MPT International 5/2017 (Oct)

Metallurgical Plant and Technology G 25074

5

ISSN 0935-7254

Severstal to modernize one of Europe’s largest blast furnaces

October 2017

Performance and reliability of EnergIron direct reduction plants

LEADING PARTNER IN THE WORLD OF METALS SMS group is your leading partner in the world of metals. As a family-owned business headquartered in Germany, quality and innovation are in our DNA. Fast and flexible, we develop individual and modular solutions – whether it’s the design of a new plant, Modernization, Digitalization, or Life Cycle Services. In close Collaboration with you, we help you ensure your success. Let’s add value along the entire value chain, together.

Leading partner in the world of metals

www.sms-group.com

EDITORIAL

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Technologies and investments that increase economic strength Technical innovation is a never-ending process, last but not least in the field of metallurgical technology. The market demand for ever new steel products stimulates investments in state-of-the-art plants, technologies and automation, even in challenging times. In this issue, MPT reports on both, technical innovations and investment projects. For example, Russia-based Severstal has started an investment programme focused on the optimization of the integrated iron and steel works in Cherepovets where the company is headquartered. The investment programme foresees among others the modernization of one of Europe’s largest blast furnaces. This refurbishing is expected to require an investment of approx. 500 million US$. Severstal recently signed contracts for the new plant equipment, providing a basis for publishing some first facts about the technical background of this modernization.

The blast furnace process still is a highly efficient production route albeit it is based on a fossil energy source (metallurgical coal). Its working counterpart is steel scrap recycling in EAF-based meltshops. The EAF process route is accompanied by a several direct reduction technologies that have been successfully introduced in the market. In this issue, MPT publishes an article featuring the current performance and reliability of EnergIron direct reduction plants. This technology has been significantly further developed over the last few decades to keep up with the rising requirements of the steel industry. Recent developments in this field have gone well beyond the mere increase of plant capacity. In principle, the technology can make use of any gaseous reducing source – besides natural gas – for example, top gases or reformed gas, and it may even use hydrogen in the future.

Dipl.-Ing. Arnt Hannewald

MPT International is also highlighting trends which overcome the barriers between the traditional process routes. Steel-based value chains are very likely to increasingly include what is referred to as additive manufacturing technologies. Traditional metalworking processes (casting, fabrication, stamping, machining) will soon no longer be the only manufacturing route for metal products. As additive manufacturing is evolving into a mature production process, steel companies will also be paying increasing attention to this innovative technology. Austria-based voestalpine is investing some 20 million euros in expanding metal powder production for additive manufacturing. In total, implementing the group’s additive manufacturing strategy will run up to a total of around 50 million euros. A look at various aspects of this strategy provides an idea of the scope of activities underway in this field.

This issue of our magazine covers various other cutting-edge developments that will certainly catch your interest. Enjoy reading.

MPT International 5 / 2017

680

PROCESS CONTROL SYSTEMS

Danieli Automation automates plants through integrated systems for equipment, process and power control, handling jobs from order placement through product delivery.

Event-prediction and problem-solving operator assistance are ensured by the innovative 3Q system.

570

SCRAP SHEARS AND SHREDDERS

Danieli Environment offers a full range of proprietary technologies for air pollution control, water treatment, solid waste recovery, noise reduction and energy savings.

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ENERGIRON DIRECT REDUCTION PLANTS

Through planning, complete systems integration and construction with our own heavy lifting equipment, provide our teams with full operational flexibility.

Danieli Engineering and Danieli Construction International: your trusted partner with 37 years of experience in on-time project delivery and cost management.

BLAST FURNACE AND CONVERTER PROJECTS

138

356

ENVIRONMENTAL PLANTS

ELECTRIC ARC FURNACES

SECONDARY METALLURGY STATIONS

2270

TURNKEY PLANTS SUPPLIED WORLWIDE

CASTING STRANDS FOR SLABS, BLOOMS, AND BILLETS

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SLAB, BLOOM, AND BILLET GRINDING MACHINES

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

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Danieli Centro Combustion and Danieli Olivotto Ferrè provide the most efficient and low consumption heating and heat treatment systems for all steel and NF metals production processes.

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HEATING AND HEAT TREATMENT SYSTEMS

Our original technology, process know-how, in-house design and manufacturing along with proprietary automation systems, environmental solutions and customer service for a competitive and sustainable steel and nonferrous metals industry.

Strength and reliability presented by numbers.

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505

1455

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HOT STRIP, PLATE AND COLD MILLS

STRIP PROCESSING AND FINISHING LINES

HEAVY SECTION, RAIL, BAR AND WIREROD MILLS

DRAWING AND PEELING MACHINES

71

SEAMLESS TUBE AND WELDED PIPE PLANTS

390

EXTRUSION AND FORGING PRESSES

139

ALUMINIUM HOT AND COLD MILLS

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››› CONTENTS

Company profile 28

thyssenkrupp Tata Steel to become Europe’s No. 2 steel producer Tata Steel and thyssenkrupp signed a memorandum of understanding (MoU) to combine their respective European steel activities

Raw materials 32

Environmental protection and energy savings by suitable material handling systems

Coverphoto: One single process control pulpit of a 600,000 t/year hot strip mill – with innovative design concepts to improve easiness of controls and reduce dependency from operators’ experience Danieli & C. S.p.A., Buttrio (UD), Italy Contact: www.danieli.com E-mail: info@danieli.com

Today, one of the main goals in optimizing iron and steelmaking processes is the consideration of environmental protection and energy saving also in the handling and conveying of the materials

Ironmaking 38

Severstal prepares for modernization of one of Europe’s largest blast furnaces

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Severstal’s investment programme is focused on the optimization of the integrated iron and steel works in Cherepovets, Russia

Performance and reliability of EnergIron direct reduction plants The recent developments of the EnergIron technology go well beyond the increase of plant capacity

Project management

Automation

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Focus on turnkey solutions for the metals industry Industrial investors and plant operators on the one hand and plant and machine manufacturers on the other will no longer be able to cope with the challenges of the future on their own, given the extreme complexity of requirements

Virtual commissioning saves time and accelerates the production ramp up Successfully accomplished projects at Austrian steel company voestalpine Stahl GmbH have demonstrated that commissioning times can be markedly reduced by simulating the equipment and functions beforehand – in a “digital factory”

Material flow logistics

Quality assurance

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56

Plate handling with a versatile system: twice as fast and doubled storage space Dutch steel service company De Boer Staal uses a versatile system for offloading stacks of plates from incoming trailers, stacking them in the yard, moving them around the premises, inside and out and reloading for despatch

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Coil storage data integrated into the warehouse management system 3tn has integrated the mechanical data of Lankhorst KLP® coil storage systems into its TWMS/metals warehouse management system

MPT International 5 / 2017

Precise thickness measurement with integrated width determination by means of laser line sensors An absolute ‘must’ in the production process is highly accurate production monitoring, which can be reliably ensured by the use of laser line sensors

60 5 VTGUUQOGVGT ƃCVPGUU EQPVTQN s on a roll for 50 years ABB highlights the 50 year anniversary of the strip flatness measurement system with a golden jubilee year

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Additive manufacturing 62

voestalpine globally expands its metal powder activities

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The group is investing some EUR 20 million in expanding metal powder production for additive manufacturing at its subsidiaries in Austria and Sweden

3D printing boosts production of spray heads for forging presses Flexible actuation of individual nozzles paired with fast handling and a homogeneously distributed coolant mist provides various benefits

Columns 8

International industry news

70

Literature service

65

Technical innovations

71

In the next issue

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Cartoon

71

Imprint

Advertisers’ index ABB AB Force Measurement AIST Association for Iron & Steel AMOVA BEDA-Oxygentechnik Armaturen GmbH BRAUN Maschinenfabrik GmbH Bürkert Werke GmbH & Co. KG Combilift Ltd. Danieli & C. Officine Meccaniche SpA EREDI SCABINI SRL Fives DMS Franz Wölfer Elektromaschinenfabrik Osnabrück GmbH Friedrich Kocks GmbH & Co. KG Guild International Inc.

51 24 72 45 68 14 17 45 43 59 15 9 49

iba AG 39 JATO-Düsenbau AG 20 Keytroller, LLC 66 KSK Kuhlmann-System-Kühltechnik GmbH 65 Küttner Ironmaking and Energy GmbH 13 Maschinenfabrik Gustav Eirich GmbH & Co. KG 25 Maschinenfabrik Köppern GmbH & Co. KG 10 MICRO-EPSILON Messtechnik GmbH & Co. KG 67 Polytec GmbH 23 Primetals Technologies Austria GmbH 31 Redecam Group SpA 35

REDEX S.A. 27 Rheinbraun Brennstoff GmbH 19 Saar-Metallwerke GmbH 30 SCHEUCH GmbH 18 SMS group 2 Stahlinstitut VDEh 16 Stein Injection Technology GmbH 37 thyssenkrupp Industrial Solutions AG 11,12 TML Technik GmbH 65 VELCO GmbH 26 Friedrich Vollmer Feinmeßgerätebau GmbH 55 Paul Wurth S.A. 21, 22

MPT International 5 / 2017

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››› INTERNATIONAL INDUSTRY NEWS

The Americas Argentina Ternium Siderar awarded scrap service contract. Harsco’s Metals & Minerals division will provide new services for scrap handling and processing at the Ternium Siderar basic oxygen furnace (BOF) steel plant in San Nicolas, the largest steelmaking plant in Argentina. With a capacity of nearly 2.5 million tons per year, Ternium Siderar produces a wide range of steel products for the construction, energy, automotive and other markets. Harsco’s services, awarded under a new five-year contract, are scheduled to begin in January 2018, replacing a local provider in favour of outsourcing to Harsco.

Mexico Deacero to renew slag service contract. Harsco’s Metals & Minerals division will extend its services under a seven-year contract renewal at the Deacero electric arc furnace (EAF) mill in Celaya, continuing more than 12 years of Harsco support at this location, since 2005. Deacero is Mexico’s largest long products producer, and its Celaya mill serves the construction sector throughout Latin America with rebar and wire rod products. Harsco’s services at Celaya include molten slag transport and metal recovery, whereby metal content is captured from steelmaking slag for reuse in the steelmaking plant.

USA Nucor Steel Gallatin orders hot strip galvanizing line. SMS group has been awarded the order to supply a “heat-to-coat” line with an annual capacity of 500,000 t to Nucor Steel Gallatin in Ghent, Kentucky.

“Heat-to-coat” technology is characterized by a compact, operator-friendly U-shape design. It includes a highly efficient turbulence pickling system, the high-power inductive heating system, FOEN galvanizing equipment MPT International 5 / 2017

and a Drever after-pot cooling system.

The line will operate at a production rate of 180 t/h and produce strips up to 6.35 mm thick and 1,854 mm wide.

Due to the integrated inductive galvannealing furnace, the line will also be able to produce galvannealed strips.

For post-treatment, a skin-pass mill, a tension leveller and a horizontal roll coater system will be integrated. Startup is anticipated for 2019.

USA SDI Indiana orders billet welding and spooling equipment. Steel Dynamics has awarded Danieli the order for a new billet welder and spooler line to be installed at its Columbia City, Indiana facility, for the production of added-value spooled coils in endless mode. The new equipment will be capable of processing 240,000 t/year of rebar from 10 mm to 25 mm and plain rounds from 10 mm to 27 mm in compact coils of up to 5.5 t. Commissioning of the new line is expected to take place in the last quarter of 2018. The combination of billet welding and spooling technologies will maximize yield because of the endless production process.

USA Nucor Tuscaloosa installs direct quenching system. Danieli has installed a direct quenching system downstream of Nucor’s plate/ Steckel mill in Tuscaloosa. The system is used to achieve a finer ferrite-bainite microstructure in the rolled product, while limiting or preventing pearlite formation. The direct quenching application at Nucor Tuscaloosa is in operation for the entire range of strip and plate thicknesses, from 4.76 to 63.5 mm, and on all the steel grades produced there. Danieli Automation supplied the automation and process control systems. Also included in the package is the CQE coil quality estimator system, a mathematical model for predicting the products’ mechanical properties in real time. Hot tests and commissioning were carried out during regular production.

News in brief Consortial partners Chadormalu Mining & Industrial Co. and Parsland Mines & Industries Development Company, Iran, have started up the new steelmaking plant built in Ardakan in central Iran. The core production units of the plant are a 170 t EAF and a six-strand continuous billet caster.

The latter was supplied by SMS Concast, a company of the SMS group.

Saarstahl, Germany, restructures its open die forging division.

The new manufacturing facilities for large forgings, which went into operation in 2010, will be shut down. The current workforce of approx. 850 employees will be reduced by half in the short term.

Hyundai Steel Company and SMS Concast successfully commissioned the revamped continuous casting machine for blooms and sections in Pohang, South Korea. The major aspects of the modernization were the introduction of a new section size of 250 mm x 350 mm and the increased level of automation for quality monitoring.

Al Ezz Dekheila Steel (EZDK), Egypt, has renewed the scrap management contract with Harsco Metals & Minerals division, extending Harsco’s scrap management services contract at the EZDK Alexandria plant by another five years.

Nippon Steel & Sumitomo Metal Corporation (NSSMC), Japan, has resumed plate production at its Oita works, seven months after the plate mill had caught fire.

Cliffs Natural Resources, USA, has re-named the company to its historical name Cleveland-Cliffs.

The company is a major supplier of iron ore pellets to the North American steel industry from their mines and pellet plants located in Michigan and Minnesota, and operator of an iron ore mining complex in Western Australia.

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KNOW-HOW FOR TOMORROW

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››› INTERNATIONAL INDUSTRY NEWS Asia China Rizhao orders process optimization solution.

Rizhao Steel has awarded Primetals Technologies with an order for implementing the newly developed “Through-Process Optimization” solution (TPO). The order comprises the intelligent Through-Process quality control system, a newly developed Industry 4.0 IT system and Through-Process know-how modules. The TPO system to be installed at Rizhao´s production complex in Shandong Province will continuously monitor and manage product quality by recording all process parameters as well as measured production and product data, starting from the liquid phase up to the final processing lines.

Quality conformance checks along the production route are carried out by a freely editable rule system.

China

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.

Köppern – Quality made in Germany.

• State of the art technology

Baosteel Meishan to modernize coal and coke storage area. At its ironmaking base, Baosteel Meishan is constructing 26 new coal silos. The Chinese steel company has placed an order with Aumund Fördertechnik GmbH, Germany, for four rotary discharge machines to extract coal from the silos. Two additional machines will extract coke from the covered coke storage. The coal silos, each 21 m in diameter and 33 m tall, are arranged in two rows of 13. The rotary discharge machines will travel under all silos even if material is not being extracted.

To reduce the dust that often comes up when coke in particular is extracted, four of the discharge machines will be equipped with a specially adapted dust suppression unit which sprays a fine mist of water to bind and control the dust. The high-volume silos occupy the same footprint as the previous stockpiles, but can hold four to five times the amount of material.

China MaSteel implements production management system. PSI Metals has been awarded by MaGang group with the order for supply and implementation of an integrated supply chain planning and full process quality management system for Maanshan Iron and Steel (MaSteel), Maanshan City, Anhui province.

PSImetals Planning will cover the complete value chain from hot metal production at MaSteel’s ironmaking site to flat steel distribution and service centres all over China. PSImetals Quality will be implemented as a full process quality management system.

• Process technology know-how • High plant availability • Quick roller replacement

China www.koeppern.de

MPT International 5 / 2017

Siemens to supply drive technology for the new Steckel/plate mill at Shandong Rizhao. The new plant will mainly use Sinamics S120 low voltage frequen-

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INTERNATIONAL INDUSTRY NEWS cy converters. The heart of this new rolling mill (supply of SMS group) will be one four-high reversing stand with a rolling force of 90 MN. SMS group will also supply X-Pact® electrical and automation systems for the entire plant. The new Steckel/plate mill, to be built in Rizhao in the Chinese province of Shandong, is scheduled to go on stream in 2019.

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Ironmaking & Energy GmbH

India JSW adds galvanizing capacity. Danieli has been contracted to supply two 450,000 t/year hot-dip galvanizing lines to JSW. The lines will be installed in Vijayanagar to apply GI and GL coatings on construction grade products in commercial applications. The vertical annealing furnaces will be equipped with radiant tubes and operated with mixed gases. The Danieli Kohler X-Jet air-wiping system will allow GL and GI coating on both sides of the strips. The skin-pass section and the tension leveller will ensure elongation up to 2%, with accuracy of +/- 0.05%.

The first coil is scheduled to be produced by the end of 2018.

BLAST FURNACE VALVES

India MIDHANI to build new wide plate mill complex.

Mishra Dhatu Nigam Limited (MIDHANI), based in Hyderabad, has awarded Danieli two contracts for the design, manufacture, supply and installation of a plate mill complex consisting of a wide plate rolling mill, including plate treatment and finishing facilities. The mill will be able to produce metal plates up to 3,100 mm wide in a large range of special alloys, including titanium, super-alloys stainless steel, HSLA steels, etc. For slab reheating, a walking hearth-type reheating furnace will be supplied. The single-stand plate mill will be designed for roll separating forces of up to 60,000 kN. The plate treatment and finishing facilities will consist of a dividing crop shear, plate leveller, roller hearth furnace and a continuous roller pressure-quenching machine. The first plates are scheduled to be produced by the second half of 2019.

· · · · ·

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India SAIL awards maintenance assistance contract for the IISCO bar mill. Danieli India will conduct preventive maintenance for the bar mill, improving plant availability. Maintenance activities will be performed in co-operation with IISCO’s maintenance team. IISCO plant, located in Burnpur, West Bengal, India, operates two rolling mills supplied by Danieli to produce steel bars and wire rod, having a capacity of 600,000 t/year and 750,000 t/year respectively.

