crease in production capacity for stainless and heat resistant crude steel worldwide. However, there are different regional trends. While China has increased its stainless steel production capacity from 2008 to 2013 by around 150% from 7 million t/year in 2008 to 18 million t/year in 2013, in other steel producing regions like the Americas, Asia without China and the EU + Africa there have been no significant changes during this period. Nevertheless, the world stainless steel production capacity is getting close to 40 million t/year. The dominating refining unit for stainless steel was and still is the AOD converter. Nearly 85% of the stainless steel worldwide is treated via the EAFAOD-Duplex process – especially austenitic steel grades for bulk production, like 304 or 316. But there are also many steel plants with lower annual production capacities using the EAFVOD-Duplex route, preferably those with a widespread product mix of low MPT International 3 / 2015

and high-alloyed structural steels, many types of stainless steels and special grades. A third process route has been coming up in the middle of the 1990s and may be a good strategy to match the variable demands of the stainless market. This is the so called Triplex process route which combines the advantages and metallurgical capacities of an AOD converter with those of a VOD unit. Considering the increasing and instable price of nickel during the last ten years, ferritic and also superferritic stainless steels have been coming more and more into the focus of stainless steel customers. Most of these grades have specifications for low carbon and nitrogen contents. These can be easily matched by a VOD unit. If both types of units, AOD and VOD, are available, it means maximum flexibility and metallurgical capability for a steel plant. There has been some tendency to either extend an existing EAF-AODDuplex production line by a VOD

unit or to install both units, AOD and VOD, from the very beginning. FFSS has done this for several reasons. The main reason for installing VOD was to have the possibility to produce a considerable share of super-ferritic stainless steels via the Triplex process route. The second reason was to optimize production either by reducing the process time in the AOD converter by applying the Triplex process route and to reduce argon consumption by using only nitrogen during the AOD process and adding a degassing step to the VOD process.

VOD process The VOD treatment generally consists of the following vacuum treatment steps: ▪ pump down, ▪ oxygen blowing, ▪ boiling out, ▪ slag reduction, ▪ final trimming.

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KettenWulf Betriebs GmbH Zum Hohenstein 15 59889 Eslohe-KĂźckelheim T + 49.(0)2973.801-0 F + 49.(0)2973.801-228 service@kettenwulf.com www.kettenwulf.com

Pan conveyor chain for sinter transport

Special duplex chain for looping tower

Coil transport chain

Deep link chain for sheet steel continuous conveyor

Special tappet chain for cooling bed pipe transport

Pan conveyor for scrap transport

STEELMAKING The oxygen blowing period as the most complex step is subdivided into several sub-steps which are adjusted to the metallurgical reactions inside the melt. During the initial phase, which only lasts for a few minutes, blowing is performed at a reduced rate from the metal bath. As soon as an intensive CO reaction, known as the “ignition”, is observed, the blowing rate is increased. During the first static blowing phase, both the blowing rate and the blowing distance remain constant but the vacuum pressure is re-

Cr oxidation above all at high Cr contents. At the usual initial carbon content of 0.20 – 0.35% C, a total blowing time of about 40 – 55 min is obtained. Once oxygen blowing has ended, the vacuum pressure is reduced to low vacuum and the melt is subjected to vacuum carbon deoxidation (boiling out) in order to lower the carbon content to the smallest possible values. The duration of this treatment phase is normally between 15 and 20 minutes, depending on the final carbon content aimed at.

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performed under low vacuum with correspondingly high stirring-gas flow-rates. An additional treatment objective is the further reduction of nitrogen with a view to also here attaining the lowest possible contents. This is favoured by reducing the oxygen activity in the steel and slag. Together with the reduction of nitrogen, also the sulphur is reduced to the required low contents. After completion of this treatment stage, the system is flooded and, via the semi-automatic lanc-

VOD

Raw material

EAF

AOD

CCM

Slab

Batch annealing furnace 400 series Re-coiling line

Re-coiling line

Reheating & Hot rolling

Black coil

Hot rolled annealing & pickling line

Production route map at Fuxin Fujian Special Steel (Picture by courtesy of FFSS)

duced continuously in order to lower the CO partial pressure and thus protect the chromium against oxidation. When the CO curve has reached its maximum, the second main blowing step is started. In the dynamic phase, the blowing rate is reduced in one or more steps in order to follow the diminishing CO reaction and, towards the end, also the blowing distance is shortened, accompanied by a further reduction of vacuum pressure and an increase of the bottom stirring rate. Towards the end of the dynamic blowing phase, the vacuum pressure may be around 10 mbar. This relatively low pressure is aimed at in order to obtain a lower degree of

Once “boiling out” has been completed, deoxidation and slag-reduction agents as well as slag formers are added (slag reduction). This treatment step is used for the chemical reduction of the Cr oxide contained in the slag in order to recover the chromium that has become oxidized during the oxygen-blowing phase. FeSi is normally used as the reducing agent and in order to neutralize the SiO2 arising during the reduction phase in terms of slag basicity, considerable quantities of lime are added and, where necessary, also fluorspar to reduce the slag viscosity. An intensive metal-slag reaction has to take place in this phase, and this treatment stage is therefore also

es, the temperature is measured and a sample taken.

Conclusions Fujian Fuxin Special Steel has extended the new existing stainless steel process line by a VOD unit to have the metallurgical capability of treating selected steel grades with low carbon and especially low nitrogen contents. By this, Fujian Fuxin Special Steel is following a prevailing tendency in China and Asia, namely to either enhance an existing production line by a VOD unit or to implement a Triplex process route for stainless steel refining already from the outset. MPT International 3 / 2015

No. 1 coil

››› STEELMAKING

Three-stage vacuum system, optimized for steel degassing processes

Mechanical vacuum pump systems to cut operating costs and reduce emissions In many steel plants, the vacuum needed for degassing processes has been generated using steam jet systems. But this necessitates enormous amounts of energy to produce the steam. In comparison, mechanical vacuum pumps are considerably more energysaving. They also lead to lower operating costs for steel manufacturers, while at the same time they are more eco-friendly through reduced emissions. In recent years, the demand for high-quality steel has risen continuously. Even though lightweight construction materials like composites are

Uwe Zöllig, Oerlikon Leybold Vacuum GmbH, Cologne, Germany Contact: www.oerlikon.com/leyboldvacuum E-mail: info.vacuum@oerlikon.com media.vacuum@oerlikon.com uwe.zoellig@oerlikon.com

MPT International 3 / 2015

currently grabbing the headlines, the demand for steel in the 21st century is greater than ever before. There is considerable demand for alloys that are more rigid or tougher, or which can be easily stretched and shaped. Depending on the use for which it is intended, the steel may need to be more resistant to corrosion or wear and tear. In order to give it these properties, steel is further treated after manufacture. Specifically, while the steel is being melted, those gases which have a negative effect on the material’s prop-

erties need to be removed. Excessively high hydrogen content, for example, makes steel brittle and susceptible to fractures. “We use special degassing systems to reduce the concentration of unwanted chemical elements such as carbon, hydrogen, sulphur or phosphorus, thereby improving the quality of the material,” explains Uwe Zöllig, senior manager Market Segment Process Industries at Oerlikon Leybold Vacuum. Different vacuum processes have proved to be particularly efficient for

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››› STEELMAKING

The robust pumps perform perfectly even under the tough conditions prevailing in steel works

this purpose. The liquid steel is treated in a vacuum chamber. As a result of the reduced pressure in the chamber, gases released can now escape to the surface of the steel, where they are removed by the suction of the vacuum system. Depending on the process selected, pure oxygen may also be blown into the vacuum chamber. This burns off any surplus carbon and phosphorus, which is then also removed by suction.

Steam jet systems are being increasingly replaced Until now, the vacuum has been created using steam jet systems. They are robust, reliable and relatively inexpensive. The downside is that a lot of energy is required to generate the steam. And if the steam is generated in gas or oil heated receptacles, large amounts of CO2 are also produced. In actual operation, there are further disadvantages, like for example the need to run the systems continuously, even if they are not used, and contaminated wastewater and downtimes due to the necessity of regular mechanical cleaning and maintenance. “For all these reasons, steam generation and complex wastewater treatment lead to substantially higher operating costs,” explains senior manager Zöllig. “Against this background, mechanical vacuum pumps have established themselves as an alMPT International 3 / 2015

ternative to steam jet systems in recent years,” he adds. “Exactly because they meet all the stringent demands steelmakers require of a vacuum system.” The fact that this technological switch is taking place now is mainly attributed to the development of modern, dry compression screw vacuum pumps. During the steel degassing process, metallic or metallic-oxide vapours are generated, which cool and condense into large amounts of particulate dust. Despite upstream filters, considerable volumes of such fine dust are still sucked in by the vacuum system, which could impede its smooth functioning. The greatest single advantage of the new types of pump is that they are extremely insensitive to dust. The fine, dry dust particles are simply pushed through the pump towards the exhaust. In addition, the robust pumps perform perfectly even under the tough conditions prevailing in steel works and require little maintenance. Compared to the traditionally-used steam jet systems, they are significantly more energy-efficient and produce no wastewater that requires treatment. Ultimately, the system facilitates the creation of a stable vacuum environment irrespective of external factors such as the surrounding or water temperature. “Mechanical vacuum systems enable operators to not only cut costs

but also reduce undesired emissions,” Zöllig summarizes.

Primetals chooses new Oerlikon technology Primetals Technologies Ltd. is convinced of the capabilities and efficiency of these pumps for the steel degassing process. A client has commissioned the plant engineering and construction specialist to build a degassing facility in Mexico for the manufacture of steel with very low hydrogen content. Such high-quality steel is commonly used in the oil and gas industries. Oerlikon Leybold Vacuum is delivering to the facility ten standardized degassing modules that have already been successfully tested and proven in the area of metallurgy. Despite a highly efficient suction capacity of almost 600,000 m3/h , the vacuum system does not require a lot of space. And because the operating company has specified that the degassing process may occasionally generate explosive gas mixtures, all components delivered must also meet demanding explosion prevention and protection requirements. Oerlikon will therefore supply pump systems certified according to the strict ATEX guidelines (for use of equipment in potentially explosive atmospheres) laid down by the European Union.

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››› STEELMAKING

Robots shall manipulate probes at the BOF In the near future, Voestalpine Stahl will use robots from Primetals Technologies in its steelmaking plant. The robot systems will manipulate the probes at the three BOF converters. The advantages that will accrue are higher sublance availability and – most of all – greater safety at work. Austrian steel producer Voestalpine Stahl has ordered three robot systems from Primetals Technologies. They will be installed at the Linz steel works to manipulate the probes at the three LD (BOF) converters. Work that was previously performed manually will in future be handled by these robots. The employees involved will no longer have to do this particular job in the hazardous area. The robot systems are equipped with a measuring probe magazine designed as an exchangeable container. This simplifies the handling of the probes and also increases reliability and availability. The robots also handle tasks such as cleaning the contact bar, monitoring the probe holder and performing correcting movements, which reduce the requirement for maintenance. The systems are scheduled to be brought into operation one by one at intervals of three months from the middle of 2015. The Linz plant already uses a number of robots from Primetals Technologies on the pouring platforms of the continuous casters. Voestalpine Stahl GmbH is one of Europe’s leading steel producers. The Linz steel plant currently has three 180-t converters in operation, each of which achieves more than 30 heats per day. The converters were equipped with sublances from Primetals Technologies 25 years ago. However, the probe manipulators have now reached the end of their service lives. The existing manipulators, therefore, are going to be replaced by a handling system consisting of a robot and a probe magazine. The Primetals Technol-

Primetals Technologies, Ltd., a joint venture of Siemens, Mitsubishi Heavy Industries and Partners; London, UK Contact: www.primetals.com E-mail: rainer.schulze@primetals.com

MPT International 3 / 2015

3D design scheme of the robot’s operational area at the BOF shop, Linz, Austria steel works

ogies delivery package includes three robot systems, the associated exchangeable container magazines and for each converter three sets of 63 probes, probe buffers, sublance centering devices, a maintenance platform, and the LanceGuard measuring system monitor. Primetals Technologies is also responsible for installing the new systems and integrating them in the existing automation.

Measuring probes in exchangeable containers simplify probe handling As the robot takes the probes directly out of the exchangeable container, this solution can also be used where space is limited. The robot has a camera system to recognize the different types of probe. The system can also reject probes that have been identified as faulty by the measuring system and set aside probes with malfunction during the measuring process for later analysis.

To ensure a high standard of measuring accuracy, the entire measuring chain, consisting of probe, contact bar, cabling and evaluation unit, is automatically tested and verified by the LanceGuard at regular intervals. Supplementary functions of the robot system are the use of test probes and the disposal of the probes after the measurement. The automatic testing and cleaning of the contact bar, measurement of the probe holder and automatic movement correction are additional advantages which reduce the forces acting on the contact system. This increases its service life and reduces the maintenance requirement. The three systems will be converted and commissioned in five-day stages while the converters are being relined. The entire system will be assembled and intensively tested, and all its functional sequences will also be tested in the laboratory in advance so that the required plant availability and productivity will be achieved as quickly as possible.

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Fully automated laboratory system accelerates sample processing and process control Taiyuan Iron & Steel (Group) has implemented a fully automated system for the dispatch, preparation and testing of samples taken from hot metal and liquid steel. The analysis is QRZ IDVWHU PRUH SUHFLVH DQG FDQ EH EHWWHU UHSURGXFHG ,W DOVR FRQWULEXWHV VLJQLĆ&#x201A;FDQWO\ towards improved control and adjustment of the steelmaking process. Over the past years, Taiyuan Iron & Steel (Group) Co. Ltd. has implemented a number of new technologies in the Taiyuan plant with the target to fur-

ther improve quality. As a component of the â&#x20AC;&#x153;Intelligent Steel Making Level 2 Modelâ&#x20AC;?, the automated system to process pig iron and steel samples defines

The project was launched with the objectives to modernize the laboratory and to create optimal prerequisites for all analysis methods, including spec-

System at Taiyuan Iron & Steel: receiving stations (right side), sample preparation machines (centre) and spectrometers (left side)

Xiaoli Liang, Taiyuan Iron & Steel (Group) Co. Ltd., Taiyuan, China; Xianchung Zeng, Herzog (Shanghai) Automation Equipment Co. Ltd., China; Hans Georg Schmitz, Herzog Maschinenfabrik GmbH, OsnabrĂźck, Germany Contact: www.herzog-maschinenfabrik.de E-mail: hg.schmitz@herzogmaschinenfabrik.de

MPT International 3 / 2015

a new standard. With the third construction phase having been commissioned in December 2014, Taiyuan Iron & Steelâ&#x20AC;&#x2122;s system is â&#x20AC;&#x201C; as far as the authors are aware of â&#x20AC;&#x201C; the largest installation for automatic sample preparation in the global steel industry. The analysis is now faster, more precise and can be better reproduced. It contributes significantly to improved control and regulation of the steel generation process.

tral, x-ray fluorescence and gas analysis, and thus meet the requirements of the â&#x20AC;&#x153;Intelligent Steel Making Level 2 Modelâ&#x20AC;?. It was also stipulated to shorten the time spent on preparing and analysing samples and to reduce the workload for the laboratory staff. In the past, samples taken in the plant had to be manually labelled before being sent to the central laboratory by pneumatic dispatch. Here, they were manually separated, ground

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and placed in the various analysis systems. Upon completion of the analysis, the results had to be recorded by hand and reported back to the steel plant. The time for transport and analysis took up to ten minutes. Preparing the samples for CNS (carbon, nitrogen and sulphur) analysis was in addition difficult and did not meet the requirements for the production of high-quality steels.

vendor should be a single source for a complete range of products for sample processing, including handling and data processing. Taiyuan Iron & Steel decided for Herzog Maschinenfabrik, a producer of machines for sample preparation with long-term expertise in the automation of sample handling.

In 2005, Herzog delivered the first machines for automatic sample preparation for the entire plant and for further transfer to the various analysis devices. This included the transport via pneumatic dispatch, cooling, cutting, punching, milling or grinding of the

The HS-FF milling machines are universally used for lollipop samples which are solely milled. The bomb samples, from which slices are separated, are sent to the HS-CF cutting and milling machines. All machines are equipped with two precision milling spindles operating independently from each other, eliminating the need to change tools after a material change, for example, from pig iron to steel. The highly robust spindle bearing ensures that even the hardest material qualities can be reliably machined. The sample counters of the earlier installed machines have already surpassed the magical milestone of one million samples. The HS-CF cutting and milling machine removes slices with a thickness

sample and the entire automation and software required for the process control. Since December 2014, the system has consisted of 41 tube lines, seven robots used in sample preparation, three HSFF and two HS-FF2000 milling machines, two HS-CF milling and cutting machines, two HUST punching machines, two HB 3000 grinders and three slag preparation systems with one HP-C jaw breaker each, one HP-M pulverizer and one HP-P press.

between 4 and 6 mm from the cylindrical samples. From these slices, samples are stamped for the C/S (carbon and sulphur) and N/O/H (nitrogen, oxygen and hydrogen) analyses. The sample left in the clamping device is finely milled before a robot transports it to the spectrometers. The machine contains a cooling system which quickly reduces the samples to the required temperature during preparation. Slices are automatically transferred from the HS-CF to the HUST univer-

Quick transport thanks to new system Installation during ongoing operation The modernization was a challenge, not only due to the large scale and complexity of the system. The system had to be installed and commissioned during ongoing operation, because nei-

Sample handling with robots

ther the production nor the laboratory operation could be interrupted at any time. It was also required to realize a wide range of interfaces between disparate analysis instruments, the sample preparation processes and primary host computers. The processing of samples from corrosion-free steels and special alloys in particular, requires very robust machinery due to the extremely high demands on milling. Because of the scale of the planned system, an essential aspect was that the MPT International 3 / 2015

sal punching machine. Within one operational step, this machine prepares four samples with a weight of approx. one gramme each. Prior to the punching, the machine inductively heats the samples, removes the scale layer and sand-blasts the surface. In the last project phase Taiyuan Iron & Steel and Herzog expanded the system to three automatic slag sample preparation lines to reduce the previously high work load of manual sample preparation. The slag is pre-crushed in the HP-C crusher, finely ground in the HP-M pulverizing mill and pressed into steel rings in the HP-P press. From there, it is transported to the x-ray analyser.

Short analysis times At the various production sites, the air tube carriers are placed in HR-HSK/B sending stations and sent to the receiving stations in the laboratory. The steel plant computer generates the ID numMPT International 3 / 2015

bers and automatically assigns them to the individual samples. The pneumatic dispatch system transports the samples at a speed of 20 m/s over distances of up to 2.2 km. Even samples taken in the most remote plant sections arrive at the laboratory in less than two minutes, where the sample tubes are delivered to the HR-HSK/L receiving stations. Robots remove the carriers, pass them to the unpacking station and then transfer the samples to the preparation cells. Carriers are automatically returned. Thanks to the precisely synchronized system components, the plant has reduced the analysis time for plain steels to between 150 and 180 s and for high-grade, special and alloyed steels to between 180 and 200 s. This has been made possible by fast transport via the pneumatic dispatch system to the laboratory, high speed sample handling, rapid unpacking and transfer to the sample preparation cells as well as the high milling speeds.

Process control by special software All processes are controlled and monitored by the Prepmaster software. It was designed specifically to meet the requirements of fast and automatic sample preparation for the steel works laboratories and can easily handle large numbers of samples and peak loads, thanks to the integrated adaptive sample administration. The â&#x20AC;&#x153;Priority Sample Handlingâ&#x20AC;? function controls the handling, so that particularly important samples are processed with priority to ensure fast results. Cameras monitor the milling image of every sample and the Prepmaster controller software alerts when milling heads must be replaced. Milling tools can be replaced quickly without requiring special tools or skills. The programmable logic controller can run 16 machining programmes that are defined via parameters, including the patented automated deburring of round calibration samples. Every sam-

STEELWORKERS KNOW... Coarse grinding of a sample by means of the cup wheel HB 3000

SIZE MATTERS!

