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Metallurgical Plant and Technology G 25074

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ISSN 0935-7254

BILSTEIN expands fully automatic batch annealing plant in Germany

April 2018

Sweden gears up for fossil-free steel production


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EDITORIAL

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MPT International is now UCKNKPIWPFGTCPGYƃCI The steel sector is in transition, and companies are adjusting their strategies to the changing markets. The entire steel community is facing the challenges of advancing digitalization, demographic issues and new rules in global trade. The same is true for the media business, the media people and the media themselves. That goes for our publishing house Verlag Stahleisen too - a company founded by the Steel Institute VDEh in Germany in the early 20th century. Setting the course for the digital era in business communication, the publishing house has been taken over as of April 1, 2018 by private investors active in the media business with very successful journals and dedicated corporate publications. This has created an even healthier basis and better prospects for the popular Stahleisen media – while strengthening their leading position in the global steel community. Joachim Berendt As of now jbd Gesellschaft für Medien und Kommunikation mbH will act as the publishing company also of the prestigious technical journal MPT International. Remaining based in Düsseldorf, we are going to continue the proven cooperation with Steel Institute VDEh and all contributing partners in the global steel community. All is set for the ongoing success of MPT International as the leading technical journal of the global iron and steel industry and your preferred source of information about metallurgical plant and technology. Actually, for our readers, nothing will change. You will continue receiving an attractive publication containing topical information about current projects, technical innovations, market developments and news from the world of steel. We are all set to start our new era with enthusiasm, dedication and keenness, and we highly appreciate any input or suggestions by our readers as we proceed along our new path. Yours, Joachim Berendt Managing Partner at jbd Gesellschaft für Medien und Kommunikation mbH joachim . berendt @ stahleisen.de

MPT International 2 / 2018


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

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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

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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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HOT STRIP, PLATE AND COLD MILLS

STRIP PROCESSING AND FINISHING LINES

HEAVY SECTION, RAIL, BAR AND WIREROD MILLS

DRAWING AND PEELING MACHINES

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SEAMLESS TUBE AND WELDED PIPE PLANTS

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EXTRUSION AND FORGING PRESSES

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ALUMINIUM HOT AND COLD MILLS


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››› CONTENTS

Events 28

AISTech 2018 – the steel’s premier event in North America

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GIFA, METEC, THERMPROCESS and NEWCAST – the trade fairs are preparing for 2019

Ironmaking – Steelmaking 32

Sweden gears up for fossil-free steel production Coverphoto: The world’s only fully automatic bell-type anMD@KHMFOK@MSVHSGTMHPTDDMDQFXDEÖBHDMBX in the heat-treatment of steel strip LOI Thermprocess GmbH, Essen, Germany Contact: www.tenova.com E-mail: service-loi@tenova.com

Nordic steel company SSAB has developed a road map for transition the business to fossil-free roduction

Raw material handling 36

Newly developed hybrid feeder for spherical materials Nickel mattes is extremely difficult to handle as it consists of particles which are almost perfectly spherical, creating challenges for the operator in its reception, interim storage and onward transportation

Continuous casting

Quality assurance

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voestalpine to upgrade bloom casting mill in Austria making it compatible to Industry 4.0 The group is investing more than EUR 100 million in future-oriented projects at its Donawitz site in Austria

New technology for classifying the homogeneity of cast products “HD scan” is a testing solution for centreline segregations of slabs and blooms that overcomes the drawbacks of visual inspection of etched samples

Hot rolling

Tube making

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New rail and section mill started up operations in Kazakhstan The first rails were produced at the first and only rail manufacturing plant in Kazakhstan

Tenaris starts advanced seamless pipe production for the demanding US oil and gas industry The company invested a total of 1.8 billion US dollars in the Greenfield project, located near the most active shale plays in the United States

Heat treatment

Cold rolling

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Cold-rolled steel manufacturer BILSTEIN expands fully automatic batch annealing plant This batch annealing plant stands out by being the only fully automatic batch annealing plant in the world. Moreover, it is the strongest-performing and most energy-efficient furnace plant of this typ e

MPT International 2 / 2018

Advanced plant concept for reduction and skin-pass operations of steel strip Cold-rolled steel manufacturer BILSTEIN ordered a high-performance plant designed for reduction and skin-pass (RCM/SPM) operations particularly of demanding steel grades


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Strip processing 56

New-generation wiping system for more uniform and thinner zinc coatings

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The new CXJ wiping system from Danieli Kohler has obliterated the old boundaries for line speed and coating weight while delivering superior quality coated strip products for the automotive industries

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Laura Metaal upgrades cut-to-length line at steel service centre The Dutch company has successfully modernized the plant in order to be able to process heavier gauge materials, ultra-high strength steel strip and also abrasive hot rolled coils

Fully automatic strapping and sampling line for steel coils of up to ultra-high-strength grades Steel grades for welded tube and pipe cover a broad range from soft low-strength to ultra-high-strength steels. It is particularly challenging for the steel producers to deliver coils to the end customers safely

Columns 8

International industry news

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Literature service

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Technical innovations

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In the next issue

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Cartoon

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Imprint

Advertisers’ index ABB AB 63 AGTOS Ges. für technische Oberflächensysteme mbH 46 AMCO united samplers and assayers GmbH 31 Aumund Fördertechnik GmbH 39 BEDA-Oxygentechnik Armaturen GmbH 55 BM S.p.A. 25 BRAUN Maschinenfabrik GmbH 25 BSE Badische Stahl-Engineering GmbH 33 Bürkert Werke GmbH & Co. KG 29 Combilift Ltd. 10 Danieli & C. Officine Meccaniche SpA 4, 5 DMT GmbH & Co. KG 47 Dr. Brandt GmbH 13 Fabris Inc. 53

Glama Maschinenbau GmbH 35 Hannover Messe Ankiros Fuarcilik A.S. 65 INTECO melting and casting technologies GmbH 67 Jasper Ges. für Energiewirtschaft und Kybernetik mbH 69 JATO-Düsenbau AG 18 KELLER HCW GmbH 60 KIRO-NATHAUS GmbH 68 Maschinenfabrik Gustav Eirich GmbH & Co. KG 15 Messe Düsseldorf GmbH 66 Metal-Expo JSC 75 MICRO-EPSILON Messtechnik GmbH & Co. KG 23 Paul Wurth S.A. 19, 20

Polytec GmbH Primetals Technologies Austria GmbH Quartz Business Media Ltd. Redecam Group SpA Saar-Metallwerke GmbH SMS Mevac GmbH Solaronics SA Stein Injection Technology GmbH TAMINI Trasformatori S.r.l. thyssenkrupp Ind. Solutions AG TML Technik GmbH TMT GmbH VELCO GmbH Ventilatorenfabrik Oelde GmbH Zumbach Electronic AG

21 76 70 61 16 2 22 24 9 37 14 57 17 71 11

MPT International 2 / 2018


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››› INTERNATIONAL INDUSTRY NEWS

Africa South Africa Acerinox to invest 5 million euros in its Columbus site. Acerinox is going to install a new slitting line at its Columbus Stainless factory. The new line will allow the company to reduce delivery times and increasing monthly exports by 3,000 tonnes.

The Americas Canada ArcelorMittal invests in modernization projects. ArcelorMittal Long Products Canada has announced major investments in its Contrecoeur, Quebec, steel production facilities. Two reheating furnaces at its Contrecoeur-East wire rod mill and its Contrecoeur-West bar mill will be replaced, with the aims to increase the company’s rolling capacity by 100,000 t/year, enable greater productivity, optimal energy use and reduced greenhouse gas emissions. The work should extend until the first half of 2020. At the same time, ArcelorMittal will be replacing the dust collector at the Contrecoeur-West steelworks by the end of 2018.