BLAST FURNACE CHARGING · · · · ·

PERFECT BURDEN DISTRIBUTION AND CENTER COKE ALL CHARGING MODELS EASY MAINTENANCE QUICK CHUTE EXCHANGE EASY REPLACEMENT OF ALL BF-TOPS BY VERY COMPACT HEIGHT

Iran Chadormalu Mining & Industrial Co. has started up a new 1.2 million t/year steelmaking complex. Located

Küttner Ironmaking & Energy GmbH Essen/Germany

kie@kuettner.com www.kuettner.com

MPT International 5 / 2017

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››› INTERNATIONAL INDUSTRY NEWS

in Ardakan, Yazd province in central Iran, the steel plant, fed with DRI pellets, comprises a 170-ton EAF and ladle furnace (provided by Tenova) and a sixstrand continuous billet caster provided by SMS Concast (SMS group). The steel company has plans for future expansion of the site with a direct reduction plant for own DRI production and DRI hot charging to the meltshop.

Also, a vacuum degassing plant shall be possibly installed later. This greenfield project was developed by German CPG Engineering and Commercial Services GmbH in partnership with Parsland Mines & Industries Development Company (PAMIDCO) and with a strong co-operation with local subcontractors.

South Korea Hyundai Steel orders new horizontal straightener for medium section mill. Hyundai Steel has placed an order with SMS group for the

supply of a straightening machine for the medium section mill at its Incheon site. The new horizontal roller straightener of type HRM 1400/1250/11009M will replace the existing straightener installed in 1995. With the new machine, Hyundai Steel will be able to roll larger sheet piles and beams up to a web height of 450 mm. In addition to extending the product range, the straightener will also help to improve the tolerances and quality of the sections. Commissioning is scheduled for autumn 2018.

Phat Group selected Danieli as technological supplier for long products casting and rolling plants and also for the plant automation. The three 6-strand continuous casters will produce billets in a range of 130 to 165 mm. Two new wire rod and bar rolling mills from Danieli will be directly connected to the billet casters in order to operate in hot charging mode. The four blast furnaces will be completed and commissioned in sequence, with the fourth being scheduled for delivering the first hot metal in 2019.

Vietnam

Europe

Hoa Phat Group speeds up erection of the new iron and steel complex. Danieli Corus has been awarded a contract for the design, supply and supervision of four greenfield blast furnaces. The four blast furnaces will have a 1,080 m³ working volume and are designed for an annual production of one million tonnes of hot metal each. Hoa

Bulgaria Elektrostomana to expand grinding ball production. The company located in Karlovo placed an order with INTECO for the engineering and supply of a new production line for grinding balls. The new plant

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INTERNATIONAL INDUSTRY NEWS consists of an inductive heating section, a roller stand as well as specialized quenching and temper sections in order to achieve the required material characteristics. The new plant can produce high-quality grinding balls with a diameter from 25 mm up to 100 mm and will be the first one of its kind in Bulgaria. The process automation is also part of the scope of delivery and services. The commissioning of the entire plant is scheduled for the beginning of 2018.

Finland SSAB to modernize hot-dip galvanizing line. SSAB has awarded SMS group a contract covering the modernization of its continuous hot-dip galvanizing line No. 3 in Hämeenlinna. The upgrade essentially involves the integration of an inductive booster into the furnace and of a new air knife system with strip stabilization. The measures will be implemented around the

end of 2017 in cooperation with Drever International, DUMA-Bandzink and EMG Automation, all companies of SMS group. The installation of a new DUMA-Bandzink Jet-Pro air knife system with EMG eMASS® strip stabilization as part of the integrated solution will save zinc and improve the quality of the coating. The line will be designed for strips between 0.4 and 3.0 mm thick and from 650 to 1,550 mm wide. In the process section, the strips will be zinc-coated at speeds of up to 160 m/ min. Equipped with two zinc pots, the line will produce galvanized and galvannealed strips as well as zinc-aluminium coated strip.

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line dedicated to producing advanced high strength steels (AHSS) for the automotive industry, replacing the current electro-galvanizing line. The new line is expected to be operational by mid-2019.

At Dunkerque, ArcelorMittal will modify the vacuum degassing unit, add steel desulphurization equipment and install a better slag retention system on the converters. These investments will increase the steel shop’s ability to produce grades with very low sulphur, phosphorus and nitrogen contents. The upgraded facilities will be operational in the fourth quarter of 2018.

Germany France ArcelorMittal plans investments in Florange and Dunkerque facilities. ArcelorMittal is going to invest 96 million euros at its Florange and Dunkerque sites. Florange will see the construction of a new 600,000 t/year Usibor®

Eisen + Stahl Service GmbH orders slitting line. Heinrich Georg Maschinenfabrik has received an order to supply a new slitting line to steel service centre Eisen + Stahl. With the new line, the company will be adding the sale of slit strip out of its own facilities to its portfolio. To date, slit strip or-

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MPT International 5 / 2017

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››› INTERNATIONAL INDUSTRY NEWS

dered by customers has been sourced from third parties. With the new slitting line, Eisen + Stahl will be able to slit the strip at its own facilities in Mannheim. The new line will be designed to handle up to 1,650 mm wide and up to 5 mm thick steel strip, or up to 2 mm thick strip in stainless grades.

It will be able to produce up to 30 slit coils from one mother coil at speeds of up to 400 m/min. The scrap chopper features Georg’s “shimless tooling” technology, which dispenses with the necessity to insert shims while the knives are being reground.

tems. The RCM/SPM will be able to roll and skin-pass 290,000 t/year of cold strip in widths between 600 and 1,350 mm and minimal final thicknesses down to 0.20 mm. SMS group will also supply peripheral equipment, such as the demineralized water unit, fire extinguishing system, closed cooling water circuit and air treatment systems, including preheating and heat recovery. The order scope also includes responsibility for equipment installation and commissioning.

ing bars and quality steel bars. The second stage will involve replacing the finishing train and installing a compact sizing unit that will improve tolerance and ovality of the final product down to the ¼ DIN. The mill will produce plain rounds from 14 to 80 mm diameter and rebars from 9.5 to 40 mm. The new equipment will provide for a future expansion of the product range to include flats from 50 x 6 mm to 140 x 60 mm. Plant start-ups of the two stages are scheduled to take place in the first and third quarters of 2018 respectively.

Germany Germany Bilstein orders reversing cold mill. Bilstein cold rolling mill has ordered a four-high reversing cold mill from SMS group. The mill will be designed for reduction and skin-pass (RCM/SPM) operations. It will come with the proven CVC® plus design and X-Pact® electrical and automation sys-

Hennigsdorfer Elektrostahlwerke to upgrade bar mill. Hennigsdorfer Elektrostahlwerke, a company of the Riva Group, has contracted Danieli to modernize its bar rolling mill.

The two-stage project will start with the installation of a new intermediate mill featuring H and H/V convertible stands to allow for a new roll-pass design for the production of reinforc-

Germany Saarstahl to invest 100 million euros in a new 5-strand billet caster. The German steelmaker will replace one of its four continuous billet casting plants. The construction work will start in spring 2018 and commissioning of the plant is scheduled for the end of 2019. The new system will be the first

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TEMA Technologie Marketing AG | Jutta Grawitter M.Sc. Aachener-und-Münchener-Allee 9 | 52074 Aachen | Germany Phone: +49 241 88970-302 | Fax: +49 241 88970-999 Email: info@metec-estad.com | www.tema.de

INTERNATIONAL INDUSTRY NEWS continuous billet caster equipped with mechanical soft reduction for the casting format 180 mm x 180 mm in the world. In order to allow the 6 to 13.5 m long billets to cool evenly and without distortion, a turnover cooling bed of approximately 100 m in length is also planned. Furthermore, the system will be equipped with state-of-the-art automation and communication technology. Even during the conception phase, Saarstahl consistently pursued an approach according to Industry 4.0. This will allow optimal integration of the new system into the highly sophisticated production processes of the steelmaking plant.

Germany Lech-Stahlwerke orders new cranes for the rolling mill. The company of German Max Aicher Group awarded Danieli Centro Cranes an order for eight electric overhead travelling (EOT) cranes for its plant

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in Meitingen, Bavaria, Germany. Two of the cranes will replace the obsolescent ones currently installed in the plant’s finished product area, while the remaining six will serve the new rolling mill. The cranes will be delivered and installed starting in mid November 2017. Lech-Stahlwerke operates an electric steel meltshop and hot rolling mill at Meitingen for the production of 1.1 million t/year of rebar, high-quality and high-grade structural steel.

Russia Severstal develops data storage resources. PAO Severstal has created a hybrid data lake as part of its digital strategy. The infrastructure is designed to store company functional data files for subsequent processing and use in Severstal’s data analysis, machine learning and artificial intelligence projects. The hybrid architecture of the storage will combine

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News in brief Tuberías Procarsa, Mexico, has put an offline spiral welded pipe plant from Schuler into operation.

The plant produces large pipes in diameters from 508 to 2,235 mm and lengths from 12 to 24.4 m.

Hadeed, Saudi Arabia, has signed the final acceptance certificate for the furnace optimization system successfully implemented

by Tenova on the DRI-fed electric arc furnace No. 5 at its Hadeed plant.

Vizag Steel, India, has started up the third converter at its Visakhapatnam steel plant, marking the successful completion of the modernization of converter shop No. 1 by SMS group.

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››› INTERNATIONAL INDUSTRY NEWS two data storage models – a private data processing centre (DPC) and leased cloud services. The project will be based on open-source software. Severstal has already signed a contract with Lenovo Group which will supply the servers. In addition, Severstal has signed a framework agreement with Microsoft for the lease of computational resources within the Microsoft Azure cloud service. The agreement will enable Severstal to benefit from a hybrid model, whilst also giving the company access to the unlimited resources of Microsoft’s public cloud. A solution based on Apache Kafka and Spark open-source software will be used for data transfer.

Severstal’s data lake will store data collected from transmitters on industrial equipment (Internet of Things), process management information system servers and manufacturing execution systems.

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Russia MMK to reline blast furnace. Danieli Corus has signed a contract with Magnitogorsk Iron & Steel Works (MMK) for the reline of blast furnace No. 1 at Magnitogorsk.

The scope of work will include design, supply, installation supervision as well as supervision of cold and hot commissioning. The reline will increase the blast furnace’s working volume by 10 %. The tuyere zone, bosh and belly will be converted from a cooling system based on cast iron staves to the “Hoogovens” cooling and lining design based on machined copper plate coolers in combination with high conductivity graphite. As part of this project, the furnace construction will be converted from lintel-supported to freestanding. The reline is scheduled to take place in the first quarter of 2018.

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MPT International 5 / 2017

Russia Evraz ZSMK to upgrade steelmaking plant. The company located in Novokuznetsk has awarded Danieli Centro Met the order for a new technological package that will increase vacuum-degassing flexibility and process control. The system will enable continuous liquid steel temperature monitoring under vacuum in the existing degassing plant. This will reduce treatment cycle time and increase VD productivity. It will also reduce the utilization of thermocouples.

Russia NLMK starts construction of a new briquetting plant. The new 700,000 t/year production facility is being built at the ironmaking site in Lipetsk. The briquettes are used as burden at the blast furnaces (BF). The new briquetting plant will process residues from ironmaking and steelmaking, i.e. a mixture of iron ore concentrate, dust captured in BF off-gases, as well as sludge formed in the process of wet scrubbing BF gases. With the launch of the new facility,

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over 250,000 t of BF sludge will be recycled and returned to the production process annually. Consumption of iron ore pellets will reduce by nine percent (about 580,000 t); consumption of coke will go down by three percent (145,000 t).

With the share of expensive raw materials in BF operations down, the cost of hot metal production will reduce by approximately two percent.

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Russia Abinsk Electric Steel Works Ltd. (AEMZ) orders a second coil compactor. The order was awarded to Sund Birsta (Danieli group). The purpose of the investment is to tie wire rod coils with up to 8 bindings, as per market request. The new equipment will be installed by the beginning of 2018 on the wire rod mill supplied by Danieli in 2015. Furthermore, a new KNB-type binding machine for loose wrapping also will be installed in the bar mill storage area. This machine will complete 1 to 7 wraps in automatic mode.

Sweden Ovako to upgrade electric arc furnace. Ovako has awarded US-based Systems Spray-Cooled the contract to modernize and increase safety on their electric arc furnace at their bar, billet, tube, and rings facility in Hofors with a Spray-Cooledâ&#x201E;˘ roof. This roof design operates at atmospheric pressure, the cooling water is not pumped across the area to be cooled. Therefore, the potential for high pressure, high volume water leaks is eliminated. The new roof will be engineered using state-of-the-art 3D laser scans of the current furnace and surrounding mill. It will also allow piping to be designed accurately for easy fitment. The new cantileverlift roof will be fabricated in Germany. Commissioning is planned to take place in January 2018.

The Netherlands Tata Steel Europe to upgrade hot-dip galvanizing line. Tata Steel Europe has contracted Danieli to upgrade its DVL#2 hot-dip galvanizing line in IJmuiden. The contract includes the design, equipment manufacturing, installation and commissioning activities for a major furnace upgrade, new automation and optimization of the entry and exit sections. The furnace section of the line will be extended by installing an additional free-flame zone and radiant tubes. A completely rebuilt gas jet cooling section will provide extremely high cooling rates and improved uniformity of strip temperature. The electrical and automation systems will be completely replaced with a new solution developed by Danieli Automation. The project will raise the lineâ&#x20AC;&#x2122;s production capacity to 460,000 t/year of coated steel, with a new product mix focused on highervalue steel grades.

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››› INTERNATIONAL INDUSTRY NEWS Turkey Çemtaą to modernize bar rolling mill. Çelik Makina Sanayi ve Ticaret A.§. (Çemtaą) has awarded Primetals Technologies an order to modernize its bar rolling mill in Bursa. The rolling mill will be equipped with new dividing and handling systems. The new hot dividing shear will allow the use of the longer 200 mm billets in production. The new abrasive disk saw will be able to cut wider layers of bars and a new automatic bundling and packing system will replace a manually operated system. The modernization is due to be completed in the fourth quarter of 2017. This current project is part of the second phase of an overall plan for mill modernization, which also includes the supply of a reversing sliding roughing stand and an intermediate train by Primetals Technologies as well as the modernization of the existing finishing facilities.

Companies Aumund establishes field service company. Aumund Group Field Service GmbH is a new company incorporated under the umbrella of the Aumund Group. It has its registered office in Rheinberg, Germany, directly adjacent to the Aumund headquarters. The company’s business is to carry out industrial installation services on behalf of the group brands Aumund Fördertechnik GmbH, Schade Lagertechnik GmbH and Samson Materials Handling Ltd., and for customers outside the Aumund Group. The installation and commissioning activities of the three companies have been amalgamated into the new service entity, setting a consistent standard for site services and commissioning over the whole of the Aumund Group. Managing director is Erwin Last. The core team of the new field service entity consists of 28 employees.

Outokumpu divests pipe plant in Florida. Outokumpu divests its pipe plant in Wildwood, Florida, USA to Ta Chen International Inc., a masMPT International 5 / 2017

ter distributor in the USA and part of Taiwan-based listed company Ta Chen Stainless Pipe, Ltd. The divestment serves Outokumpu’s financial and operational interests, allowing Outokumpu to focus on its stainless steel production in the USA in Calvert, Alabama and Richburg, South Carolina.

Thus, Outokumpu’s other operations in the USA remain unchanged.

Liberty completes Hartlepool acquisition from Tata Steel UK. Liberty House has completed the purchase of two pipe mills at Hartlepool from Tata Steel UK and appointing top steel pipe specialist, James Annal, to head its new pipe and tube division. The group aims to supply the 84” and 42” longitudinal submerged arc welded (LSAW) mills at Hartlepool with steel from its plate facilities in Scotland where it plans to develop capability to make heavy-duty API grade steel used in the energy industry. The pipe mills have a combined capacity of 250,000 t/year.

Sanjeev Gupta, executive chairman of the Liberty House Group, sees the completion of the Hartlepool acquisition as a basis to upgrade the liquid steel production facilities the group is buying at Whyalla, South Australia and the plate mills at Dalzell and Clydebridge in Scotland to make high-value-added API grade plates that can be rolled at Hartlepool to supply pipeline projects worldwide.

SGL Group sells CFL/CE business to Triton. SGL Group signed the sale and purchase agreement to sell its cathodes, furnace linings, and carbon electrodes (CFL/CE) business to funds advised by Triton. Triton seeks to invest in and support the positive development of medium-sized businesses headquartered in Europe, focusing on businesses in the industrial, business services and consumer/ health sectors. The 31 companies currently in Triton’s portfolio have combined sales of around 14.4 billion euros and around 89,000 employees.

The sale will result in a book profit of approx. 130 million euros in the current fiscal year of SGL Group.

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With regards to the closing of the sale of the graphite electrode business to Showa Denko, final discussions with the US authority on merger clearance are ongoing.

Severstal acquires debt obligations of Yakovlevsky mine. PAO has acquired from Gazprombank rights for loans and accrued interest of Metalgroup LLC as well as collateral for the loans. Metal-group LLC is the owner of the mining license for the central part of the Yakovlevsky iron ore deposit.

Severstal has historically been one of the mine’s major customers. The total resource base of the Yakovlevsky deposit exceeds 9.6 billion t. The ore has an iron content of 61.4%.

Nucor to acquire cold finish facilities in Missouri and Mexico. Nucor Corporation has agreed to acquire St. Louis Cold Drawn, Inc., a manufacturer of cold drawn rounds, hexagons, squares, and special sections that mainly serve the US and Mexican automotive and industrial markets. This acquisition fits with the strategy of expanding Nucor’s position in cold finished bar products.

St. Louis Cold Drawn has two manufacturing locations, one in St. Louis, Missouri, and the other in Monterrey, Mexico. They have a combined annual capacity of 200,000 t. The addition of these facilities will increase the total capacity of Nucor’s cold finished bar and wire facilities to more than 1.1 million t/year.

ExxonMobil and Primetals Technologies sign agreement. ExxonMobil and Primetals Technologies have signed a global lubricants agreement to provide lubricants and enhanced technical services exclusively to Primetals Technologies customers.