Sample number more than tripled

ple is milled at the optimal removal and cutting speed of the particular material. The Prepmaster controller software starts each programme. The individual machining steps, like sample clamping, sample height measuring or cutter selection are performed automatically. When Prepmaster detects anomalies such as deviations of the milling surface from the standard, it initiates a re-preparation of the sample or diverts the following samples to other machines. The processes are visualized on multiple displays. Standard interfaces enable a flexible use at different locations in the plant and by different operators at the same time. The remote control function enables easy remote maintenance as well as fast and simple service when required. Prepmaster features various backup and redundancy options and ensures uninterrupted system operation even in the event of fault.

Since 2005, the system has been working 24 hours a day, 365 days a year. Each machine prepares 250 to 300 samples per day. The laboratory staff can focus on more sophisticated activities such as PC work or machine maintenance. Although plant production has increased significantly and the sample number was more than tripled to over 3,000 per day, the number of laboratory staff was not increased. Yet, the automatic, programme-controlled sample preparation has substantially increased the accuracy and reproducibility of the analysis results and forms the basis for optimal quality of the manufactured steel. The analysis results are considerably more reliable and stable than they were previously. Sample analysis has become a decisive factor in process control. It is an indispensable element of the “Intelligent Steelmaking Level 2 Model” and substantially contributes to the optimal steel composition. The digital data can be used in all downstream processes during steel manufacture and processing. Production times have been reduced and significant energy savings have been realized with the system, resulting in lower overall costs. Furthermore, the concentration of expensive materials in alloyed steels can be controlled more closely. By now, each machine that was delivered in the first phase has processed more than one million samples without any need for repair work on site. Unplanned operational downtimes causing a delay in the analysis have not occurred since the initial commissioning. For the future, Taiyuan Iron & Steel is planning to improve the analytic method of special steel products by further implementations of automatic systems for a rapid analysis of ultra-low C, S and N samples. For example, automatic gas analysers can be integrated into the system and connected to the Herzog sample punching systems. Furthermore, the connection of the existing semi-automatic slag preparation lines to the automatic system and the integration of the XRF analysis of slags are currently being discussed. MPT International 3 / 2015

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş CONTINUOUS CASTING

Deburrer

Powder feeder

Preheating station

Marking machine

1A?PjLE Shroud manipulator

Reading and tracking system

Overview of the AMT CCM Package

Torch cutting machine

Optimizing ancillary processes in continuous casting The â&#x20AC;&#x153;Alpine Metal Tech Continuous Casting Machine Package (AMT CCM Package)â&#x20AC;? has been developed as a complete solution of harmonized integrated systems dedicated to optimizing the continuous casting process. It comprises state-of-the-art technologies, e.g. for ladle and tundish preheating, a shroud manipulator, powder feeder, torch cutting PDFKLQH DQG GHEXUUHU PDUNLQJ DQG UHDGLQJ HTXLSPHQW VFDUĆ&#x201A;QJ PDFKLQHV DV ZHOO DV optical devices for measuring and inspecting slabs, blooms or billets. Austria-based Alpine Metal Tech (AMT) perfects the continuous casting process by integrating ancillary units. Alpine Metal Tech integrates technologies formerly known as individual brands like: â&#x2013;Ş Numtec, â&#x2013;Ş GeGa, â&#x2013;Ş Magnemag, â&#x2013;Ş Koch H&K and â&#x2013;Ş Knorr. All these components are harmonized, communicating with each other over several process stages. In doing so, they

GĂźnter Kienast, Alpine Metal Tech Holding, Regau, Austria Contact: www.alpinemetaltech.com E-mail: guenter.kienast@alpinemetaltech.com

MPT International 3 / 2015

optimize the continuous casting process from the steel ladle down to the inspection of the semi-finished products, such as slabs, blooms and billets, increasing the productivity of the entire continuous casting plant.

How to fully exploit a casterâ&#x20AC;&#x2122;s performance potential? Torch cutting is an example that clearly shows how untapped potential of a continuous casting machine can be leveraged. While in the past torch cutting, deburring, marking and identifying used to be considered separately, the individual components involved in these activities are now controlled interactively. For example, the torch cutting machine receives information from the downstream components about the cutting precision and

the quality of the cut surface. Such information helps to optimize the adjustment of the torch cutting nozzles, ensuring perfect deburring and creating an optimal surface for the subsequent marking operation. Combining the torch cutting and the marking equipment in one system also facilitates material tracking while increasing process security. The newly developed â&#x20AC;&#x153;inline markingâ&#x20AC;? system marks the head end of the slab or billet before the torch cutting process starts. This method ensures that every cast product is unambiguously marked before it is cut off from the strand. The system is space-saving and dispenses with additional activities. The uniform visualization of all components of the AMT CCM Package as well as the consistent user guidance make the process transparent and assist the personnel in the con-

CONTINUOUS CASTING

Shroud manipulators during testing

trol room. All process data are stored in a database and can be retrieved at any time. In addition, the package reduces the implementation effort when building a new plant or revamping an existing one because there is only one interface connecting the individual package systems with the process control and the level-2 automation systems.

Innovative systems along the continuous casting process chain The AMT CCM Package not only harmonizes the various components of equipment that make up a continuous casting machine and are crucial to the quality of the cast products. This one-stop shopping solution also means that there is only one person of contact for various key plant components and there are clear responsibilities in all matters of plant construction, commissioning and service. The intelligent interacting of the various plant units is also beneficial to preventive maintenance. For example, the automatic burr detection system indicates when it becomes necessary to readjust or replace the deburring ham-

‹‹‹ 103

Shroud manipulator during operation

mers and/or the nozzles of the torch cutting machine. The reading system signals when the stamps of the marking unit need to be replaced. Along the complete process chain from the steel ladle down to the reading of the markings, Alpine Metal Tech excels not only by integrating the various plant components. The individual systems also feature numerous innovations that lead to higher product quality, lower energy consumption and simplified processes.

Preheating, shroud OCPKRWNCVKQP CPF ƃWZ feeding In the automatic preheating station using the “Multi Tasking Burner”, AMT Gega for the first time combines in one machine the drying of ladles and tundishes at temperatures between 300 and 500°C and the preheating at between 1,200 and 1,400°C. As a result of the uniform flame distribution and the use of recuperative systems for air preheating, AMT Gega achieves high energy efficiency. The plants supplied by AMT Gega are in line with the latest in safety standards. They fully comply with the extremely exacting criteria of

DIN EN 746 for industrial thermal processing plants. The AMT Numtec shroud manipulator is a semi-automatic device for easy and safe handling of the shroud. The hydraulically and electrically actuated manipulator is controlled by a joystick. Even in exceptional situations, the safety control mode ensures that the movements are executed as prescribed and there is no risk of collisions. The hydraulic actuation generates a constant clamping pressure even if the power supply fails. The shrouds are cleaned in the AMT Gega blowout station, the “oxygen shower”. The manipulator takes shrouds requiring cleaning to the station. There the cleaning takes place automatically. The AMT Numtec casting flux feeder spreads the casting flux evenly and at a constant rate onto the surface of the molten steel in the mould. Unlike pneumatically actuated systems, this flux feeder can handle both powder and granulated fluxes. By controlling the speed of the rotating spiral, the feeding rate can be highly accurately adjusted and synchronized with the casting speed. In slab casting, it is also possible to reproduce the mould contour, facilitating the exact feeding of MPT International 3 / 2015

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››› CONTINUOUS CASTING

the casting flux onto the surface of the molten steel. Also below the casting platform, AMT Gega machines are in service. For cutting the cast strand in the casting radius, the company supplies its proven emergency cutting unit, which features burners that are so compact that they can make a cut between the rollers of the continuous casting machine.

Torch cutting, deburring and UECTƂPI In the field of torch cutting equipment, AMT Gega regularly attracts the industry’s attention by newly developed innovative solutions. A current

Marking machine during operation

example is the new Shel nozzle. Compared to conventional nozzles used in torch cutting, the new nozzle saves 20% of time while reducing fuel gas consumption by 35% and oxygen consumption by 22%. The nozzle is an integrated part of the new, modular torch cutting system which includes features like automatic control of the flames and automatic monitoring of the nozzle wear. With the automatic flame control, based on the measurement of various parameters, and the nozzle wear detection system, which also permanently monitors various different parameters, AMT Gega achieves ideal cuts with minimal burrs and surfaces perfectly suited for marking. AMT Gega is the only manufacturer of torch cutting machines providing a solution that ensures that the torch cutting machine is automatically disengaged from the casting strand in an MPT International 3 / 2015

emergency situation, such as the failure of power or pressure supply. This reliably avoids any damage to the surface of the cast slab. Failure of a torch cutting machine at a continuous casting plant may have severe consequences. Therefore, safety and reliability of operation have highest priority for AMT Gega. The machines comply with all requirements specified in DIN EN 14753 (safety requirements for machinery and equipment for continuous casting of steel). A highlight of the AMT Numtec deburring machines is that they remove burrs on the fly, i.e. the cast product does not need to be stopped. Symmetrical hammers exactly follow the slab

detection system communicates with the torch cutting plant, allowing the nozzles to be readjusted if need be, and with the deburring machine, to ensure that the hammers are optimally adjusted for any operating conditions. AMT Gega offers scarfing equipment for different tasks. The manually operated manipulator is used for both selective and complete surface scarfing. AMT Gega has developed the strip scarfer and systems that scarf two sides at the same time, accelerating the scarfing of products on all four sides. These solutions are increasingly in demand above all in Asia, where especially the automotive producers require that all semi-finished products are completely scarfed. As the machines sup-

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contour. One innovative feature of the machine is that it is being pressed against the bottom edge of the product while it is operating. This allows the machine to work extremely precisely. Another novelty is the optical residual burr detection system which uses thermographic cameras mounted below the roller table. So far, the result of the deburring process could only be inspected after the slab had left the runout roller table. If there were any burrs left, these had to be removed by scarfing in a separate operation. Now, the edge at the head end is automatically checked right after deburring. Should there be any burrs left, the slab will be immediately moved backwards and deburred one more time. Only when the burrs have been completely removed, will the slab be discharged from the roller table. The residual burr

plied by AMT Gega have the functionality to perform selective scarfing, they are also more cost-efficient than plants scarfing but the complete surface.

Marking, handling and inspection At the METEC trade fair, Alpine Metal Tech will introduce the new AMT Numtec stamp marking heads for permanent letter or matrix markings of up to approx. 100 mm height. The marking head is also designed to stamp data matrix codes which contain more information than mere alphanumerical characters and are better suited for automatic reading devices. In order for markings to be readable also from a great distance, for example, from a crane cabin, AMT Numtec has developed a new type of paint. This paint is applied to the surface of the face side to be marked. When the

CONTINUOUS CASTING stamp hits the head end face, the paint is being pressed into the indentations. As a result, it clearly contrasts from the rest of the surface area. The benefit is a permanent marking which is also readable from great distances. Even if the paint has come off the surface area, the permanent marking will be retained. Alpine Metal Tech has also come up with various solutions aimed at simplifying operations. The new inline marking machine, which is installed behind the torch cutting machine, applies permanent markings to the head end face of the slab or billet before the product is cut; i.e. every product is readily identifiable from the very beginning, making material tracking between cutting and marking superfluous. This ensures that the marking is retained even in the case of manual interventions during the material flow, such as the removal of a slab from the roller table by crane. As the torch cutting machine and the marking unit form one common system, this solution is very space-saving. The run-out roller table can be designed accordingly shorter. AMT Koch H&K, the youngest member of the Alpine Metal Tech Group, designs and supplies equipment such

as roller tables for continuous casting plants, equipment for lengthwise or cross transfer of products downstream the continuous casting machine, for intermediate storage, for cooling as well as rolling and storage of the finished products. Additionally, AMT Koch H&K integrates the automation solutions of the individual components of the AMT CCM Package into an integral system â&#x20AC;&#x201C; including the drive, control and instrumentation equipment, media supply, process data acquisition and visualization. AMT Numtec offers a full line of solutions for reading and identification tasks. The company is the only manufacturer to supply harmonized systems for both marking and reading. This guarantees that both technologies fit smoothly together and the systems achieve reading rates of almost 100%. At the end of the continuous casting process, systems from AMT Knorr measure the geometry of the semi-finished products, i.e. slabs, blooms or billets, and inspect their surfaces. The company supplies complete customized systems integrated into the plant environment, including systems for charging and discharging the material, the visualization systems and the link to the level-2 automa-

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š 105

tion. Knorr uses laser-based light section systems for measuring the geometry and straightness and for surface inspection.

Image processing Vision systems are becoming increasingly common in continuous casting plants. In this environment, the emphasis is more on the automatic assessment of camera images and not so much on the measurement of clearly defined physical values. Typical questions arising are: â&#x2013;Ş Is there enough casting powder in the mould and is it evenly spread on the steel surface? â&#x2013;Ş Is the scarfing result optimal? â&#x2013;Ş Is there any burr left? If yes, how critical is it? â&#x2013;Ş Are the markings correct? In these cases, the performance of image processing plays a decisive role. Measurable data must be derived from camera images. For this reason, Alpine Metal Tech has established its â&#x20AC;&#x153;Visionâ&#x20AC;? department, which will concentrate on the development of both recording technology capable of coping with the challenging conditions prevailing in continuous casting plants and suitable evaluation software.

framag Industrieanlagenbau GmbH /FVLJSDIOFS 4USBÂ&#x2022;F " 'SBOLFOCVSH 5FM 'BY & .BJM L BDIMFJUOFS!GSBNBH DPN www.framag.com

framagâ&#x20AC;&#x2DC;s NEW torch cutting nozzle technology t TNBMMFTU DVUUJOH HBQ t NJOJNJ[FE MPTT PG NBUFSJBM BOE NPOFZ t QFSGFDU DVUUJOH RVBMJUZ BOE BDDVSBDZ t IJHIFTU DVUUJOH TQFFE t TIPSUFTU DZDMF UJNF t TIPSUFTU MFOHUI PG DVU TMBCT QPTTJCMF t MPXFTU HBT BOE PYZHFO DPOTVNQUJPO

Slab cutting and grinding technologies provided as a service to meet highest quality demands of the hot strip mill

Cross-company cooperation to GZRCPF UNCD Ć&#x201A;PKUJKPI UGTXKEGU 7K\VVHQ.UXSS 0LOO6HUYLFHV 6\VWHPV LV H[SDQGLQJ Ć&#x201A;QLVKLQJ VHUYLFHV RQ VLWH RI +ÂžWWHQZHUNH .UXSS 0DQQHVPDQQ DQ LQWHJUDWHG LURQ DQG VWHHO ZRUNV DOVR ORFDWHG LQ 'XLVEXUJ *HUPDQ\ 6ODEV DUH VXSSOLHG WR +RHVFK +RKHQOLPEXUJ KRW UROOLQJ PLOO D VXEVLGLDU\ RI 7K\VVHQ.UXSS 6WHHO (XURSH ThyssenKrupp MillServices & Systems is a highly capable engineering services provider with particular expertise in the metal-producing and fabricating industries as well as other sectors with complex production processes. Its product portfolio comprises the entire customer value chain, from slag management, in-plant logistics and production support to maintenance, project business and packaging. ThyssenKrupp MillServices & Systems has concluded a five-year service contract with Hoesch Hohenlimburg, a hot rolling mill sourcing narrow slabs from HĂźttenwerke Krupp Mannesmann (HKM), an integrated iron and steel works located in the south of Duisburg, Germany.

ThyssenKrupp Steel Europe, Duisburg, Germany Contact: www.thyssenkrupp-steel-europe.com E-mail: erik.walner@thyssenkrupp.com

MPT International 3 / 2015

Here, ThyssenKrupp MillServices & Systems has started up new slab slitting and grinding facilities. The new equipment allows the slabs to be cut to size exactly as required and ground. This results in a further overall improvement to the quality of the strip steel products. â&#x20AC;&#x153;We are delighted to have won this contract. Our cooperation with Hoesch Hohenlimburg is a good example of synergies at work in the ThyssenKrupp group,â&#x20AC;? says Timm Jesberg, head of finishing services. Previously the slabs for Hoesch Hohenlimburg, a subsidiary of ThyssenKrupp Steel Europe, were processed by an external service provider. After discussions on how to retain resources within the group, the companies jointly planned and implemented the new slitting line. Both sides extract advantages from the cooperation. Short transportation distances and a warehouse management system tailored to the needs of the hot strip mill save time and money for Hoesch Hohenlimburg. â&#x20AC;&#x153;This cross-company cooperation is a win-

win situation for us and our customers, who benefit from our specific services and the further improvement in the quality of our material,â&#x20AC;? said Dr. Jens Overrath, CEO of Hoesch Hohenlimburg, during the start-up of the line. One of the biggest improvements is in logistics. The existing storage areas and the processing equipment on the HKM site are now close together and linked among other things by rail sidings and transport cranes. For example, the slit slabs from the line are loaded using a special 80 ton cross transporter. It can carry up to six slabs, stacked pyramid-like in three layers. Hoesch Hohenlimburg GmbH is a specialist supplier of narrow hotrolled steel strip. Founded over 160 years ago in Hagen, Germany, the company employs around 900 people. Most of its narrow strip products are sold to cold rolling mills and automotive component suppliers. Hoesch Hohenlimburg sees itself as a specialist for custom applications and can cost-efficiently produce even small batches.

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The evolution of thin-slab casting and rolling plant technology $IWHU KDYLQJ VLJQLĆ&#x201A;FDQWO\ FRQWULEXWHG WR WKH FRQWLQXRXV H[SDQVLRQ RI WKLV SURGXFWLRQ PRGH DQG DIWHU DQ H[WHQVLYH FDPSDLJQ RI WKHRUHWLFDO UHVHDUFK DQG SK\VLFDO WHVWLQJ LQ UHIHUHQFH SODQWV 'DQLHOL KDV SURJUHVVLYHO\ GHYHORSHG RYHU WKH \HDUV D QHZ JHQHUDWLRQ RI WKLQ VODE FDVWLQJ DQG UROOLQJ OD\RXW PDUNLQJ D QHZ SKDVH LQ WKH HYROXWLRQ RI WKLV SURFHVV process are embodied in the acronym DUEÂŽ, which stands for Danieli Universal Endless (Danieli patented technology â&#x20AC;&#x201C; US patent n. 8087449, 3 January 2012).

Over the last 25 years the thin slab casting and rolling process has been gaining a major market share in the production of hot rolled strip, progressively eroding the areas previously of exclusive domain of conventional mills. This is mainly thanks to the competitiveness of the process over conventional ones, and to the growing ability of this technology to cover the majority of market niches, well beyond the boundaries of the commodity market. After having significantly contributed to the continuous expansion of this production mode and after an extensive campaign of theoretical research and physical testing in reference plants, Danieli has progressively developed over the years a new generation of thin slab casting and rolling layout, marking a new phase in the evolution of this process. The new step-ahead is epitomized by the name QSP-DUEÂŽ. This configuration belongs to the Quality Strip Production (QSPÂŽ) family, which is Danieliâ&#x20AC;&#x2122;s strip-quality-oriented thin slab based plants. The innovative features of the

Alessandro Pigani, Paolo Bobig, Mike Knights, Stefano Martinis, &CPKGNK % 1HĆ&#x201A;EKPG /GEECPKEJG 5 R # Buttrio, Italy Contact: www.danieli.com E-mail: sales@dwu.danieli.it

MPT International 3 / 2015

What makes this new concept different is the ability of â&#x20AC;&#x153;universalâ&#x20AC;? rolling modes thanks to the fact that, now, within one single plant it is possible to perform coil-to-coil, semi-endless and endless rolling modes, making this plant a major technology innovation compared to the previous generation. This new approach can be seen as the natural evolution of the original concepts that marked the progress of the thin slab route, namely the application of the vertical curved design thin slab caster and the separation of the rolling stands into high reduction units and finishing units.