Mexico ArcelorMittal Lázaro Cárdenas orders hot strip mill and hot skin pass mill. ArcelorMittal México has placed an order with Primetals Technologies to supply a hot strip mill and a hot skin pass mill for its production site in Ciudad Lázaro Cárdenas, Michoacán State. This will enable ArcelorMittal Lázaro Cárdenas to process the slabs produced in its works on site. The hot strip mill will be erected on a turn-key basis, including power supply, mechanical equipment, drives and automation. The project will be executed in an open consortium with Mexican construction companies. Design capacity will be 2.5 million t/year of hot strip. The hot strip mill will consist of MPT International 2 / 2018

a roughing mill and a seven-stand finishing mill and roll slabs with thicknesses of 220 or 250 mm. The hot skin pass mill will be designed to process 650,000 t/year. The start-up of both mills is planned for 2020. All equipment will be engineered and supplied by Primetals Technologies. In addition to the mechanical equipment, Primetals Technologies will also be in charge of the engineering and supply of automation and drive systems.

USA AK Steel signs on-site service contract. Harsco‘s Metals & Minerals division has expanded its business relationship with flat-rolled steel producer AK Steel. The agreement calls for the use of Harsco’s innovative ScrapMaster™ program for scrap management services including inbound scrap handling and inspection, basket preparation and hauling, and delivery route maintenance at AK Steel’s Mansfield, Ohio site. Harsco also currently provides similar services at AK Steel’s site in Butler, Pennsylvania.

News in brief ArcelorMittal Hochfeld, Germany, has brought on stream the new LD (BOF) converter constructed by Primetals Technologies. The new converter has a tapping weight of 150 t and replaces the previous “K2” converter. Tata Steel and Swansea University, United Kingdom, have opened the Steel & Metals Institute, a long-term research and innovation collaboration between Tata Steel and Swansea University. Engineers and researchers will be working on a range of new materials to meet the emerging need for next-generation steels. Mechel, Russia, has launched SIN beam production from its own rolled flats at a new automated production line built by Zeman at the Chelyabinsk works. SIN beams are an exclusive type of welded H- and I-beams, with extra durability and yield strength due to corrugated webs.

USA Gerdau to expand section size at SBQ mill. Gerdau’s special steel mill in Monroe, Michigan, will transition to a 240 mm square bloom as part of an overall initiative to enhance the steel cleanliness necessary for evolving critical applications in the automotive market and other industries. This project is an expansion of the capability of the mill’s continuous casting machine that was originally installed in 2012. The switch to a larger section size will result in a greater reduction ratio, improved surface quality and cleaner steel with fewer inclusions. Production of the new section size is slated to start in September 2018. The company has recently invested in several other pieces of diagnostic equipment to evaluate improvement in steel cleanliness, including the latest automated SEM, image analysis for extreme value analysis and ultrasonic immersion testing equipment with low, medium, and high frequency capability.

ArcelorMittal India has submitted an offer for Essar Steel India Limited in connection with the joint venture between ArcelorMittal and NSSMC to jointly acquire and manage Essar Steel. YISAD, Turkish Flat Steel Import, Export and Industry Association, has decided to join Eurometal. YISAD, based in Istanbul, was established in 2003 and represents the complete scope of the flat steel sector. NLMK, Russia, has begun hot testing of its new turbine generator unit No. 5 at its Cogeneration Plant in Lipetsk. Once commissioned, the 60 MW new generator will improve the reliability of the energy supply, reduce energy procurement costs and increase the share of in-house power generation.


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››› INTERNATIONAL INDUSTRY NEWS

USA Steel Dynamics to build new water treatment plant. Following the order for a new billet welder and spooler line to be installed at SDI Structural and Rail Products in Columbia City, Indiana, SDI has now ordered a water-treatment plant from Danieli to complete the project. The new water-treatment plant will include the indirect cooling circuit and direct cooling circuits. The plant will be equipped with Danieli-patented sand filters. The new SDI water-treatment plant will be designed to allow for a future rolling mill expansion. Commissioning is planned to take place by the third quarter of 2018.

USA Liberty Steel to re-open recently-acquired mill. Liberty Steel prepares to re-open its Georgetown mill in South Carolina, which it acquired from ArcelorMittal in December 2017.

Following maintenance and upgrade of equipment, the company aims to restart production at the plant in the second quarter of the year and intends to operate its electric arc furnace at full capacity as soon as feasible. Over the remainder of 2018, Liberty Steel Georgetown will focus on ensuring wire rod coils from its rolling mill are meeting customer specifications and, thereafter, the plant will ramp up production to meet customer demand.

USA CMC acquires steel mill assets in four US states. Commercial Metals Company (CMC) has entered into a definitive agreement to acquire certain rebar assets from Gerdau. The acquisition includes steel mills located in Knoxville, Tennessee; Jacksonville, Florida; Sayreville, New Jersey, and Rancho Cucamonga, California, with annual mill rolling capacity of 2.5 million t, as well as 33 rebar fabrication facilities.

USA Republic Steel ready to restart Lorain facilities. Lorain Pig Iron, which is jointly owned and operated by Republic Steel and ERP Iron Ore, has engaged technical service providers to review and submit proposals for the recommissioning of Republic Steel’s blast furnace 4 in Lorain, Ohio. LPI is expected to commence the production of pig iron at the blast furnace before the end of 2018. The furnace will be recommissioned in partnership with the United Steel Workers and is expected to produce and distribute over 1.0 million t/year of pig iron to customers within the United States. Republic Steel has also announced that it is positioned to restart its idled electric arc furnace, casters and rolling mills on short notice as response to the recently announced steel tariff. Republic currently has open capacity at its Canton melt shop and would restart Lorain which would provide new production capacity to support the SBQ bar & coil and seamless tube round markets.

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INTERNATIONAL INDUSTRY NEWS

USA United States Steel to restart Granite City Works. United States Steel Corporation will restart one of two blast furnaces (“B” blast furnace) and the steelmaking facilities at its Granite City Works in Illinois. The additional capacity will support anticipated increased demand for steel in the United States. Both Granite City Works blast furnaces and its steelmaking facilities were idled in December 2015. The plant’s hot strip mill was idled in January 2016. The hot strip mill was restarted in February 2017 as the company adjusted its hot strip mill operating configuration to meet customer needs after deciding to accelerate the pace of its asset revitalization efforts. Granite City’s “A” blast furnace remains idled.

USA Nucor Steel Kankakee to build new merchant bar mill. Nucor Steel Kankakee has chosen SMS group as the

primary technology supplier for its new 500,000 t/year merchant bar mill. The new facility will be installed at its existing bar mill located in Bourbonnais, Illinois, with production scheduled to commence in 2019. The new plant will be designed to produce a wide range of merchant bar products to complement the existing product portfolio. It will consist of 16 stands, including five dual-drive convertible stands, all equipped with quick-changing device. Additional highlights will be a multi-line straightening machine with automatic bar positioning and feeding device and automatic roll changing system. The new generation high-precision profile gauge MEERgauge® with surface defect detection capability allows Nucor Steel Kankakee a contactless precision measurement for optimal bar production processes. Braun Maschinenfabrik will supply two combined abrasive cut-off and friction sawing machines, type TSFS 12 FP, for the new mill. The two high-performance cutting facilities will be able to be operated as abrasive cutting machines with 1,270 mm cutting wheels or as friction saws with 1,050 mm metallic saw blades for

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warm or cold cutting of 1,160 mm wide layers of round bars, rebar, channels, flats, as well as equal and unequal angles.