The offer includes three new product families engineered specifically for the performance requirements of Primetals Technologies high-speed long rolling and flat rolling systems.

Primetals Technologies has preferentially endorsed all three product fam-

ilies for use in its equipment. The offer also includes an enhanced new equipment warranty. The companies will provide a suite of equipment and lubrication technical services to help customers who use the new products to optimize equipment performance.

These services, performed globally by ExxonMobil and Primetals Technologies field engineering teams, include specialized training in products and lubrication best practices, lubricant analysis, equipment troubleshooting and maintenance support.

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KNSS starts commercial operation. PT Krakatau Nippon Steel Sumikin (KNSS), a joint venture established in Cilegon, Indonesia, by Nippon Steel & Sumitomo Metal Corporation (NSSMC) and PT Krakatau Steel (PTKS) for the production and sale of automotive flat steel products, started commercial production in July 2017.

The facility includes a galvanizing, annealing and processing line, which integrates continuous annealing and a continuous galvanizing.

Shortage of graphite electrodes threatens to strangle steel production. The European Steel Association EUROFER is concerned about the tight supply conditions for carbon graphite electrodes. These graphite electrods are indispensable not only in electric arc furnace (EAF) steelmaking but also in the ladle furnace (LF) metallurgy stages of both the EAF and blast furnace production routes.

Graphite electrodes are made from high quality needle coke. “This global shortage has been caused by the idling of global production capacity over the past few years, followed by production stoppages recently enforced by the Chinese authorities as a result of additional environmental standards,” said Axel Eggert, director general of EUROFER. European steel production is dependent on imported graphite electrodes. “Steel producers will need to be very cautious and take the necessary steps in order to prevent production disruptions caused by any prolonged shortage of electrodes,” Axel Eggert continues.

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››› INTERNATIONAL INDUSTRY NEWS

Personalities Management changes at Schade Lagertechnik. Karl-Heinz Fiegenbaum, managing director of Schade Lagertechnik, has retired. His successor is Christoph Seifert, who has been serving the company as technical managing director since February 2015. Klaus Paul takes over from Christoph Seifert as technical managing director.

New managing director and CEO of BlueScope. BlueScope has announced Mark Vassella as its new managing director and CEO from 1 January 2018, after Paul O’Malley announced his retirement effective 31 December 2017. Mark Vassella joined BlueScope in 2007, and is currently chief executive BlueScope Australia and New Zealand.

MPT International 5 / 2017

New business unit president for Ovako in Hällefors. Erik Bohman has been appointed as the new business unit president of Ovako Hällefors. He takes over from Mathias Tillman, who has held two parallel roles over the past year. Mathias Tillman will from now on focus on his responsibilities as Ovako’s executive vice president group sales.

Erik Bohman

U. S. Steel names executive vice president and chief financial officer. United States Steel Corporation has appointed Kevin P. Bradley as executive vice president and chief fi-

nancial officer. Bradley, who will be based at U. S. Steel’s Pittsburgh headquarters, will report to David Burritt and join the company’s executive management team. In this position, he will lead all aspects of the company’s financial enterprise, including internal and external reporting, credit, tax and treasury services, investor relations, internal controls and internal audit administrative oversight. He will also assist in developing and implementing the company’s strategic initiatives, including their ongoing transformation.

New executive appointments at Outotec. Gustav Kildén has been appointed senior vice president, strategic customers and business development.

He succeeds Adel Hattab, who has decided to leave Outotec to join another company. Kildén is currently president of market area Europe & North Africa

at Outotec. New president of the Services business unit will be Tomas Hakala. Both Kildén and Hakala will be executive board members.

Gerdau appoints Gustavo Werneck new CEO. The current CEO of Gerdau, André Gerdau Johannpeter, and executive vice presidents Claudio Johannpeter and Guilherme Gerdau Johannpeter will concentrate their future efforts in the boards of directors

Gustavo Werneck

of Gerdau and Metalúrgica Gerdau, in which they already are members.

Gustavo Werneck, currently executive director of the Brazil operation, will be the new chief executive officer (CEO) of Gerdau starting from 1 January 2018, succeeding André Gerdau Johannpeter. Werneck, 44 years old, has been in the company for 13 years.

He will lead Brazil based Gerdau S.A. and Metalúrgica Gerdau S.A. in the new phase of evolution of corporate governance, which was being planned for more than 12 months.

ArcelorMittal appoints new management team in Italy after taking over ILVA. Matthieu Jehl, vice president, ArcelorMittal, will be appointed chairman and chief executive officer of AM Investco Italy Srl, effective 1 December 2017. Matthieu is currently CEO of the ArcelorMittal Gent cluster in Belgium. Additionally, Samuele Pasi, who joins ArcelorMittal from JP Morgan, has been appointed general manager of ArcelorMittal, and chief financial officer of AM Investco and head of institutional relationships, Italy, effective immediately. Upon completion of AM Investco’s acquisition of Ilva, Matthieu and Samuele will become CEO and CFO of Ilva respectively.

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››› INTERNATIONAL INDUSTRY NEWS

CEO recruited for the fossil-free steel initiative in Sweden. Mårten Görnerup has been appointed chief operating officer (CEO) of the newly established joint venture company HYBRIT Development AB. He joins HYBRIT from Metsol, a technical consultancy firm in the steel sector. Mårten Görnerup formally assumed the post of CEO on 1 September and will gradually step up his involvement in the JV company. HYBRIT was initiated by SSAB, LKAB and Vattenfall with the goal of developing a steelmaking process that emits water rather than carbon dioxide by replacing the current blast furnace process using coal and coke with a process based on hydrogen gas.

Berry Metal appoints new head of sales. Keith R. Gallagher has been appointed vice president sales marketing of Berry Metal Co., Harmony, Pa./ USA. His appointment was effective in September 2017. He reports to David Werner, president and chief operating officer at Berry Metal since September 2016.

TimkenSteel names leaders for commercial operations. Tim Haubenstricker has been named vice president of sales, and Rob Feielin has

MPT International 5 / 2017

been appointed vice president of business development and product management at TimkenSteel, Canton, Ohio/USA. Both are longtime TimkenSteel employees.

Events ›

6 – 9 November 2017 Chicago, USA Organizers: Messe Düsseldorf www.fabtechexpo.com

Fabtech 2017. This key industry event is held every two years, mapping the entire spectrum of metalworking and processing. For the first time, in 2017, it will also feature an expanded pavilion showcasing tubes, tube end products and the tube trade.

›

17 November 2017 Bhubaneswar, Odisha, India Organizers: Mukherjee Infomedia Pvt. Ltd. www.steelmetallurgy.com

Indo-Asian Iron & Steelmaking Conference. A flurry of projects in infrastructure development, railway net-

work, roads and highway expansion undertaken by the government of India are poised to push steel demand up in future. The conference will delve deep into the future of the steel sector of India and the ASEAN region.

›

5 – 8 December 2017 Teheran, Iran Organizers: Messe Düsseldorf www.messe-duesseldorf.de

Iran Wire 2017. This exhibition maps the entire spectrum of wires, cables, tubes, pipes, sections and related industries. International exhibitors will showcase their products on this attractive entry point into the emerging Iranian market.

›

17 – 19 December 2017 Dubai, UAE Organizers: Al Fajer Information & Services www.metalmiddleeast.com

Metal Middle East Dubai. This international trade fair will host four exhibitions under one roof: Tube Middle East, Wire & Cable Arabia, Welding & Cutting Middle East, and Tekno 2017. Visitors will benefit from the comprehensive spectrum of technology showcased.

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››› COMPANY PROFILE

thyssenkrupp Tata Steel to become Europe’s No. 2 steel producer Tata Steel and thyssenkrupp signed a memorandum of understanding (MoU) to combine their respective European steel activities in a 50/50 joint venture. The companies expect annual synergies in the range of €400 million to €600 million. If an agreement will be signed according to schedule in early 2018, the closing of the merger is expected by 2018 year-end.

The integrated iron and steel works of thyssenkrupp is located in Duisburg, Germany (© picture: thyssenkrupp)

thyssenkrupp and Tata Steel have signed a memorandum of understanding to combine their European steel activities in a 50/50 joint venture. Their aim is to create a leading European flat steel player to be positioned as quality and technology leader. The new entity is set to have pro-forma sales of about €15 billion per annum (Rs 115,000 crore) and a workforce of about 48,000,

thyssenkrupp Steel Europe, Duisburg, Germany Contact: www.thyssenkrupp.com Tata Steel Europe, London, UK Contact: www.tatasteeleurope.com

MPT International 5 / 2017

currently at 34 locations. Shipments are envisioned to be about 21 million tons a year.

5VTCVGIKE CPF EWNVWTCN ƂV Dr. Heinrich Hiesinger, CEO of thyssenkrupp AG, says: “Under the planned joint venture, we are giving the European steel activities of thyssenkrupp and Tata a lasting future.

We are tackling the structural challenges of the European steel industry and creating a strong No. 2. In Tata, we have found a partner with a very good strategic and cultural fit. Not only do we share a clear performance orientation, but also the same understanding of entrepreneurial respon-

sibility toward workforce and society.”

Natarajan Chandrasekaran, chairman of Tata Steel, says: “The Tata Group and thyssenkrupp have a strong heritage in the global steel industry and share similar culture and values.

This partnership is a momentous occasion for both partners, who will focus on building a strong European steel enterprise. The strategic logic of the proposed joint venture in Europe is based on very strong fundamentals and I am confident that thyssenkrupp Tata Steel will have a great future.”

To be named thyssenkrupp Tata Steel, the planned joint venture will be managed through a lean holding company based in the Netherlands. It is to have a two-tier management structure comprising a management board and a supervisory board. Both boards are to have equal representation from thyssenkrupp and Tata. The codetermination structures in Germany, the Netherlands and Great Britain will be retained. thyssenkrupp intends to contribute its Steel Europe business to the planned joint venture. There are also plans for the joint venture to include thyssenkrupp MillServices & Systems GmbH, a steel mill services provider that is part of the Materials Services business. Tata would add all of their flat steel activities in Europe.

The memorandum of understanding signed on 20 September 2017 paves the way for thyssenkrupp to involve employee representatives at thyssenkrupp AG and in the Steel business in the process ahead on an ongoing basis.

All employee participation rights will continue to be respected as before. In

COMPANY PROFILE the months ahead, due diligence will be conducted. In the process, the negotiating parties will give each other access to confidential business documents to the extent permissible between competitors. Based on this as well as on discussions with the entire supervisory board, it is envisaged to sign a contract in early 2018. Closing – the effective start of the joint venture – could take place in late 2018 following antitrust approval by the relevant authorities.

Synergies and job cuts expected In the initial years – from closing onward – the joint venture partners plan to focus on establishing the joint venture and leveraging synergies. These are anticipated among other things from integrating sales, administration, research and development, joint optimization of procurement, logistics and service centres as well as improved capacity utilization in downstream processing.

After the ramp-up phase, the joint venture partners expect annual synergies of €400 million to €600 million. Additionally, the production network is to be reviewed starting in 2020 with the aim of integrating and optimizing the production strategy for the entire joint venture. It is not yet possible to quantify the additional synergies from this integration in detail. The scope for optimization also depends on numerous external factors such as the outcome of the Brexit negotiations and the implications that follow. Other external parameters include the development of the regulatory environment in areas such as emission trading and international trade policy.

The two joint venture partners expect that leveraging the cost synergies across the entire entity will require a reduction in workforce over the years ahead by up to 2,000 jobs in administration and potentially up to 2,000 jobs in production. This burden is expected to be shared roughly evenly between the two parties. “We will not be putting any measures into effect in the joint venture that we would not have had to adopt on our own. On the contrary: By combining our steel activities, the burdens for each partner are

lower than they would have been on a stand-alone basis,” said Hiesinger. thyssenkrupp Tata Steel would have a robust capital structure that is well matched by the underlying free cash flows of the company. It would benefit from the scale and distribution network capability of the combined assets to achieve quality, technology and cost leadership in the European steel industry. It is also the clear intent of both partners to remain as long term investors and continue the present network configuration of all the upstream hubs in the proposed joint venture company.

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29

There are five reasons why combining the European steel activities of thyssenkrupp and Tata is the best possible next consolidation move for both parties: (1) Economies of scale are a key success factor in a market caught up in ongoing consolidation. Combining thyssenkrupp Steel Europe and Tata Steel Europe results in a powerful new European No. 2 for quality flat steel with a very competitive market position and promising growth prospects.

(2) The (steel) businesses of thyssenkrupp and Tata are a good complementary fit. thyssenkrupp is stronger in the

Tata Steel Europe operates two integrated iron and steel works, in Ijmuiden, NL (photo) and Port Talbot, Wales/UK (© picture: Tata Steel)

European steel sector under pressure The steel industry has faced massive challenges in Europe for many years: Steel demand is characterized by a lack of dynamic. There is structural overcapacity in supply and constantly high import pressure. This leads to the fact that various stages in the value chain are operating well below capacity. Consequently, all producers are under pressure to fill capacity and forced to pass on restructuring gains to the market time and again. The result is a downward spiral and a need for restructuring about every three to four years, with major steel assets coming under threat of closure in the medium term.

OEM sector while Tata’s strength lies with industrial customers. The main operating locations in Duisburg (Germany), IJmuiden (The Netherlands) and Port Talbot (Wales/UK) have good logistics links and serve customers in different, economically powerful regions. That makes for significantly broader overall coverage of customer sectors throughout Europe.

(3) Performance orientation: The steelworks of thyssenkrupp and Tata rank among the most efficient facilities in Europe. Thanks to effective cost management, both producers operate at a profit. The two companies have paved the way for this over recent years, step by step and independently of each other: Tata, for instance, with MPT International 5 / 2017

30

››› COMPANY PROFILE

the restructuring of the Port Talbot steel works and by selling long steel activities, and thyssenkrupp with the sale of the steel mill in Brasil CSA and capacity adjustment at the German iron and steel works HKM. (4) Innovative strength: Both partners aspire to quality and technology leadership in the European steel industry and continually develop innovative products and solutions for customers.

High-tech steels are frequently the basis of industrial value chains in Europe and a key competitive differentiator.

(5) Culture and capabilities: The two partners each have a highly capable and dedicated workforce who strongly identify with their company. thyssenkrupp and Tata have a cultural DNA equally characterized by the will to embrace change in order to secure their future. And both companies have the backing of strong share-

holders through a trust structure that perpetuate the ideas and values of the original owners.

Further milestone on strategic way forward for thyssenkrupp At thyssenkrupp AG, the Steel Europe business will be accounted for on the balance sheet as a discontinued operation after signing. From closing of the transaction, the 50-percent share in the joint venture will be accounted for using the equity method, meaning based on the proportionate carrying amount of the investment. When the joint venture comes into effect, this will bring about a significant improvement in key balance sheet ratios for thyssenkrupp AG, most notably in the equity ratio and in gearing (ratio of net financial debt to equity). At the

same time, the move creates a solid financial structure for the steel business.

The planned joint venture marks another key milestone on thyssenkrupp’s strategic way forward. In its evolution into a strong industrial group, thyssenkrupp has two priority aims: reducing dependency on the highly volatile steel business and enabling optimum development of all business areas.

Heinrich Hiesinger, CEO of thyssenkrupp AG: “We have always targeted the best solution for thyssenkrupp.

A joint venture with Tata is the only option that addresses the structural overcapacities in the European steel market, that creates substantial added value through synergies and at the same time is in line with our corporate culture. This also marks a clear commitment to our roots, as the joint venture enables thyssenkrupp to retain its involvement in steel.”

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MPT International 5 / 2017

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››› RAW MATERIALS

Improvement of environmental protection and energy savings by suitable material handling systems Today, one of the main goals in optimizing iron- and steelmaking processes is the consideration of environmental protection and energy saving in every plant area.

Not only the processing of iron ore, reducing agents and additives has to be taken into consideration but also the handling and conveying of the materials between the different process steps. This article provides some sustainable solutions for the iron and steel industry.

Material handling systems were originally developed to convey, extract or process materials between different process steps. Today’s requirements go beyond these main tasks. In addition to the material handling itself, Aumund additionally takes into consideration minimization of the environmental impact. Bulk material during transport and treatment is influenced by the surrounding atmosphere and the processes themselves.

Resulting material alterations could be a decrease in grain sizes with potential dust generation or oxidation at elevated temperatures.

The generation of dust can be limited by minimized relative movements between the material handling systems and the material itself. However, such fine particles or dust cannot be avoided in most material handling processes so that further handling should be designed in such way that the release of dust to the environment is minimized. Aumund has developed and established material extraction solutions in closed systems which are widely used in China and South East Asia to reduce environmental pollution by fine particles.

High temperature applications for material conveying on the other side

Dr. Rainer Bertling, Frank Reddemann, Aumund Fördertechnik GmbH, Division Metallurgy, Rheinberg, Germany Contact: www.aumund.com E-mail: metallurgy@aumund.de

MPT International 5 / 2017

Multiple silo arrangement using various rows of Aumund rotary discharge machines (Pictures: Aumund)

allow substantial energy savings in processes in which materials such as sinter, pellets or direct reduced iron (DRI) are typically cooled down for further handling. Aumund developed special hot conveying systems for heavy duty applications such as the handling of very abrasive material like sinter or conveying of hot DRI or temperatures up to 1,100°C under inert atmosphere.

Rotary discharge machines Dust exposure resulting from open stockpiles especially in storage are-

as close to the sea with high wind velocities can be reduced by changing towards closed storage systems. Such closed systems are typically either buildings closing the stockpiles or silos.

There are various systems in use for the stacking and reclaiming of raw materials such as coal, iron ore, limestone or coke. This paper focuses on the application of underground systems to reclaim the stored material from underneath silos or hoppers.

The use of large size silos allows for an increased storage volume on a limited footprint. Depending on the neces-

RAW MATERIALS sary size and amount of silos as well as the mixing requirements, various parallel lines of Aumund rotary discharge machines (RDM) can be applied over a length of several hundred metres underneath either stockpiles or rows of silos with capacities of up to 4000 t/h per machine.