Plant concepts developed for the thin slab route At present, two different layout concepts have been developed for the thin slab route. Conventional plants, conceived with one or two casting strands, are connected to the rolling mill through long tunnel furnace(s), which have the function of reheating and equalizing slab temperature as well as of guaranteeing sufficient buffer time in case of either scheduled stoppages of the mill (i.e. work rolls change) or unscheduled interruptions of material flow. Danieli consolidates this QSPÂŽ layout by reaching world record results, both in productivity and quality.

In recent years, thanks to a progressive increase in mass flow due to increased casting speeds, inherited from the last generation of thin slab casters

operating at ultra-high speeds, in combination with the reliable introduction of induction heating technology in place of a tunnel furnace, it was possible to develop the QSP-E ÂŽ layout: a new generation of extremely compact plants, specifically dedicated to the production of ultra-thin gauges. The latter made possible thanks to the application of the endless rolling process (i.e. the direct and uninterrupted connection between casting and rolling), to overcome the obstacles represented by the well-known problems of strip threading when producing thin gauges in coil-to-coil mode. The QSPÂŽ plants have made it possible to drastically widen the steel grades mix of thin slab based processes and to ramp up plant productivity well in excess of 3 million t/year, also thanks to the possibility of operating with two casting strands. These plants were initially conceived for the application of coil-to-coil rolling and then for the semi-endless process to roll thinner gauges below 1 mm. On the other hand, the QSP-EÂŽ concept made it possible to optimize the production of ultra-thin gauges in endless mode, while showing little flexibili-

CONTINUOUS CASTING – HOT ROLLING ty in the production of more sophisticated grades, due to the rigid link between casting and rolling. In case of endless rolling, the caster is in fact forced to always run at very high casting speeds and this is not possible for all the steel grades due to metallurgical reasons. Moreover, the endless process has proven to be economically competitive only for the production of coils having strip thickness below 1.5 mm, but as soon as the strip thickness is increased, the power required by the induction heaters to continue operating in endless mode becomes excessively high, making it economically necessary to return to coil-to-coil mode. Since the QSP-E® has a compact layout configuration, with slab reheating provided by the induction heating

buffer because caster restranding has to be synchronized with roll changes in the mill, which are quite frequent in endless mode, due to significant wear and thermal deterioration of the rolls in continuous contact with the strip. As a consequence, caster sequencing (i.e. plant yield optimization) is reduced compared to plants operating in coil-to-coil mode, where the sequence length is determined by SEN refractory life and not by roll change scheduling. Also, the QSP-E® layout does not allow the plant’s capacity to be doubled by adding a second casting strand, hence limiting the overall productivity in the range of 2 million t/year, depending on the product mix. This in spite of significant investment cost, thus making the specific investment per ton not particularly attractive. All in all, these factors have negatively influenced the expansion of the endless process, notwithstanding its indisputable advantages, when it comes to ultra-thin gauge production.

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in thin slab casting and rolling plants, able to unify in a single production line all the winning features that up to now have been developed using different approaches, while eliminating the limiting factors of each one of them. This is the backbone concept behind the development of the Danieli Universal Endless layout, which features the following: ▪ high productivity, thanks to an unprecedented combination of slab thickness and speed, ▪ high production flexibility, able to operate in coil-to-coil, semi-endless and endless rolling mode, ▪ high operational flexibility, due to the presence of the tunnel furnace and relevant buffer time. It covers the full spectrum of steel grades produced for flat products, including the most sophisticated ones rolled via thermo-mechanical rolling (API pipeline grades) or temperature-controlled rolling (multiphase products) as well as the grades which require moderate casting speeds like peritectic, electrical steels and high-carbon grades, being crack-sensitive.

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system, there is no buffer time between caster and mill and this creates significant limitations on the operational flexibility of the entire production line. Additionally, plant yield and productivity are affected by the absence of

It also covers the full spectrum of geometrical strip dimensions, ranging from 0.8 mm ultra-thin gauges, produced in endless mode, up to 25 mm thick strips. This, of course, in combi-

In a continuous effort to improve existing processes and technologies and overcome their current limitations, Danieli has developed a new concept

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nation with an unbeatable transformation cost, lower than any other process presently available.

DUEÂŽ thin slab caster The vertical-curved caster features 5.5 m main radius, designed to operate with a single slab thickness of 110 mm after dynamic soft reduction, within the casting speed range from 2.5 up to 6.8 m/min, depending on the steel grade. Such an unprecedented combination of slab thickness and speed makes it possible to easily reach the mass flow conditions required by the full endless production mode, particularly when ultra-thin gauges of commercial grades are produced. This caster, the logical development of the already consolidated vertical curved Danieli design, takes full advantage of the experience acquired over more than 25 years dedicated to perfecting this design, as well as the considerable experience gained in ultra-high speed casting. Industrial operation at high speed has been extensively experienced since 2008 in the Posco CEM minimill (Korea), where a Danieli thin slab caster usually works in the speed range from 6.0 to 7.0 m/min, with peak of 8.0 m/ min. Special patented mould and oscillator design, dynamic air-mist secondary cooling, plus dynamic soft reduction ensure superior slab quality. The combination of the afore mentioned slab geometry and caster design features makes it possible to obtain a mould fluid-dynamic similar to a medium slab, resulting in a higher control of the solidification process and in a much easier and more stable operation MPT International 3 / 2015

compared to a conventional thin slab process. Stability and easiness of operation are key points for endless operation, where repeatability and steadiness of operation are a must. Dynamic soft reduction is a basic tool in thin slab casters; in conjunction with the vertical curved design it provides the best control of internal and surface slab quality in any casting conditions. It provides the mill with a thicker slab compared to the traditional thin slab approach, with a remarkable increment in the reduction ratio from slab to strip for this kind of plant, which in turn allows the production of a wider product mix. The possibility of covering the entire production range with one slab thickness only, regardless of final product gauge, clearly brings significant operating advantages. The caster can therefore produce up to about 3 million t/ year on a single casting strand, covering a wide range of steel grades such as low, medium and high carbon, high strength low alloyed, peritectic, silicon, pipeline, API and more. The flexibility of Danieliâ&#x20AC;&#x2122;s mould design, which guarantees stress/strainfree solidification in the shell, makes it possible to perform continuous slab width adjustment during casting. The absence of limitations or constraints in the slab width makes production flexible and profitable. The mouldâ&#x20AC;&#x2122;s narrow faces are designed with a special profile, and an

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on-board mould width adjustment system provides the ability to dynamically change mould narrow side taper to suit changing conditions, i.e. steel grade, casting speed, sticking detection, providing consistent strand support in all production modes, including endless. Moreover, a dynamic secondary cooling system, complete with width partialization adjustment, makes it possible to optimize the temperature of the slab edges, eliminating the possibility of corner cracks even for the most crack-sensitive grades such as HSLA (high strength low alloyed) and HC (high carbon) grades.

Tunnel furnace The tunnel furnace is conceived to operate in coil-to-coil mode like in conventional thin slab rolling plants, in semi-endless mode, able to accommodate long mother slabs that are the equivalent of several coils, and in full endless mode. This unit provides a fundamen-

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tal buffer function that increases plant flexibility and provides the possibility of performing work roll changing as a background task, without affecting the operation of caster and meltshop, â&#x20AC;&#x153;switchingâ&#x20AC;? from endless to coil-to-coil operating mode during roll changes, which in any case does not reduce plant productivity.

DUEÂŽ rolling mill The DUEÂŽ mill is the natural evolution of Danieliâ&#x20AC;&#x2122;s QSPÂŽ concept, which features separation of the mill stands into high reduction units and finishing units, in order to perform dual step rolling. This configuration includes: â&#x2013;Ş a dedicated high-pressure descaling unit at finishing mill entry (in addition to the one at high reduction stand entry) to limit imprinting scale phenomena on the bar, thus significantly improving the surface quality of the final coil, â&#x2013;Ş an intensive cooling system, incorporated into the descaler box at finishing mill entry, used when producing TMR and/or API grades in order to guarantee the correct bar temperature profile and proper control of grain growth that are essential features of the thermo-mechanical rolling process, â&#x2013;Ş a crop shear, beneficial for thin gauge production, used to cut the transfer bar head and/or tail end, in order to have smoother threading into the finishing mill as well as reducing tail chew-up, â&#x2013;Ş an induction heating system, for consistent production of thin and ultra-thin gauges in endless mode. Induction heaters are individually mounted on a retractable frame so they can be transferred off-line for maintenance purposes or when they are not being used (i.e. during coil-to-coil production mode). The number and size of mill stands are designed to cover a wide range of strip thickness, from 25 mm down to 0.8 mm, starting from 110-mm-thick slabs, guaranteeing superb geometrical and mechanical properties. The mill stands are equipped with all state-of-the-art features for utmost strip crown and profile control, bearing in mind that these control functions also have to be operational under load conditions as required by the endless rolling process. The line is complete with a laminar cooling system and coiling area, made up of a high-speed shear (used to cut MPT International 3 / 2015

the coil to length when working in endless or semi-endless mode), threading devices, pinch rolls and downcoilers, already fully tested and presently in operation at the Arvedi plant, Italy.

Automation Using the original technology developed by Danieli Automation, named 3Q, it was possible to overcome the challenges the DUEÂŽ process posed for the automation system. In fact, not only is the automation system required to control the process but it also has to assist operators in properly running the process, providing the necessary experience to develop an innovative process. Since DUEÂŽ is a highly integrated process, encompassing casting, reheat-

ing, rolling, cooling and coiling, a single virtual pulpit solution was selected. This means that all operators can easily communicate either verbally or visually, consolidating the concept of â&#x20AC;&#x153;one crewâ&#x20AC;? running the plant. Moreover, the operators are assisted in managing the plant by a new operator interface concept covering multiple hierarchical levels, each one of which oriented to a specific operational function. Changing the strip thickness during rolling requires a very accurate tracking system and a set of smart strategies to simultaneously achieve the required thickness variation while minimizing the transition length. The same concept applies to width changing during casting. Both technologies strongly improve the plantâ&#x20AC;&#x2122;s utilization factor,

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adapting â&#x20AC;&#x153;in-lineâ&#x20AC;? production to orders, and reducing the number of coil widths kept in inventory. To obtain the required mechanical properties of the rolled strip in all operating modes, the transfer bar and strip cooling are controlled by an integrated set of sophisticated cooling models that combine physical equations with an advanced adaptation system. Synchronizing caster and rolling mill is one of the enabling technolo-

simplifying power pack serviceability. Induction heaters are completely designed and manufactured in-house, on the basis of a high quality control plan to achieve uniform machine ratings. Crown, flatness and wear control in endless plants is paramount. Danieli has developed a complete set of online mathematical models to achieve the target crown, flatness and edge drop on the final strip. Control strategies are changed â&#x20AC;&#x153;on-the-flyâ&#x20AC;? accord-

dedicated instruments installed in key positions throughout the plant. Root cause analysis is performed to access the cause of surface defects.

Rolling modes As mentioned above, thanks to its layout configuration, the Danieli Universal Endless mill is able to work in coilto-coil, semi-endless and endless rolling modes, selecting the most suitable production mode according to final product specification (i.e. endless mode is economically convenient for strip thicknesses up to 1.5 mm). Selecting the optimum rolling mode is possible with the DUEÂŽ layout, in accordance with casting speed and final strip thickness.

Coil-to-coil rolling mode

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In coil-to-coil rolling mode, the slab generated in the caster is cut to length by the pendulum shear at the caster exit. Each slab is transformed into a single coil. In coil-to-coil production mode caster and mill operate with different mass flows; each one can be optimized according to the specific needs of each unit, which are different, in order to guarantee the best product quality. Coil-to-coil process is advisable for the production of strip thicknesses of more than 1.4 mm. However, by applying intermediate bar reheating with the induction heating system it is possible to have a more stable and reliable rolling condition for the production of thin gauges down to 1 mm, without having to speed up the bar, once the coiling operation starts, in order to limit temperature losses.

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gies for endless rolling. A new control algorithm has been developed to provide a smooth, reliable link between caster and rolling mill in all operating conditions, while continuing to produce top quality strip. Temperature control using induction heaters provides increased heating efficiency. The new unique design is based on a fully digital control of the heating power and a smart circuit diagram that have made it possible to obtain high heating efficiency while MPT International 3 / 2015

ing to the actual rolling mode, the expected rolling campaign and in order to use the most effective actuator in each section of the plant. On-line assessment of internal quality parameters for both slab and coil is achieved thanks to the advanced in-house-developed slab quality control system and coil quality estimator. The latter is able to calculate the mechanical properties of the coils in real time, thus allowing timely corrective action. Surface quality is checked on line thanks to

The mother slab generated in the caster (corresponds in length to approx. five coils) is cut to length by the pendulum shear at caster exit. After rolling, coils are cut to length by the high speed shear at coiling area entry. In semi-endless production mode caster and mill operate with different mass flows, just like coil-to-coil production mode. However, in this case there is less material loss, since there are less head and tail end crops at the crop shear at finishing mill entry, due to the smaller number of slabs being threaded into the mill.

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CARNIVAL Come and marvel at ... &ƌŽŵ ϭϲƚŚ ƚŽ ϮϬƚŚ ŽĨ :ƵŶĞ ϮϬϭϱ ƚŚĞ /Ed K ĂƌŝŶǀĂů ŽĨ dĞĐŚŶŽůŽŐŝĞƐ ŽƉĞŶƐ ŝƚƐ ŐĂƚĞƐ Ăƚ ƚŚĞ DĞƐƐĞ ƵƐƐĞůĚŽƌĨ͘ ĞƐŝĚĞƐ ŶƵŵĞƌŽƵƐ ĐƵůŝŶĂƌǇ ĚĞůŝŐŚƚƐ ƚŚĞ ĨŽůůŽǁŝŶŐ ƚĞĐŚŶŝĐĂů ĂƩƌĂĐƟŽŶƐ ĂƌĞ ĂǁĂŝƟŶŐ ǇŽƵ͗ ůĞĐƚƌŝĐ ƌĐ &ƵƌŶĂĐĞ tŝƚŚ ƚŚĞ ĂĐƋƵŝƐŝƟŽŶ ŽĨ ƉĂƚĞŶƚƐ ĂŶĚ ŽƚŚĞƌ ŝŶƚĞůůĞĐƚƵĂů ƉƌŽͲ ƉĞƌƚǇ ƌŝŐŚƚƐ ŽĨ &h ,^ ƚŚĞ ďƌĂŶĚ ǁĂƐ ďŽƌŶ ƵŶĚĞƌ ǁŚŝĐŚ ǁĞ ĂƌĞ ŶŽǁ ŽīĞƌŝŶŐ ǇŽƵ ƚŚĞ ůĂƚĞƐƚ ŝŶŶŽǀĂƟŽŶƐ ŽŶ ƚŚĞ ĞůĞĐƚƌŝĐ ĂƌĐ ĨƵƌŶĂĐĞ ƐĞĐƚŽƌ͗ ƚŚĞ ƚĞůĞƐĐŽƉŝĐ &͕ ĐŚĞŵŝĐĂů ĞŶĞƌͲ ŐǇ ƐǇƐƚĞŵƐ ďǇ ͕ ĂƐ ǁĞůů ĂƐ ƚŚĞ /^ ĞůĞĐƚƌŽĚĞ ĐŽŶƚͲ ƌŽů ƐǇƐƚĞŵ ďǇ ǁŝůů ĚĞĮŶŝƚĞůǇ ŝŶƐƉŝƌĞ ǇŽƵ͘

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ĂƐƟŶŐ dŚĞ ƉƌŽĚƵĐƚ ƉŽƌƞŽůŝŽ ŽĨ ĐŽǀĞƌƐ ĐŽŶƟŶƵŽƵƐ ĐĂƐͲ ƟŶŐ ĨŽƌ ůŽŶŐ ƉƌŽĚƵĐƚƐ ĂƐ ǁĞůů ĂƐ ƐƉĞĐŝĂů ŵĂĐŚŝŶĞ ƐŽůƵƟŽŶƐ ĨŽƌ ƚŚĞ ƉƌŽĚƵĐƟŽŶ ŽĨ ƐƉĞĐŝĂů ƐƚĞĞůƐ͘ &ŝŶĚ ŽƵƚ ŵŽƌĞ ĂďŽƵƚ ŽƵƌ ƌŽďƵƐƚ ĐŽŶƟŶƵŽƵƐ ĐĂƐƟŶŐ ŵĂĐŚŝŶĞƐ ǁŝƚŚ ŚŝŐŚĞƐƚ ƋƵĂůŝƚǇ ŽĨ ƚŚĞ ĮŶĂů ƉƌŽĚƵĐƚ͕ ůŽǁ ŵĂŝŶƚĞŶĂŶĐĞ ƌĞƋƵŝƌĞŵĞŶƚƐ ĂŶĚ ŚŝŐŚ ŽƉĞƌĂƚŽƌ ĨƌŝĞŶĚůŝŶĞƐƐ͘

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^ƉĞĐŝĂů DĞƚĂůůƵƌŐǇ tĞ ĂƌĞ ƚŚĞ ŵĂƌŬĞƚ ůĞĂĚĞƌ ŝŶ ƚŚĞ ĮĞůĚ ŽĨ ^Z ƉůĂŶƚƐ ĂŶĚ ĂďůĞ ƚŽ ƉƌŽǀŝĚĞ ǇŽƵ ĐƵƐƚŽŵŝǌĞĚ ƉůĂŶƚ ĐŽŶĐĞƉƚƐ͕ ǁŝƚŚ ŝŶŐŽƚ ƐŝǌĞƐ ƌĂŶŐŝŶŐ ĨƌŽŵ ůĂď ƐĐĂůĞ ƵƉ ƚŽ Ă ŵĂǆŝŵƵŵ ŽĨ ϮϱϬƚ͘ ůƐŽ ŐĂͲ ƚŚĞƌ ƐŽŵĞ ŝŶĨŽƌŵĂƟŽŶ ŽŶ ŽƵƌ ůĂƚĞƐƚ ǀĂĐƵƵŵ ŝŶĚƵĐƟŽŶ ƉůĂŶƚ ;s/DͿ͕ ǁŚŝĐŚ ũƵƐƚ ŚĂƐ ďĞĞŶ ƉƵƚ ŝŶƚŽ ŽƉĞƌĂƟŽŶ͘

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tĞ ĂƌĞ ůŽŽŬŝŶŐ ĨŽƌǁĂƌĚ ƚŽ ǇŽƵƌ ǀŝƐŝƚ ͊ Booth No. E09, Hall 4 INTECO Group tŝĞŶĞƌ ^ƚƌĂƘĞ Ϯϱ ͻ ϴϲϬϬ ƌƵĐŬ ĂŶ ĚĞƌ DƵƌ ͻ ƵƐƚƌŝĂ ͻ ƵƌŽƉĞ WŚŽŶĞ нϰϯ ϯϴϲϮ ϱϯ ϭϭϬͲϬ ͻ &Ăǆ нϰϯ ϯϴϲϮ ϱϯ ϴϰϰ ͻ ŝŶƚĞĐŽ͘ĂƵƐƚƌŝĂΛŝŶƚĞĐŽ͘Ăƚ ͻ ǁǁǁ͘ŝŶƚĞĐŽ͘Ăƚ

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Furthermore, it is possible to reduce the minimum strip thickness rolled in the mill, since for the coil generated from the central portion of the mother slab, even when the rolling speed is increased, there is no risk of â&#x20AC;&#x153;flying headâ&#x20AC;? on the runout table, as the strip is already under tension between mill stands and downcoiler. In the DUEÂŽ layout the semi-endless process is mainly applied for the production of thin strips if the endless process cannot be applied due to insufficient mass flow, i.e. in the case of medium carbon, HSLA or high carbon grades, or in the case of liquid steel shortages. With the DUEÂŽ configuration, even during production in semi-endless rolling mode, it is possible to have a more stable and reliable rolling condition for the production of thin gauges, thanks to the induction heating system, without having to speed up the bar when the coiling operation starts, in order to limit temperature losses. Without the semi-endless process, the DUEÂŽ layout can be even more compact, since for coil-to-coil and endless mode, the length of the tunnel furnace alone can be shortened to less than 100 m, thus further reducing Capex and Opex.

in the area of 850Â°C, regardless of the casting speed.