Asia China Jianlong Beiman orders core components for high-speed wire rod mill. Jianlong Beiman Special Steel, based in Qiqihar, has awarded SMS group a contract to supply core components for a high-speed wire rod mill for quality steel. The centrepiece of the new wire rod mill, which has an annual capacity of 500,000 t, is ten-stand wire rod finishing block. The wire rod mill, designed for low-temperature rolling, will receive a cooling and equalizing loop upstream of the block and be able to produce wire rod in diameters from 5.5 to 25 mm and rebar with diameters ranging from 6 to 16 mm at finish rolling speeds of up to 115 m/s. In addition to the wire rod finishing

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››› INTERNATIONAL INDUSTRY NEWS

News in brief Tata Steel, United Kingdom, has installed a transfer bar cooling system in its hot strip mill at Port Talbot, allowing the company to manufacture more higher-value steels. The transfer bar cooling system is to increase the volume capacity of the hot strip mill by more than 150,000 t/year. EVRAZ ZSMK, Russia, has issued the final acceptance certificate for electric arc furnace No. 2 modernized by Primetals Technologies. Tata Steel, India, has unveiled the solid liquid separation (SLS) plant for slurry from the gas cleaning process at its Joda ferro alloys plant in the Keonjhar district, Odisha. The SLS plant is an environment-friendly initiative, set to recover manganese-rich solid from the wet gas cleaning slurry. Egyptian Steel has started production in its No. 2 micromill supplied by Danieli. The mill features endless casting and rolling technology to produce commercial steel rebar for construction applications. ŽDB Wireworks, Czech Republic, has completed the first part of the modernization of its unpatented wire facilities in Bohumín. The company, a subsidiary of Trinec Iron and Steel, has reconstructed a part of the rolling mill with an annual capacity of about 60,000 t and has built a new hall for the annealing section. Next, a third annealing furnace will be built. Severstal, Russia, has brought on stream a production line for polymer-coated rolled steel products at its Cherepovets metal coating workshop No. 3. The workshop features new equipment for a polymer coating line and a hot-dip galvanizing unit. Cockerill Maintenance & Ingenierie CMI supplied the main process equipment.

MPT International 2 / 2018

block, SMS group’s scope of supply also includes two cantilever compact roughing stands, the group of shears upstream of the block, and the loop laying head including pinch roll unit. SMS group is also supplying the design for the LCC® loop cooling conveyor with three-fan technology, as well as the coil handling system. Commissioning is scheduled to take place in spring 2019.

China Wälzholz to expand production of high-performance steel strip. Since 2014 Wälzholz has operated the first German cold rolling mill in China, at the site of the former Service Center Waelzholz New Material in Taicang, approximately 60 km north of Shanghai. Wälzholz has now ordered a new cold reversing mill from Danieli to expand the production of high-performance steel strip. The new mill will be designed to roll a wide product mix of special steel grades, from an entry thickness of more than 5 mm down to a finish thickness of below 1 mm at a maximum strip width of 670 mm. Danieli Automation will provide electrics and automation. An intelligent data analysis systems, ready for Industry 4.0, will be connected to Wälzholz proprietary process data management system. Additionally, a new slitting line will be designed to slit the finished coils from the cold mill into narrow strips down to 12 mm width and maximum 20 slits.

China Shougang Jingtang to build pelletizing plants. Outotec will design and supply two iron ore pelletizing plants to Shougang Jingtang United Iron & Steel located in Caofeidian. The pelletizing plants, each with annual capacity of 4 million t of iron ore pellets, will be based on Outotec’s modern travelling grate technology. The plants are scheduled to be commissioned in 2019.

China Nanjing Iron & Steel to revamp continuous bloom caster. Nan-

jing Iron & Steel United has awarded Primetals Technologies the order to revamp its bloom caster No. 8 at the steel plant No. 3 in Nanjing. The caster, supplied by Primetals Technologies, was originally designed as a five-strand machine but was set up and has been operated as a three-strand caster since 2008. The current revamp will encompass the installation of a fourth strand, enabling the production of an additional bloom format with a rectangular cross section of 320 mm x 420 mm. The revamped caster is scheduled to come on stream in June 2018.

China Shandong Steel Rizhao commissions blast furnace. Shandong Steel Group Rizhao has blown in the first blast furnace at a new production site which is to help phase out older ironmaking facilities in the group. Just 26 hours after the blow-in, the first hot metal was tapped from the furnace for which Paul Wurth supplied top charging and slag granulation technology. The current phase of construction at Shandong Steel Group Rizhao consists of two blast furnaces with 5,100 m³ inner volume each. They will be fitted with central feed Bell Less Top® charging systems and Paul Wurth’s INBA® cold water system with two dewatering drums for reliable slag sand production. Commissioning of blast furnace 2 is scheduled for summer this year. Paul Wurth also designed the coke batteries for this plant project and will supply single-oven pressure control valves and level 2 automation packages.

China Pangang orders measuring system for rail production. Panzhihua Iron and Steel (Pangang) has ordered a measuring system from Nextsense. Based on non-contact measurement technology, the OSIRIS Hot laser-measurement system achieves extremely accurate measuring results and, being a combined system, it identifies both profile deviations and surface defects in one step. This will allow Pangang to continu-


INTERNATIONAL INDUSTRY NEWS ously monitor the rail rolling process, identify periodic defects and respond to them immediately.

China Masteel to install high-pressure billet grinding machine. Maanschan Iron & Steel (Masteel) has ordered a high-pressure billet grinding machine from Braun Maschinenfabrik. The multi-functional design will allow automatic bright grinding and corner grinding as well as spot grinding. The machine is scheduled to become operational in November 2018. Braun Maschinenfabrik will also supply other core equipment, such as the grinding carriage, loading and unloading cross conveyors, the lubrication system, the complete hydraulic and the electrical and automation systems of the facility.

China Hangzhou orders bell-type annealing plant. Tenova LOI Thermprocess has received an order from Hangzhou XZB Tech for the supply of an HPH® (high performance hydrogen) bell-type annealing plant for wire rod to become part of the new works installed in Huzhou. The order is for the delivery of a furnace plant with three annealing bases, two heating hoods and one jet cooling hood. Each annealing base will feature a useable diameter of 4,200 mm and a useable height of 5,300 mm, resulting in an average charge weight per base of approximately 48 t of hot-rolled or drawn wire coils. The production is scheduled to start in late autumn 2018.

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India JSW Dolvi orders reheating furnaces. JSW Dolvi Works is expanding its production capacities for high-quality strip. Fives has signed a contract with JSW for the design and supply of two reheating furnaces of the Stein Digit@l Furnace® design for a new hot strip mill. The furnce will be designed for a capacity of 450 t/h of slabs. The furnaces will feature the new generation of AdvanTek® burners, all installed on the furnace sidewalls. The employed level 2 process optimization system will enable control of the slab temperature profile in real time.

Iran Mahshahr Pipe Mill Company signs service and modernization contract. The company has signed a comprehensive service and modernization contract with SMS group for its large-diameter pipe mill in the Khuzestan province. In 2016, a team of specialists from SMS group and MPM conducted an audit aimed at inspecting the current maintenance status of the large-diameter pipe mill located in Mahshahr. Following the audit, a comprehensive service and modernization contract has now been agreed based on the list of recommendations compiled by SMS group. The contract includes the overhaul of the complete pipe welding equipment, replacement of both X-ray testing units and of the entire hydraulic control system. The plant will also be equipped with the new SHAPE automation system, which controls the forming process based on a continuous calculation of the optimum forming parameters. SMS group is also supplying an integrated maintenance management system.

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China Baosteel places follow-up order for reclaimers. Schade Lagertechnik has won an order from Baosteel Iron & Steel, Shanghai, for an additional supply of four semi-portal reclaimers. The machines will have a rail span of around 38 m and a capacity of 1,500 t/h. Commissioning of the reclaimers is planned for mid-2019.

Measuring mechanical variables electrically

AISTech 2018 | USA May 7–10 2018 | Philadelphia Stand 3052

Iran National Iranian Steel orders billet casting machine. National Iranian Steel Company has ordered a six-strand billet casting machine from SMS Concast. The plant will be part of a newly built EAF-based meltshop and designed for an annual capacity MPT International 2 / 2018

Precise. Durable. Innovative. Rombacher Huette 9 44795 Bochum Germany Phone: +49-234-94393-0 Fax: +49-234-433431 Mail: Web:

info@strip-tension.com www.strip-tension.com


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››› INTERNATIONAL INDUSTRY NEWS

of more than 800,000 t of billets. The Concast casting machine will have a casting radius of 9 m and produce billets of 130, 150 and 200 mm square in lengths ranging between 6 and 12 m. The caster will feature Convex® moulds arranged in the cartridge-type mould unit, a pre-assembled quick-change unit. The secondary cooling process will be divided into four zones, with the cooling parameters being set according to the section size, steel grade and casting speed. With the level 2 automation system installed, the secondary cooling process can be dynamically controlled on the basis of a software model. The machine will also be equipped with a cantilever-type tundish car on the casting platform, a tundish stopper system for submerged casting, a hydraulic short-lever oscillation system of the latest generation and fully integrated PLC for automatic operation of the entire plant.