The Aumund RDM travels inside the tunnel under which a discharge wheel reclaims the bulk material from one or both sides of the hopper bottom.

Discharge wheels of up to 8 m diameter are available. Depending on the type of machine all drive systems are contained within a single compact heavy-duty housing or completely contained and sealed within the machine itself.

Aumund RDMs with only two instead of six discharge arms or a single or double swivel facility travel to the pre-selected areas of the hopper. For example, to specific silos with a specific type of raw material, where they discharge different bulk materials, such as different types of coals, by turning the discharge wheel. The different areas can be quickly reached with a fast gear on the travel drive. In case of a double swivel discharge the swivel mechanism accesses both sides of the hopper table, thus allowing the blending of materials.

The other method of blending different types of raw materials is defined by the number of parallel rows and the number of machines per line allowing extracting different materials at the same time from different silos. Nevertheless, only a limited number of machines are required as not each silo needs to be permanently equipped with an extracting conveyor.

Another important feature of the Aumund RDM is that it complies with explosion protection regulations as it operates strictly to the first-in/first-out principle. Whereas the material storage by stackers and reclaimers on open or closed stockpiles needs to reclaim the raw material from the top or the side, respectively, the extraction from below will always extract first the material stored first.

Benefits of the Aumund RDM can be summarized as follows: ▪ Dust emissions can be reduced by converting open stockpiles into an enclosed silo system.

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33

Block version of an Aumund rotary discharge machine

Framing of an RDM block version

▪ No special dust control, no risk of material losses and no fugitive dust pollution or ground water pollution can occur.

▪ The footprint or space requirement of silos is lower than for stockpiles of the same volume.

▪ The Aumund rotary discharge machine with discharge wheel for extraction from silos can achieve a defined blend of separately stored materials.

▪ With the first-in/first-out principle, material solidification is avoided and safety is enhanced.

Hot sinter conveyor In the sinter process the sinter is often conveyed from the crusher behind the sinter belt to the sinter cooler either directly by a chute to a sinter cooler installed underneath the sinter machine or via vibrating feeders. Such vibrating conveyors typically require intensive maintenance activities and lead to significant wear as well as noise and dust emissions caused by the vibration movement of the machine itself. Furthermore, it may cause disintegration of the sinter.

MPT International 5 / 2017

34

››› RAW MATERIALS

Principle of sinter discharge by vibrating feeder

Due to the avoidance of the relative movement between the highly abrasive sinter material and the conveyor itself, the application of Aumund sinter conveyors minimize sinter disintegration, wear, dust generation and maintenance requirements. Such solutions are installed either as a replacement of existing unfavourable systems or in new installations where the layout does not allow a direct discharge from the sinter machine or crusher onto the sinter cooler, which would not be the most cost efficient solution either.

Another development in sinter handling is the use of a sinter shaft cooler with improved heat and energy recovery. In order to achieve an optimized heat recovery the counter flow principle is applied. This also uses an increased height of the sinter bed for most effective heat transfer. Different systems are currently available. With these types of counter flow sinter cooler not only substantial energy can be recovered, but also diffusive dust emissions are minimized as it is a closed system [1, 2].

The Aumund hot sinter conveyor lifts the hot sinter up to higher charging levels filling it into the sinter cooler. Different pan conveyor types can be applied for inclinations of up to 60° (in case of bucket apron conveyors). As the conveying capacity and geometry of the conveying system are directly related, it has to be taken into consideration that the greater the lifting height, the smaller the conveying capacity. The best applicable design will be developed according to the layout requirements.

MPT International 5 / 2017

Principle of sinter discharge by Aumund conveyor

For maximized energy recovery the heat loss of the sinter before entering the sinter cooler must be minimized.

Accordingly the chosen sinter conveyor is to be insulated. Closed Aumund systems with such heat insulation have already proved successful in numerous hot DRI conveying solutions, which additionally operate under non-oxidizing atmosphere [3].

These are the main benefits of the Aumund hot sinter conveyor: ▪ Compared to vibrating feeders, energy consumption and noise emissions are reduced (and hence improved working conditions achieved) as well as wear and maintenance.

▪ The overlapping design of the pans prevents spillage.

▪ The special design and selection of the pan material ensure reliable and torsion-free operation without mechanical altering of the sinter.

▪ Different locations and charging height levels can be reached, what may be especially important if a sinter cooler is replaced.

▪ An insulated conveyor minimizes heat losses and maximizes heat and energy recovery from a downstream sinter cooling system.

Energy-optimized DRI conveying Energy recovery and utilization were already Aumund’s goal when they developed the hot conveying solutions for DRI plants. Instead of cooling the direct reduced iron (DRI) after the reduction process for further handling, the direct feeding of DRI into the elec-

Sealed cover for Aumund hot conveyors

tric arc furnace (EAF) significantly reduces energy consumption of the EAF and shortens tap-to-tap times. Accordingly, a large number of installations have been realized starting in the year 2002 [4]. New installations of direct reduction plants today usually provide a hot charging option to an adjacent meltshop.

Specific energy savings of the integrated plant depend on the individual situation of each application including DR furnace and EAF capacities, plant layout or EAF charging scheme. Current experience shows that savings of up to 120 kW per t of liquid steel and EAF productivity increases of up to 20% are possible.

Besides the significant energy savings achieved by hot charging of DRI into the EAF, steel production via the DRI-EAF route also has a smaller carbon footprint compared to the blast furnace (BF) process route. DRI-EAF steelmaking has substantially lower CO2 emissions per t of steel, as such technology is mainly natural gas based. However, total energy consumption of both steelmaking routes is of about the same level [6].

Designing hot conveying systems, Aumund has to take special design features into consideration. Whereas for sinter and pellet transport sys-

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››› RAW MATERIALS

Aumund bucket conveyor

tems mainly deep-drawn pan conveyors are used, hot DRI is mostly conveyed by bucket apron conveyors allowing higher inclinations to elevate the material into intermediate bins above the EAF. In addition, this type ensures the lowest surface area while providing the greatest possible volume to reduce the contact area with the surrounding atmosphere. This achieves a small potential reaction surface and an optimized thermal radiation for energy saving.

Lifting heights of up to 110 m and conveying capacities up to 400 t/h have already been achieved. The lifting height is limited by the chain strength as just increasing the chain size would also increase the total weight of the conveyor system. With the development of chains that have a specific breaking strength, each single chain of 3,000 kN, Aumund provides the world’s strongest solution and consequently achieves the maximum lifting height for chain conveyors.

In comparison to the use of a pneumatic conveying solution the Aumund pan conveyor substantially reduces dust losses as no dust is being generated during the conveying of the material.

Furthermore, the pneumatic transport requires several times more energy and higher maintenance costs [3].

Benefits of the Aumund hot DRI conveyor can be summarized as following: ▪ substantial energy savings compared to scrap or cold DRI charging MPT International 5 / 2017

Aumund HBI cooling conveyor with water vapour suction system

▪

▪

▪

▪

into EAF, reduced tap-to-tap times and increased EAF productivity, sustainability by availability and reliability, easy handling (no material fluidization/slow-down required), minimum loss of temperature in the hot DRI, minimized re-oxidation and carbon losses, significantly lower energy consumption and less degradation and fines generation than in pneumatic conveying systems, short return on investment.

Cooling of hot briquetted iron (HBI) In recent years the use of merchant HBI has become more and more popular as a replacement for scrap in the EAF charge. This achieves higher grade steels, increases production and reduces CO2 emissions. In addition to EAFs, HBI is also increasingly used in blast furnace operation. In order to secure sufficient HBI supply against the backdrop of growing demand, voestalpine of Austria has built and recently commissioned 2 million t/year HBI plant in Texas, USA [7].

For further handling and transport the HBI needs to be cooled after the DR furnace. Quenching with water directly after the briquetting process used to be a common way of cooling but has some major disadvantages. Experience has shown that e.g. open quenching systems produce dust loaded steam

clouds which result in dust pollution and equipment wear. Furthermore, the fast cooling process may cause cracks and potential fragmentation leading to additional fines.

In order to avoid these problems and achieve the best quality HBI under the most environmentally friendly (i.e. clean) conditions, Aumund developed the patented HBI soft cooling conveyor using water mist for a smooth cooling effect and avoidance of sludge generation in a closed system. On the basis of a thermodynamic model the amount of injected vapour is calculated not to exceed the amount necessary to achieve the required HBI temperature, which is typically around 100°C. Such a system has also been installed and successfully commissioned at voestalpine’ recently built HBI plant in Texas.

These are the main benefits of the Aumund HBI cooling conveyor: ▪ mist cooling with minimum water consumption, ▪ no sludge generation, ▪ clean environment through closed cooling system, ▪ improved HBI product quality through soft cooling process avoiding cracks, and ▪ minimized re-oxidation and fines.

Conclusions Material handling systems play a major role in optimizing energy con-

RAW MATERIALS sumption and environmental conditions in steelmaking processes starting from the raw material treatment all the way to product handling. Aumund, together with its partners in steelmaking technologies and operation, developed solutions to minimize dust release to the environment during handling of hot materials, such as pellets, sinter, DRI or HBI, at the same time improving energy consumption and environmental influences along the value chain of production processes.

Solutions on the basis of conveying equipment are available and can be customized according to individual requirements to solve problems in connection with dust emissions in raw material storage, hot pellets or

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37

References [1] M. Boeberl, E. Fehringer, Efficient sinter cooling with optimized energy recovery, energy saving and emission reduction, Proceedings, 7th European Coke and Ironmaking Congress – ECIC, Linz (2016), p.267 [2] H. Kassebaum, Modern design of sinter coolers, Proceedings, 7th European Coke and Ironmaking Congress – ECIC, Linz (2016), p.715 [3] F. Reddemann, J. Knopfle, Hot transport conveying of DRI for energy and productivity benefits, Direct from MIDREX, 1st Q 2009, p.6 [4] F. Reddemann, Energy-optimised conveying solutions for DRI, Millennium Steel 2010, p.45 [5] M. Moritz, F. Reddemann, Direct feeding of hot iron into the melt shop at Hadeed, MPT International 6/2005, p.26 [6] J. Schenk, H.B. Lüngen, Potentials of direct and smelting reduction processes for an efficient application in Europe, stahl und eisen 136, Nr. 6 (2016), p.26 [7] C. Ravenscroft, R.L. Hunter, DRI plant operation for steel mill sustainability, Proceedings, AISTech (2016), p.473

sinter, leading to equipment damage.

Smart conveying solutions additionally avoid high maintenance costs, help

to reduce energy consumption in the steelmaking process, last but not least when planning future installations.

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MPT International 5 / 2017

38

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş IRONMAKING

Severstal prepares for modernization of one of Europeâ&#x20AC;&#x2122;s largest blast furnaces Severstalâ&#x20AC;&#x2122;s investment programme is focused on the optimization of the integrated iron and steel works in Cherepovets, Russia. The company has started preparations for the refurbishing of blast furnace No. 5. With the project expected to require investment of DSSUR[LPDWHO\ PLOOLRQ 86 ELOOLRQ UXEOHV WKLV LV WKH Ć&#x201A;UVW ODUJH VFDOH UHQRYDWLRQ within the current investment programme.

Russia-based Severstal, a leading vertically integrated steel and mining company, has signed contracts for the engineering and supply of equipment for the refurbishment of blast furnace No. 5 (called â&#x20AC;&#x153;Severyankaâ&#x20AC;?) at the Cherepovets iron & steel works in Russia. Blast furnace No. 5 is currently one of Europeâ&#x20AC;&#x2122;s largest blast furnaces by volume. The design capacity of the furnace is more than 4 million t/year. The plant provides about 50% of the hot metal for the Cherepovets iron & steel works (CherMK). Two companies, Danieli Corus and Paul Wurth, will provide state-of-the-art plant technology and supervise the commissioning and installation of the supplied equipment.

Blast furnace No. 5 has been operating for over 14 years and current refurbishment project is expected to double its lifespan

New furnace casing Netherlands-based engineering company, Danieli Corus B.V. will provide the furnace casing and the cooling system equipment including the copper coolers. The blast furnace shell, refractories and cooling system will be replaced and the scope of work for the majority of these items is based on design, supply and construction, and commissioning supervision. Following the outstanding achievements with blast furnace No. 4, which was converted by Danieli Corus

Danieli Corus, IJmuiden, The Netherlands Contact: www.danieli-corus.com Paul Wurth S.A., Luxembourg Contact: www.paulwurth.com Severstal, Cherepovets, Russia Contact: www.severstal.com

MPT International 5 / 2017

to a â&#x20AC;&#x153;Hoogovensâ&#x20AC;? type cooling and lining system in 2005, Severstal has decided to apply this technology to their flagship blast furnace as well. This cooling and lining design is based on machined copper plate coolers in combination with high conductivity graphite, which is the only design with proven capability of achieving campaign lengths in excess of 20 years regardless of ironmaking process circumstances. In addition to copper staves installed in the taphole area, the furnace will be equipped with a full ring of copper stave coolers in the upper hearth.

der to Paul Wurth comprises a completely new, parallel-hopper design Bell Less TopÂŽ charging system with a hopper volume of 80 m3 and a chute transmission gearbox with the most efficient and reliable pressurized cooling system.

After positive experience with Paul Wurthâ&#x20AC;&#x2122;s BFXpert level-2 automation solution at the currently operating blast furnace No. 5, Severstal ordered an upgrade and extension of this system, with new functionalities of the models for even more efficient process control.

New auxiliary plants State-of-the-art charging system and process automation Paul Wurth S.A., a Luxembourg-based company of SMS group, will provide various mechanical plant equipment and process automation. Severstalâ&#x20AC;&#x2122;s or-

The blast furnace top gas will be cleaned by a Paul Wurth two-stage top gas cleaning plant consisting of a new type axial cyclone for the dry separation of coarse particles and an annular gap scrubber with a demister for fine dust elimination and more accurate control of the top gas pressure than provided by

IRONMAKING

‹‹‹

39

septum valves. This configuration of the top gas cleaning system and its possible set points ensure high cleaning efficiency (dust load on clean gas: less than 4 mg/ m³ s.t.p.) and a significant reduction of sludge production. It also provides the possibility of higher metallics return rates into the main metallurgical cycle.

Furthermore, Paul Wurth will supply four INBA® slag granulation plants with dynamic dewatering of the slag sand. With the cold water system and steam condensation, an officially recognized best available technology (BAT) will be applied for targeted emission control at lowest level.

After completion of the project, “Severyanka” will be again one of the largest blast furnaces in the world (Pictures by courtesy of Severstal)

First large-scale renovation within Severstal’s current investment programme Alexander Shevelev, chief executive officer of Severstal, said: “The blast furnace No. 5 has been operating for over 14 years and this refurbishment project is expected to double its lifespan.

This is an ambitious project which will require a variety of innovative technical solutions. Since the very first stages of design, we have been constrained by strict environmental regulation, which the engineering and equipment suppliers must also comply with.

Industry leading technology will ensure that the refurbished blast furnace consistently performs at a high level, conserving resources and employing a fully automated and environmentally friendly process for the smelting of cast iron.”

As previously announced by the company, this refurbishment will be the first in a series of large-scale renovations of the company’s fixed assets.

Alexander Shevelev added: “Severstal’s investment programme is focused on the optimization of CherMK. Last year we modernized the four-stand hot rolling mill. This year we have begun working on the galvanizing line No. 3. Now we are focusing our attention on the iron making site refurbishing blast furnace No. 5. With the project expected to require investment of approximately 30 billion rubles, this is the first large-scale renovation within this programme.”

The investment during 2017 will be about 2% of the total cost of the ironmaking complex reconstruction project. From 2018 to 2019, the plan is to

build the auxiliary facilities at the complex. The main technological equipment and equipment for the automated control system will be installed in 2020. The work will be carried out by engineering and repair departments from specialist companies.

Outlook After completion of the project, at more than 6,000 m³ useful volume, “Severyanka” will be again one of the largest blast furnaces in the world. The furnace has 40 tuyeres and four tapholes and is designed for an annual production of more than 4.7 million t of hot metal. The reline is scheduled to commence in early 2020, with deliveries of materials to site taking place in 2019.

40

››› IRONMAKING

Performance and reliability of EnergIron direct reduction plants The recent developments of the EnergIron technology go well beyond the increase of plant capacity. The DRI produced is recognized as a unique premium material for steelmaking, thanks to its high metallization and energy content. The basic process scheme remains unchanged for any gaseous reducing source (off gases from coke ovens or blast furnaces, natural gas, reformed gas) and it is also ready to use hydrogen in the future.

EnergIron plant at Nucor Steel Louisiana, USA

The direct reduction technology has significantly evolved over the last decades to keep up with the new requirements of the steel industry. The major challenges that the direct reduction sector had to face were mainly related to: ▪ the increase of production capacity, that until the early 2000s was a bottleneck towards the downstream steelmaking process, ▪ the OPEX reduction, a fundamental factor that allows greater competitiveness in times of downward pricing, ▪ the increase of the DRI quality, a fundamental step to optimize the EAF operations and therefore to in-

Alberto Piccoli, Dario Pauluzzi, Danieli & C. S.p.A., Buttrio, Italy Contact: www.danieli.com, www.energiron.com E-mail: a.piccoli@danieli.it d.pauluzzi@danieli.it

MPT International 5 / 2017

crease the DRI appeal as a valuable feeding material, ▪ the flexibility and ease of operation, allowing plant owners to consider a wider range of raw materials (i.e. more opportunities) while keeping the process in a steady state and fully under control.

Among all the available technologies, EnergIron characterized itself since its establishment by raising the bar and setting new limits to all these challenges imposed by the dynamicity of the steel sector.

In just one decade, EnergIron was successful in increasing the production capacity of a single direct reduction (DR) module from a maximum of 1.2 million tons of DRI per year to the largest operating DR plant in the world, capable of producing 2.5 million t per year of premium quality DRI. This upsizing is more difficult to achieve than one may think and it was possible thanks to continuous improvements; in fact, during the last 10 years EnergIron realized the first 1.6

million t/year plant, than the capacity was progressively raised to 1.9 million t/year, 2.0 million t/year and finally to 2.5 million t/year, that still today remains the record. Each one of these successful projects was a world’s first and a new challenge. Today, EnergIron can provide a well proven DR module that fits all the steelmaking needs.