Thermo-mechanical rolling mode The installation of an intensive cooling system between the high reduction stands and finishing mill stands allows production of high added value pipeline grades such as API. The intensive cooling system is applied in coil-to-coil mode

with the DUEÂŽ configuration from slab to transfer bar and from transfer bar to the final strip can be higher than in other thin slab route plants, allowing the production of API grades in greater thicknesses and making it possible to apply spiral welded pipes in high-pressure large diameter gas transportation lines. Additionally, the use of a powered cooling system on the runout table allows further grain refinement and transformation hardening, taking advantage

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Endless rolling mode Recent developments in ultra-high casting speed pioneered by Danieli mean that the thin slab caster can now generate sufficient mass flow for a full endless process. The slab generated in the caster is continuously rolled in the mill in endless mode: coils are cut to length by the high speed shear at coiling area entry. In endless production mode, caster and mill operate with the same mass flow in order to ensure an uninterrupted process. With the DUEÂŽ layout the endless rolling mode is mainly utilized for massive production of thin and ultra-thin strips, overcoming the difficulties implied by other production mode as well as with higher plant yield. With the DUEÂŽ configuration, thanks to the proper mass flow of a 110-mm-thick slab at a casting speed in excess of 6 m/min, the induction heating system allows stable production of ultra-thin gauges down to 0.8 mm, in stable and repetitive conditions, with strip temperature at finishing mill exit MPT International 3 / 2015

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and, when in use, the induction heating system is put off-line. It is an essential tool for applying a real thermo-mechanical rolling process as it cools the transfer bar below the no-recrystallization temperature. In this way the risk of partial recrystallization in the finishing mill and the consequent non-uniform microstructure is prevented, and the coils produced are also suitable for arctic applications (down to -60Â°C). With a 110-mm-thick starting slab, the reduction ratio that can be obtained

of the potential of acicular ferrite and bainitic microstructures. In this way it is possible to save on the cost of expensive alloying additions and increasing the strength of the produced coils.

Modular plant design Depending on specific needs (such as liquid steel availability, market situation, product mix, Capex, etc.) the DUEÂŽ configuration can also be implemented in steps, starting with a classic

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QSPÂŽ layout. For instance, depending on liquid steel availability, phase 1 of the project can focus on limited production of HRC, rolling thin gauges on seven stands, down to a 1 mm strip thickness in coil-to-coil mode, starting from a 70 mm slab. At a later stage, when additional liquid steel is available, phase 2 could see a boost in production by increasing slab thickness up to 110 mm, and adding the necessary caster segments as well as one more rolling stand in order to continue producing 1 mm strip thickness in coil-to-coil mode. The last stage could be the implementation of the â&#x20AC;&#x153;endless packageâ&#x20AC;?, by installing an induction heating system and a highspeed shear in order to produce ul-

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tra-thin gauges down to 0.8 mm strip thickness in full endless mode.

Conclusion The DUEÂŽ (Danieli Universal Endless) is a solution to overcome the existing limitations of current thin slab casting and rolling configurations. It constitutes a universal tool able to reach all the production niches of the flat products market, by applying the process that is best suited to each steel grade and product. Thanks to the combination of slab thickness and casting speed, never-before-seen production rates are possible, up to 3 million t/year on a single casting strand, making the Capex investment per t extremely attractive.

The layout configuration, together with an effective combination of thermal energy (gas-fired tunnel furnace) and induction heating, optimizes energy consumption, making DUEÂŽ a truly â&#x20AC;&#x153;greenâ&#x20AC;? plant, while also reducing Opex by about 15 â&#x20AC;&#x201C; 20% compared to the current benchmark of thin slabbased plants. Coil-to-coil and endless, thermo-mechanical and multi-phase, ultra-thin and thick products are now all possible in a single production line. This makes both niche products with high-added value and the mass production commodities segment within reach of this new plant, which today represents the most extensive application of flexibility.

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Rizhao Steel counts on thin slab technology for high-quality production :LWK SUHVHQWO\ Æ&#x201A;YH $UYHGL (63 OLQHV WKH &KLQHVH VWHHO SURGXFHU 5L]KDR 6WHHO LV QRZ IRFXVLQJ RQ WKH KLJKO\ DWWUDFWLYH ORFDO DQG H[SRUW PDUNHWV IRU KLJK TXDOLW\ WKLQ JDXJH VWULS SURGXFWV 7KH QHZ FDVWLQJ UROOLQJ FRPSOH[ LV GHVLJQHG IRU D WRWDO DQQXDO SURGXFWLRQ FDSDFLW\ RI PLOOLRQ WRQV RI KLJK TXDOLW\ XOWUD WKLQ KRW UROOHG VWULS SURGXFWV ZLWK ZLGWKV RI XS WR PP DQG WKLFNQHVVHV GRZQ WR PP 7KH Æ&#x201A;UVW OLQH EHJDQ RSHUDWLRQV LQ VSULQJ Rizhao Steel, an integrated iron and steel works in the city of Rizhao, Shandong province in Eastern China, selected the Arvedi ESP (endless strip production) process to vary its production to high-quality, thin-gauge hot-rolled strip. Following an initial investment in mid-2013 for two new Arvedi ESP plants, each with an annual production capacity of 2.55 million t, a second order was placed with Primetals Technol-

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MPT International 3 / 2015

ogies for the supply of three additional Arvedi ESP lines that will have a combined rolling capacity of 5.95 million t/ year. The lines are designed for the production of different strip-width ranges: from 900 mm to 1,600 mm (three lines), and from 900 mm to 1,300 mm (two lines). In all five lines, strip is rolled to a minimum thickness of 0.8 mm. A wide variety of steel grades will be produced for a broad spectrum of steel products and industrial sectors. Primetals Technologies is responsible for the engineering of the Arvedi ESP plants, and supplies mechanical equipment, media-control systems, technological packages and automation systems. The lines are controlled by completely integrated basic-automation (level 1) and process-optimi-

zation systems (level 2) for all casting and rolling operations.

1XGTCNN RNCPV EQPÆ&#x201A;IWTCVKQP The layout and the expected results of the five new plants are based on the plant design and performance of the existing Arvedi ESP production line at Acciaieria Arvedi SpA, which has been successfully operating in Cremona, Italy, since 2009. Like in Cremona, the 180-m-long Chinese plants are much more compact than conventional casting and rolling mills. A short line length means that lower investments are required for land, civil works, buildings, piping, cabling and construction. Four plants are positioned pairwise in a mirrored arrangement with the drives

CONTINUOUS CASTING – HOT ROLLING installed on the outer side of two each line, and with the control pulpits and roll shops positioned between the line pairs. Liquid steel for the wider Arvedi ESP lines is supplied from new BOF meltshops with 300 t BOF converters; for the narrower lines the steel will be delivered from existing converter meltshops with 63 t converters.

%QPVKPWQWU ECUVGTU The bow-type casters of all five lines perform continuous strand bending and unbending, and they are equipped with a straight mould for the casting of steel at thicknesses between 90 mm and 110 mm. Online strand-width adjustments are performed using DynaWidth mould-width adjustment technology. This solution allows the target strand width to be accurately met without the need for an edger. The casters are equipped with 11 strand segments

control to be achieved with work-roll bending, since the hot core of the cast strand is softer and therefore has a higher formability for shape control.

+PFWEVKQP HWTPCEG CPF ƂPKUJKPI OKNN The intermediate strip exiting the high-reduction mill then enters the induction heater, which features a short length of only 10 m. This enables the strip to pass through the furnace in less than 15 seconds, which is decisive for minimum scale formation. Only one descaler – installed immediately before the five-stand finishing mill – is therefore required for the entire line. Unnecessary strip-temperature losses are thus avoided, allowing a more perfect control of the thermo-mechanical rolling parameters. Following reheating and descaling, the intermediate strip then en-

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rolling of perfectly flat strip by the last three finishing stands, which are outfitted with conventional work-roll contours. Long-stroke shifting of the work rolls under load, which is regulated by a wear-compensation model, maximizes the service life of the rolls before surface grinding is required. What’s more, thanks to the endless mode of operation in Arvedi ESP plants, strip impact on the rolls – typical for batch-operated plants during strip-head threading – is eliminated. This aspect also contributes to a significant extension of the workroll lifetime. For example, in a typical production sequence comprising 3,000 t of liquid steel, a total of 170 km of strip – with a considerable portion of 1 mm gauge – is rolled by the final stand.

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each, and the metallurgical length of all casters is just over 20 m. Three high-reduction mill stands are installed immediately after the final caster segment in order to utilize the remnant heat energy of casting for the initial rolling step. In addition to major energy-cost savings, this enables perfect crown and wedge

ters the finishing mill equipped with five 4-high finishing stands. Because strip shaping has already taken place in the high-reduction mill, only the first two finishing stands are equipped with SmartCrown rolls that are designed with a bottle-shaped roll contour. This serves as the basis for final

carried out by a high-speed shear. The endlessly produced strip with coiled weights of up to 32 t is distinguished by highly uniform geometrical and mechanical properties throughout its entire length. Because strip-head and -tail cropping is unnecessary with endless production, an average yield of MPT International 3 / 2015

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş CONTINUOUS CASTING â&#x20AC;&#x201C; HOT ROLLING

more than 98% is achieved from liquid steel to the coiled product in Arvedi ESP lines. The fully integrated automation system enhanced with an advanced tracking model ensures exact cutting procedures and coil scheduling in accordance with production orders. The entire process, including all plant technology and automation systems, is protected by Arvedi and Primetals Technologies patents.

2TQLGEV GZGEWVKQP Executing such a complex project in 20 months is a master piece of project management and requires perfect cooperation between Rizhao Steel, main contractor, suppliers and erection company. As the new plants 1 â&#x20AC;&#x201C; 3 are almost identical to the master plant in Cremona, many drawings could be sent to the manufacturers within the first weeks of project start. Only this allowed to stick to the very tight time schedule. Also using mainly the same manufacturers as for the plant in Italy contributed to a smooth execution. As manufacturing took mainly place in China, transport times could be limited as well. And finally achieved the erection company under the guidance of Rizhao Steel the nearly impossible to install the whole plant from groundbreaking to completion within 12 months. In parallel to the commissioning of line 1, plant 2 was already close to finish of the installation, while ground-

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breaking for plant 3 took place end of 2014. Deliveries of equipment for line three have already started. Project work for plants 4 and 5 which are in the second plant complex is also progressing right on schedule. Generally, the overall project plan foresees a very integrated project execution ending up with the startup of the last plant in 2016.

# UWEEGUUHWN UVCTV Quick ramp-up of the new Arvedi ESP lines to their designed production capacity was supported by comprehensive training of Rizhaoâ&#x20AC;&#x2122;s operational and maintenance personnel. Basic training comprised theoretical training at Primetals Technologies in Linz and Erlangen for mechanical, electric and automation equipment. This was followed by three weeks of theoretical and practical instruction at the Arvedi ESP plant in Cremona. In a second module

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with hands-on training, operators were involved with routine operational and maintenance practices for two months at the Arvedi plant in Cremona. During the first year of operation at Rizhao Steel, onsite training and assistance is provided by specialists from Acciaieria Arvedi. The combination of experienced Arvedi experts and welltrained Rizhao personnel ensures reliable plant operations and the production of high-quality final products. After a project period of only 20 months the first coil on line 1 was rolled in spring 2015. With the experience of the startup of the ESP line in Cremona, Italy in a first step the caster was started in combination with the high reduction mill and pendulum shear producing plates which are pushed and piled in the related section. After fine tuning of the coupling of caster and high reduction mill in the next step the finishing mill, laminar

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cooling and down coiler were included and combined allowing the plant to produce first coils in semi-endless and endless mode. Due to the well trained Rizhao operators the production was ramped up quickly. Minimum gauges below 1 mm were reached after 2 months of operation.

/GGVKPI OCTMGV FGOCPFU YKVJ C OKZ QH CFFGF XCNWG RTQFWEVU The reliability and stability of the Arvedi ESP process have been well proven in more than five years of operation at Acciaieria Arvedi and now in China. A broad range of advanced steel grades are produced for a wide range of industrial applications. Thanks to the uniform and exceptional quality of the thin- and thick-gauge strip, the products command premium prices on the market. Major cost savings result from the significantly lower energy consumption, reduced alloying requirements and high product yield. The product mix of the new Chinese plants will comprise low-carbon steels and ultra-low-carbon steels, medium-carbon steels as well as high-strength low-alloyed (HSLA) and dual-phase steel grades. Thanks to the constant process parameters of endless operation, particularly with respect to the strip-temperature profile, production of advanced steel grades is accomplished with a far higher degree of accuracy compared to conventional casting-rolling process-

es. For example, over-alloying is avoided during production of HSLA and pipe grades, which results in considerable cost savings for producers.

%QPENWUKQP From a quality point of view, the final products produced on an Arvedi ESP line are characterized by superior geometrical strip quality and flatness. Outstanding surface quality is proven by a major European automotive supplier who tested the ESP-material on his cold rolling mill. Very high strip homogeneity along its entire length is ensured as in endless operation no strip heads or tail ends are passing the machine. The cut happens just before the down coiler at the high speed shear and the strip never faces strip threading or tail out procedures as known from conventional batch operated processes. This also contributes to considerably extended work-roll lifetime. Due to the constant process parameters and strict strip temperature guidance a reduced consumption of alloys for production of advanced steel grades is noticed. Excellent process stability is not only demonstrated on lowest mould breakout figures and cobble rates but can be seen also on the overall yield of more than 98% from liquid steel to coil. With consideration to the numerous benefits offered by the Arvedi ESP process, the five new plants in China will provide Rizhao Steel with the basis for long-term business success in China and abroad. MPT International 3 / 2015

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Rolling process optimization by OGCPU QH RTQĆ&#x201A;NG OGCUWTGOGPV between the passes %HIRUH SURGXFLQJ D QHZ UROOHG SURĆ&#x201A;OH WKH UROO VWDQG PXVW EH RSWLPDOO\ VHW XS 7KH $XVWULDQ PHWURORJ\ FRPSDQ\ 1H[W6HQVH *PE+ KDV GHYHORSHG D SRUWDEOH GHYLFH IRU PHDVXULQJ KRW UROOHG SURĆ&#x201A;OHV EHWZHHQ WKH SDVVHV ZKLFK VLJQLĆ&#x201A;FDQWO\ VKRUWHQV WKH VHW XS WLPH SHU UROOLQJ FDPSDLJQ 7KHVH WLPH VDYLQJV GLUHFWO\ WUDQVODWH LQWR D KLJKHU XWLOL]DWLRQ RI WKH UROOLQJ PLOO Even in modern rolling mills with high levels of automation the methods for verifying the proper shape and dimensions of the rolled product are often of a very simple nature and time-consuming. In many cases, it is still common practice to cut samples and compare shapes on a profile projector. On the other hand, there are stationary profile measurement systems which work accurately and quickly, but are expensive and not flexible enough to allow them to be quickly moved to a different position in the rolling mill. In order to fill this technological gap, the measurement systems supplier NextSense has developed the â&#x20AC;&#x153;Calipri Hotâ&#x20AC;? system. By means of this portable device it has become possible to measure the profile between the passes. Such a solution had been requested by rolling mill operator Mannstaedt GmbH, producer of special steel sections for diverse industrial applications. Compared to commodity steel production, these specialized applications call for small production lots, leading to frequent profile changes on both of the companyâ&#x20AC;&#x2122;s rolling mills. Consequently, the mills very often have to be completely reset.

New measurement system saves time â&#x20AC;&#x153;Calipri Hotâ&#x20AC;? eliminates the effort of cutting, quenching and machining the samples as it is placed around the sec-

Albert Niel, NextSense GmbH, Graz, Austria; Christian Trappmann, Mannstaedt GmbH, Troisdorf, Germany Contact: www.nextsense.at E-mail: albert.niel@nextsense.at

MPT International 3 / 2015

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tion directly in the rolling mill in the position to be measured. By placing the instrument around the rolling stock, it becomes possible to capture the complete contour with a laser-based system and measure a closed contour of the section at any intermediate stage. Measurements can take place at any intermediate rolling stage, and the results can be directly compared with the nominal values and used to correct the roll gap, if necessary. It is possible to make a virtual cut through the rolling stock to be measured and display the quality-relevant data in a matter of seconds. Measured in time, Mannstaedt could save approximately five minutes in each campaign. With nearly 500 campaigns being rolled on the light-section mill every year the annual time saving amounts to some 42 hours. The fact that the assessment of the dimensional accuracy would be available in much less time provides the benefit

that the operators can react faster and initiate any corrective measures more quickly. This not only applies to measurements after a changeover to a new size, but also to general quality monitoring along the production chain. Using â&#x20AC;&#x153;Calipri Hotâ&#x20AC;?, for example, at the cooling bed for checking the final contour would make it possible to recognize outof-spec contours at an earlier stage and reduce the amount of blocked material. In addition to the reduced set-up time, the measurements provide more information on the current rolling process due to the hot measuring method. Previously, hot state dimensions could not be measured. â&#x20AC;&#x153;Calipri Hotâ&#x20AC;? makes it possible to measure them directly, allowing for a more precise adjustment of the rollers. Thus, it is no longer necessary to wait until the sample has cooled down to calculate its dimensions. This property creates benefits especially for the development of new roll pass designs.

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Calipri technology: facts and ƂIWTGU “Calipri Hot” is a further development of the Calipri system specifically designed for the requirements of rolling mills. Calipri is based on the technology of laser light section. This enables the measurement of the complete profile (360°) of differently shaped objects, regardless of the harsh environmental conditions in rolling mills. Temperatures beyond 1,000°C, dust, steam and vibrations do not affect the measuring accuracy of 0.1 to 0.2 mm. Subsequently, the measured profile line can be individually analyzed and documented.

relatively to each other. Measuring these shifts allows the calculation of the angles and the mathematical compensation of measurement errors. The system can be placed and removed by hand, the thermal load on the equipment is low compared to a stationary system, and heat protection can be reduced to a minimum. As it is not possible to cover the whole section to be measured by a mobile device, the system scans the object to be measured dynamically, producing a multitude of measurements with unknown geometric relationships, each showing just a part of the whole section. Out of these

The Calipri technology can be applied to any arbitrary cross section with some distinct features of the contour, which allows the software to match each new measurement unambiguously with the previously recorded ones. Profiles like rails or beams fulfil this requirement. For rectangular profiles, the edge radius is sufficient. The only critical sections are round bars, since the profile shape looks exactly the same from all perspectives. To overcome this limitation, static reference objects can be mounted in the field of view of the sensor which allow it to align subsequent measurements by means of these pass points.

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The measurement takes approximately 10 seconds during which some 70 single images are taken by the camera from different positions and pre-processed by the sensor’s electronics. The sensor itself is moved along a 270 degree circle track by means of a gear wheel. The whole time needed for one measurement including the time for mounting and removing the system is under 30 seconds. Measurement errors are avoided by using multiple laser lines instead of one. If the orientation of the measurement head changes, this causes the three laser lines in the images to shift

series of measurements, an automatic selection is made of those sections needed for a good reconstruction. In the next step, these sections are aligned to each other using a best-fit approach. The aligned measurements are smoothed and sampled equidistantly, thus providing a closed contour of the cross section to be measured. Based on this contour arbitrary dimensions like length, angles or radii can be measured either interactively by mouse or by pre-defining measurement rules for a certain cross section and applied automatically to each measurement.