Iraq United Brothers Holding orders steelmaking plant. United Brothers Holding has awarded Danieli the order for a new steelmaking plant, which will be installed within an existing building in the industrial area of Khor Al Zubair, near Basra. The new plant will have a production capacity of 500,000 t/year of billets. It will consist of a 70 t electric arc furnace, a 70 t ladle furnace equipped with a ladle lifting system, a material handling system supplying the EAF and LF with ferroalloys and additives, and a fume

dedusting plant for both furnaces. A 9-m-radius continuous casting machine will produce 150 mm x 150 mm billets on four strands. Danieli will provide all technological equipment including level 1 and level 2 automation systems, as well as advisory service for erection and plant startup. Project execution is planned to take less than two years with production start-up expected by summer 2019.

Japan Topy Industries to install spooler technology. Topy Industries has chosen Danieli K-Spool technology to produce high-quality, compact hotrolled coils. This new installation will make Topy Industries the first Japanese steelmaker to operate spooler technology. The line, to be installed at the Toyohashi Rolling Mill, Aichi Prefecture, will produce 240,000 t/year of spooled bar coils weighing from 1 to 3.5 t at a maximum coiling speed of 35 m/s. Perfectly shaped, no-twist spooled bars will be wound into compact coils by two K-Spool stations. Danieli Automation will provide automation and control systems, while strapping and labelling equipment will be manufactured by the Swedish Danieli Group company Sund Birsta. Additionally, a two-pass fast finishing block supplied along with a Hi-Profile measuring system and a Danieli QTS-quenching and tempering system will upgrade the existing finishing mill. The line is planned to start production in summer 2018.

Japan JFE Steel orders off-gas cleaning system. Primetals Technologies has received an order from JFE Steel to supply an off-gas cleaning system for its new sinter plant at the Fukuyama production site. The Meros (maximized emission reduction of sintering) plant will clean the process gas resulting from the operation of the Fukuyama 3 sinter plant, which will also be supplied by Primetals Technologies. The Meros system reduces SOx content by more than 97%, brings down dioxins concentrations to less than 0.1 ng-teq/Nm³ and reduces dust significantly. The new system is expected to be started up in the fourth quarter of 2019, together with the sinter plant.

Malaysia PMB Silicon to build two submerged arc furnaces. PMB Silicon, based in Sarawak, has contracted SMS group to supply two submerged arc furnaces for the production of silicon. The planned production capacity is 32,000 t/year of silicon. Commissioning is scheduled for autumn 2018. SMS group’s scope of supply includes the basic and detail engineering as well as the equipment for the 24 MW furnaces, which essentially comprises two rotating gear units, the furnace vessels, gas hoods, the installation of a power supply and mains voltage compensation system, and the supervision of erection and commissioning. A special feature are the rotating furnace vessels, which prevent car-

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MPT International 2 / 2018

ENGINEERING | PRODUCTION | SERVICE


bide precipitation in the furnace mix. With this new plant, PMB Silicon is securing its in-house silicon production.

Europe Austria voestalpine gets green light for hydrogen pilot plant. voestalpine has received the approval for the construction of the world’s largest pilot plant of its type for CO2-free production of hydrogen at the site in Linz. The H2FUTURE project will conduct research which explores, amongst others, the potential use of hydrogen in the individual stages of steel production. The pilot plant will be erected in a new building immediately adjacent to the voestalpine power plant at the site in Linz. The centrepiece of the new research facility will be the world’s largest PEM (proton exchange membrane) electrolyser, with a capacity of 6 MW and able to produce 1,200 m³ of hydrogen an hour. The electrolysis system developed by project partner Siemens will achieve a higher output efficiency than comparable systems to date. In a PEM electrolyser electrical energy – in this case electricity generated from renewable sources by project partner Verbund – is used to break down water into its constituent parts, hydrogen and oxygen. The H2FUTURE project consortium consists of voestalpine, Verbund, and Siemens, as well as the Austrian Power Grid (APG), together with scientific partners K1-MET (Metallurgical Competence Center) and ECN (Energy research Centre of the Netherlands). The project is funded as part of the European Commission’s Horizon 2020 programme (Joint Undertaking Fuel Cells and Hydrogen) through to 2021.

Czech Republic Trinec Iron & Steel launches major investments. The company is planning to invest largely in the modernization, reconstruction and repair of production plants in order to achieve higher added value of its steel products. The measures include the construction


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››› INTERNATIONAL INDUSTRY NEWS

of new annealing furnaces, another peeling and finishing line, the installation of additional billet grinders and completion of the reconstruction of one of the casting strands to allow for the production of 600-mm-diameter blooms. A new processing line for steel bars will be set up near the existing treatment station for bright bars. Approximately, onethird of the overall investment volume will go into environmental projects. Trinec Iron & Steel plans to produce 2.55 million t of steel this year, about 30,000 t more than in 2017, enabled among others by the newly reconstructed and modernized production facilities.

France ArcelorMittal to install new direct-fired furnace. Andritz has received an order from ArcelorMittal Atlantique & Lorraine to supply a direct-fired furnace for its new continuous galvanizing line at the plant in Florange. The order is part of ArcelorMittal’s project to convert an electro-galvanizing line to a continuous galvanizing line in the Florange plant. The Andritz scope of

supply and services further include engineering, the automation and electrical equipment as well as supervision of erection work and commissioning. Start-up is planned for the third quarter of 2019.

Germany ArcelorMittal to upgrade flat steel service centre. ArcelorMittal Germany is expanding its Neuwied service centre, which processes 30 t coils produced at the group’s steel mills in Bremen and Eisenhüttenstadt in Gemany and in Ghent, Belgium. The plant processes around 400,000 t/year of steel. This year’s major investments comprise an additional slitting line, a new coil wrapping unit, two robot cells for automatic setting of the slitting tools and two additional crane systems.

Germany Feralpi Stahl Germany performs refurbishments during annual shutdown. Feralpi Stahl

Germany uses the traditionally less busy winter months for major repairs to its facilities. During last December and January, a number of key activities were performed at the Riesa facilities. For example, the electric arc furnace was fitted with a new manifold with sliding sleeve as well as refurbished electrode arms. In the tapping area, the ladle rail track was completely refurbished and a new heat protection wall was built. The continuous caster was given a new turret top, the roller tables and the inclined elevator received new steel substructures and a new overhead crane was built.

Germany Ilsenburger Grobblech to build new heat treatment line. A new heat treatment line is going to be built at Ilsenburger Grobblech, a subsidiary of Salzgitter AG. This project, which is the largest single investment in this location to date, is part the concentration of Salzgitter AG’s heavy plate activities in Ilsenburg. The new heat treatment line will be supplied by SMS

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MPT International 2 / 2018


INTERNATIONAL INDUSTRY NEWS group. It will essentially consist of a shot-blaster, two roller hearth furnaces, a MultiFlex-Quench®, a plate leveler, a cleaning and priming line, and a water treatment plant. SMS group is also going to supply the electrical and automation systems and implement the material and process models. The new heat treatment line will be designed to anneal and further process more than 200,000 t/year of heavy plate in thicknesses between 5 and 175 mm and widths up to 3,500 mm. The between 4 and 24-meters-long plates will weigh up to 28 tons. Also all the ancillary facilities such as the plate conveying system, complete with the cooling beds and the plate feeding and centering equipment, are part of SMS group’s supply package. Commissioning is scheduled to take place early in 2020.