Standard modules are available with capacities from 0.25 million t/year to 2.5 million t/year.

The basic process scheme remains unchanged for any gaseous reducing source (CO gas, BF gas, NG, reformed gas) and it’s also ready to use hydrogen, that in the future is envisaged to replace carbon for all the high energy intensive industries. Energy efficiency is a milestone on which this technology has been developed, so, thanks to the careful design, the energy requirements of any EnergIron plant hit the lowest levels for this industry, and finally this results in the lowest OPEX. To make all this possible, it is of fundamental importance to cover every single detail and make sure that the plant is always operating at its optimal working point. The EnergIron process is controlled by more than 5,500 analogue and digital variables, which are automatically analyzed by the automation system. All the process variables coming from the field instruments are constantly collected by the various acquisition systems (PLCs, HMIs), providing a valuable set of information for continuously monitoring and optimizing the process. The proprietary EnergIron advanced software takes advantage of this huge potential by managing integrated data collection, analysis, and web reporting with powerful statistical tools to support decision-making. This finally

IRONMAKING

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41

makes it possible to further optimize the process efficiency, by detecting the optimal set points in real-time, with consequent important energy savings.

Maximizing the production capacity As mentioned before, EnergIron is the pioneer in increasing DR plants production capacity, with the objective of satisfying all requirements from the downstream steelmaking process.

Production data collected from various plants in operation and hereby summarized prove the following facts.

The design and installation of high capacity DR plants (>1.6 million t/year) started in 2006 with the establishment of the EnergIron alliance. Today, EnergIron’s high capacity plants are a consolidated reality.

Direct reduction plants based on technologies other than EnergIron and designed for high capacities are today still prototypes, either under construction or in start-up phase, while EnergIron can count on a reference of five DR plants capable of exceeding 2.0 million t/year, namely: Emirates Steel nos. 1 and 2, Suez Steel Co., Ezz Rolling Mills and Nucor Steel Louisiana.

The scaling up of EnergIron DR plants from 1.6 to 2.5 million t/ year was progressive and smooth.

The higher gas pressure at which EnergIron plants operate is certainly the cornerstone for this success, resulting in smaller reactor diameter for the same plant capacity that finally results in better gas distribution and product quality.

Thanks to the experience gained in this last decade of implementation of high capacity plants, EnergIron has completely debugged the design, optimizing process and plant equipment in team-up with operators and vendors.

As a result of such debugging, today the EnergIron high capacity plants can properly perform according to standard operational availability.

At Lebedinsky GOK the DR plant (capacity 900,000 t/year HBI) achieved 1,100,000 ton per year. However, it took one year to adjust the unproven iron ore pellet chemistry in the upstream pellet plant. Then 113% availability was reached the year after, while operating staff was still trained on the job. At Emirates Steel the DR plant #1

The DR plant at Ezz Steel (Egypt) was started up within only 29 days until completion of the performance tests

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has reached 90% availability within 3 years and DR plant #2 has reached 95% availability within 2 years. In 2014, both DR plant were upgraded from 1.6 to 2.0 million t/year reaching 100% stable production within six months.

The final proof of the EnergIron maturity is its outstanding learning curve. The latest EnergIron high-capacity plant to be started up is the AlEzz module in November 2015, having experienced a world record start-up period: in only 29 days from the first produced DRI, the plant was already operating well above the design values and learning curve, achieving up to 112% of the guaranteed production value. This can grant to the operating company a 20% shorter payback period. Moreover, the EnergIron team project execution concept is to support the operating company and its contractors in all project activities from kick-off meeting till end of performance test, as well as during post commissioning period. This approach allows fulfilling

the contractual time schedule without delays.

Latest generation of EnergIron plants As a result of the extensive experience acquired during recent projects, EnergIron plants incorporate all the features needed to provide maximum plant availability, reliability and performances. In particular, the process gas heater (PGH) now incorporates only proven solutions already implemented in the oil & gas industry. The collaborative approach with reputable vendors has resulted in equipment design which takes into account all lessons learned from previous projects and improves the equipment reliability. In particular, the updated design of ZR heaters features a system to maintain it at full efficiency by removing traces of deposited carbon without affecting the metallic structure of tubes. This system, normally used at Suez Steel, Nucor Steel and also at the Ternium plants, demonMPT International 5 / 2017

42

››› IRONMAKING

Company

Emirates Steel

Suez Steel

Nucor Louisiana

Ezz Steel

No. of modules

2

1

1

1

Modul capacity

2.0 million t/year

1.95 million t/year

2.5 million t/year

1.95 million t/year

Carbon content

1.5% – 2.5%

3.0% – 4.0%

3.0% – 4.5%

1.5% – 2.5%

Metallization

94% – 96%

94% – 96%

94% – 96.5%

94% – 96%

Product

Hot DRI feed to EAF

Hot DRI feed to EAF

Cold DRI

Cold DRI

Start-up

2009/2011

2013

2013

mid 2015

Unmatched experience in high-capacity modules

strated to be effective and fast enough to allow full cleaning of ZR PGHs in less than 24 hours. Moreover, the automation system monitoring the PGH is able to detect in advance any possible malfunction (e.g. CO monitoring in the fumes, thermal efficiency calculations etc., flowrate detection for every single pass, thermocouples map on the ducts), immediately putting the plant in stand-by mode and the heater in safe condition, thus preserving and extending its lifetime.

Additionally, proper redundancy is granted for all critical instrumentation and pumps. The core of the plant is the DRI reactor, the pressure vessel where reduction of the oxides takes place. Its design is carried out by EnergIron specialists, while the manufacturing is normally performed in Danieli workshops, in accordance with the most stringent quality standards.

In all EnergIron plants, whether they are Micro modules of 200,000 t/year or Jumbo modules of 2,500,000 t/year, the material flow, gas distribution and thermal profile are always kept in the optimal design range, guaranteeing a uniform high-quality product.

The above solutions are applied and well proven in all EnergIron plants.

Other similar technologies are only now beginning what EnergIron started 10 years ago with its high capacity plants, with many more challenges due to the lower operating pressure and bigger equipment size.

Actual productivity during recent years During the entire debugging phase for each one of the latest generation plants, the EnergIron team always remained side by side with the staff of MPT International 5 / 2017

6JGTOCN GPGTI[ QH JQV &4+ ECP DG TGEQXGTGF D[ JQV VTCPUHGT HTQO VJG TGCEVQT FKTGEVN[ into the EAF (Courtesy of Suez Steel)

the operating company to find a reliable and prompt solution to the unavoidable issues emerging during the first months of operation. The result of this team-up effort is that today these plants are consistently operating with nominal operational availability and at the lowest OPEX for the entire DR sector.

In recent years, productivity of EnergIron plants has been negatively affected by low steel demand worldwide and, in the case of the Egyptian plants, also by lack of natural gas (NG) availability. In any case, plants availability is satisfactory and each plant produced at the desired rate.

In general terms, the inconsistent NG availability in Egypt is a major challenge for smooth operation of all the DR plants in that area. Since the

two EnergIron plants (Suez Steel Co., Ezz Rolling Mill) have been lighted up for the first time, NG availability drastically changed from one day to the other, forcing operators to change process parameters and production rate over and over again to maintain the targeted DRI quality. As a matter of fact, the EnergIron process proved to be able to operate successfully under these challenging conditions, thanks to its excellent flexibility.

On the other hand, during the last 12 months, steel demand in the Gulf region improved and Emirates Steel targeted to increase the DRI output from its plants at nominal values. Since then, the EnergIron plants are working constantly at nominal capacity (2.0 million t/year).

44

››› IRONMAKING

Low OPEX is the key to competiveness over the years

ronment: as compared to other processes for which the overall efficiency is below 70%, for this scheme the efficiency is above 78%. This arrangement ultimately turns into very low natural gas consumption, even lower than 2.35 Gcal/t.

crease of +5%. EnergIron offers the most reliable and efficient system (Hytemp®) to connect the DR plant with the steelmaking plant up to a 500-m distance.

Hytemp® provides a continuous, inertized feeding system that is closed, sealed and maintenance free.

The low utilization factor of direct reduction plants due to world steel downturn rewards those facilities capable of producing at lower OPEX. The selection of the best DR technology for a new plant shall consider the capabilities during the entire life (+25 years) of the plant: Valuable DRI and more Conclusion In terms of productivity and availAs the EnergIron brand may suggest, EnergIron is the technology perfectability, the mature EnergIron plants this technology is designed to produce ly fitted for tomorrow’s challenges. It have demonstrated to be equal to DRI with high internal energy and val- is characterized by low OPEX thanks or even better than mature plants ue in use. EnergIron provides the flex- to high yield (<1.40) and high energy based on any other competing tech- ibility to set the DRI characteristics as efficiency (NG <2.35 Gcal/t). Also, it nology. provides high quality DRI with high required by final user: For any NG-based direct reduction Metallization. EnergIron plants metallization (96%) and wide carbon plant, the sum of costs for iron ore pel- can produce high quality DRI, with content (1.5% – 4.5% C), the latter inlet, natural gas and electricity accounts guaranteed metallization up to 96% cluded mainly as iron carbide (>95% for more than 90% of the total DRI production cost. As a matter of fact, Unit EnergIron III EnergIronZR in terms of yield and energy efficiency of OPEX, Nominal capacity t/year 200,000 – 2,500,000 200,000 – 2,500,000 EnergIron technology shows remarkable reYield (iron ore/DRI) t/t <1.38 <1.38 sults compared to other Metallization % >94 >94 DR technologies, thanks to its distinguishing proNG consumption Gcal/t <2.6 <2.35 cess configuration.

El. energy consumption kWh/t <30 <75 Yield. Gas velocity through the reactor is Oxygen consumption m³/tDRI (s.t.p.)

0.0 – 7.0 40 – 60 minimized thanks to the CO2 emissions* kg/tDRI 256 159 higher operating presNOx emissions (BAT) kg/tDRI 0.030 0.030 sure. Therefore, smaller pellets are acceptable (* with selective removal and export) (less screening losses) and material losses are mini- 'PGTI+TQP RNCPVU KP QRGTCVKQP RTQXGF VQ JCXG NQYGT EQPUWORVKQPU VJCP CDQXG PQTOCN XCNWGU mized thanks to negligible dragging by off gases.

Remet generation is also minimized (Nucor is the only plant in the world Fe3C). The Hytemp® technology exthanks to the possibility to bypass the with guaranteed Met = 96%). ploits the enormous thermal energy reactor during the early stage of plant Chemical energy. Carbon con- of the >600°C hot DRI by a hot transramp-up. Records of 1.35 t of iron ore tent is easily adjustable 1.5 – 4.5%; up fer to the steelmaking plant and direct pellets per t of produced DRI have been to 95% of which as iron carbide (Fe3C), feeding into the EAF. Designed with high plant capacity repeatedly achieved. that provides additional energy to the Energy efficiency. NG consump- EAF and stabilizes the DRI vs. re-oxi- up to 2.5 million t/year EnergIron is tion for EnergIron III is as low as 2.6 dation. To date, no other DR technolo- very flexible in terms of the reducing Gcal/t and the energy of the steam in gy has proved to be capable of produc- agent – ready to use hydrogen as well as excess is recovered in order to produce ing at industrial scale DRI with quality off gases from blast furnaces and coke or save electricity, leading to the low- comparable to the EnergIron high-car- ovens. CO2 recovery is already intrinest electrical energy consumption for bon DRI. sic in the process design. NOx emisany DR technology (in the range of Thermal energy. The most effi- sions are low due to elimination of re30 kWh/t). EnergIron ZR further im- cient way to decrease the liquid steel former burners (ZR) and adoption of proves the overall energy efficiency production costs is to recover the ther- BAT techniques. No catalysts need to up to levels unattainable for any oth- mal energy of the hot DRI. Hot DRI with be disposed since the DRI itself (ZR) is er DR technology. Since the reducing a temperature of >600°C is transferred used as a catalyst; in case of EnergIron gases are generated inside the reac- to and directly fed – still hot – into the III configuration, catalyst’s life is 3 tor, most of the energy supplied to the EAF. The potential for energy savings times that of other processes (reformprocess is taken by the product, with for every 100°C in DRI is approx. -26 er operating with steam excess) and minimum energy losses to the envi- kWh/tls. It results in a productivity in- sensibly cheaper.

MPT International 5 / 2017

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46

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş PROJECT MANAGEMENT

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Focus on turnkey solutions for the metals industry Industrial investors and plant operators on the one hand and plant and machine manufacturers on the other will no longer be able to cope with the challenges of the future on their own, given the extreme complexity of requirements. SMS group has responded to this development with the expansion of its turnkey segment with a focus on integrated projects.

A new vision and mission of SMS group Those who do not just want to keep pace with the times but lead the competition and actively drive developments will have to bring together and bundle an increasing number of competencies of very different kinds. This holds true for both plant operators and plant manufacturers. Only in very close partnerships and with a smart division of responsibilities based on mutual trust will it be possible to succeed in the globalized competitive environment.

SMS group has responded to this development with a new vision: â&#x20AC;&#x153;Leading Partner in the World of Metalsâ&#x20AC;?. With this claim and aspiration, familyowned SMS group is going to tackle the challenges of the future, following one main guiding principle: the customerâ&#x20AC;&#x2122;s success â&#x20AC;&#x201C; along the entire value chain of the global metals industry.

The new vision and mission will also have practical effects on how business

SMS group, DĂźsseldorf, Germany Contact: www.sms-group.com E-mail: alexander.heck@sms-group.com

MPT International 5 / 2017

will be done in the future. â&#x20AC;&#x153;Naturally, we have always developed new processes jointly with our customers. But we believe that such joint development activities will become even closer in the future.

More intensive collaboration will result in technologies tailored to the specific needs and goals of the customers. By relieving the customers from certain tasks, they can concentrate on their business

and metallurgical core competences. In this way, both parties contribute the best of their expertise to the partnership,â&#x20AC;? explains Marcel Fasswald, member of the managing board of SMS group GmbH. As an example, one of the worldâ&#x20AC;&#x2122;s most advanced and most sustainable production facilities for silicon metal is being created in the town of HĂşsavik in northern Iceland by the investor PCC SE

+PHTCUVTWEVWTG CPF DWKNFKPI EQPUVTWEVKQP CTG WUWCNN[ KPENWFGF KP C VWTPMG[ RTQLGEV

PROJECT MANAGEMENT

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

47

&KHHGTGPV '2% EQPVTCEV OQFGNU RTQXKFG OQTG Ć&#x192;GZKDKNKV[ KP VJG FGUKIP QH VJG VWTPMG[ RTQLGEVU

from Duisburg, Germany. This is one of the largest single investment projects in the history of PCC. SMS group has implemented the turnkey project. Dr. Peter Wenzel, chairman of the board of directors of PCC BakkiSilicon hf, confirms that SMS groupâ&#x20AC;&#x2122;s approach has proven highly successful in practice: â&#x20AC;&#x153;PCC develops, finances and operates industrial plants all over the world. More often than not, the investment projects we handle are extremely complex, especially in the case of greenfield projects. For this reason we always look for possibilities to entrust experienced cooperation partners with part of the responsibilities â&#x20AC;&#x201C; particularly engineering tasks, as in case of our project in Iceland.

There we are building a silicon-metal work of the latest design, which is definitely an outstandingly complex industrial project. From the very beginning, SMS groupâ&#x20AC;&#x2122;s turnkey team has been by our side as highly competent partners.

These expertsâ&#x20AC;&#x2122; know-how goes far beyond technological and engineering expertise, as they take on the responsibility for all EPC activities, including time and budget planning. The close cooperation with SMS group as our EPC partner has not only given the PCC management a sense of confidence but also our investment and financing partners.â&#x20AC;&#x153;

Turnkey business in transition In order to meet the customersâ&#x20AC;&#x2122; growing demand for this type of services, the SMS groupâ&#x20AC;&#x2122;s Turnkey division has

been constantly strengthened and expanded in terms of specialist expertise and human resources. While initially the main focus was on the supply of plants and the commissioning process, the demand has shifted increasingly towards complex integrated plants. â&#x20AC;&#x153;The SMS groupâ&#x20AC;&#x2122;s Turnkey division adopts an approach which integrates the product areas involved in each specific case. This allows SMS group to offer integrated plant concepts from a single source, maximizing the cost-benefit ratio and minimizing interfaces for the customer,â&#x20AC;? says Alexander Heck, head of SMS groupâ&#x20AC;&#x2122;s Turnkey division. As a proficient turnkey partner, SMS group offers a wide and varied portfolio of services and contract models to cater to each customerâ&#x20AC;&#x2122;s individual requirements. Marcel Fasswald, member of the managing board of SMS group: â&#x20AC;&#x153;As an internationally positioned plant engineering company for the metallurgical industry, SMS group implements customized turnkey projects all over the world. More than 50 percent of our staff is located outside of Germany. With our worldwide network of locations and branches we offer our customers global presence in all key markets. We have in-depth country-specific knowledge of local standards and safety and environmental regulations, and advise our customers accordingly. Worldwide, not many companies can claim to have the resources and the profound and extensive expertise necessary to implement

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projects of any scale. Numerous successful reference projects implemented

by SMS group impressively show that SMS group is one of them.â&#x20AC;?

Expanded portfolio of solutions and greater Ć&#x192;GZKDKNKV[ The last few years have shown a significant evolution of the turnkey business driven by the demand for greater flexibility and more comprehensive portfolios. Accordingly, SMS group has adjusted its organization and range of services to the current market and customer requirements. Besides the supply of the equipment and the electric & automation systems, the service scope today also includes project management, various consulting services, for example, on country-specific legal requirements and all aspects of health, safety & environment (HSE). On reMPT International 5 / 2017

48

››› PROJECT MANAGEMENT

quest, SMS group also provides assistance in all matters of financing.