References [1] DePiero, F.W., and Trivedi, M.M., “3-D Computer Vision using Structured Light: Design, Calibration, and Implementation Issues”, Advances in Computers (43), 1996, Academic Press, pp. 243 - 278 [2] Niel, A.; Deutschl, E.; Gasser, C.; Kaufmann, P.: “A handheld profile measurement system for high accurate wear measurement of railway wheels”, SPIE International Symposium on Optics East, Two- and Three-Dimensional Methods for Inspection and Metrology III, Boston, 2005. MPT International 3 / 2015

After the evaluation of the data – which takes approximately five seconds – and calculation of the dimensions the result is immediately displayed on the screen.

System in operation end of 2015 The “Calipri Hot” system is currently under development and the first prototypes are being tested in different mill environments. Successful tests on hot 140 mm x 100 mm rectangular billets have been performed in a rolling mill in Austria. The first system permanently used under production conditions will be installed at the rolling mill of Mannstaedt GmbH in Troisdorf, Germany, probably in the fourth quarter of 2015. The marketing of the system in different sizes for different measurement ranges is planned to start at the beginning of 2016.

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Torqset ST2/25 combined with a torsionally elastic coupling; installed at MK Metallfolien GmbH in Hagen, Germany

Safety couplings in rolling mills Rolling mill operators can tell tales of woe about damage to the drives of mill stands, with universal shafts being the weak point of the mill. Safety couplings increase the service lives of universal shafts, while reducing costs. Since the first rolling mills revolutionized industry more than 150 years ago, they have been an indispensible technology for production of semi-finished products. Our world would indeed look quite different without flat and long rolled products such as strip, sheet, sections or wire rod. Accord-

Christopher Monka, R+W Antriebselemente GmbH, Klingenberg, Germany; Stefan Riediger, hpl Neugnadenfelder, Ringe, Germany Contact: www.rw-kupplungen.de E-mail: hasenstab@rw-kupplungen.de

MPT International 3 / 2015

ing to the ground rules of our market economy, growing demand is naturally accompanied by the constant need to increase productivity. Service lives are to be increased, at the same time reducing production costs . In a rolling mill, production costs are decisively influenced by set-up times, scheduled maintenance intervals and downtimes due to damage. Practically every operator of a rolling mill can tell tales of woe about damage to the drive of the mill stand. There is basically the same drive concept in all rolling mills, be they of the 2-high, 4-high or 20-high design: an electric motor is coupled with a power divider transmission or a pinion gear unit. The

gear unit is subsequently connected by universal shafts to the drive rolls of the mill stand. Since the gears are designed with higher safety factors than the universal shafts, the universal shafts are the weak point in the drive train. First and foremost they can be destroyed in cases of too high torques occurring briefly during accidents (strip breakage) or overloads, if the mill stand is operated to its limit. Since such universal shafts have a delivery time of several weeks, they have to be stocked as spare parts to minimize the downtime caused by a universal shaft fracture. But replacing the universal shafts is also relatively time-consuming, thus involving an expensive loss of production.

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Cost saving with safety couplings Integrating a safety or overload coupling is frequently omitted in new plants for cost reasons. A widespread opinion in existing plants is that retrofitting is not possible. However, if one compares the spare parts inventory and production downtime costs with the purchasing price of a safety coupling, it becomes clear that this would be an expedient investment. It is usually possible in existing mill stands to simply retrofit the coupling between the motor and the gearbox, replacing the existing standard coupling. This is usually a torsional stiff gear or disc pack coupling. As an alternative, the safety coupling can also be placed on the electrically driven side between the gearbox and the universal shaft. The mode of operation of a safety coupling is simple: If a predefined torque is applied to the coupling, it disengages the connection between the drive and electrically driven side within a few milliseconds. This disengagement also has the effect that the existing kinetic energy no longer has a destructive effect on the drive components to be protected. Once the damage has been rectified, only a mallet or a lever is required to re-engage the coupling. In contrast to the previously widely used shear pin couplings, special knowledge about additional consumable materials such as pins, lubricants and the like is not required. The coupling is completely maintenance-free.

Torqset as solutions in practice MK Metallfolien GmbH, a company based in Hagen, Germany, produces MPT International 3 / 2015

foils used in particulate filters for cars. The 20-high reversing stand rolls stainless steel between 178 mm and 380 mm wide from an incoming strip thickness of 1 mm down to less than 0.025 mm. The strip is rolled from 2,500 m to a length of 20 km at the most. To this end, the asynchronous motor delivers a nominal torque of just 3.7 kNm at around 225 kW and 565 rpm in the lower speed range. There was a crash last year. Apart from breakage of the joint of the universal shaft, the gear coupling between motor and gearbox was also damaged. Enquiries were made with several coupling manufacturers. Delivery times would be more than ten weeks. A standstill of the entire plant for such a long period would have been extremely unsatisfactory. In addition, within the scope of the continuous improvement process in place at the company, a solution whereby such cases could be avoided in the future was sought. The suggestion to use a safety coupling came from German rolling mill manufacturer hpl Neugnadenfelder Maschinenfabrik. Yet these types of coupling are not standard stock goods that can be delivered off the shelf. hpl could help here with support of R+W Antriebselemente GmbH, a coupling specialist. A solution available at relatively short notice replaced the old gear coupling as shaft-to-shaft connection and at the same time fulfilled the function of an overload coupling. However, the design of the coupling is unusual. The model of the Torqset ST2/25 type is pre-set at 6,610 Nm and is combined with a torsionally elastic coupling. In contrast to a torsionally stiff coupling, this version requires a consider-

ably shorter delivery time. A torsionally elastic coupling in the main drive of a mill stand is surely unusual, frequently because of the required stiffness, but the elasticity in this place is negligible. The elastic compensating element of the selected coupling has a dynamic torsional stiffness of 230 x 10Âł Nm/rad. This means an angle of torsion of less than one degree in normal operation at around 3,700 Nm. It was not possible to reliably assess in advance whether this angle of torsion would influence the production result. Everyone concerned was aware of the risk. However, the prospect of being able to bring the rolling mill back into production several weeks earlier was worth the attempt to use this coupling. After three months of running in three shift operation with around 40 different strip dimensions per week, the coupling was inspected and appeared to be just as fresh as on the day of delivery. According to JĂśrg Giersbach, the technical manager of MK Metallfolien GmbH, the low angle of torsion generated by the elastic coupling had no negative effect on the result in production. R+W was able to deliver a safety coupling for the 2-high reversing cold mill of R. Mendritzki Kaltwalzwerk GmbH & Co. KG. There had occasionally been failures of the universal shafts in the past due to production-induced overloads. Steel for widely differing industries is being rolled in the Bochum rolling mill plant. The max. 300-mmwide material is rolled with an incoming thickness of 10 mm down to 0.5 mm at a speed of 150 m/min. According to production manager Waldemar Steier, the coupling has already disen-

HOT ROLLING gaged a few times and has thus paid for itself several times over. The coupling of the Torqset ST4/10 type is a safety coupling integrated in a gear coupling with minimal backlash. In addition the customer received at its request an integrated brake disc for the existing parking brake.

Functional principle Naturally the Torqset ST couplings can be used not only in reversing

stands. Their use is justified in all machines in which components in the drive train must be protected in the case of overloads. Drive and the electrically driven side of the coupling are engaged by ST safety elements. Inside these ST safety elements, a ball, one half of which protrudes from the element and sits in a detent on the other side of the coupling, is pre-stressed axially by disc spring packs. Once the circumferential force acting on the ball reaches a certain torque, the ball slips

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into the safety element and the coupling is disengaged within a few milliseconds. To re-engage the coupling, it has only to be turned into the correct position and a slight axial force must be applied to the safety element, e.g. by striking with a mallet or by the leverage of a crowbar. The Torqset couplings are available in different sizes and are of modular construction. If required, the preset disengaging torque can subsequently be adapted to the application any time.

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Trust a partner who knows the steel industry from the inside. Contact our experts today. quakerchem.com info@quakerchem.com

MPT International 3 / 2015

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş COLD ROLLING

Cold rolling mill designed for the production of high-quality steel strip for automotive application Chinese steel producer Tangshan Iron and Steel Group Co. Ltd. has brought into production its new cold rolling mill. It consists of a coupled pickling line/tandem cold mill (PLTCM), a continuous annealing line and a galvanizing line. Each individual plant unit is linked to an integrated automation system. The new cold rolling mill of Tangshan Iron and Steel Group Co. Ltd., was constructed at the Tangshan site in Hebei province, China. It has now been brought into production and the first coil was rolled in January 2015. The new rolling mill consists of a coupled pickling line/tandem cold mill (PLTCM), a continuous annealing line and a galvanizing line. Each individual plant unit is linked to an integrated automation system. This enables high availability and output to be achieved while maintaining consistently high product quality. The rolling mill has an annual capacity of 1.8 million t of high-strength cold strip and will produce high-quality steels for the Chinese automotive industry. Tangshan Iron and Steel intends to enter this demanding market. The order was worth more than 100 million euros, and was received by a consortium led by Primetals Technologies in the second quarter of 2013. New cold rolling mill at Tangshan Iron and Steel

Mechanical equipment Primetals Technologies designed and supplied the mechanical, electrical and process equipment for the cold rolling mill. The PLTCM mill consists of five 6-high rolling stands, enabling extremely high-strength steels to be rolled within tight tolerances. SmartCrown rolls and special actuators and control systems ensure that the finished products have the required flatness. The en-

Primetals Technologies, Ltd., a joint venture of Siemens, Mitsubishi Heavy Industries and Partners; London, UK Contact: www.primetals.com E-mail: rainer.schulze@primetals.com

MPT International 3 / 2015

try thickness of the strip ranges from 1.5 to 6 mm, and this is rolled down to a final thickness of between 0.2 and 2.5 mm. The line produces strips with widths ranging from 700 to 1,600 mm. Accordingly, both, the continuous annealing line and the galvanizing line process strip steel with the same thickness range and widths. The furnaces for the continuous annealing line were provided by Selas Andritz, Paris, France. The welding machines were supplied by Hugo Miebach GmbH, Dortmund, Germany. The PLTCM, annealing and galvanizing lines have a common, integrated automation system, comprising basic automation (Level 1) and process automation (Level 2), as well as process models developed specifically for cold

rolling mills. This enables all the plant units to be coordinated precisely with one another, which ensures high availability and output, while maintaining consistently high product quality. Primetals Technologies was also responsible for supervising the installation and commissioning of the cold rolling mill. Tangshan Iron and Steel is part of the Hebei Iron and Steel Group. With an annual production of almost 46 million t in 2013, it is the largest steel producer in China. The Tangshan production site has been in operation for 70 years. In recent years, Primetals Technologies had previously supplied an AOD converter, a vacuum decarburization plant and a continuous galvanizing line to Tangshan, and also coupled the tandem cold rolling mill to the existing pickling line.

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New process increases pickling speed and reduces length of pickling lines A new process based on spray pickling modules, will allow the removal of scale from the strip surface much more effectively than in conventional turbulence pickling lines. Thus, carbon steel strip can now be pickled in markedly less time, and newly built pickling lines can be designed with a shorter length. Moreover, it will be possible to easily adapt WKH SLFNOLQJ SDUDPHWHUV IURP FRLO WR FRLO DQG PD[LPL]H OLQH Ć&#x192;H[LELOLW\ Pickling lines are more and more often becoming bottlenecks in the production chain, limiting the capacity

of the entire works. When processing todayâ&#x20AC;&#x2122;s advanced steel grades, production process parameters become

tially reduces the required duration of exposure. This makes it possible to process even steel grades that are more difficult to pickle at a much higher speed than before. Compared to conventional turbulence pickling, spray pickling achieves an equivalent surface quality in far less time. In laboratory tests, the pickling time, for example, for the 1.1231 grade was reduced from 55 to 14 seconds, for the 1.8159 grade from 39 to 18 seconds and for IF (interstitial free) steel from 33 to 10 seconds. In many cases it will now be possible to pickle many steel grades at a much higher speed. In other cases, where pickling at an acceptable speed has not been possible so far due to restricted lengths of the existing pickling tanks, this will now become feasible.

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MPT International 3 / 2015

increasingly complex â&#x20AC;&#x201C; and pickling thus more difficult. Some operators of turbulence pickling lines face the necessity to dramatically reduce the process speed in order to allow the acid to act long enough on the strip surface. The spray pickling technology developed by CMI Industry Metals substan-

Newly built pickling lines integrating CMIâ&#x20AC;&#x2122;s spray modules will require much less space than conventional turbulence pickling lines. Modernizing existing lines with the spray pickling technology will allow for much higher strip speeds. At the same time, the temperature of the pickling liquor can be reduced. The new, patent-pending technology consists of several nozzles arranged across the width of the strip. These nozzles spray the acid onto the strip surface from above and below with high pressure. This approach adds a mechanical effect to the chemical processes taking place during pickling. The impinging acid jet alone allows for the removal of an important part of the scale adhering to the strip surface.

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3D view of the spray module

The process also increases the contact intensity between the acid and the strip surface: While the laminar and turbulent boundary layers occurring during conventional so-called turbulence pickling result in a shielding effect on the steel surface, these interfaces are broken up whenever a jet of pickling liquor impinges on the strip surface.

%QORCEV JKIJN[ GHĆ&#x201A;EKGPV URTC[ RKEMNKPI OQFWNGU Inside the spray pickling modules, several spray headers are arranged above and below the strip. The pickling liquor is ejected from the nozzles at high speed with pressure of one to three bars. A typical spray module is only about 8 m long. The length of newly built pickling lines can be reduced from about 80 m (typical length of a conventional turbulence pickling line) down to below 50 m. This also reduces the requirement of workshop space. Due to this short length, there MPT International 3 / 2015

is no need to have any strip guides inside the modules, which may otherwise damage the strip surface. The spray modules are arranged in cascades within the pickling tanks. In each cascade, the strip first runs through the spray module, where intensive scale removal takes place, and then through a pickling tank, where the strip surface is homogenized. With a length of approximately 16 m, every individual cascade is much shorter than a turbulence pickling tank of the same capacity. At the end of the line, the strip runs through a rinsing tank, as in conventional pickling lines. By combining spray pickling modules and pickling tanks in a specific way, this process opens up numerous new possibilities. CMI designs the modules according to customerâ&#x20AC;&#x2122;s specific optimization target â&#x20AC;&#x201C; for example, minimized line length, maximized capacity, minimized energy consumption or a combination of various targets. The options vary from the installation of just one spray

module at the line entry to a layout with several cascades of spray pickling modules and pickling tanks arranged in series.

/QFGTPK\CVKQP ECP DQQUV RNCPV ECRCEKV[ D[ RGTEGPV In addition to the construction of new lines, upgrading existing lines has become an increasingly important issue, especially against the background of the growing number of innovative, difficult-to-pickle steel grades. Whereas in the past, the modernization of pickling lines was basically limited to the replacement of the pickling tanks, the introduction of spray pickling now provides a fundamental improvement to the process in terms of superior pickling performance and flexibility gains. If the modernization target is to maximize the capacity while retaining the existing space, the strip speed may be increased from about 180 m/ min to 300 m/min through spray pick-

STRIP PROCESSING

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ling. In this case, the line would have about the same length as a traditional turbulence pickling line, but an almost 70% higher throughput.

*KIJ ƃGZKDKNKV[ VQ RTQEGUU C XCTKGV[ QH UVGGN ITCFGU The spray pickling technology also increases the flexibility in the operation of pickling lines. In conventional turbulence pickling lines, adjusting the pickling parameters is basically limited to the possibility of changing the strip speed. With spray pickling, it is now also possible to vary the pressure of the frequency-controlled circulation pumps within wide ranges or even switch off individual modules. This enables the pickling line to be set to optimal conditions for different steel grades in a very short time – even from one coil to the next. The new process also makes it possible to pickle at lower temperatures than in the past, with the positive effect of saving energy costs. Lowering the liquor temperature, for example from 90°C to 70°C, can save more than 20% of those costs. Moreover, spray pickling requires much less process liquor than conventional turbulence pickling. Accordingly, the quantity of liquid to be heated is smaller. A spray module contains 6 to

Spray pickling technology (left) requires only about one third of the liquor volume of a turbulence pickling line

8 m3 of pickling liquor, i.e. only about one third of the liquor requirement of tanks in conventional turbulence lines with comparable capacity.

(KTUV GZRGTKGPEG RKEMNKPI VKOG TGFWEGF D[ RGTEGPV CMI installed the first spray pickling line as part of a modernization project. The line, which features two short spray modules arranged in a triple pickling cascade, has been in op-

eration since September 2014. First results demonstrate a cut of the pickling time for IF-DDQ grades (interstitial free, deep drawing quality) by more than 15% and for IF-EDDQ grades (interstitial free, extra-deep drawing quality) by more than 30%. Exploiting the full potential of the process by installing several cascades of spray modules and pickling tanks in series may reduce the pickling time to less than 70% of usual turbulence pickling times.

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6JG PGY DCVEJ CPPGCNKPI RNCPV CV $KNUVGKP EQORTKUGU VYGNXG DCUGU CP[ JQQF Ć&#x201A;VU QP CP[ HTGG DCUG

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Dr. Peter Wendt, LOI Thermprocess GmbH, Tenova Group, Essen, Germany; Gerald Zwickel, Bilstein GmbH & Co. KG, Hagen, Germany; Heiner Witke, Kranbau KĂśthen GmbH, KĂśthen, Germany Contact: www.tenova.com E-mail: Peter.Wendt@tenova.com

MPT International 3 / 2015

plier of cold rolled flat steel products. The production is based on most advanced, computerized manufacturing facilities. Diligently coordinated process steps ensure the production of cold strip products of top quality. Bilstein can guarantee that all steps of the manufacturing chain â&#x20AC;&#x201C; from the receipt of the material down to quality control â&#x20AC;&#x201C; are perfectly harmonized. A zero defect strategy calls for perfect and reliable process and quality control in areas where the degree of automation is very high. This target is

achieved by ensuring uninterrupted monitoring and documentation of all defined process parameters. As part of a project aimed at increasing the capacity of its cold rolling mill in Hagen-Hohenlimburg, Bilstein has installed a new batch annealing plant. During the design phase of the plant, the key focal areas were the achievement of excellent annealing results, efficient energy use and low operating costs. Heated-up coils still contain approximately 70 percent of the energy input required for the heating to an-

STRIP PROCESSING nealing temperatures. This potential was to be exploited. No energy was to be input for cooling the coils after the annealing treatment in order to avoid that unused heating energy is released to the atmosphere. The idea was to exploit the energy contained in the coils in the best possible way. Furthermore, the entire annealing process was to be made highly reproducible by introducing automated processes a far as possible. These requirements eventually resulted in an automatic crane concept enabling the coils, hoods and intermediate convectors to be transported with a constant high level of precision. This presented the manufacturers of both the annealing plant and the crane equipment with a great challenge because never before had such a solution â&#x20AC;&#x201C; automatic crane operations in a batch annealing plant â&#x20AC;&#x201C; been implemented anywhere in the world. Another objective was to design an annealing plant capable of meeting the future requirements for many years to come. As early as at this initial stage, the plant was designed for the future option to heat treat wide-strip coils with a specific ring weight of 23 kg/mm, outside coil diameters of up to 2,030 mm, strip widths of up to 1,350 mm and a maximum coil weight of 30 t. The maximum annealing temperature of 850Â°C would also make it suitable for new material grades.