Germany HKM orders ladle treatment stations. Hüttenwerke Krupp Mannesmann (HKM) has awarded Primetals Technologies an order to supply two 285 t ladle treatment stations for the LD basic oxygen furnace plant at its Duisburg-Huckingen location. The plants will be designed for a fully automated annual treatment capacity of 5.6 million t of liquid steel. Copper-plated roofs will be used to lengthen the service life and assure the quality of the melt. To enhance safety at work, LiquiRob systems will handle tasks that formerly had to be performed manually, such as temperature measurement and sample taking. In addition, the phosphorous content of the melts can be reduced, and higher proportions of alloying elements processed. Commissioning is scheduled for autumn of 2019.

Germany Vallourec to implement new MES system. Vallourec is restructuring the production processes in all its European plants. The existing legacy systems at the various sites will be gradually replaced by an MES standard solution based on PSImetals. PSI will deliver its PSImetals Production, Quality, Logistics and Planning components. The harmonized MES model solution for Europe will first be used at the pilot plant of the Mülheim production site.

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News in brief Acerinox Europe, Spain, has commissioned a new annealing and pickling line and a new cold-rolling mill with at its production facilities in Campo de Gibraltar. TimkenSteel, USA, has commended full commercial production of the new heat-treatment line supplied by SMS group. The AQTF (advanced quench-andtemper facility) is in operation at the Gambrinus Steel Plant in Canton, Ohio. Huai’an Special Steel and Hebei Jingye Iron and Steel, China, have selected Danieli Corus for the design, supply and installation supervision of sublance-based process control systems for their BOF steelmaking plants.

Germany Saarstahl orders billet caster. Saarstahl AG has ordered a fivestrand billet caster from SMS Concast. The new caster will be installed in the Völklingen steel plant. The new casting machine, designed for a capacity of 850,000 t/year of billets, will produce 180 mm x 180 mm square billets in a wide range of steel grades, including bearing steels, spring steels, cold

heading wire rod and free-cutting steels. The caster will come with stateof-the-art equipment such as Convex moulds, hydraulic mould oscillator, electromagnetic mould and strand stirrers, mechanical soft reduction and modern automation and communication technology according to Industry 4.0 standards. Start of operation is planned for the third quarter of 2019.


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››› INTERNATIONAL INDUSTRY NEWS Germany

Russia

Stahlwerk Annahütte places order for abrasive cut-off machine. Stahlwerk Annahütte has placed an order with Braun Maschinenfabrik for a gantry-type dry traverse abrasive cutoff machine, type TS 10 FP, for cutting layers of hot-rolled bars downstream of the cooling bed. The existing cold shear will remain in use for cutting secondary steel grades. A special challenge of this turn-key project is the integration of the new high-performance cutting facility into the existing rolling mill under extremely tight space conditions. Commissioning and performance testing of the new machine is scheduled to take place in August 2018.

MMK to build new sinter plant. Magnitogorsk Iron and Steel Works (MMK) is completing the final preparatory stage of work for the construction of a new sinter plant in Magnitogorsk. The contract for the supply of equipment for sinter plant No. 5 was placed with Sinosteel. Work on the site began in December 2016 with the construction of the electric substation No. 68. The installation of the main technological equipment started in March 2018, firstly on sinter machines No. 1 and No. 2. Commissioning of the new sinter plant is scheduled for the end of 2019.

Russia Russia Vyksa Steel Works to install new slitting line. The company, located in the Nizhny Novgorod region, has ordered a new slitting line from the FIMI Group. The line is to be designed for processing strip of 1,600 width and 0.8 to 6.0 mm thickness. Installation of the new plant is scheduled for the second part of 2018.

Russia Severstal to build new blast furnace No. 3. Severstal has announced its investment plan for 2018. One of the most significant projects of Severstal’s steel division in 2018 will be the construction of the new blast furnace No. 3. Designed for an annual output capacity of 2.9 billion t, the new furnace is scheduled to be ready for operation in 2022. New technological solutions introduced during the construction process will significantly reduce the environmental impact of the blast furnace. The construction of blast furnace No. 3 will reduce the CAPEX required for the planned refurbishment of blast furnace No. 5, which has now been postponed until 2022. Other major investment projects are the further modernization of the rolling mill-2000 and the technical revamping and modernization of turbine generator No. 5. MPT International 2 / 2018

MMK to upgrade wire rod mill. Magnitogorsk Iron and Steel Works (MMK) has selected Danieli to modernize its wire rod mill 170, which was supplied by Danieli in 2003. The aim of the modernization is to introduce the Danieli H3 technology to improve mechanical properties of the finished products. The existing Danieli Centro Combustion furnace will be revamped in order to separate the heating and soaking zones, reducing material decarburization. LLH+ type oil-film bearing laying heads with double pipe rotors will be installed to provide stable and vibration-free operation at high speeds and to maintain in-balance conditions. Also the cooling area will be upgraded to ensure adequate and uniform cooling of wire loops and desired mechanical properties. Newly designed water boxes and water control valves after the wire rod block will optimize water cooling and guarantee a stable rolling process. The electrical and automation part of the modernization will be carried out by Danieli Automation. The project is scheduled to be completed before the end of 2018.

Russia MMK to modernize hot strip mill. Magnitogorsk Iron & Steel Works (MMK) has signed a contract with SMS group regarding the supply of equipment to be used in the re-


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INTERNATIONAL INDUSTRY NEWS construction of the finishing train of hot-rolling mill 2500 at sheet rolling plant No. 4. Under the terms of the contract, the equipment will be supplied over a period of three years. This measure is part of MMK’s long-term strategic development programme and is aimed at modernizing the finishing train and improving the automated control system.

Russia NLMK introduces business suite platform. NLMK Group is introducing the new generation SAP S/4HANA business suite. This platform will not only streamline current business processes but also enable the use of cloud, Internet of Things and machine learning technologies on an industrial scale without technical upgrade. More than 20 information and production systems of NLMK Group’s Russian and European enterprises have integrated with the SAP S/4HANA suite. It serves over 6,500 users already. NLMK-SAP Innovations Lab already employs the business suite for its projects.

Spain Acerinox to upgrade electric arc furnace. At the Acerinox Europa plant in Campo de Gibraltar, Algeciras, the refrigerated vault of electric arc furnace No. 2 is going to be replaced. This measure will reduce refractory and electrodes consumption and increase furnace availability. Also water and maintenance requirements will be reduced as a result of this measure.

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Turkey Hasçelik orders abrasive cutoff machine. Braun Maschinenfabrik has received an order from Hasçelik for the supply of a high-performance dry traverse abrasive cut-off machine, type TS 12 F, with associated equipment. The machine will be used to cut layers of SBQ products after the cooling bed, replacing an existing cutting unit. Special features of the new abrasive cut-off machine are its high throughput capacity, the outstanding quality of the cut bar ends and its reliability in continuous operation. Installation on site will take place during a short standstill of the rolling mill in August. Commissioning and performance testing of the installed facility are scheduled to be completed by the beginning of September 2018.

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United Kingdom British Steel plate mill’s plant and machinery to be sold off. Plant and machinery from British Steel’s mothballed Scunthorpe plate mill will be sold off after the company revealed it would not be re-opening the manufacturing facility. The mill stopped production two years ago under previous ownership and, after much consideration, the company has decided the plate operation will close permanently. Redundant plant from the mill will now be sold after the company appointed the specialist firm of Apex Auctions to manage the sale of equipment. As the mill stands idle there will be no job losses.

Sweden Sandvik invests in metal powder plant. Sandvik is investing in a new production plant for titanium and nickel fine metal powders within the business area Sandvik Materials Technology. The investment will complement the company’s existing powder offering. The facility will be located in Sandviken, near in-house titanium raw material supply and the center for

Too hot to handle?

United Kingdom Liberty Speciality Steels reignites mothballed EAF. The N-Furnace at Liberty Speciality Steels in Rotherham, South Yorkshire, has been reignited, after being mothballed by previous owners during the steel crisis two and a half years ago. The 800,000 MPT International 2 / 2018

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››› INTERNATIONAL INDUSTRY NEWS

t/year furnace, which turns scrap metal into specialised steels for uses such as vehicle gearboxes or aircraft landing gear, will now play a pivotal role in Liberty’s overall Greensteel strategy. The switch-on marks the culmination of five months engineering work by a team of 35 people to repair and upgrade the equipment. It will triple Liberty’s capacity to melt scrap into liquid steel at Rotherham, making the company the largest steel recycler in the UK, with a capability to melt over 1.2 million t/year.