SMS group has expanded its turnkey service offer with a clear focus on integrated projects. These encompass steel structural work including all supporting structures for the plants, and construction of buildings complete with media, and energy supply systems for all components and systems within the entire plant.

Within its portfolio, SMS group also takes care of building infrastructure such as electrical installations and plumbing, air conditioning systems and safety engineering and the laboratory equipment for product inspection along the entire metallurgical process chain. The portfolio is rounded out by logistics services, including the provision of cranes for on- and offsite handling of material in connection with the production proper and supporting auxiliary processes.

As core services, SMS group takes over the responsibility for time scheduling and time management and plans complete integrated plants, i.e. including balance of plant (BoP) scope. Thus BoP scopes are already taken into account during layout planning and in the project schedule, as SMS group bears the responsibility not only for an optimized plant layout, but also for the timely erection of the buildings, auxiliary facilities and infrastructure systems.

The growing demand for more flexibility in the design of turnkey projects also reflects in the contract forms.

Contract models offered by SMS group include: ▪ EPC (General Contractor), ▪ EPC (Consortium), ▪ Convertible EPC and ▪ EPCM. In the classic EPC contract, SMS group acts as general contractor or as part of a consortium. The customer signs the turnkey contract either solely with SMS group or with the consortium.

A Convertible EPC contract consists of two phases: After a preliminary phase of front end engineering design (FEED) and an open book estimate (OBE) of the costs of the BoP packages, the contract is converted into an EPC contract.

The EPCM model entails two separate contracts between the customer and SMS group: one contract covering MPT International 5 / 2017

EPC (General Contractor) for a project in Iceland As general contractor, SMS group supplies a submerged arc furnace (SAF) complete with auxiliary plants. As part of the project design, SMS group optimized the plant concept in close cooperation with the customer and paved the way for ECA-covered financing through the participation of construction partner.

EPC (Consortium) in Indonesia Supported by the customer, a consortium was formed for the supply and erection of a hot strip mill. For the construction and building scopes, local partners were selected and included in the consortium led by SMS group.

EPC (Consortium) in the United Arab Emirates A consortium under the leadership of an Indian partner was set up for the construction of a large-pipe production plant. Within the consortium, SMS group is responsible for the supply, installation and commissioning (EPC) of the complete process line, including the laboratory facilities.

EPC (Consortium) in India Jointly with SMS India and a further process partner, SMS group leads a consortium entrusted with the construction of a forged wheel plant in India. In the sales phase of the project, SMS group and the customer agreed that SMS group should make a proposal for a BoP package, upon which the customer placed the order with SMS group.

Convertible EPC (General Contractor) in Malaysia On the basis of an EP proposal for the supply of a submerged arc furnace (SAF), a FEED and OBE analysis had been conducted with the aim to assess the total investment costs of the project. After the engineering and the estimate had been completed, both parties agreed to transform the original order into an EPC contract with SMS group acting as general contractor.

EPCM in Kazakhstan During the proposal assessment phase, SMS group and the customer agreed that in addition to the supply of the process technology SMS group should also provide various management services for the BoP scope as the customer lacked suitable in-house resources. These services mainly included the preparation of tender documents and assistance to a local engineering institute responsible for adapting the international standards relevant for the project to the corresponding local regulations.

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the supply of the process plants (EP) and one for the provision of selected management and other services, with the aim to erect an integrated plant complete with supplementary equipment and auxiliary plants.

A key success factor for turnkey solutions is the closely coordinated collaboration with the building and construction subcontractors. These companies often not only contribute technical expertise to the project but also local know-how and a network of specialist service providers.

Current projects and orders An impressive list of reference plants provide an overview of how the wide range of turnkey solutions can be adopted in practice and which forms the partnership and cooperation between SMS group and its customers may take. Turnkey projects under way and under preparation all over the world are great in number and variety. Building on its wide ranging expertise and its global network of partners, SMS group is well positioned to develop successful and flexible solutions in close cooperation with its customers.

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50

››› AUTOMATION

Virtual commissioning saves time and accelerates the production ramp up “Virtual commissioning” provides the possibility of testing and verifying the perfect functioning of automation systems and optimizing controls and process steps before the “real” commissioning takes place in the metal industry. Various successfully accomplished projects at Austrian steel company voestalpine Stahl GmbH have demonstrated that commissioning times can be markedly reduced by simulating the equipment and functions beforehand – in a “digital factory”.

Automation processes have been tested and optimized long before the equipment is actually commissioned (Picture by courtesy of Küttner Automation)

In modernization or rebuilding projects, every single day counts. Once a plant has been taken out of operation for a rebuilding measure, everything possible is done to bring it back on stream as fast and smoothly as possible. There is a permanent pressure on the project management: Unforeseeable delays often occur during the installation of the mechanical equip-

ment. As a result, the time left for commissioning of the electrical equipment is only very short. Against this backdrop, the success of a modernization or revamping project largely depends on how quickly and reliably the hardware and control software can be tested and optimized.

The “digital factory” Friedhelm Bösche, Küttner Automation GmbH, Trier, Germany Contact: www.kuettner-trier.de E-mail: f.boesche@kuettner-automation.de

MPT International 5 / 2017

In numerous projects, Küttner Automation – the company within the Küttner group specialized in automation systems – has made it possible to reduce commissioning times and accelerate ramp ups by applying the approach of “virtual commissioning”.

The process is based on the creation of a testing environment in which all mechanical, hydraulic, pneumatic and electrical components of the control systems are connected into a “digital factory”. This simulation scenario allows processes to be optimized. Faults in the functional sequence can be identified and corrected beforehand, i.e. prior to the installation on site. As a result, all automation sequences have been tested and approved before the new plant goes live.

The control equipment is commissioned in a virtual environment at a very early stage of the project – in parallel with the manufacture and assembly of the machinery. This reduces or eliminates time pressure for testing and fine-tuning of the control software as is very often the case when these activities take place during the “real” commissioning. Therefore the commissioning activities on site can concentrate on the signal and field level. Moreover, the virtual approach often results in a shorter ramp-up phase, as there will be fewer failures and plant standstills.

Friedhelm Bösche, head of Software Development at Küttner Automation in Trier, always offers virtual commissioning as an option for modernization projects. “Simulating the preliminary commissioning involves some effort in the beginning. But this pays off later on in the form of major time savings. We know from a great number of projects that the time needed to commission the real systems can be cut by up to 75 percent when the software has been pre-tested in a virtual commissioning scenario.”

AUTOMATION

‹‹‹

On-site experiences Küttner Group recently modernized the automation of the iron ore blending unit at the sinter plant of voestalpine Stahl, Linz (Austria). Küttner Automation supplied the process automation that previously underwent the virtual commissioning. During this phase the Austrian steelmaker gained full confidence about the reliability of the process technology. Plant operators of voestalpine Stahl were involved in the virtual testing at an early stage as a precondition of a very short commissioning phase later on. As a result the very tight time frame of only twenty hours for the on-site commissioning was aligned.

Performing “virtual commissioning” will dramatically reduce the time needed for the commissioning on site

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51

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Plate handling with a versatile system: twice as fast and doubled storage space 'XWFK VWHHO VHUYLFH FRPSDQ\ 'H %RHU 6WDDO XVHV D YHUVDWLOH V\VWHP IRU RIĆ&#x192;RDGLQJ VWDFNV RI SODWHV IURP LQFRPLQJ WUDLOHUV VWDFNLQJ WKHP LQ WKH \DUG PRYLQJ WKHP DURXQG WKH SUHPLVHV LQVLGH DQG RXW DQG UHORDGLQJ IRU GHVSDWFK 7KH &RPEL 6& UDQJH ZDV LQLWLDOO\ GHYHORSHG IRU HFRQRPLFDO FRQWDLQHU KDQGOLQJ EXW LW LV RI PDMRU EHQHĆ&#x201A;W LQ RWKHU LQGXVWU\ VHFWRUV ZKLFK KDQGOH H[WUHPH RU RYHUVL]HG ORDGV 0RUH VWRFN FDQ EH DFFRPPRGDWHG RQ VLWH DV SODWHV FDQ EH VWRUHG FORVHO\ WRJHWKHU ZLWK MXVW D FRXSOH RI PHWUHV ZLGWK EHWZHHQ HDFK VWDFN 6LJQLĆ&#x201A;FDQW WLPH VDYLQJV KDYH DOVR EHHQ DFKLHYHG ZKHQ LW FRPHV WR ORDGLQJ DQG XQORDGLQJ WUDLOHUV Lifting and moving 35 t loads of steel plate efficiently and safely is a tough job, and one that Rico Honselaar, operations manager of Dutch De Boer Staal knows only too well. Having looked at Combilift, Gallinagh, Co Monaghan, Ireland Contact: www.combilift.com Mabo-lifting Nederland BV, MC Enkhuizen, The Netherlands Contact: www.mabo-lifting.nl De Boer Staal, Uitgeest, The Netherlands Contact: www.deboerstaal.nl

MPT International 5 / 2017

various methods for handling these extreme loads at the companyâ&#x20AC;&#x2122;s site at Uitgeest, to the northwest of Amsterdam, De Boer Staal found the solution in the form of a 35 t capacity Straddle Carrier from the Irish specialist manufacturer Combilift, which they say is â&#x20AC;&#x153;ideal, flexible and cost effectiveâ&#x20AC;?.

De Boer Staal is a wholesale distributor and has large stocks of sheet steel, profiles and bulb flats in all standard sizes, grades and thicknesses, mainly for the shipbuilding industry. It also operates an in-house coating line together with steel cutting from its affil-

iated company De Boer Snijbedrijf. It is therefore able to offer a flexible and comprehensive service in complete shipbuilding kits and fast completion of projects for its customers.

In spite of the wide range of equipment on the market, none of these were a match for De Boer Staalâ&#x20AC;&#x2122;s requirements for a versatile system for offloading stacks of plates from incoming trailers, stacking them in the yard, moving them around the premises, inside and out and reloading for despatch. Any heavy duty forklifts powerful enough to lift 35 t are extremely large, very

MATERIAL FLOW LOGISTICS

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53

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The tailor made machine is 1.3 m wider in the load area than

hydraulic spreader with individually controlled clamps

standard

expensive and have a high unladen weight. They are also not the safest machines for handling plates which can be up to 12 m long and over 3 m wide and their size hampers any attempts to move the loads into the cutting and painting areas. Further options of overhead cranes or gantries were discounted as these are fixed and therefore limited to use in one specific area.

“We initially found out about the Combi-SC on the internet and contacted the distributor for the Netherlands, Mabo-lifting Nederland BV, for further information,” says Rico. “Together with Mabo-lifting’s Kristiaan Feldkamp we visited a concrete company that was using a Combi-SC and it was immediately 100% obvious that it would ensure the stable handling of our products, too. We worked with Kristiaan and the manufacturers to come up with a highly customized specification which included features such as a hydraulic spreader with clamps which independently clamp the front and rear of the load when it is lifted. The dimensions were also tailor made for us – the machine is 1.3 m wider in the load area than standard, at 4.3 m, and the height is 4.25 m compared to the standard 4.95 m to accommodate the size of the plates and to enable the machine to go inside without needing a telescopic facility. The light own weight of the Combi-SC is also an

advantage as we do not have to worry about extra ground reinforcement.”

Manoeuvrable, nifty and remote controllable The Combi-SC range was initially developed for economical container handling, but it quickly became apparent that it would be of major benefit in other industry sectors which handle extreme or oversized loads, and De Boer Staal is a prime example. The machine’s small turning circle and manoeuvrability enable it to go anywhere on site and space utilization has been optimized. Rico reckons that 50% more stock can now be accommodated on site as plates can be stored closely together with just a couple of metres width between each stack – this would have been impossible with a heavy duty forklift which needs large areas for manoevering. At busy times the Combi-SC is on the go for 10 hours a day, moving 10,000 t of plates and in just three months of operation since it was delivered it has already clocked up 255 hours. It is no surprise therefore that significant time savings have also been achieved when it comes to loading and unloading trailers: the Combi-SC can unload ten loads from one trailer a day compared with five using a crane.

De Boer Staal’s machine is the first LPG powered Combi-SC to be operational in the Netherlands. According

to Kristiaan, the LPG powered engine has enabled substantial cost savings over a very expensive Tier 4 diesel engine that would accord to the directives for indoor operation. De Boer Staal also chose a remote control model for a number of reasons: the relatively compact size of the premises makes it suitable for pedestrian operation for a start, and it can be operated by one employee without the need for a banksman. All around visibility of the working environment together with a lack of manual handling guarantees a high level of safety for all personnel involved. The three operators also found the theoretical and practical training by Mabo-lifting’s field engineers easy and quick.

A strong solution “Both Mabo-lifting and Combilift understood what we needed,” says Rico Honselaar. “With our Combi-SC, which our employees have named ‘Ted’ after the famous Dutch strongman Ted van de Parre, we have found the best solution to our problem. It gives us the independence to offload and move our loads whenever and to wherever we want and we have maximized our space utilization so we can order in volume and stock larger quantities of plate than before. ‘Ted’ was affordable and will pay for itself in a short space of time.”

MPT International 5 / 2017

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››› MATERIAL FLOW LOGISTICS

Coil storage data integrated into the warehouse management system 3tn has integrated the mechanical data of Lankhorst KLP® coil storage systems into its TWMS/metals warehouse management system. It eliminates the risk of entering ZURQJ GDWD ZKHQ FRQƂJXULQJ D PDQDJHPHQW V\VWHP IRU D FRLO VWRUH )LUVW H[SHULHQFH DW $XVWULDQ VWHHO FRPSDQ\ YRHVWDOSLQH KDV VKRZQ WKDW WKH GDWD LQWHJUDWLRQ DOVR VDYHV WLPH Optimization of coil logistics and storage is one general approach of the warehouse management system TWMS/metals from 3tn. For each load case and storage place, the software calculates the loads acting on the coil stops and the resulting force

because any incorrect data input may be a potential safety hazard.

3tn has now integrated the mechanical data of the commonly used KLP® coil storage systems from Lankhorst Mouldings into its TWMS/metals warehouse management system.

look very much alike but have different properties, for example, in terms of maximum allowable load or coil temperature.

Later on, when the storage rows are being arranged, the system will send out a warning in case the elements are

Safe and correct coil storage relies on a multitude of parameters for both, the coils and the storage place (© Picture: Lankhorst Mouldings)

vectors. The configuration of a warehouse management system used to entail the manual entry of a great number of values, among others minimum and maximum coil diameters, maximum load and the resulting force vectors for the coil cradles, wedges, stops, etc in use. That is a challenging task,

Thorsten Tönjes, 3tn Industriesoftware GmbH, Holzwickede, Germany Contact: www.3tn.de E-mail: info@3tn.de

MPT International 5 / 2017

When configuring a coil store, the data of Lankhorst’s KLP® coil storage systems, KLP® RollStop systems or KLP® Rollblocks can now be simply clicked on with the mouse. Re-entering of data is not necessary.

By integrating these values from the coil storage system, 3tn enhances safety in various respects: First of all, the users can be sure that the data of each component has been correctly assigned. Only data of those KLP® systems actually in use in the mill are stored in the system. Pre-configuring the system in this way largely reduces the risk of mistaking components that

not properly configured; for example, in case a coil stop designed for coil diameters of up to 1,800 mm is intended to accommodate coil diameters of up 2,000 mm.

The integrated data also make work easier for the users: They simply choose the required items from a list and configure the warehouse with a few clicks on the mouse. Nevertheless, they still have the flexibility to define specific rules for each individual storage place.

It is possible, for example, to specify for a certain area that the coils may not be stacked, for example, in an area where blocked coils are stored.

MATERIAL FLOW LOGISTICS

For each load case and storage place, TWMS/metals calculates the load acting on the coil stops and the resulting force vectors (Š Picture: 3tn)

Bas Brouwer, manager of the â&#x20AC;&#x153;Steel Industryâ&#x20AC;? business unit at Lankhorst Mouldings, sees many synergies between warehouse management and coil storage: â&#x20AC;&#x153;Our products and the warehouse management systems from 3tn are in use in numerous mills around the

globe. Therefore it was only logical to combine the two systems. We jointly offer our customers a maximum of safety.â&#x20AC;?

Also for Thorsten TĂśnjes, one of the two managing directors of 3tn, safety in the coil store is a key issue: â&#x20AC;&#x153;We calculate for each coil the loads acting on

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55

the coil stops, and Lankhorst has the expertise to guarantee that the stops will safely accommodate these loads.

3tn software and Lankhorst hardware have been combined within one unique solution. This will take the already high safety of our systems to the next level.â&#x20AC;?

At its Linz (Austria) steelworks, voestalpine Stahl GmbH operates numerous KLPÂŽ storage systems from Lankhorst Mouldings. 3tn is currently implementing TWMS/metals in 28 warehouses of the mill, for the first time integrating KLPÂŽ data. This provides voestalpine Stahl GmbH a central management tool capable of pre-setting the parameters for the 3tn warehouse management system in the various warehousing areas and ensuring that only those coil stop types physically available in the mill can be clicked on. This enhances safety, makes for more ease of operation and practically rules out the risk of errors.

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MPT International 5 / 2017

56

››› QUALITY ASSURANCE

Precise thickness measurement with integrated width determination by means of laser line sensors In the production of slabs, metal sheets and coils, thickness and width are important parameters, since these dimensions are essential for further processing. Product deviations cost a lot of money and time. Accordingly, an absolute ‘must’ in the production process is highly accurate production monitoring, which can be reliably ensured by the use of laser line sensors.