A fundamentally new approach Bilstein involved LOI in the planning at a very early stage. LOI had already implemented several other successful projects at Bilstein. Therefore, the employees were familiar with the conditions at the rolling mill. For the issue of heat recovery, several alternatives were discussed. Measures like an enhanced insulation of the heating hoods or the recovery of waste heat from the flue gas would have provided only insignificant savings. Additionally, Bilstein deliberately decided against a solution based on the pairwise operation of two adjacent bases as this would have significantly restricted operating flexibility. The target was to implement a flexible mode allowing any heating or cooling hood to be used at any time and on any base.

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The intensive discussions with LOI eventually brought about the idea that it would not be appropriate to consider the energy balance of the annealing shop separately, but to take the entire works into account. The fundamentally new aspect of this approach was that the excess energy would be decoupled as part of a comprehensive energy management system and made available to other energy using units within the works either as electricity or heat. It was decided to use the Organic Rankine Cycle (ORC) process to convert the heat into electric power. When this decision was made, the process had already proven its efficiency in first prototype applications, however, not in batch annealing plants. This presented those involved in this project with a new challenge. For the project at Bilstein, annealing furnaces featuring the LOI-developed bypass cooling equipment were chosen. In these fur-

naces, the heat is extracted from the coils and transferred to a thermal oil by means of hydrogen. The oil, which attains temperatures of up to 270Â°C, is an ideal medium for evaporating ethanol in an ORC plant. Additionally, warm water is decoupled at different stages of the process and appropriately used for different purposes within the works. Thus, Bilstein pioneered the use of excess heat at different â&#x20AC;&#x201C; partly fairly low â&#x20AC;&#x201C; energy levels. Comprehensive calculations showed that this concept would be sustainable and, once implemented, would not result in any loss of capacity. Kranbau KĂśthen GmbH conceived the solutions for the fully automatic handling of coils, hoods and convectors, which due to the use of hydrogen had to comply with the high safety standards required for the transport of loads with a higher risk potential. LOI MPT International 3 / 2015

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and Kranbau KĂśthen GmbH received the order in 2011. Currently, the new plant anneals hot and cold-rolled medium-wide strip coils weighing up to 15.4 t. The outside coil diameters range between 1,000 and 2,000 mm. The coils are 150 to 650 mm thick. The natural-gas-heated LOI batch annealing facility comprises twelve bases with six heating and six jet cooling hoods.

about three times larger than the previously usual size. Another key feature of the new annealing plant is the automatically controlled hydrogen purging programme, which optimizes the hydrogen flow in order to always obtain a uniformly clean strip even if there are varying stack heights. The energy recovery during cooling takes place in two steps. First, hydrogen between 700 and 350Â°C hot is

Electricity and heat for the works The annealing plant can handle stack heights of up to 5,600 mm. Twelve special burners are used at each heating hood. The annealing bases operate with a 100-percent hydrogen atmosphere as inert gas. They are equipped with a bypass cooling system. The average hourly annealing rate of the bases at a delta T of 30 K amounts to 2.82 t. In order to reduce the fuel consumption in the heating hoods, LOI preheats the combustion air to about 600 to 650Â°C by means of recuperators. In conventional plants, the combustion air temperature is usually between 300 and 400Â°C. The recuperator surface is MPT International 3 / 2015

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extracted from the hood. In a special bypass cooler (gas/thermal oil), the hydrogen heats the thermal oil to a maximum temperature of 270Â°C. The heated thermal oil is guided through a ring

line. In the downstream ORC process, the ethanol evaporates. A reciprocating piston expander generates electricity. Bilstein uses these piston-type machines â&#x20AC;&#x201C; modified truck engines with a connected generator â&#x20AC;&#x201C; instead of gas turbines because they operate highly efficiently over a broad operating range. Another reason is that the cooling water leaves the machine at a temperature of approximately 70Â°C. Therefore it can also be fed into the heating circuit. If during the cooling process the gas temperature falls below 350Â°C, water is decoupled into a second bypass cooler (gas/water) and fed into a secondary circuit at a temperature of about 80Â°C. This secondary circuit is connected to a system of ring pipes which supplies the high-bay racks and the air curtains at the doors to the bays as well as the tanks holding the emulsion, which must be kept at a constant temperature of about 50Â°C.

Automatic crane operation The annealing plant is the first in the world to operate with automated crane movements. Only one person

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is needed to monitor the crane operations from the control room. There is no personnel within the operating range of the crane. The two-beam overhead travelling crane built by Kranbau KĂśthen GmbH transports the coils, convectors as well as the heating and cooling hoods. Equipped with two lifting hoists with payloads of 50 and 28 t respectively, the crane spans 32.8 m. This payload allows it to lift coils of up to 1,350 mm width in the future. Redundant, two-channel absolute position encoders determine the positions of the crane, the trolley and the lifting gear. Displacement transducers measuring the crane travel are arranged on both sides in order to immediately recognize and correct any misalignment of the crane. The high precision of the transducers allows them to determine the position of the gripper with a tolerance below +/- 15 mm, taking into account all influences from the crane travelling movement, the trolley and the lifting hoist. The swing damper is a camera-guided system. The camera focuses on a hairline cross on the gripper. The crane control system takes into account the different centres of gravity of the loads. Coils are very heavy and their centre of gravity is halfway down. Heating hoods, however, are much lighter with their centre of gravity much lower. LOI took account of the automated crane operation by modifying the design of the bases to the effect that they are hydrogen leak-proof under all circumstances. The automatic gripping tongs feature different tools allowing them to lift equally and securely the coils, the convectors and the different types of hoods. As the system works without any intervention by man, the tongs feature sophisticated sensing equipment, such as distance and tilt sensing devices as well as laser light sensors for controlling the gripping operation. An RFID antenna receives signals containing the hood numbers sent out by RFID chips installed in the hoods. In consideration of the fully automatic crane movements above pressurized hydrogen pipes, the crane features a full range of advanced safety equipment. The drive systems for the travelling and lifting movements feature two drives each. This ensures safe continuation of operation at half speed â&#x20AC;&#x201C; MPT International 3 / 2015

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and thus permanent availability of the system â&#x20AC;&#x201C; should one of the drives fail. Each lifting gear contains two rope systems. Should one rope break, the second one will be available to carry the full load. The winding drums feature brakes for an emergency stop in case the driving gear breaks. These brakes act directly on the shoulder ring. They will be instantly actuated in the events of excessive speed, impermissible speed differences or deviations from nominal values. The plant complies with all requirements stipulated in the applicable regulations, for example in DIN EN 13135. The entire annealing shop area is surrounded by a protective fence containing nine protective doors. One person in the control room operates and monitors the complete plant. The control room is situated eight metres above the floor, providing an optimal view over the entire annealing shop. The actual loading stage of the annealing bases is visualized on monitors. The plant control system is linked with production data acquisition systems of Bilstein and LOI. It coordinates the transport and storage of the coils, hoods and convectors. The integrated warehouse management system assigns storage places to the coils. It generates and sends the corresponding travel orders to the crane control system. In doing so, the warehouse management system takes into account storage rules, such as the maximum stacking height, and performs plausibility checks.

The coils are delivered from the rolling mill. When the coils have been unloaded, an operator scans the coil bar code by means of a manual device. The crane automatically takes the coil to its storage place. Then the empty annealing bases are loaded. Coils and convectors are stacked in an alternating sequence. At the end, the hoods are placed over the stacks. LOI has employed a multi-media coupling, which automatically establishes all connections for the gas supply (natural gas, hydrogen and nitrogen) and the electrical signals.

Positive rĂŠsumĂŠ The rĂŠsumĂŠ after two-and-a-half years of operation is positive in every respect. The initially set targets have been met. Plant operation is trouble-free. All automated crane operations have proved highly reliable. No coils have been damaged as a result of the automatic operation. There are only very few exceptional cases in which the crane is operated manually. In order to obtain reliable information about energy use and associated costs, Bilstein uses the software package MESSDAS to monitor the energy management. For detailed analyses, the software acquires values such as consumption data for hydrogen, nitrogen and natural gas as well as the heat rates. Fuel consumption of the annealing shop is about 11 percent lower than in the case of a conventional design. While the energy requirement of con-

STRIP PROCESSING

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ergy as a result of heat decoupling. The additional electricity consumed by the heat recovery equipment amounts to just 21,000 kWh. A â&#x20AC;&#x153;hotâ&#x20AC;? inert gas outlet in the annealing base has been specially designed for this application. This solution extends the intervals required for cleaning the flanges at the bases. During the more than two years of operation, it has not yet been necessary to clean the flanges or replace any seals. From the outset, Bilstein has planned the new annealing shop and the entire infrastructure with a future expansion by additional bases in mind. Starting in July 2015, four more bases will be added to the current 12-base plant. Additionally, it is planned to transport the coils in conjunction with the intermediate convector plates in order to halve the number of crane movements.

in the basement

ventional plants is usually about 180 kWh/t, the new plantâ&#x20AC;&#x2122;s energy use has been reduced to about 160 kWh/t. The plant achieves the energy efficiency promised by LOI without compromising on capacity. Three percent of the recycled energy is converted into electricity, 55 percent into thermal energy for other heat consuming units at various places in the works. The recycling rate amounts to about 58 percent, corresponding to a

39 percent increase in energy efficiency. Per charge, the ORC plant generates approximately 300 kWh electricity. In total, 5,300 kWh of thermal energy are obtained from the decoupling of heat. Since the new plant was built, Bilstein has saved approximately 350,000 euros on electricity and natural gas costs per year. The evaluation of the heat meters has shown that, alone in 2014, Bilstein was able to recover 1.5 million kWh of en-

Conclusion The new batch annealing plant at the Bilstein cold rolling mill is the worldâ&#x20AC;&#x2122;s first featuring automatic crane operation. Its innovative heat recovery concept and energy management also make it the most energy efficient plant of its kind in the world. During cooling, it recovers energy from the hot coils and generates electricity and heating energy for other units in the works.

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MPT International 3 / 2015

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Strip guiding technology in furnace atmospheres using ultra-wideband radar technology Detection of strip position is the absolute crucial element for all strip guiding solutions. Traditionally this task is performed either with optical, capacitive or inductive sensors. EMG has a track record for stable sensor solutions also for furnaces and high temperature applications up to 1,100°C. The latest generation of EMG’s technology portfolio for furnace solutions is based on the so-called Vivaldi antenna technology. Vivaldi antennas are co-planar antennas with ultra-wideband characteristics. With EMG-Vivaldi® the current limitations of radar, capacitive or inductive sensor solutions for furnaces could be overcome. The new sensor is located outside the furnace atmosphere and measures through the furnace wall in a certain wavelength region of the radar spectrum. It focuses on the edge of thin metal strips (gauges > 0.1 mm) through a non-conductive/non-metal and gas-tight isolation of the furnace wall. Therefore costly cooling of sensors inside the furnace is not necessary. The furnace wall is completely closed and the strip can never hit or damage the sensor itself. Another important feature is the easy calibration based on simple reference measurements. The system is maintenance-free and promises therefore very low costs of ownership. The results of one of the first installations at California Steel, USA, show the EMG-Vivaldi® technique can also replace older systems, in a riskless and comparatively easy manner: “The installation was easy and accomplished on schedule. System set-up was coordinated well by EMG personnel and the steering control was excel-

EMG Automation GmbH, Wenden, Germany Contact: www.emg-automation.com E-mail: nicol.otterbach@emg-automation.com

MPT International 3 / 2015

EMG-Vivaldi® sensor box

lent from the very beginning,” says John Wray, senior engineer at California Steel Industries. “The system has been operating very well – without any issues since the installation in 2013.” EMG Automation GmbH, a company of the Elexis group, belongs to the leading suppliers of regulation systems as well as quality assurance in automated manufacturing processes. Fields of application are fast running continuous production processes in the metals industries, especially in the steel industry. The product portfolio includes, besides quality assurance systems, strip running regulators.

Conclusion EMG-Vivaldi® represents the newest generation of EMG strip guiding sensors for application in harsh environments, like high temperature annealing furnaces. It utilizes ultra-wideband radar technology for a sensor solution enabling the strip edge detection through gas-tight furnace walls. By that it realizes a long-held dream of strip position measurement in continuous annealing furnaces without interfering the furnace atmosphere or the furnace geometry. In the meantime various industrial projects e.g. at California Steel, ThyssenKrupp Steel, ArcelorMittal and others proofed the industrial robustness and accuracy of EMG-Vivaldi®.

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Automated coil handling at slitting lines hpl-Neugnadenfelder Maschinenfabrik developed the “Coil-Hover“ – a coil handling system that accelerates stowing of coils after slitting. It minimizes the risk of damages when coils are moved from the turnstile to the storage area. The largely automated operation also reduces personnel costs. The new Coil-Hover is designed for the handling of coils with an outer diameter of up to 2,000 mm and a width of up to 300 mm. It largely automates the separation of coils and their take-over from the turnstile as well as their tilting, strapping and further transport to the storage area. Thomas Pieper, sales manager at plant manufacturer hpl, explains the extraordinary name: “The new system is named Coil-Hover, because all the way to the strapping tables and storage area the coils are indeed hanging under the swivelling table. Their transport from one station to another bears practically no risk of damage to the material – they seem to be floating coils.” hpl-Neugnadenfelder Maschinenfabrik will launch the new handling system at the upcoming METEC 2015 trade fair in Düsseldorf, Germany in June. The core of the system is a swivelling table on slides, which supersedes

Thomas Pieper, hpl-Neugnadenfelder Maschinenfabrik GmbH, Ringe-Neugnadenfeld, Germany Contact: www.hpl-group.de E-Mail: info@hpl-group.de

MPT International 3 / 2015

The swivelling table on slides moves the split rings to the strapping table

the commonly used crane. Coils are just held under this table by a vacuum or magnetic force applied on the coil, thus no crane hooks or rollers are needed for transportation. A single person is required for the complete handling after the strip has passed the slitting line. For taking the split rings away from the turnstile, the Coil-Hover positions the swivelling table in front of the first ring. After the integrated spreading tools have contact with the inner coil core, the suction zones – in case of ferromagnetic strips the magnets – are activated. The split ring is then tightly clamped allowing the coil to be lifted by approximately 10 mm and taken away from the turnstile.

The split rings are turned 90° by means of hydraulic cylinders while being transported to the strapping tables. The coil is “floating” under the swivelling table in this position – only held in place by a vacuum or the magnets. After reaching the strapping table, the coil is put down and strapped. Afterwards, it is taken up by the Coil-Hover and placed on a lift table which is then leaving the line area. Ferromagnetic strips are held on the swivelling table by fail-safe electro permanent magnets. These magnets feature a floating bearing allowing even the transport of curved coils. They reach holding forces up to 5 t. For the handling of non-ferromagnetic strips, the swivelling ta-

STRIP PROCESSING

ble is equipped with an aluminium suction plate with several suction rings holding the split ring securely in place. Depending on the diameter of the split ring to be handled, the according suction rings are automatically put into operation. Even for split ring diameters of 1,300 mm, the suction plate provides a holding force of 2.5 t.

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The system is of modular design and can be individually extended and adapted. Up to 60 split rings per hour can be handled using the version with two Coil-Hovers and two strapping tables. One transport skid is travelling between the turnstile and two strapping tables, the other one between the strapping tables and the storage area.

Typical turnstile – here without Coil-Hover

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15 kW semiconductor laser machine for surface treatment of steel strip

Targeting steel surfaces LIMO is developing a 35 kW semiconductor laser featuring sophisticated beam shaping and high beam quality. Using this new laser system, the development project partners DLP DW LQLWLDWLQJ D QHZ W\SH RI ODVHU VXUIDFH WUHDWPHQW 7KH ODVHU ZLOO EH DEOH WR LQƃXHQFH WKH SURSHUWLHV RI VWHHO VWULS VXUIDFHV LQ DQ HQHUJ\ HIƂFLHQW ZD\ ThyssenKrupp Steel Europe, the researchers of Fraunhofer Institute for Materials and Beam Technology, and LIMO Lissotschenko Mikrooptik GmbH have initiated development work on a new laser technology which the partners are planning to use for the improvement of properties of steel strip surfaces. The collaboration is part of a research project funded by the German Federal Ministry of Education and Research (BMBF) and scheduled to be completed by 2017. LIMO Lissotschenko Mikrooptik GmbH, a leading company in laser beam shaping, launched its largest joint research project so far in November 2014. The company will contribute 3.6 million euros to BMBF’s “OSLO” project. This project name is an acronym and stands for the German meaning of “surface-functionalized steel strip ma-

Jens Meinschien, LIMO Lissotschenko Mikrooptik GmbH, Dortmund, Germany Contact: www.limo.de E-mail: m.singermann@limo.de

MPT International 3 / 2015

terials using laser surface treatment in a continuous wide-strip process”. The Fraunhofer Institute for Materials and Beam Technology (IWS) focuses on application-oriented research and development. Together with flat steel producer ThyssenKrupp Steel Europe (TKSE) and Dortmund-based LIMO, they will be researching how the properties of ferrous steel strip materials can be influenced in a targeted manner by laser surface treatment in a continuous in-line wide strip process. In order to provide steel with better corrosion protection, for example, the laser will be able to uniformly heat the steel’s surface layers over the entire strip width. Thanks to the uniform heating, the alloying or surface melting process will in addition be extremely energy-efficient and environmentally friendly, since the laser only heats the surface, rather than the entire volume of the wide strip. The success of the OSLO project depends on the laser system and beam shaping unit for the short-time heat treatment of the coated steel strip. “To enable these types of short-time surface treatments, a laser system never before available anywhere in the world has to create a

length-scalable, uniform and extremely thin line of light,” says Jens Meinschien, vice president innovations management at LIMO. “To meet this challenge, we’re engineering a powerful 35 kW semiconductor laser featuring sophisticated beam shaping and high beam quality.” Using this new LIMO laser system, the OSLO project partners aim at developing a new type of laser surface treatment, and possibly making it technically mature for a series production. The laser system is scheduled to be used in the demonstration machine at TKSE in Dortmund, Germany. With a process speed of min. 50 m/min and strip width of 300 mm, the demonstration machine is simulating real-life production. “Under the moniker ‘photonics industry meets steel industry’, this collaboration between big industry, small business and research delivers a synergy effect that will help secure Germany’s role as a centre of steel manufacturing,” Jens Meinschein adds. “LIMO plans to use OSLO to expand its position as a manufacturer of light tools for large-area surface processing and is attempting to position itself as a longterm supplier of the steel industry.”

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148

››› ENVIRONMENTAL PROTECTION

A transparent venturi scrubber for testing performance improvement strategies To meet the newest environmental regulations, many existing gas cleaning systems have to be upgraded. SMS group and the University of Nottingham have developed a full scale test rig to better understand the physical phenomena inside the throat section RI YHQWXUL VFUXEEHUV ([SHULPHQWDO ƂQGLQJV KHOS WR GHULYH PRGLƂFDWLRQV WR LPSURYH HIƂFLHQF\ %?Q kMU

Dust collection from off-gas in a venturi scrubber is a complex phenomenon that numerical models are not able to capture accurately in its physics. Therefore, the decision to study the involved effects via experimental means was straightforward. A test rig was constructed at industrial scale in a university laboratory. The idea was to investigate the limiting factors for grade separation efficiency of microscopic particles contained in the gas exhaust from steelmaking plants. In the years before, research has concentrated on defining the limits of scrubber separation efficiency. There are experimental data available as well as observations at lab scale and data from industrial scale operations. However, there are still questions remaining about whether the less obvious characteristics of a venturi scrubber can be pursued to offer improvements. Because each installation is customized in terms of capacity and the design of the respective steel plant, each scrubber’s geometrical configuration is unique and theoretical findings from literature regarding scrubber performance cannot be applied directly, but have to be adjusted to the local conditions of the actual scrubber investigated.