Companies Eurofer’s 2017 report and 2018 outlook. The manufacturing industry and construction sector in the EU benefited in 2017 from an investment-led domestic upturn and improving exports. EU28 apparent steel consumption grew by 1.1% year-on-year in the third quar-

ter of 2017. Overall, domestic deliveries rose by 4.4% year-on-year, while steel imports fell by almost 14% year-onyear. According to Axel Eggert, director general of Eurofer, prospects for the continued recovery of EU steel demand are positive. The expected strength of most steel-using sectors bodes well for the demand side of the EU steel market. The supply side situation could, however, continue to be negatively affected by import distortions. 2017 has been a strongly expansionary year for steel-using sectors in the EU. The steel tube sector posted the strongest yearon-year jump in production activity, followed by the mechanical engineering sector, electrical domestic appliances and construction. As had been anticipated, growth in automotive output moderated somewhat. The outlook for 2018 and 2019 is positive, although activity in steel-using sectors will settle back into a more moderate pace of expansion owing to waning momentum in the tube sector and automotive industry. Output in the EU’s steel-using

sectors is forecast to grow by 2.2% in 2018 and by 1.8% in 2019.

thyssenkrupp welcomes approval of collective agreement for planned steel joint venture. thyssenkrupp has welcomed the clear approval given by the members of the German trade union IG Metall for the collective agreement on the joint venture in which thyssenkrupp and Tata Steel plan to combine their European steel operations. thyssenkrupp and its employee representatives had agreed to enter into a collective agreement which among other things safeguards jobs until September 2026. The intended joint venture partner Tata Steel is also currently in the process of dialogue with its employee representatives. In parallel with this, due diligence is under way. In addition, independent expert opinions have been commissioned by thyssenkrupp on the economic viability of the joint venture

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INTERNATIONAL INDUSTRY NEWS and the UK pension liabilities of Tata Steel Europe.

Gerdau to sell wire rod operations to Optimus Steel. Gerdau and Optimus Steel have entered into a definitive agreement to sell Gerdau’s mill in Beaumont, Texas, and downstream locations Beaumont Wire Products and Carrollton Wire Products to Optimus. The mill has a melt shop capacity of approximately 700,000 t and is capable of producing both wire rod and coiled rebar. The transaction is subject to regulatory clearances and is anticipated to close before year-end of 2018.

Schmolz + Bickenbach takes over parts of Asco Industries. Schmolz + Bickenbach is going to acquire the sites and facilities of Frenchbased Asco Industries. The acquisition follows the strategy of actively participating in the consolidation of the European specialty steel industry. The transaction includes the acquisition of the most important locations of Asco Industries, with production remaining focused on the production and processing of special steel for the oil & gas, automotive and mechanical engineering markets, as well as the production of ball-bearing steel.

Katakura Steel Tube becomes NSSMC subsidiary. Nippon Steel & Sumitomo Metal Corporation (NSSMC) has completed the acquisition of Katakura Steel Tube by acquiring additional shares of common stock of Katakura Steel Tube Co., Ltd., an equity-method affiliate of NSSMC with a 24.9% shareholding. Through this transaction, Katakura Steel Tube has become a consolidated subsidiary of NSSMC with an 80% shareholding.

Butech Bliss and Nelson Steel Technology Group form strategic bidding agreement. Butech Bliss and Nelson Steel Technologies have entered into a strategic bidding agreement. Both parties will jointly mar-

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ket and sell push-pull, semi-continuous and continuous pickling lines in the United States, Canada, and Mexico. Butech Bliss/Nelson Steel pickle lines include the latest technical developments available in the marketplace. Butech Bliss equipment is ruggedly designed to stand up under the most demanding circumstances. The process wet section is provided by Nelson Technologies.

Böhler companies with new name. The Böhler companies in the High Performance Metals Division of the voestalpine Group have included the word “voestalpine” in their company names. They are now operating as voestalpine Böhler Edelstahl, voestalpine Böhler Aerospace (formerly Böhler Schmiedetechnik), and voestalpine Böhler Bleche.

Guild International under new ownership. Guild International, a company specialized in coil joining equipment for the steel processing, tube producing and stamping industries, has new ownership. The company was purchased by three long-term employees: Joseph Thomas, formally vice president of operations, has been named president; William Maruschak will continue as chief financial officer; and Mark Wagner, formally sales engineer, has been named vice president of sales. Until the purchase, Guild International was owned by Michael Wheeler, son of Donald Wheeler, the original founder of the company. Mike Wheeler will continue on as chairman of the board. Guild International was established in 1958. The company holds many patents for their coil joining processes and equipment.

Siemens and partners sign joint charter on cybersecurity. At the Munich Security Conference 2018, Siemens and eight partners from industry signed the first joint charter for greater cybersecurity. Initiated by Siemens, the Charter of Trust calls for binding rules and standards to build trust in cyMPT International 2 / 2018

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››› INTERNATIONAL INDUSTRY NEWS

bersecurity and further advance digitalization. In addition to Siemens and the Munich Security Conference, the companies Airbus, Allianz, Daimler Group, IBM, NXP, SGS and Telekom signed the charter.

Höganäs acquires surface coating division from H.C. Starck. Höganäs AB has taken over the division for surface coating – Surface Technology & Ceramic Powders (STC) – of metal powder producer H.C. Starck. The acquisition of STC is the third in a row for Höganäs during a short time period. In November 2017 Höganäs acquired Metasphere Technology, a Swedish start-up that has developed a new atomizing technology using plasma for high performing materials for surface coating and additive manufacturing. In February 2018 Höganäs acquired Alvier PM-Technology, a Swiss company specializing in designing and manufacturing tools for pressing metal powder components.

Personalities Management appointments at Stahl-Holding-Saar, Dillinger and Saarstahl. Michael Müller and Fred Metzken are going to step down from active management positions in the course of 2018. Michael Müller will retire from the position of chairman of the management board of Stahl - Holding - Saar (SHS) and Fred Metzken from the position of spokesman of the management board of Dillinger and Saarstahl, and as member of the management of SHS. Tim Hartmann has been

Tim Hartmann

appointed as chairman of the management board of SHS and as chairman of the boards of directors of Dillinger and Saarstahl. As board member, he will also take responsibility for finance.

Ovako appoints vice chairman of the board. Tore Bertilsson has been appointed vice chairman of Ovako Group AB’s board of directors. Tore Bertilsson has extensive industrial experience from leading positions and directorships.

Gerdau’s North American long steel division to receive new leadership. Peter Campo, president of Gerdau’s North American long steel division, has left the company. Due to the relevance of the North America business, Gerdau CEO Gustavo Werneck will lead the operation for the next few months until the new leader is announced.

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INTERNATIONAL INDUSTRY NEWS New managing director at Samson Materials Handling. Samson Materials Handling has appointed Dale Lockley as the new sole managing director. Samson Materials Handling is

Dr. Sabine Maaßen

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Krupp von Bohlen und Halbach Foundation for a period of five years and succeeds Dr. Ralf Nentwig, who decided to stand down from the supervisory board.

Dale Lockley

New HR Manager for thyssenkrupp Steel Europe. Dr. Sabine Maaßen has taken over the position of chief human resources officer of thyssenkrupp Steel Europe. She succeeds Thomas Schlenz, who resigned his mandates for health reasons at the end of January 2018.

New president of World Refractories Association. Stefan Borgas, CEO of RHI Magnesita, has been elected new president of the World Refractories Association (WRA). He assumes the presidency previously occupied by François Wanecq, former CEO of Vesuvius plc, for two years.

NLMK appoints vice president. NLMK has appointed Mikhail Arkhipov as vice president for human resources and management systems. He will coordinate HR management Mikhail Arkhipov

part of the Aumund group of companies which specialises in professional bulk handling solutions. Dale Lockley joined the company in 2016.