Thickness measurement with integrated width measurement in a single system

The steel production and processing market is a hard-fought one in which competition is keen. Thus, steel man-

Achim Sonntag, Micro-Epsilon Messtechnik GmbH & Co. KG, Ortenburg, Germany Contact: www.micro-epsilon.com E-mail: Achim.Sonntag@micro-epsilon.com

MPT International 5 / 2017

ufacturers have to face a variety of challenges in order to be and remain competitive. Demands on the production process are becoming increasingly strict, the use of raw materials must be optimized and numerous standards require compliance with various limits. To comply with all the conditions, regulations, parameters and standards and to be able to measure and determine with precision, measuring instruments are the only rational and

economical solution. They function as consistent, reliable and highly accurate control units in the production process. In both hot- and cold-rolling processes, deviations from the specified dimensions often occur right at the beginning of the production chain. If the thickness fluctuates and the thickness and/or width deviate from their nominal values, then not only are the material costs no longer acceptable but the result may be qual-

QUALITY ASSURANCE

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ity deteriorations which, among other things, give rise to difficulties during the further processing of production goods and can in the end lead to complaints and massive financial losses.

Comparison of measurement methods The sector of metal thickness measurement is dominated by three different principles. The first to be mentioned are contact methods in which, preferably, measurement heads are used, one above and one below the object. Owing to the contact during measurements such devices often wear more rapidly and so create problems during production. Furthermore, measurements are made only at individual points, so that only approximate information can be obtained about the thickness variation.

Radiometric methods work with isotope radiation or an X-ray source, which however is damped by the sheet itself. In this case radiation is emitted and received by a transmitter, and from the difference between the emitted and received radiation the mean thickness is determined. Depending on the alloy and the condition of the material, the method can be more reliable or less so. On top of that there are costs for radiation protection and for regular safety testing, which of course entails regular expenses.

Compared with other methods, optical methods based on laser triangulation have advantages. They measure without contact and therefore without wear. Moreover, independently of the condition of the material it is possible to carry out an exact geometrical measurement in relation to the strip surface.

In the latest generation of thickness measuring units from Micro-Epsilon laser line triangulation sensors (= profile sensors) are used, which generate further advantages. During the processing of cold strip, large vertical movements often take place, for example in longitudinal slitting machines owing to the forces exerted by the blades on the strip. Laser point sensors come up against their limits in this application. The higher information

density generated by a profile sensor here demonstrates its advantages. In the profile sensor the laser spot is extended to a line. The measurement is obtained from a â&#x20AC;&#x153;best-fit lineâ&#x20AC;? through the cloud of points produced by the sensor. As a result, the distance-to-resolution relation is considerably better than with the point sensor, since the variation of the said line is calculated from the interplay of numerous partial resolutions. In essence, more measurement values over a larger area are available, which when averaged give greater precision. In summary, by virtue of the best-fit line this characteristic is so improved that ultimately the resolution of the line sensor at a larger measurement distance is better than that of the point sensor. Thanks to the above measures, with line-scanners a working gap of 190 mm with a measuring range of 40 mm and a precision of Âą5 Îźm is achieved, whereas with point sensors in the same range only about Âą25 Îźm can be achieved.

Measurement systems arranged in C- and O-frames For differential thickness measurement with distance sensors a constant sensor distance is vital. As a rule two different design types are used, which

on account of their shape are referred to as C-frames or O-frames.

In the C-frame, the sensors are mounted fixed on an upper and a lower arm and the frame is moved as a unit to reach the measurement position. C-frames are best suited for applications involving narrow strips, since with increasing material width the oscillation susceptibility of the upper boom increases. For the calibration of the C-frame, during coil exchange a master-component moves automatically into the measuring gap and so balances the system for new measurements. The advantage of the C-frame is that during threading-in or in hazardous situations due to so-

C-frames can be moved completely clear of the production line, but for that they need more space than an O-frame MPT International 5 / 2017

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››› QUALITY ASSURANCE

termed ski effects (the strip curves upward on one side) or alligator effects (the strip curves upward and downward) at the start of the strip, the C-frame can be removed completely from the line. However, this demands space, which above all in the area of the service centre is often not available.

Here the O-frame is a better option because of its compact structure. Precisely because of the constant measuring gap, which is a decisive criterion for the precision of such a unit, the O-frame has major advantages. The de-

only slowly and for that reason there is as a rule sufficient time for taking the necessary action without compromising the manufacturing process. In this context, help is provided by the concept of the “compensation frame” patented by Micro-Epsilon. For this an additional, temperature-invariant frame is integrated into the system parallel to the upper and lower booms, and the support of each measurement sensor is extended with a so-termed compensation sensor. These sensors determine the distance of the support from the compensation frame.

A variation of the measuring gap is thus converted to the extent of 100 percent to the distances of the compensation sensors from the compensation frame. In that way, the change can – so to speak – be eliminated and the measuring gap held constant at an uncritical level.

Thickness measurement with integrated width measurement in longitudinal slitting shears Measurements made using an O-frame are extremely precise and, thanks to their compact structure, can also be made when space is limited

sign of this version is based on a stable frame which is integrated in the production line. By virtue of the rigid frame, strip widths of up to 4,000 mm can be inspected for thickness, profile, width, etc. This version also has an auto-calibration unit. During the measurement, the sensor system continually passes across the metal strip and so collects profile data over the full width of the strip material.

Constant measuring gap In combination with the O-frame, a constant measuring gap is a basic prerequisite for precise results. Here, monitoring of the measuring gap with an additional displacement-measuring sensor technology or by iterative calibration at process-uncritical times has proved its worth. Temperature changes influence the geometry of the machine frame and therefore the measuring gap. However, these temperature-related changes take place MPT International 5 / 2017

Owing to the high lateral resolution of the linear sensors, besides thickness measurement the edges of the material being measured can be very accurately identified. In longitudinal slitting shears this makes it possible to determine the transverse profile for each individual ring. For methods with a large measurement spot that is very difficult, since the lateral resolution of the method is often not sufficient for this measurement task if the slit strips are narrow. For rings that are cut from strips and which are very close to the minimum tolerance limits, with the help of a thickness measurement unit based on profile scanners the yield obtained from a coil can be increased. A ring produced can still be within tolerance while those adjacent to it can no longer be sold, or not as part of the order concerned. When there is only one thickness profile, whose lateral resolution is imprecise, then it may be that a ring with acceptable dimensions is no longer brought into circulation. The possibility of edge detection also enables precise width measurement. In addition to the sensor system for thickness measurement a third laser line sensor is integrated in the system, which can be

positioned independently. Thus, the two edges of a strip can be detected synchronously and any clustering has no effect on the measurement result.

While the thickness sensor system is moved continuously across the width of the material as a whole, the width sensor is in each case positioned at the next cutting gap. As soon as both sensors detect the edges of the strip, the width measurement for the strips is carried out.

Thickness measurement of laminate sheets A further application for which the laser line sensors are predestined is the thickness measurement of laminate sheets. Methods involving penetrating radiation cannot be used for this.

For example, if the laminates are made with outer sheets and a web structure on the inside, then radiation methods only measure the material fraction in the measuring gap but not the dimensional accuracy of the product. Laser line scanners only determine the geometrical dimensions of such sheets and recognize undulations, which give information about problems during processing.

Thickness measurement in hot rolling mills Hot rolling is a special challenge with regard to thickness measurement as the measurement accuracy is affected by different influences.

For example red-hot glowing surfaces make it difficult for red laser types to provide a stable measurement. However, the application patented by Micro-Epsilon involving a blue laser on red-hot glowing materials achieves significantly better results.

Another critical factor is the temperature itself. In addition to material temperatures significantly higher than 1000°C, another 100°C affect the system frame. In order to achieve reliable results in this environment, the frame design must be resistant to thermal changes. The accuracy between two calibration processes must be within specified tolerances.

Furthermore, adequate cooling is required in order to ensure operation of the electronic components according to their thermal specifications.

FIVES TECH + FIVES TEAM FIVES, AFFORDABLE CAPEX ULTIMATE OPEX The global offer covers carbon, stainless and silicon sectors in long and flat products, as well as tube and pipe, including complete solutions for strip processing, reheating and rolling: — Metallurgical and technological process expertise — NeoKoil® strip processing line and reheating furnace design and supply — Thermal and mechanical technologies and proprietary equipment (furnaces, rapid cooling systems, cold rolling mills, etc.)

— Induction heating — Surface treatment solutions — Automation systems — Full range of services: cost optimization, upgrade, training, operation and maintenance assistance, etc.

www.fivesgroup.com — Steel http://steel.fivesgroup.com/

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş QUALITY ASSURANCE

5VTGUUQOGVGT OGCUWTGU VJG HQTEG FKUVTKDWVKQP QP VJG TQNN CU QPG RCTCOGVGT HQT Ć&#x192;CVPGUU QH VJG UVTKR

5VTGUUQOGVGT Ć&#x192;CVPGUU EQPVTQN s QP C TQNN HQT [GCTU ,Q $SULO D FRPSOHWHO\ QHZ VWULS Ć&#x192;DWQHVV PHDVXUHPHQW WHFKQRORJ\ ZDV LQWURGXFHG LQ WKH PHWDO LQGXVWU\ )RU WKH Ć&#x201A;UVW WLPH WKH QHZO\ GHYHORSHG 6WUHVVRPHWHU V\VWHP ZDV GHOLYHUHG IURP $VHDĹ&#x2019;V QRZ $%%Ĺ&#x2019;V IDFWRU\ LQ 9ÂŚVWHU§V LQ 6ZHGHQ WR WKH &DQDGLDQ DOXPLQXP FRPSDQ\ $OFDQ QRZ 1RYHOLV $%% LV QRZ KLJKOLJKWLQJ WKH \HDU DQQLYHUVDU\ ZLWK D JROGHQ MXELOHH \HDU The fifty years of Stressometer development have been focused to making it a general tool to improve rolling mill profitability in a sustainable way. It all began with the interest of finding some way of measuring flatness during rolling in order to achieve automatic flatness control. Until the 1960s, flatness during rolling was manually controlled through visual and audible observations by the operator. The introduction of automatic gauge control had helped rolling mill operators achieve

Lars Jonsson, Flatness Systems, ABB AB, Västerüs, Sweden Contact: www.abb.com/measurement E-mail: lars.oi.jonsson@se.abb.com

MPT International 5 / 2017

closer steel strip thickness tolerances, but the problem of strip flatness measurement and control still remained.

In the mid-1960s, Dr. O. G. Sivilotti of Alcan, Kingston, Ontario/Canada, approached Asea to find out whether a sensor could be developed to measure strip flatness. Proceeding from his ideas, a joint development between Asea and Alcan started. Decision was taken to base the development on a mill-duty measuring roll with Pressductor sensors. The first system was installed in Alcanâ&#x20AC;&#x2122;s cold rolling mill in Kingston, Canada in 1967 where it underwent comprehensive tests.

The idea was to control the transversal stress distribution in the strip, thus improving the strip flatness. The assumption was that a controlled strip stress dis-

tribution, i.e. strip flatness, would lead to improvements in strip quality and mill productivity. The hypothesis turned out to be correct. Using the Stressometer equipment, Alcan substantially improved the flatness of the rolled strip and achieved higher yield and less strip breaks. It also meant higher productivity through higher mill speed and shorter pass times. The success was a fact.

Innovations over the years The first Stressometer installation in 1967 did show the potential, and financial impact, of flatness control for the rolling industry. However, since then demands of flatness control from strip users and from different types of rolling mills have continuously been

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Stressometer is the sensor system of VJG ƃCVPGUU EQPVTQN U[UVGO YKVJKP VJG rolling mill automation

increasing. The need for better flatness tolerances to get even higher yield and productivity was far from saturated.

The development has resulted in a lot of innovations in the area of flatness measurement and control for the benefit of rolling mills all over the world.

The most important innovations are: ▪ 1967, world’s first flatness system, delivered to Alcan Kingston Canada ▪ 1970, improved resolution of measurement; 52 mm zone width used instead of 84 mm ▪ 1976, first microprocessor based system (Intel 8080) ▪ 1977, world’s first digitally closed loop flatness control (Kobe Steel, Japan) ▪ 1980, world’s first flatness control system for a cluster mill (Outokumpu) ▪ 1982, further improved resolution of the measurement; 26 mm used instead of 52 mm ▪ 1989, digital colour graphic HMI ▪ 1989, world’s first flatness control based on actuator influence functions ▪ 1990, new technology for measurement of strip width and edge position – MSS (Millmate Strip Scanner) ▪ 1993, measurement and compensation of strip temperature in steel applications ▪ 1994, new transducer and roll for foil applications ▪ 1998, world’s first Web browser based HMI for industrial applications ▪ 2001, new system generation with future safe architecture ▪ 2002, seamless roll for surface-critical applications ▪ 2006, predictive flatness control ▪ 2007, foil roll with 26 mm resolution ▪ 2011, flatness control with automatic process identification ▪ 2013, optimal coordinated control through ESVD for cluster mills ▪ 2014, digital maintenance-free signal transmission unit

▪ 2017, fully digital system, RoHS (Restrictions on Hazardous Substances) compliant.

In a tough global competition on rolled strips and foil, the number one priority for rolling mills today is to invest in improved competitiveness. A modern flatness system, such as Stressometer, has the possibility to deliver improved competitiveness through increased strip quality and productivity and reduced production costs in order to get maximum financial advantage from such an investment.

The Stressometer system has a number of unique properties and features which enable it to fulfill market requirements better than other flatness systems on the market. For the rolling mill, these properties and features mean considerable production benefits and improved profitability. Three important benefits, brought by Stressometer, are improvement of yield, pass time and strip breaks. These factors have a direct impact on the “Bottom Line” of the rolling mill and can also relatively easily be calculated.

Stressometer will not only mean improved strip quality and productivity, it is also very important that production costs such as energy and maintenance costs are reduced. Today’s customers are reporting positive impact of both productivity and strip quality directly after commissioning of their Stressometer system. Productivity increase of 10% is not unusual. They also report payback times of less than a year.

Ready to meet future challenges The Stressometer system has since 1967 been a great success for ABB and

its customers. Since, more than 1,200 systems and 1,500 measurement rolls have been delivered. The Stressometer version of 2017 is fully digital and thus prepared for ABB Ability which is a common cloud based platform for all ABB’s products and systems. It will enable customers such as rolling mills to use advanced cloud based services for optimization of their production.

For the coming years, ABB expects to continue collaboration with the rolling industry for the future challenges. One way of doing so is to integrate products and systems, such as Stressometer, with the so called Industrial Internet of Things (IIoT). This will for instance enable rolling mills within the same group to optimize their operation on a global basis. Production assets will be used in the most efficient way, maintenance periods and extent could be predicted, and the global production capability could be planned to match the actual demand from strip users. Remote commissioning, process analysis and fault tracing are other services that are enabled with the IIoT technology.

ABB Ability is the name of the platform that will make all this possible in the near future. For Stressometer customers the digitalization through ABB Ability solutions will enable to continue the journey to the next level of improvements in productivity and strip quality and to do so in a secure and sustainable way.

MPT International 5 / 2017

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››› ADDITIVE MANUFACTURING

voestalpine globally expands its metal powder activities The voestalpine Group’s High Performance Metals division continues to consistently pursue its strategy of promoting this pioneering technology internationally. voestalpine is investing some EUR 20 million in expanding metal powder production for additive manufacturing at its subsidiaries Böhler Edelstahl GmbH & Co KG, Austria, and Uddeholms AB, Sweden. In total, implementing the additive manufacturing strategy will run up to around EUR 50 million.

Metal additive manufacturing – also known as 3D printing – has revolutionized metal processing like no other process. Digital design data is used to add material layer by layer in order to create highly complex parts with completely new forms and functionalities without any material loss. The base material are different types of processed metal powder. Despite the technical challenges, metal-based additive manufacturing offers a lot of future potential, especially in sectors such as the aerospace, automotive, toolmaking, and medical industries that require very sophisticated custom products. “voestalpine, with its comprehensive knowledge in manufacturing metal powder and in the design, development, and production of ready-to-install components, is a global pioneer in 3D printing. We want to consistently push ahead with our activities in this area by setting up new research and development centres in non-European growth markets,” says Wolfgang Eder, CEO of voestalpine AG.

Regional expansion and technological progress Being the inception, voestalpine opened the group competence centre for metal additive manufacturing in Düsseldorf in September 2016. Today, the 14 employees are primarily involved in development. Just about four months ago, the first expansion step took place in Asia: The setup of

voestalpine AG, High Performance Metals division, Linz, Austria Contact: www.voestalpine.com E-mail: peter.felsbach@voestalpine.com

MPT International 5 / 2017

“We are successively establishing metal additive manufacturing services close to our customers,” say Franz Rotter, head of the High Performance Metals division

the voestalpine Additive Manufacturing Center Singapore Pte. Ltd signifies a technological expansion of European activities and opens up access to this growing market in the Southeast Asia region. While the team in Düsseldorf is known for producing finely structured, lightweight small parts and tools, the Singapore team specializes in manufacturing and repairing objects weighing up to 600 kilograms.

“In line with our global service strategy, we are successively establishing metal additive manufacturing services close to our customers. The focus is on applying different additive manufacturing processes to best meet their individual requirements,” states Franz Rotter, member of the voestalpine AG management board and head of the High Performance Metals division.

The voestalpine Technology Institute Asia that will open in 2017 in Taiwan is the group’s third research centre

for metal additive manufacturing. The centre will have its own technology that supplements the other research centres’ technologies. At the same time, capacity for high-tech printing for both research and commercial purposes is being built up in Toronto, the first voestalpine site for this manufacturing process in the NAFTA region.

Million euro investments in metal powder production To keep up with the increasing demand for high-quality metal powders (e.g. based on stainless steels, tool steels, nickel-based alloys, and titanium) for 3D printing, voestalpine is increasingly investing and expanding capacity at the group companies Böhler Edelstahl GmbH & Co KG, Austria, and Uddeholms AB, Sweden. Following the setup of state-of-the-art at-

ADDITIVE MANUFACTURING omization lines for powder production at the two sites in 2016, a total of EUR 20 million is currently being invested in similar systems. Working in close cooperation with the new research centres, innovative powder types that are even more corrosion-resistant and stronger will be developed for increasingly sophisticated applications. Both voestalpine production companies benefit from long-standing experience in manufacturing powder steels. In total, the voestalpine Group is currently investing around EUR 50 million in building up leading expertise in the area of metal additive manufacturing.