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Phong Bui, Volker Trappmann, SMS group, Düsseldorf, Germany; Barry J. Azzopardi, Ian McCarthy, Donald Giddings, University of Nottingham, UK Contact: www.sms-group.com E-mail: buit@sms-group.com

MPT International 3 / 2015

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ENVIRONMENTAL PROTECTION The transparent venturi scrubber presented here is an industrial scale installation. It visualizes the behaviour of the water in the gas flow. Tests on particulate collection show the effect of separate functions of the venturi in isolation. The test rig offers the opportunity to test industrial scale venturi scrubbers to see what is going on inside the highly turbulent and mixing water-gas stream whilst monitoring the effect of changes on the particle collection efficiency. Results are shown here of cross jet atomization and velocime-

Design and manufacture of the test venturi In steelmaking processes large volumes of off-gases are produced (in the order of hundreds of thousands of cubic metres per hour). Due to energy efficiency and environmental issues the exhaust gas, mainly carbon monoxide, from e.g. a BOF process (basic oxygen furnace) is being reused in the steelmaking process and therefore has to be cleaned from unwanted dust particles. Ultimately, particles in the order of micrometres

‹‹‹ 149

quiring an induction fan to draw the gases through the pressure gradient across the venturi, and water pumping to deliver in the order of 1,500 m³/h (s.t.p.) across the water pressure gradient. To reduce the pressure gradients and the required water rate could make operational cost savings, and improving the grade efficiency is increasingly stringently required by European authorities and respective national legislations around the world. A good description of the challenges for the Chinese iron and steel

Nozzles on one side of the venturi throat section

try and measurement of the droplets formed. The particle collection in the free air leaving the system is used to determine the grade separation efficiency. The scrubber is found to perform well at its current design point. From the observations of the behaviour in the rig, insights into optimization aspects for the SMS group venturi scrubber are readily apparent.

remain and usually a venturi scrubber removes this as far as possible using atomized water. The size is in the order of 15 m high, 2 m wide and having a convergence from 2 m down to tens of cm at the throat, producing peak gas velocity in the order of 100 to 250 m/s to atomize the water delivered to the throat. This process alone is energy and resource intensive, re-

industry now and in future was recently given by Zhang et al. [1]. The mixture of droplets with collected dust particles and the cleaned gas is directed after the diffuser section to a water droplet separator to remove all the water and the captured dust from the gas stream prior to being released to the atmosphere or to a gas tank. MPT International 3 / 2015

150

››› ENVIRONMENTAL PROTECTION

Improvement of collection GHƂEKGPE[ The physical effects of dust collection processes in a venturi scrubber have been described by previous research and are well accepted in the industry. These are listed here since their effects must be considered on the test rig. The incoming gas forms a turbulent gas flow; liquid jets in cross flow (LJCF) interact with the cross flow via liquid atomization with a very complex atomization liquid pattern of ligaments, bag formation, and large and small droplets; dust particles interact with the liquid. Available models in literature are based on spherical droplet and spherical dust interaction and neither the scrubbing liquid droplets nor the dust are ideally spherical. Furthermore experimental tests performed by Mayinger and Neumann (in 1978) showed that a major part of the collection process is already performed before the liquid reaches the stable droplet size distribution [2]. The throat width is commonly adjusted by flaps in the throat which form a backwardfacing step in a multiphase situation. In 1972 Calvert conducted early experiments demonstrating the ability of a venturi scrubber to collect particles of size 1 μm and 0.75 μm [3]. In order to remove an increasing amount of the particles, it is generally accepted that increasing gas velocity and liquid to gas ratio will improve collection efficiency; but there is a question over whether this is sufficient to remove the particles beyond a limit, and at which point it becomes impractical to make improvements in this way. More recently, in 2013, Ali et al. demonstrated in a laboratory scale venturi scrubber that collection efficiency for 1 μm particles can be as high as 99.5% given sufficiently high gas velocity up to 200 m/s [4]. But the efficiency does not necessarily transpose on scaling to the industrial scale. Other researchers demonstrate laboratory scale tests of observation of atomization and dust collection in filter paper in an attempt to explain the operation and to make improvements on operation. For full scale validation a full scale test rig is required providing conditions which closely resemble full operation conditions. The test rig design is based on dimensionless groups in order to match test rig to a full scale plant. MPT International 3 / 2015

It is important to maintain similarity of the following dimensionless characteristic numbers. Reynolds number (Re) represents the scale of inertia to viscous forces for both the liquid jets and gas stream. Weber number (We) is important where there is a boundary between liquid and gas, and it registers the ratio of inertia to surface tension force. The momentum ratio of the liquid jet and the gas stream is expressed by the ratio of their respective We, and it is important that this is the same between the test rig and the industrial installation in order to maintain jet deflection trajectory. The gas and liquid density ratio, although different must

Well balanced air and water rates

be assessed. The Ohnesorge number (Oh) is significant to maintain the liquid jet breakup regime/behaviour, and is the ratio of viscous forces to the combination of surface tension and inertia forces. Liquid-to-gas ratio must be the same in both cases and dust similarity must be ensured (density and size distribution).

Purpose of a laboratory venturi scrubber designed to industrial scale The industrial sized test rig developed by SMS group and The University of Nottingham is able to provide a fully optically assessable scrubber at full operation flow rates and offers a method of collection efficiency measurement for comparison of variable operation conditions and configurations. To improve the process it is necessary to find the physical limits of the collection efficiency at the scale of the industrial process; the process is accompanied by a highly turbulent multiphase (gas, liquid, solid particles) flow. The highly turbulent and optically dense twophase flow of water and gas provides a challenging environment in which to isolate the effects controlling dust collection. But a fully transparent version of the cross section of the full scale venturi scrubber can be isolated in the laboratory and inspected by laser visualization. High speed photography and dust collecting techniques can be applied to investigate the multi-dimensional characteristics of the flow.

Construction of a full scale laboratory venturi scrubber rig

Increased water rate at constant air rate leads to an impingement of a major part of the scrubbing water to the opposite throat wall

To devise a rig which demonstrates all the full scale characteristics of the industrial plant the following considerations must be taken into account: scaling of the gas flow rate for gas property matching between laboratory air and process gases; reducing the scale of the 3rd dimension so that only a proportion of the depth and therefore of the gas flow rate need to be considered; ensuring sufficient depth to allow proper representation of any water atomization characteristics; allowing full optical access for observations as the need arises; reducing the overall height of the installation, which can be considerable due to the slow expan-

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sion rate of the diffuser section. The plant has a rectangular cross section and for the lab scale only a relatively thin slice has been taken. To reduce the depth for laboratory observation, it is important to identify which characteristics of the 3rd dimension must be preserved in order to accurately record the behaviour of the dust capturing features of the complex multiphase flow, and what is the minimum that can be accepted. The larger the 3rd dimension, the more significant the costs become, not only the costs of construction and space management, but also of operation. With a multi-nozzle injection, whether it

istics. We believe that this can be done by considering film thickness and the requirements for laser visualization of the flows. The strategy adopted here was to surround a central, 2-D plane with the expected surrounding flows. Since there are usually opposing jets, a central jet with one jet on each side should represent the behaviour on the central plane well enough. Jets close to the wall will be subject to wall effects. A pair of water jets is placed at each side of the central plane. Given the high velocity of the jets, in the order of tens of m/s, the likelihood of the Coanda effect (the attraction of the jet to the wall due to recirculation created near

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Side view of cross nozzles

be in a circular cross section or a rectangular cross section, there must be a minimum number of nozzles acceptable to demonstrate the flow characterMPT International 3 / 2015

the wall) will be negligibly small on the jet atomization as observed during tests. The boundary layer is likely to grow as for a flat plate, and over the

region of atomization and particulate capture, is negligibly thin. The film thickness is therefore the only reasonably risky aspect of having a reduced 3rd dimension. But with careful consideration of nozzle design and observation of the order of magnitude of film formation, this effect can be reasonably assessed during testing. This thin version of the plant allows significantly reduced flow rates of water and air compared to the industrial plant. The entire venturi scrubber is constructed in acrylic sheet so that atomization of the jets into droplets can be clearly seen. FEM simulations have been performed to find out the strengthening requirements for the pressures experienced in operation. The diffuser section has finished the work of capturing particulate by the time the atomization process is completed; this stands to reason since by this stage the droplets and the particulate will be travelling at very nearly the same velocity and so interaction opportunity is greatly reduced. Therefore since the pressure recovery rate can be indicated by a reduced length, the rig was installed with only approximately one third of the length of the industrial plant. The cyclone separator is required to extract most of the water from the air flow in order to eject the air to atmosphere via the fan, silencer and extraction duct. The design was made corresponding to established practice, but with a significantly reduced cone section. Although the cone section height reduction results in a poorer droplet separation efficiency the benefit from making the overall rig height less was necessary, and in practice, only a small proportion of the injected water is lost to atmosphere. The cross section jets are supplied from a manifold liquid distribution unit to guarantee a uniform exit velocity for all nozzles from the water pump, which was devised to produce as little pressure drop in the water line as possible. With standard pneumatic-type push fittings and nylon semi-rigid hosing, the water supply nozzle diameter can be quickly changed. The attachment of different nozzle diameters is made possible by a replaceable insert in the throat wall which can receive any diameter of tube up to 12 mm. The fan driving the air through the rig was a centrifugal fan with a 1.5 m

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Contents Complete index to companies, in alphabetical order by country Country-speciﬁc statistics, including key data from the steel economy (production, imports, exports) Company proﬁles (in alphabetical order): Company name/address, phone/fax, Internet/e-mail Management: Chairman, CEO Production plants Production programme Index to products Index of names

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diameter impeller. Gas flows of up to 2.1 m³/s and at pressures up to 20 kPa can be achieved and a total mass flux of water of 4 l/s at a pressure of 4 bar is available via a ground floor mounted pump which returns the water from the cyclone into the venturi.

Instrumentation The main investigation effort is applied via pressure transducer, high speed photography and particle image velocimetry (PIV) and by dust sampling. The pressure transducer used is standard 0 – 1 bar absolute with pressure taps at seven vertical positions in the venturi section of the rig. The high speed photography is done with a Phantom V4 high speed camera controlled by Dantec Dynamics FlowManager software, used with frame rates up to 2,000 frames per second with a screen size of 1 M pixel. A pair of synchronized high speed pulsed laser system from Litron lasers capable of 2,000 pulses per second of 15 mJ for 4 nanoseconds is used to obtain high speed PIV images. This system of high speed PIV is used with full field view and with a long range microscope lens to obtain images of the droplets formed by the atomization process in an aperture through the rig wall representing a 3 mm sided square section of the flow. Dust sampling was performed using a cascade impactor with a sampling rate of 2 l/min of air over a 10 s sampling time. The cascade impactor samples air which is drawn through a cascade of apertures with decreasing cross section causing an increase in air velocity; as the air passes through an aperture, a grease covered microscope slide is impacted by the air; any particles in the air which cannot turn out of the path and follow the air at the velocity leaving the aperture are caught on the slide. The particles remaining in the air are carried through the subsequent aperture. The slides were then viewed on a digital imaging microscope and the images analysed for particle count and size.

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Jet atomization: droplets in the order of 15 to 100 μm

Nozzle characteristics Initial photography of the cross flow jets reveals the importance of ensuring correct gas and water flow rates. If the water rate is increased beyond the opMPT International 3 / 2015

Example of particle size analysis from the microscope analysis of the slides from the cascade impactor

ENVIRONMENTAL PROTECTION erating point, then the atomization and jet trajectory can be worsened. High speed PIV on the cross flow jets shows the initial jet instability close to the wall, followed by a wavy pattern in the jet as it starts to expand, and then finally the bag breakup of droplets and ultimate atomization. Complete atomization occurs within a very short distance after the nozzles, as expected from the literature. The amount of water impinging on the depth-wise walls was seen to be only little by a film in the order of less than 1 mm thick moving in the order of 3 m/s based on PIV measurements. The pressure profile registered an increase subsequent to the jets. A side on view also shows the impact of meeting staggered jets from the opposing wall of the throat of the venturi.

Atomization A long range microscope lens was used through an aperture in the side wall of 5 mm diameter to see the droplets formed by atomization. A very fine atomization was achieved of a single cross flow jet, over a length of approximately 200 mm. The jet has an obvious history of waviness in the jet which produces a wavy pattern of the atomized cloud of droplets as the distance from the nozzle orifice on the left increases. Droplet properties like velocity and size are not only relevant to the dust collection mechanism. The precise knowledge of these two values is of major importance for a well designed subsequent droplet separator. The location of the observations was on the upper right side limit of the jet atomization since the droplet population further into the cloud is far too dense to observe the individual droplets through.

‹‹‹ 155

Particle collection A small dose of test particles having a mass mean diameter of 7 μm and a minimum diameter of 1 μm was delivered into the venturi inlet. The cascade impactor drew air from the exhaust duct post-cyclone and sampled the dust from the air which had not been collected. The dust is so small that it follows the air stream if it is not separated by the water atomization process. The dust embedded in the Vaseline gel on the surface of the slide is difficult to see under normal illumination, so steps are taken to enhance the image and then a particle sizing algorithm is applied, which was compared to sampling by eye to check the method. The method was able to identify particles down to sub-micron sizes and was used to provide a relative measure of separation efficiency knowing the incoming size distribution and total mass and what remained on the slides.

Conclusions A full scale venturi scrubber test rig has been developed in a collaborative project between SMS group and The University of Nottingham; this provides: full optical access, pressure loss measurements of the venturi throat physical processes, i.e. liquid atomization process and gas flow pressure loss due to geometrical conditions; collection efficiency measurements which properly relate the impact of different settings. Nowadays, the latest generation of SMS Siemag venturi scrubbers already achieve exhaust gas dust concentrations of less than 20 mg/m³ (s.t.p.). The results obtained so far show that improvements in operation costs and overall collection efficiency to the existing configuration are possible.

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References [1] Zhang, S., Worrell, E., Crijns-Graus, W., Wagner, F., Cofala, J., 2014, Co-benefits of energy efficiency improvement and air pollution abatement in the Chinese iron and steel industry. Energy (78) p. 333-345. [2] Mayinger, F., and Neumann, M., 1978, Dust collection in venturi scrubbers. German Chemical Engineering, (1) p. 289-293. [3] Calvert, S., Lundgren, D., Mehta, D.S., 1972, venturi scrubber performance. Journal of the Air Pollution Control Association (22), 7, p. 529-532. [4] Ali, M., Yan, C., Sun, Z., Gu, H., Mehboob, K., 2013, Dust particle removal efficiency of a venturi scrubber. Annals of Nuclear Energy (54) p. 178-183. MPT International 3 / 2015

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End track-out and dust problems Dirty public roads and dust-contaminated air are tolerated less and less by legislators and the public. Wheel washing systems together with the recently introduced dust control cannons can offer a complete solution for an escalating environmental problem. For more than 25 years, the wheel washing systems by the Swiss company Frutiger have been at work in over 3,500 operations worldwide under the brand name MobyDick. Whenever contaminated trucks from industrial areas, construction sites, mines or dumpsites drive out directly onto the public roads, MobyDick wheel washing systems can prevent dangerous contamination from getting onto the roads and highways. As a further positive effect, pollution of the air by dust around the areas is also considerably reduced. A common area of application for wheel washing systems is the bulk industry like ironmaking sites, for example. In past years, Frutiger has successfully installed various wheel washing

mud onto the public roads. The problem is more even severe, because harbours are typically located near urban centres. Similar problems are also common in iron and steel works. The handling of incoming coke and ore creates mud and dust in the work area. Due to the high number of transports made by rail in the industry, Frutiger has also developed a washing system for rail freight wagons. As every site is different depending on the type of soiling, the number of trucks per hour and the spatial conditions, Frutiger offers an extended range of different MobyDick standard models, in addition to special tailor-made solutions with many aspects. A drivethrough system that is easy to use and

Dust control cannons Handling large amounts of bulk material, coal, coke or ore and the influence of local winds can cause a general dust cloud above an area. This can cause serious health, environmental and political problems. Dust sources constantly vary in their type and scope; therefore, they require specific solutions. For this reason, in addition to its wheel washing systems, Frutiger, together with its Belgian partner Savic Engineering, offers a wide range of MobyDick dust control cannons and complete dust control strategies for the steel, mining, bulk handling, recycling and construction industries. These range from small water cannons with a 10 m throw distance to big, pow-

Vehicle can pass through the fully-galvanized system at a

Wheels and the undercarriage are washed out using a well-

walking pace

arranged low-pressure nozzle pattern

systems in this sector. Harbours are a typical location, as large amounts of bulk material are on- and off-loaded from ships, stored and transported out using trucks. Material falling out of the wheel-loader buckets or from the conveyor belts contaminates the stocking area. From there, the trucks carry the

Frutiger Company AG, Winterthur, Switzerland Contact: www.mobydick.com E-mail: a.perret@frutiger.com

MPT International 3 / 2015

has very low maintenance requirements is usually recommended for the bulk industry. A typical washing process only takes 30 seconds, which is important given the unsteady amount of traffic in many bulk handling operations. After an incoming truck has automatically activated the washing process, the vehicle can pass through the fully-galvanized system at a walking pace and the wheels and the undercarriage are washed out using a well-arranged low-pressure nozzle pattern. The wash water remains in a closed circle and is constantly recycled for the next wash, minimizing water use.

erful versions with a throw distance of over 70 m. The water cannons produce fine water droplets in a sufficient quantity that are adapted to the dust source and the dust type. This allows optimization of water and energy consumption, and therefore, a significant reduction in operating expenses. Individual machines are available in different sizes and in many different configurations. Custom-made manual or automatic systems fully adapted to the specific situation in order to solve customers’ dust problems are also available.