New member of supervisory board of thyssenkrupp. Prof. Dr. Dr. h.c. Ursula Gather has joined the supervisory board of thyssenkrupp AG. She has been delegated by the Alfried

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MPT International 2 / 2018


26

››› INTERNATIONAL INDUSTRY NEWS

New management appointment at Mechel. Russian mining and metals company Mechel has appointed reports Nelli Galeeva as chief financial officer. Prior to this appointment, Nelli Galeeva headed Mechel’s accounting and tax department and oversaw work on the group’s consolidated international financial reporting. She has been a member of the company’s management board since 2016.

New CEO for Tenova Metals. Roberto Pancaldi, former chief operating officer of Tenova Metals, has been appointed the new Tenova Metals chief executive office. He succeeds Andrea Rocca, who, after five years in Tenova, has taken new responsibilities in Tecpetrol, another company of the Techint Group. Roberto Pancaldi joined the Techint Group as process engineer in 1988 and has spent his entire career in Techint and then in Tenova. Roberto Pancaldi

Aditya Mittal

the Nickel Institute to take up the new position of manager, market development, South East Asia. Juerg Schweizer will cover the region from his base in Singapore. He takes on responsibility for the Nickel Institute’s market development activities in Asian countries outside Japan and China.

Changes on managing board of SMS group GmbH. Harald Rackel, currently head of digitalization at SMS group GmbH, has left this post to join the managing board of elexis AG, a subsidiary of SMS group. On July 1, 2018, he will take over the position of chief executive officer from Siegfried Koepp, who is due to retire on June 30. Dr.-Ing. Katja Windt has been appointed managing director of SMS group GmbH. To take on her new post, she is leaving her position as president of the Jacobs University of Bremen. As a member of the SMS group managing board, she will be responsible for the digital solutions and electrical and automation systems divisions.

tal Europe, as president ArcelorMittal in addition to his current responsibilities. As president and chief financial officer, he will continue to report to the chairman and chief executive officer, Lakshmi Mittal.

ArcelorMittal appoints new executive officer. Henri Blaffart has retired from his duties as member of the management committee and as head of human resources and corporate services of ArcelorMittal. His position as executive vice president and head of human resources will be assumed by Bart Wille.

Events

Nickel Institute announces new appointments in market development. Richard Matheson has been promoted to director, market development, of the Nickel Institute. He succeeds Nigel Ward who will continue to support the work of the Nickel Institute in an advisory role during the next few months. In his new role, Richard Matheson will continue to develop the markets for nickel. At the same time, Juerg Schweizer has joined Richard Matheson

Primetals Technologies appoints new CEO and chairman of the board. Primetals Technologies has appointed Satoru Iijima as chief executive officer and board chairman. He succeeds Primetals Technologies’ current chief executive officer and chairman, Yasukuni Yamasaki, who will continue to serve as a director of the board. Starting 2015, Satoru Iijima served as president and chief executive officer of Primetals Technologies USA.

Satoru Iijima

Aditya Mittal appointed as president of ArcelorMittal. ArcelorMittal has appointed Aditya Mittal, group chief financial officer and chief executive officer of ArcelorMitMPT International 2 / 2018

7 – 10 May 2018 Philadelphia, Pa., USA Organizers: Association for Iron & Steel Technology AIST www.AISTech.org

AISTech 2018. AISTech conference and exposition provides a global perspective on the technology and engineering expertise necessary to power a sustainable steel industry. A key event to demonstrate products and services to the world’s leading steel producers, suppliers, consultants and academics.

16 – 19 May 2018 Beijing, China Organizers: CIEC Exhibition Co., Ltd., www.mm-china.com

Metall + Metallurgy China. Largest exhibition in the equipment manufacturing industry in Asia and the second largest in the world. 10th Chi-


INTERNATIONAL INDUSTRY NEWS na International Steel Congress, organized by CISA and MC-CCPIT once every two years, is a high-level conference focusing on strategic issues facing the steel industry.

29 May – 1 June 2018 Moscow, Russia Organizers: Messe DüsseldorfMoscow www.metallurgy-russia.com

Metallurgy – Litmash. Two international exhibitions in parallel: Metallurgy: international trade fair for metallurgy technology, processes and metal products – Litmash: international trade fair for foundry technology, supplies and castings

13 – 15 June 2018 Venice, Italy Organizers: Associazione Italiana di Metallurgia (AIM) www.aimnet.it/ics2018.htm

ICS 2018. The 7th International Congress on Science and Technology of Steelmaking will incorporate a conference on heat treatment and surface engineering

25 – 28 June 2018 Jakarta, Indonesia Organizers: SEAISI www.seaisi.org

SEAISI 2018. The Annual International Conference and Exhibition of the South East Asia Iron and Steel Institute (SEAISI) will focus on the theme: ASEAN steel industry – next leap of transformation

8 – 13 July 2018 Paris, France Organizers: Mines ParisTech www.thermec2018. sciencesconf.org

Thermec 2018. The 10th edition of this conference series will cover all aspects of processing, fabrication, applications of both ferrous and non-ferrous materials, composites including biomaterials, fuel cells/hydrogen storage technologies, batteries, supercapacitors, nanomaterials for energy and structural applications, aerospace structural metallic materials, etc.

29 – 31 August 2018 New Delhi, India Organizers: ITEI, the Indian subsidiary of ITE Group (UK); The Indian Institute of Metals www.mmmm-expo.com

MMMM 2018. The 12th Minerals, Metals, Metallurgy & Materials exhibition and conference will again provide a key networking platform for showcasing products, technologies and processes to industry professionals from the world over.

13 – 14 September 2018 Aachen, Germany Organizers: Institute for Metallurgy of the Technical University RWTH Aachen ask.iehk.rwth-aachen.de

Aachen Steel Colloquium. The 32rd Aachen Steel Colloquium held under the motto “Metallurgy and Change 4.0” will focus on current developments of and imminent challenges for the iron and steel industry as well as related science and R&D.

18 – 19 September 2018 Aachen, Germany Organizers: TEMA Technologie Marketing AG www.sis-world.com

SIS.Europe. The Surface Inspection Summit (SIS) is the industry event for the surface inspection community. Topics like yield management, 3D checks, high-end multi-stage classifi-

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27

er, augmented reality enter a new stage of development also in surface inspection.

25 – 27 September 2018 Vienna, Austria Organizers: The Austrian Society for Metallurgy and Metals ASMET www.icsti2018.org

ICSTI 2018. The International Congress on the Science and Technology of Ironmaking will bring together plant operators, plants suppliers and R&D experts. Topics discussed will include cokemaking, iron ore production and handling, sintering, steelmaking, recycling, as well as automation and digitalization in coke and ironmaking.

10 – 12 October 2018 Taranto, Italy Organizers: Associazione Italiana die Metallurgia (AIM) www.aimnet.it/eosc2018

EOSC 2018. The 8th European Oxygen Steelmaking Conference will focus on the latest development in primary steelmaking, ladle metallurgy, plant operation experience, automotive and on-line process analyses, improving steel quality and environmental protection.

16 – 19 October 2018 Stockholm, Sweden Organizers: Jernkontoret www.icrf2018.com

ICRF 2018. The Ingot Casting, Rolling and Forging Conferences are organized by different European metallurgical societies and associations. ICRF 2018, held in Sweden, will include the following topics: metallurgy of ingot casting, casting technology, additives for ingot casting, remelting technologies, rolling and forging of ingots, heat treatment, simulation, etc. MPT International 2 / 2018


28

››› EVENTS

AISTech 2018 – the steel’s premier event in North America AISTech 2018 – the Iron & Steel Technology Conference and Exposition – will take place at the Pennsylvania Convention Center in Philadelphia, PA/USA on 7 – 10 May 2018. The industrial leader town hall forum and the president’s award breakfast are the two most exciting events planned for AISTech 2018. The exhibition will feature an unrivaled display of steel technology AISTech 2018 – the Iron & Steel Technology Conference and Exposition – will incorporate North America’s biggest steel event of the year. More than 7,000 attendees are expected to attend

The 2018 exposition is slated to have similar record figures as last year, with more than 500 exhibitors. The AISTech 2018 exposition is an opportunity to meet face-to-face with the individuals

AIST conference program The technology conference will showcase more than 550 presentations on aspects of iron and steel manufacturing technology. Highlights include the latest

AISTech is the steel industry’s biggest annual trade show and exposition in the U.S.A. (Picture from the archives)

this global event, which will feature technologies from the world over, allowing steel producers to compete in today’s global market. Association for Iron and Steel Technology (AIST), Warrendale, PA, USA Contact: www.aist.org

MPT International 2 / 2018

who specify, design, deliver and commission plants and facilities associated with the production and processing of iron and steel. The exhibition will feature more than 500 U.S. and international companies for an unrivaled display of steel technology. The exposition will be available for all attendees to explore.

environmental technologies throughout the iron- and steelmaking process; safe work practices and procedures for projects, production, and maintenance; cutting-edge research and advancements in the processing, product development, and application of steel; and discussions on efficient material movement both within the facility and to the customer.