The voestalpine AG’s High Performance Metals division is focused on producing and processing high-performance materials and customer-specific services including heat treatment, high-tech surface treatments, and additive manufacturing processes. Due to its unique sales and service network at about 160 sites around the world the division offers its customers material availability and processing as well as local points of contact. The division is the global market leader for tool steel and a leading provider of high-speed steel, valve steel, and other products made of special steels, as well as powder materials, nickel-based alloys, and titanium. The most important customer segments are the automotive, oil and natural gas exploration, and mechanical engineering industries as well as the consumer goods and aerospace industries. In the business year 2016/17, the division reported revenue of around EUR 2.7 billion, of which about 50% was generated outside Europe, and an operating result (EBITDA) of EUR 395 million; it has around 13,700 employees worldwide.

New research centre for the development of advanced long steel products voestalpine invests also in development and conventional production of high-quality steels. On company grounds in Donawitz/Austria, voestalpine is setting up a 2,800 m² “Metallurgy Center” research facility that will work on steels of the future starting in 2018. The center will supplement the steel research centre at the flat steel site in Linz. “Ongoing development of steel is the basis for ensuring that our

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Metal powder production plant at Böhler Edelstahl in Austria, a company of voestalpine Group

final products meet the highest quality criteria. A small version of an entire steel plant will be built in the research centre, enabling us to transfer our findings directly to the large plants,” says Franz Kainersdorfer, member of the management board of voestalpine AG and head of the Metal Engineering division. The goal of the project is to develop new high-performance steels with even higher strength, lower weight, and better corrosion resistance – especially for the mobility and energy sectors. The use of these future materials will allow, for example, stronger yet lighter drive rod components to be used in automotive construction, thereby reducing fuel consumption.

While the existing Metal Engineering division operating plants require a minimum production quantity of 68 t of steel, development in the “Metallurgy Center” will work with comparatively low weight units of around 4 t. The characteristics of the new steel grades will be tested in normal machining processes for producing rolled

wire, rails, and seamless tubes. This should help to significantly shorten innovation times for high-performance steels and to supply customers with small quantities, something that has not been possible to date.

The voestalpine Group’s Metal Engineering division is one of the world’s leading providers of special rails for the railway infrastructure, quality rolled wire especially for automobile manufacturers, and high-tech seamless tubes for the oil and gas industry.

The division is to set up a new continuous casting line for producing extremely pure steels as a sophisticated pre-material for premium rails, quality rolled wire, and high-tech seamless tubes. The new caster, which will be set up parallel to the existing line and will replace it in future, features fully digitized process control and is state-of-the-art with respect to Industry 4.0. The highly automated production line with an annual capacity of up to 950,000 tons is scheduled to start operation in 2019.

MPT International 5 / 2017

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş ADDITIVE MANUFACTURING

3D printing boosts production of spray heads for forging presses For the production of spray heads for forging presses, SMS group takes advantage of the opportunities afforded by additive manufacturing. Flexible actuation of individual nozzles paired with fast handling and a homogeneously distributed coolant mist shortens cycle times of the forging press and extends the service life of the dies.

Spray heads used in closed-die forging presses serve to remove scale from the dies between the individual press strokes, to cool the surface, to apply lubricants and dry the die surface. Performing these activities, conventional spray heads reach their limits time and again.

Therefore, SMS group began to manufacture such spray heads using a 3D printing method. The starting material is fine powder based on polyamide, and the result is 3D-printed spray heads that are 90 percent lighter than identical parts made of steel. This allows the use of handling systems faster than those employed before. Also, the compact 3D spray heads can be produced tailored to the design of the respective dies.

SMS group, DĂźsseldorf, Germany Contact: www.sms-group.com E-mail: thilo.sagermann@sms-group.com

SMS group offers the forging industry linear, cam-controlled or servomotor-driven spray systems and industrial robots. The new 3D spray heads shorten the cycle time of the forging press and hence raise its output. The low weight of the spray heads facilitates their installation and replacement and, at the same time, reduces wear of the handling systems.

Proven technology taken one step further Actuation of the 3D spray heads, too, offers SMS group completely new options. Each nozzle can now be actuated separately, both for spraying and for separately blowing out atomizer air, either simultaneously or offset in time.

Consuming a minimum of spray medium, the heads produce a spray pattern that is homogeneously distributed over the tool surface and, consequently, achieve a long tool service life.

3D printing offers the opportunity to deviate from the laminar design

of the previous generation of spray heads. The perforated structure prevents spray medium from accumulating on the spray head. The interior of the individual channels is flow-optimized and precludes the formation of deposits. As 3D spray heads have no parting lines, the spray medium is not exposed to air during downtimes and cannot dry out.

From the proven disk spray heads also developed by SMS group, the design engineers adopted the principle of external-mix two-component nozzles which produce an extremely fine aerosol. Contrary to internal-mix systems, segregation of the individual components cannot occur with this technology.

To switch the nozzles, SMS group continues to use for the 3D spray heads the tried and proven membrane material employed for disk spray heads. The membrane platelets are located directly at the nozzle. The short switching times allow for high dynamics, while dripping is precluded.

Spray heads printed to the 3D method have less weight, CTG RTQEGUU QRVKOK\GF KP FGUKIP CPF OQTG Ć&#x192;GZKDNG KP WUG MPT International 5 / 2017

TECHNICAL INNOVATIONS

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Secondary cooling system for sophisticated steel grades CONTINUOUS CASTING Pneumatically operated water control valves and related automation systems form the centrepiece of the HD spray system, an air-mist cooling system newly developed by SMS group for continuous casters. It is a scalable water distribution and control system which, compared to conventional solutions, requires far less space and pipework. The secondary cooling water is regulated and distributed only just before the cooling nozzles. This does away with negative influences such as long control lines or pressure losses. What’s more, the use of HD spray means a 30% reduction in process air consumption.

At ArcelorMittal Bremen, SMS group’s HD spray technology is to be installed as part of the modification of the twostrand vertical bending machine. SMS group’s supply scope includes the entire basic and detail engineering, delivery and erection, and supervision of commissioning.

Contact: www.sms-group.com

Pneumatically operated water control valves

WORKING SOLUTIONS FOR EXTREME CONDITIONS

TML Technik GmbH | A Company of the Fon: +49 (0)2173 - 95 75 100 | Fax: +49 (0)2173 - 95 75 400 E-mail: info@tml-technik.com | www.tml-technik.com

ENGINEERING | PRODUCTION | SERVICE

Water-cooled components for the steel industry 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.

Kuhlmann-System-Kühltechnik 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

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››› TECHNICAL INNOVATIONS

Automatic furnace control system for EAFs STEELMAKING The Danieli Q-Melt automatic furnace control uses real-time process variables to perform automatic closed-loop control of the chemical and electrical furnace profiles. Danieli has recently installed Q-Melt process control and the latest More sidewall injection technology to upgrade the 150 t EAF of Kroman Çelik in Turkey. The execution of the revamping took just nine days and resulted in a rapid productivity ramp-up. Just a few weeks after start-up, the new Danieli Q-Melt adaptive process control significantly improved overall EAF performance in terms of higher productivity, shorter tap-to-tap times and lower overall consumption rates.

Contact: www.danieli.com Principle of the furnace control system

Mobile leak detector SPECIAL EQUIPMENT Edwards is launching a new precision leak detector designed for fast, accurate leak detection and customizable for any application. Edwards’ ELD500 is ready to go in under two minutes from power on. Users can benefit from simple pass/fail readings through to detailed analysis via the easy to read control interface, and due to the low weight and integrated carry handles it is mobile enough to be bench top or trolley mounted. At the push of a button the ELD500 can easily be set to work in either vacuum mode for precise measurement of leak rate, or sniffer mode for identifying the leak location. The system achieves excellent repeatable accuracy through calibration with the integrated test leak source and high quality mass spectrometer, so it could be used on a production line, where consistent measurement repeatability is critical, or in a laboratory environment where typically the measurement of extremely low leak rates is needed. The leak detector comes in three variants, FLEX, WET and DRY, plus an extensive catalogue of accessories.

Contact: www.edwardsvacuum.com

Leak detector MPT International 5 / 2017

New lubricant analysis programme ANALYTICAL EQUIMENT ExxonMobil has launched Mobil ServSM lubricant analysis, a new mobile-enabled used oil analysis service. The new service will help operators identify equipment issues before they happen and avoid unscheduled equipment maintenance. The service, which replaces ExxonMobil’s SignumSM, is vital in helping engineers maintain a healthy and reliable operation. When monitored regularly, the used oil analysis programme helps to enhance equipment reliability, reduce maintenance costs and unscheduled downtime, improve equipment durability and reduce lubricant consumption. It can also help to extend oil drain intervals, which in turn improves safety by reducing intervention with machinery.

Designed to streamline the entire used oil analysis process from initial sample gathering to final reporting, the service leverages scan-and-go technology with QR Codes so customers can easily deliver used oil samples to ExxonMobil’s oil analysis laboratory. Customers can then access results and customized equipment recommendations on mobile or tablet devices using a cloud-based app and share it with any other parties, as needed.

The new services package can also eliminate labels and paperwork and facilitates real-time communication of sampling scheduling and results. However, customers will still be able to manage and assess their reporting manually. In addition to the new, user-friendly interface, the system also offers improved response time. The used oil analysis programme offers a full 360° analysis allowing operators to track productivity trends and spot any anomalies. With 25 testing options available users are able to pick and choose the right test package for their operation.

Contact: www.exxonmobil.com

SHORT WAVELENGTH

INFRARED CAMERA

NEW thermoIMAGER TIM M1 for non-contact temperature measurement of metal surfaces Highly dynamic CMOS detector with frame rates up to 1kHz Optical resolution up to 764 x 480 pixels Temperature range from 450°C to 1800°C

/@RRHU@SHNM ×THC solutions

Spectral range from 0.92 to 1.1μm Extremely lightweight, robust and compact License-free analysis software and complete SDK included

SURFACE TREATMENT In steel manufacturing, the galvanizing process provides corrosion protection to the steel substrate followed by passivation to protect the zinc surface.

Choosing an effective passivate chemistry with an appropriate regulatory consideration is a growing challenge given varying regional requirements. To meet this demand, Quaker Chemical offers the Primecoat™ line which consists of product options of hexavalent chromium (Cr6+), trivalent chromium (Cr3+) and chromium-free technology to satisfy process needs. The key benefits of the Primecoat™ line of products include transparent film, good appearance even at higher coating weights and excellent corrosion protection.

Contact: www.quakerchem.com

Phone +49 - 8542 1680 www.micro-epsilon.com/tim

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››› TECHNICAL INNOVATIONS

Machining centres with integrated measurement SPECIAL EQUIPMENT Heinrich Georg Maschinenfabrik has integrated a two-point measurement system in its “ultraturn MC” series horizontal machining centres. These machines process workpieces weighing 10 t and more, with diameters of 1,000 mm upwards. Georg uses a travelling two-point measuring system attached to the frame, which automatically measures the workpieces directly in the machine by two opposing probes. This technique ensures high precision and high reproducibility. “ultraturn MC” machines are used among other things for complete machining of turbine and generator rotors as well as crankshafts.

While a measuring team would need several hours to manually measure the diameters or the axial run-out of workpieces on the machine, measurement with the integrated two-point system is completed after just a few minutes. The system is also applicable to Georg’s classic lathe series for roll and turbine rotor machining, or it can be retrofitted to existing lathes made by Georg or other manufacturers.

BRAUN Innovations tions for Steel chnology for Cutting-edge technology ding cutting and grinding

B

Two opposing probes detect the diameter of rotating parts in the lathe

Contact: www.georg.com

Automatic sampling manipulator for EAF STEELMAKING A new generation of CATFIS automatic EAF temperature and sampling manipulator, developed by More with four axes and four degrees of freedom, operates through the EAF slag door and fits into very constrained and confined areas. The main features of CATFIS 2.1 include high movement versatility, anti-collision system, sturdy equipment for minimum maintenance requirements and reduced risk of injuries. In June 2017, a CATFIS 2.1 manipulator was successfully commissioned at Ovako Imatra in Finland, where it operates at an 80 t spout EAF. Contact: www.more-oxy.com

office@braun-steel.com

• High-performance cut-off machines • Multi-functional grinding machines • Automated turn-key solutions • Technical consulting • Life-time service support

INNOVATIONS FOR STEEL

www.b raun- steel. c o m

BRAUN Maschinenfabrik GmbH - Austria BRAUN Machine Technologies, LLC - USA BRAUN Machine Technologies (Beijing) Co., Ltd. - PR China

Sampling manipulator MPT International 5 / 2017

TECHNICAL INNOVATIONS

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Precision thickness measurement with compact sensor system GAUGING TECHNOLOGY Micro-Epsilon has extended its C-frame product range for thickness measurement with a gauge particularly well suited for precision measurement of narrow strips. The sensor provides extremely high-precision results combined with ease of use and a compact design. The measurement process is performed on a non-contact, wear-free basis.

The new thicknessSENSOR system consists of two laser triangulation sensors that are fixed opposite to each other on a frame, measuring against the target from both sides.

The evaluation unit integrated into the frame calculates the thickness values and outputs them analogically via tension and current or digitally via Ethernet. The sensors can be easily aligned for the respective measurement tasks. Due to its extremely compact size, the system can also be easily integrated into restricted installation space. The contact-free system reliably measures strip and plate made of metals and plastics. It can be used as a data source for documentation purposes and monitoring tasks. The intuitive web interface provides the new sensor system with particular ease of use and enables the user to load individual presets for the respective measurement task. Up to eight user-specific sensor settings can be stored and exported in the setup management

feature. The measurement task can be optimized using signal peak selection and freely adjustable signal averaging.

Contact: www.micro-epsilon.com

C-frame thickness gauges

© Utz Peter Greis, Düsseldorf

Cartoon

MPT International 5 / 2017

››› LITERATURE SERVICE

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Induction heating 6 pages, English A brochure featuring the EBS induction heating system supplied by ABP Induction Systems for forging applications. Aspects highlighted include the coil design, IGBT technology, the heating processor, zone control technology and simulation software.

Contact: E-mail:

www.abpinduction.com info@abpinduction.com

Insulation technology 4 pages, English, German This brochure provides comprehensive information about the Thermo-Protector insulation system offered by Lippmann for thermal insulation and protection of flexible and complex piping systems and components. The product is suitable for temperatures ranging from -50°C to +250°C. Contact: E-mail:

www.lippmann-gmbh.com info@lippmann-gmbh.com

Sensors for steelworks Sensors for steelworks

SENS OR S M A DE IN GER M A N Y

24 pages, English A comprehensive brochure outlining the range of sensor products made by Proxitron. Different sensor types are presented and examples of application provided, such as material detection and monitoring in continuous casting plants, on roller beds, at reheating furnaces, rolling mills, etc.

Contact: E-mail:

www.proxitron.de info@proxitron.de

Cooling systems for industrial furnaces Cooling systems for industrial furnaces

12 pages, English A company brochure setting out the range of activities and expertise of Reining Heisskühlung.

The company is specialized in the design and construction of cooling systems for industrial furnaces used in ferrous and non-ferrous metallurgical processes.

Reining Heisskühlung For more than 70 years: the name says it all

Keeping Transformer Vaults and Control Rooms Clean

For

STEEL MILLS

Contact: E-mail:

www.reining-heisskuehlung.de mail@rh-gmbh.com

Air cleaning solutions 4 pages, English This brochure presents air cleaning systems supplied by The Systems Group for applications in steel mills, such as at transformer vaults, compressor intakes or control rooms. The system is of modular design with virtually unlimited component configurations. Filter cleaning takes place automatically.

Contact:

MPT International 5 / 2017

www.tsg.bz

IN THE NEXT ISSUE…

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Ironmaking Lebedinskiy GOK commissions new direct reduction plant in Russia The new direct reduction plant will produce 1.8 million t/year of hot briquetted iron (HBI). The plant completed the seven-day performance test with 100% achievement of the guarantee parameters. Already during the test period, HBI production exceeded the design criteria.

Steelmaking – Automation Successful upgrading of automation system in steelmaking plant of Hadeed Saudi Iron & Steel As part of a turnkey project, the Level 2 process automation system and the Level 3 production planning system for three EAFs, two ladle furnaces and two of the three continuous casters and auxiliary equipment have been completely replaced.

New process models provide noticeably more efficient steelmaking and refining. The implemented solution is designed to allow gradual integration of additional digital enhancements.

Hot rolling voestalpine opens advanced wire rod mill in Austria The new high-tech wire rod mill at the site of voestalpine Metal Engineering division in Leoben/Donawitz in Austria will produce 550,000 t/year of premium wire rod for sophisticated applications in the automotive, energy, construction and mechanical engineering industries.

Strip processing Fully automatic strapping and sampling system for steel coils, including ultra-high-strength grades Steels for tube and pipe cover a broad range of grades, from soft low-strength to ultra-high-strength steels, with product thicknesses of over 25 mm. It is particularly challenging for the steel producers to safely deliver coils to the end customers. A fully automatic strapping and sampling system has been developed that meets the technical requirements particularly for ultra-high-strength grades.

This preview may be subject to change.

Metallurgical Plant and Technology

Advertising Manager: Sigrid Klinge

+49 211 6707-552, Fax +49 211 6707-923-552 e-mail sigrid.klinge@stahleisen.de Distribution Dept.: Gabriele Wald

+49 211 6707-527, Fax +49 211 6707-582 e-mail gabriele.wald@stahleisen.de Production Manager: Burkhard Starkulla e-mail burkhard.starkulla@stahleisen.de

Published by: Verlag Stahleisen GmbH P.O. Box 10 51 64, 40042 Düsseldorf, Germany e-mail mpt@stahleisen.de Publisher: Steel Institute VDEh Executive Member of the Management Board: Dr.-Ing. Peter Dahlmann Internet: www.mpt-international.com Editorial Staff: Chief Editor: Dipl.-Ing. Arnt Hannewald

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MPT International 5 / 2017

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