MPT International

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Metallurgical Plant and Technology

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş TECHNICAL INNOVATIONS

Bearing-free magnetic encoders SPECIAL EQUIPMENT The bearing-free magnetic encoder series MAG, offered by Johannes HĂźbner GieĂ&#x;en is now available as a modular system. The flexible mechanical design makes it possible to individually adapt the encoder system to the installation situation on site. This provides a maximum of design freedom, as it will be possible to implement encoder solutions in situations where it is not possible to use standard encoders, for instance, to design extra slim encoders for confined spaces or with additional wide magnetic tracks for applications involving large axial shaft movements. The modular MAG system includes both incremental and absolute encoders. They provide the user with high-precision signals thanks to special multiple scanning technology. And in addition to special pulse-wheel constructions for high-speed ranges they boast robust mechanical properties and fastening elements designed for heavy-duty applications. The magnetic encoders are suitable for applications with shaft diameters up to 1,500 mm, with or without a free shaft end. This opens up new options for designers to create solutions, for example, for applications where there is a large

shaft diameter or no free shaft end available to attach the encoder. Moreover, systems with a split pulse wheel are ideal for retrofitting. The system is also optionally available with a speed switch as well as an integrated FOC transmitter for signal transmissions via fibre optic cables. Contact: www.huebner-giessen.com Modular magnetic encoder system

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Strain measurement device MATERIALS TESTING Designed to dramatically reduce errors from thermal and lighting variations, the advanced video extensometer AVE 2, introduced by Instron, conforms to the most rigorous testing standards, such as ISO 527, ASTM D3039 and ASTM D638. This second generation advanced video extensometer utilizes patented measurement technology for most accurate non-contacting strain measurement. The fully-integrated device easily adapts to the normal fluctuations of environmental conditions in the lab and is easily adapted to any testing machine on the market that uses a Âą10 V analogue input. The AVE 2 utilizes the real-time 490 Hz data rate while also achieving a 1-Îźm accuracy. Its versatility allows for testing under multiple environmental conditions and can be used for advanced strain measurement with digital image correlation (DIC). It measures both modulus and strain to failure of almost any material including plastics, metals, composites, textiles, films, bio-materials, and many more. Contact: www.instron.com

Video extensometer

Permanent marking of metals SPECIAL EQUIPMENT The FL Fiber Laser marking system developed by REA Jet applies high-resolution characters or machine-readable codes to metals and plastics. The system is consumable-free and low-maintenance. Typical applications include embossing and colour change marking (annealing) of metals, marking by using laser transfer foils as well as the marking of multi-layer films. The FL satisfies rising demand for direct part marking (dpm) of metal components. The high beam quality and energy density guarantee short marking times and excellent readability of even the smallest characters. Texts and graphics may be freely designed, the use of TrueType fonts and UTF-8 coding allows the display of international characters. The FL can also be integrated into existing production lines. The system meets the requirements of laser protection class 1 for installation into machines. 10, 20, 30 and 50 Watt lasers are available. No replacement of lamps or diodes is required. The system is operated by an intuitive, graphical user interface or via PC. The user can switch between two operating modes. In the pulsed operating mode the Device for high-resolution permanent marking codes are engraved. The continuous mode is often used for colour removal and the thermal annealing of metals. REA Jet offers a cross-device control concept with uniform interfaces for its laser and inkjet systems, enabling the operator to control several coding and marking operations with one instruction. Contact: www.rea-jet.de

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New alignment solution for vertical machines SPECIAL EQUIPMENT Aligning vertical-mounted machines such as pumps no longer demands a great deal of patience and expertise. Prüftechnik has just released vertiSWEEP®, a continuous measurement method that eliminates the need to stop the shaft rotation at fixed positions to take the necessary readings. This benefits maintenance engineers and operators of large pump installations where shaft rotation may be difficult to control. Unlike other common three-point methods in the market, vertiSWEEP® users only need to rotate the shaft once while the system automatically captures hundreds of measurement points. This guarantees best quality measurements in less time and with less effort. Contact: www.pruftechnik.com

Alignment system

Transformer technology for electric arc furnaces STEELMAKING The EAF SMARTrafo is a tailor-made transformer for electric arc furnaces used in steel production, namely for up to 1,700 V and up to 200 kA. The EAF SMARTrafo developed by TES Transformer Electro Service optimizes consumption according to the real plant needs. It consumes only when it is necessary, electricity is used better and maintenance services are reduced and simplified. The system efficiency has also been demonstrated by the

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MPT International 3 / 2015

TECHNICAL INNOVATIONS

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Multi-tonnage containers for electrical steel coils LOGISTICS A pilot project has been launched by NLMK to develop a new system of logistics at its main production site in Lipetsk: electrical steel coils will now be delivered in multi-tonnage containers. Compared to the use of railway cars, multi-tonnage containers allow halving transportation

costs. Using intermodal transportation without additional transshipment operations also minimizes the risk of damage in the process of transporting and handling the goods. Contact: www.nlmk.com

Drive concept for slag and clinker processing vertical mills DRIVE TECHNOLOGY As cement producers have different requirements for drives in vertical roller mills, the latest developments in the area of drive train technology offer a wide range of options. Especially in the case of higher mill outputs, cement producers nowadays frequently favour drive systems with multiple motors and gearboxes with milling force decoupling. In a cooperation with Loesche, gearbox manufacturer Renk has developed the Cope gearbox for Loesche’s clinker and slag mills. This gearbox offers a redundancy of up to eight motors at the motor end. As this power train retains the normal dimensions, the systems is also suitable for retrofit gearboxes in existing mills. The Cope gearbox is primarily available for mill outputs between 4,000 and 12,000 kW. With this drive concept, the companies offer a highly redundant innovative drive system for large and very large vertical mills. Contact: www.loesche.com

Dino Capitanio - AIC Founder

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aic@aicnet.it - www.aicnet.it

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Instrumentation for industrial laboratories ANALYTICAL EQUIPMENT The EchoLAB brand of Echord (Echo Research & Development) stands for tools and solutions for chemical, metallurgical and physical laboratories. The products include microscopes, hardness testers, machines for physical tests, equipment for sample preparation and technical furniture for the laboratory. EchoCONTROL is the brand summarizing instrumentation for industrial laboratories, process control and non-destructive testing. EchoLAB IM 500 BD is a high-end inverted metallographic microscope used for the observation and identification of the structure for metals and alloys and is widely used especially in metallographic laboratories. The IM 500 BD is a trinocular microscope using the EchoMET software for the analysis of metallographic samples. The software is userfriendly and includes over 70 metallographic examination modules for grain size, inclusions, size distribution, pearlite and ferrite content, graphite spheroidization, decarburization grade, etc. The SM 502 continuous zoom, stereo microscope is a model with an alloy cast square base and an arm allow-

ing a wide range of head movements also for large samples. Ring-type LED illumination makes it possible to use only reflected light for the analysis of opaque samples. Contact: www.echord.it Metallographic microscope

(MSDFQ@SDC ×THC process solutions A New Era In Technology ROLLTEX EDT (electro discharge texturing) machines for cold strip mill rolls

ROLLSCAN Surface and subsurface inspection equipment IRU Á DW SURGXFW PLOO UROOV

SCM Automated in-chain and off-line continuous caster measuring systems

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TUBE AND PIPE MAKING With their integrated fluid process solutions for tube and pipe making operations, Quaker contributes to the optimization of manufacturing processes in this sector. On the front end, Quaker provides fire-resistant hydraulic fluids, specialty greases, and hot forming and rolling lubricants for seamless pipe production. In welded tube processes, the corrosion preventives applied on incoming coiled substrate help optimize subsequent tube-forming operations. Further downstream, Quaker offers innovative metalworking fluids for pipe-threading applications and stringent finishing operations. At the back end, the coatings can be customized to meet increasing market performance demands. The fully-integrated tube and pipe product line includes Quakercoat®, low-to-zero VOC (volatile organic compounds) water-based and zero VOC UV coatings, and high-solids based varnishes which offer superior curing, adhesion and corrosion protection properties. The Quakercool® line of water-soluble, metal working coolants including soluble oils, semi-synthetics, true solution synthetics and synthetic emulsions that provide a wide range of performance capabilities such as corrosion inhibition, cleanliness, and chip handling to meet the customer’s requirements in metal forming and cutting operations. The Ferrocote® series contains temporary or longterm corrosion preventives formulated to be easily removed if needed through conventional alkaline cleaning or degreasing procedures, specifically developed to protect metal surfaces from corrosion for up to one year or more. Contact: www.quakerchem.com

TECHNICAL INNOVATIONS

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Mixing plants for zinc recycling RECYCLING Worldwide zinc consumption currently exceeds 10 million t. Recycling of zinc from scrap steel is becoming an increasingly viable alternative to extraction of zinc from ore. Recycling currently meets about 30% of the zinc demand. The Waelz process has been the standard technique for processing zinc-laden dust and sludge for many years. Recycling material containing zinc oxide is fed into rotary kilns up to 50 m in length, where it remains for four to twelve hours. At temperatures up to 1,200°C, the oxide in the material is reduced to zinc, which is in the gas-

eous state under these conditions. The zinc vapour reacts with the oxygen in the kiln atmosphere to form zinc oxide, which is captured as dust, as so-called Waelz oxide, and subsequently used in zinc production. The dust has to be processed with a carbon source to produce a stable granulate, and Eirich granulating mixers are used worldwide for that purpose. One system for a large producer of high-grade zinc and zinc alloy in Russia is ready for delivery, and engineering work for a second system was comContact: www.eirich.com pleted at the end of 2014.

Work roll grinding ROLLING MILLS A new roll grinding machine introduced by Heinrich Georg Maschinenfabrik works fully automatically in conventional and CBN grinding. The machine is designed for centre lengths of 5,000 mm, grinding diameters of up to 700 mm and roll weights up to 10 t. The grinding operation is characterized by the absence of vibrations or swing motions of the machine. Other benefits of the machine are short handling and machining cycles and a long lifetime. The headstock can be displaced as a whole with the fixed main axis and the displaceable counter part. Further design features include the hydrostatic bearing of the grinding axle and the grinding saddle, the very precise U-axis with a resolution of 0.01 μm and the U1-axis for exact horizontal roll alignment. The machine comes with advanced measuring and control equipment. Contact: www.georg.com

Complete view of the grinding machine

MPT International 3 / 2015

164

››› TECHNICAL INNOVATIONS

Complete solutions for ring production METAL FORMING With a new ring-rolling mill for Electrostal in Russia, Siempelkamp has expanded its product portfolio by including additional production stages. The Russian steelmaker will be able to carry out the entire ring manufacturing process from melting of the metal via the production of the preforms through to the finished rolled ring by integrating two Siempelkamp plants into its production facilities. The new 200 MN closed-die forging press is the first of this dimension with an integrated tool heating system. This tool heating system keeps the upper and lower die at a constant 800°C between the forging operations. With the press Electrostal will manufacture, among other products, creep-resistant forgings with lengths of up to 1,200 mm and widths of 800 mm. Prior to delivering the closed-die forging press, Siempelkamp supplied a ring rolling mill for the downstream production process. The ring rolling mill, designed for maximum radial and axial pressing forces of 6,300 kN, was successfully started up in June 2014. The mill was initially designed to produce rings made of steel and special materials such as nickel-based, titanium, and aluminium alloys with a maximum diameter of 2,500 mm. During the testing phase at Siempelkamp’s workshop in Krefeld, the maximum diameter was extended to 4,000 mm; the maximum ring height is about 600 mm. The supply for Electrostal also includes the complete hydraulic system, the automation system as well as the newly developed SicoRoll control system. Siempelkamp is also retrofitting Electrostal’s existing 4,000 t open-die forging press. After the upgrade, the press

will be able to carry out closed-die forging in addition to open-die forging, making it a multi-functional press. As part of the retrofit, Siempelkamp will overhaul the water hydraulic control system of the press. After the upgrade, Electrostal will be able to achieve a +/- 1 mm tolerance with the movable beam during the pressing process. Contact: www.siempelkamp.com

Ring rolling

,NSNQR RODBHÖB@KKX CDRHFMDC ENQ RSDDK OK@MS applications DRIVE TECHNOLOGY On the basis of the Simotics 1LE1 motor platform, Siemens has developed industry-specific motors for steel plants. The ventilated Simotics DP steel plant motors expand the range of roller table motors and are specially designed for applications in the steel industry where they meet the high demands in terms of vibrations and shocks according to Class 3M4. Versions of these new motors are optimized for use with converters of the Sinamics S120 series and, as integrated drive systems, contribute to reliable and efficient operation. In network operation, the IE3 efficiency class ensures particularly high energy savings. The motors are available in 4- and 6-pole designs with shaft heights from 112 to 280 mm and in the torque range from 20 to 578 Nm. This range of motors comprises not only mains powered motors, but also versions optimized for converter operation with special insulation systems. When used together with the Sinamics S120 drive system, these motors form an integrated drive system that contributes to particularly dynamic and reliable production processes. Furthermore, operation with the Sinamics S120

MPT International 3 / 2015

converter enables group drives to be implemented with a high level of synchronization. Contact: www.siemens.com

Motor tailored to the requirements of steelmaking plants

TECHNICAL INNOVATIONS

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Fine dust extraction technology ENVIRONMENTAL PROTECTION Shougang Qian’An Iron and Steel has been placed an order with the SMS group to retrofit the steelworks with three hydro-hybrid filter systems. This project will be the first to include the installation of a filter system newly developed by SMS. The hydro-hybrid filter systems will be integrated into the exhaust duct downstream of the existing wet scrubbers. Thanks to the innovative solution of combining the existing wet scrubber and the electrostatic precipitators, clean gas dust contents down to 10 mg/Nm3 can be achieved. While the main dust load will be separated in the existing wet scrubber, removal of the fine dust, which has not taken place in the past, will from now on be handled by the new unit. The separation of fine dust particles from the off-gas is based on the principle of electrostatic precipitation. This technology is not only a solution of how to cope with ecological challenges but will also provide an economic return. While reducing the pressure loss, the hydro-hybrid filter system also provides the possibility of markedly reducing electricity consumption. Contact: www.sms-group.com .C[QWV QH VJG ƂPG FWUV ƂNVGT U[UVGO

Cartoon

Taking a look ahead at METEC: Maybe in the not too distant future, developments like the “Internet of things IoT”, “Cloud Computing”, “Pervasive Computing” and “Ubiquitous Computing” will allow all processes of a steel mill to be connected as if they were built directly on a computer motherboard. MPT International 3 / 2015

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››› LITERATURE SERVICE Non-contact speed and length gauge 12 pages, English This brochure features Beta LaserMike’s LaserSpeed gauges. The gauges measure the absolute values of speed and length using dual beam laser Doppler velocimetry. The system is available with the added feature of being able to measure zero speed and automatically detect forward and reverse direction. Contact: E-mail:

www.betalasermike.com sales@betalasermike.com

Mobile metals analyzer 6 pages, English A brochure describing the features of Bruker’s analyzer system Q4 Mobile. This is a mobile optical emission spectrometer designed for all fields of application in metal sorting and analysis, such as incoming goods inspection and mix-up tests. The brochure presents the key performance features as well as the innovative aspects of the system. Contact: E-mail:

www.bruker.com/oes info@bruker-elemental.com

Condition monitoring 62 pages, English, German A comprehensive book providing detailed information on the fully automatic condition monitoring system, Peakanalyzer, offered by GfM Gesellschaft für Maschinendiagnose. It provides information on the installation, configuration and commissioning of the system, technical data, offline vibration diagnosis and various application examples. Contact: E-mail:

www.maschinendiagnose.de mailbox@maschinendiagnose.de

Billet cooling FLEX your cooling. Improved strand quality through optimized cooling.

12 pages, English, German A brochure featuring the Billetcooler Flex® air mist nozzle designed by Lechler. Aspects covered include the flexibility of the flow rate and spray angle stability, heat transfer, spray format optimization, technical data as well as advantages of the innovative nozzle design. Contact: E-mail:

www.lechler.com info@lechler.de

Mill stand arrangements 24 pages, English A brochure outlining the technical features and advantages of the Danieli Morgårdshammar P-600 roll unit, with the focus being on the various mill stand arrangements, for which the roll unit has been designed, as well as on the arrangements of guides. Contact: E-mail:

MPT International 3 / 2015

www.morgardshammar.se mh@morgardshammar.se; office@mh-guides.de

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Non-contact length and speed measurements 8 pages, English, German This brochure outlines the performance characteristics, technical features and advantages of Polytec’s line of LSV laser length and speed sensors. The descriptions include various examples of application and an overview of available accessories. Contact: E-mail:

www.polytec.com info@polytec.de

Refractories for the steel industry 20 pages, English, German A comprehensive brochure setting out the range of refractory products and services for the steel industry offered by RHI. These comprise basic and non-basic mixes and bricks, prefabricated products, slide gate plates, isostatically pressed products, special repair systems, etc. Contact: E-mail:

www.rhi-ag.com steel@rhi-ag.com

Special working solutions for steel mills 32 pages, English, German, Russian A detailed brochure presenting the range of specialized equipment, such as debricking machines, drilling machines, slag raking machines, gunning manipulators, converter relining machines and steel mill loaders, supplied by TML Technik for steel mill applications. Contact: E-mail:

www.tml-technik.com info@tml-technik.com

ENGINEERING | PRODUCTION | SERVICE

Measuring and controlling strip shape 8 pages, English In this brochure, Vollmer presents its approach to strip shape measurement in cold rolling, using different measuring rolls. The results from the measuring rolls and from a dedicated optical system can be used for automatic flatness control in rolling mills. Contact: E-mail:

www.vollmergmbh.de contact@vollmergmbh.de

Bleeder valves 4 pages, English A product brochure describing the key features and benefits of Paul Wurth bleeder valves for blast furnaces. The various valve components and installation positions are explained in illustrations, and technical data are provided of all the three bleeder sizes available. Contact: E-mail:

www.paulwurth.com paulwurth@paulwurth.com

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››› IN THE NEXT ISSUE…

Steelmaking – Environmental protection New type of off-gas filter for vacuum steel degassing plants Off-gas treatment in vacuum steel degassing plants protects the environment and the vacuum pumps. Bag filters generate a considerable pressure drop which is detrimental to the metallurgical performance of the plant. Large filter plant volumes and over-dimensioned suction ducts are costly remedies, as they involve high investment and operation costs. A flat sleeve filter needs only half the height and half the filter volume compared to the conventional round sleeve filters. The new filters use the same sleeve material as conventional filters based on round sleeves. Practice-proven in vacuum plants, this sleeve material is subjected to a water and oil repelling Teflon bath treatment.

Reheating – Hot rolling Practical advices to ensure accurate data from temperature profiling in slab reheating Mathematical modelling is widely used throughout the steel industry to control the transient times and drop out temperatures of steel slabs during reheating prior to rolling. Reheating furnaces are large dynamic entities, consuming vast amounts of energy. Therefore their operation efficiency depends on the control accuracy of the mathematical model. But the mathematical model is essentially theoretical, requiring regular verification. This is done by inputting actual temperature data from a test slab with thermocouples placed at critical positions and depths. The thermocouples feed temperature data back to the recording instrument to log the temperature profiles measured at these positions. A high degree of accuracy is achievable in slab reheating trials if careful consideration is given to the selection of the instrumentation, software, and especially the thermocouples.

Strip processing Slitting line for ultra thin gauges Ever thinner, narrower, more precisely rolled and with minimized burr – this is what more and more customers buying slit strip expect from their products. Customers also demand increasingly greater coil lengths in order to minimize the machine set-up times in downstream processes, such as the sheathing of fibre-optic cables or the manufacture of medical-grade tubing for injection needles, which are welded over a length of several kilometres. In such applications, the edges of the slit strip must be extremely precisely cut to ensure a perfect welded joint. This preview may be subject to change.

Published by: Verlag Stahleisen GmbH P.O. Box 10 51 64, 40042 Düsseldorf, Germany

+49 211 69936-200, Fax +49 211 69936 -128 e-mail mpt@stahleisen.de Publisher: Steel Institute VDEh Executive Member of the Management Board: Dr.-Ing. Peter Dahlmann Editorial Staff: P.O. Box 10 51 64, 40042 Düsseldorf, Germany e-mail mpt@stahleisen.de Chief Editor: Dipl.-Ing. Arnt Hannewald

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+49 211 69936 -121

MPT International 3 / 2015

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+49 211 69936-260, Fax +49 211 69936-262 e-mail gabriele.wald@stahleisen.de Production Manager: Burkhard Starkulla e-mail burkhard.starkulla@stahleisen.de Production/Layout: Mike Reschke e-mail mike.reschke@stahleisen.de Advertising rate card No. 38 of 01.01.2015 Publication: Every 2 months Annual subscription rate (incl. postage): Germany: € 209.00 incl. 7% VAT Member states of the EU: subscribers with VAT ID number € 195.33; subscribers without VAT ID number € 209.00 Other countries: € 209.00 Single copy: € 42.00 Minimum subscription period 12 months. Termination of subscriptions can only be made from 31st December and notice of termination must be received by the Publishers by 15th November. Otherwise, the subscription is automatically renewed and payable for a further 12 months.

© 2015 Verlag Stahleisen GmbH, Düsseldorf This journal and all articles and illustrations contained in it are protected by copyright. With the exception of statutory allowable cases, utilization without the consent of the publishers is a punishable offence. This is particularly applicable to reproductions, translations, microfilming and storing and processing in electronic systems. Upon acceptance for publication, the author agrees to grant, transfer and assign to the pub-lisher all exclusive rights to publish the work during the lifetime of the copyright. In particular, the publisher will have full authority and power to reproduce the work for commercial purposes in copies of any form (microfilm, photocopy, CD-ROM, or other means) and/or to store the work in electronic or other databases. Certification of circulation by the German Audit Bureau of Circulation (IVW) Permit number: 011-224, ISSN 0935-7254

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