EVENTS The three day technical program will kick off on Monday with the J. Keith Brimacombe memorial lecture. The 2018 Brimacombe memorial lecturer is John G. Speer, John Henry Moore Professor of Physical Metallurgy and director, Advanced Steel Processing and Products Research Center, Colorado School of Mines. His lecture is titled “The Continuing Development of Modern Steel Products.�

President’s award breakfast and town hall forum The AIST president Randy C. Skagen, vice president and general manager Nucor Steel Tuscaloosa Inc., will host the president’s award breakfast on Tuesday, 8 May, in the Grand Ballroom of the Pennsylvania Convention Center. Recognizing steel industry excellence, the President’s Award Breakfast program consists of the presentation of prestigious AIST Board of Director Awards, including AIST’s Steelmaker of the Year, followed by a keynote presentation from Roger Newport, chief executive officer, AK Steel. His presentation is titled “Providing innovative and sustainable steel solu-

tions.� He will discuss AK Steel’s focus on driving innovative steel solutions to meet and exceed customers’ needs, and how the industry is driving alternative and sustainable steel answers for today’s demanding marketplace. Once again, a major highlight of the event will be the town hall forum, which will be held on Wednesday morning, 9 May, at the Pennsylvania Convention Center. The town hall forum provides an insider’s view into today’s steel industry from the people who know: a panel of respected leaders from some of the U.S. industry’s best-regarded companies. 2018 town hall forum panelists are the following VIPs: ▪ James Bruno, senior vice president – Automotive Solutions, U.S. Steel Corp., ▪ Mark Millett, president and chief executive officer, Steel Dynamics, Inc., ▪ Anand Sen, president, TQM and Steel Business, Tata Steel Ltd., India, ▪ B. Thad Solomon, vice president and general manager, Nucor-Yamato Steel Co. The forum panelists will discuss the Trump administration’s recent Section

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29

232 decision and the implications for the global steel markets and the international trading system. They will also offer some insights on the market forces driving the recent round of capital investments.

Activities for students and young professionals; plant tours Young professionals and students with a technical interest in the iron and steel industry can substantially benefit from attending AISTech. The student schedule includes a plant tour, presentation and poster contents. At the “Steel to students reception�, students from various universities meet for a brief orientation and reception with representatives from a number of steel companies. Young professionals can meet for a roundtable discussion and a networking reception. Three plant tours will be held in conjunction with AISTech 2018. Carpenter Technologies Corp., Inductotherm Corp. together with Consarc Corp., and U. S. Steel – Mon Valley works will host the respective industry tours. The plant tours are on a first-come-firstserved basis and are limited.

The motor for your metal production )RUDSXUHDQGIJDZOHVVPHOW7KH0)&PDVV IJRZFRQWUROOHULVGHVLJQHGZLWKDPRWRUYDOYHIRU UHJXODWLRQRISUHVVXUHVXSWREDUDQGUHOLDEOH RSHUDWLRQHYHQXQGHUWKHPRVWVWULQJHQWFRQGLWLRQV7R HQVXUHKLJKHUSURFHVVUHOLDELOLW\LQWKHJDVbVXSSO\WKH YDOYHFDQEHUHJXODWHGDWIXOOGLÄłHUHQWLDOSUHVVXUH$QG WKHVHOIORFNLQJGULYHHQVXUHVWKDWWKHPRWRUYDOYHLV QRWDÄłHFWHGE\SUHVVXUHIJXFWXDWLRQV,QDGGLWLRQWKH 0)&IHDWXUHVWKHODWHVWGLJLWDOWHFKQRORJ\â&#x20AC;&#x201C; ZLWK WKHLQWHJUDWHGEXVLQWHUIDFHLWLVUHDG\IRU,QGXVWU\ High-pressure MFC Type 8746: 0RUHUHOLDELOLW\LVQRWSRVVLEOH <RXFDQGHSHQGRQLW :HPDNHLGHDVÉ&#x2C6;RZ ZZZEXUNHUWFRPHQW\SH


30

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş EVENTS

The steering committee of the trade fair quartet gave green light for â&#x20AC;&#x153;The Bright World of Metals 2019â&#x20AC;?

GIFA, METEC, THERMPROCESS and NEWCAST â&#x20AC;&#x201C; the trade fairs are preparing for 2019 Following the kick-off meeting of the steering committee, preparations for â&#x20AC;&#x153;The Bright World of Metalsâ&#x20AC;? are hotting up. The registration period for exhibitors has started in -DQXDU\WKHRIĆ&#x201A;FLDOGHDGOLQHIRUH[KLELWRUUHJLVWUDWLRQLVDSSURDFKLQJ The time has come round again: the four trade fairs GIFA, METEC, THERMPROCESS and NEWCAST are in the process of starting. Invitations have been sent to exhibitors. Companies from all over the world can register for â&#x20AC;&#x153;The Bright World of Metalsâ&#x20AC;? and

Messe DĂźsseldorf, Germany 25 - 29 June 2019 Contact: www.gifa.com www.metec.com www.thermprocess.de www.newcast.com

MPT International 2 / 2018

reserve the best stand locations with immediate effect. From 25 to 29 June 2019, the global steel and metals sector will be focussing on foundry technology & castings, metallurgy and thermoprocess technology in Halls 3 to 5 and 9 to 17 on the exhibition site, where the joint motto will be â&#x20AC;&#x153;The Bright World of Metalsâ&#x20AC;?. â&#x20AC;&#x153;Our four GMTN technology trade fairs are unmatched anywhere in the world and implement a unique conceptâ&#x20AC;?, explains Friedrich Kehrer, Global Portfolio Director Metals and Flow Technology at Messe DĂźsseldorf GmbH. â&#x20AC;&#x153;Only here in DĂźsseldorf are decision-makers, experts, suppliers

and users from the global foundry, metallurgy and heat engineering industries able to obtain a complete insight at four trade fairs at the same time, to enjoy unparalleled networking opportunities and to promote and shape the current trends for the markets of the futureâ&#x20AC;?. About 78,000 visitors and more than 2,200 exhibitors from all over the world will be turning DĂźsseldorf into the global capital of â&#x20AC;&#x153;The Bright World of Metalsâ&#x20AC;? again in June 2019. The fundamental decisions have been taken too: the steering committee held its initial meeting at the end of 2017, the central features of the GMTN


EVENTS events have been specified and the individual trade fair presidents have been elected. The President of GIFA & NEWCAST is Heinz Nelissen (Director of Vesuvius GmbH), the current President of METEC is Marcel Fasswald (that time member of the management board of SMS Group GmbH) and the President of THERMPROCESS is Joachim G. Wünning (Director of WS Wärmeprozesstechnik GmbH).

GIFA – a major role since 1956 GIFA, the International Foundry Trade Fair and Technical Forum, has been a traditional member of the Düsseldorf trade fair portfolio for a long time now. GIFA has played a major role since 1956 and succeeded at its last event in 2015 not only in producing outstanding results (942 exhibitors from 47 different countries, 48,783 trade visitors – 54 per cent of them from outside Germany) but also in presenting countless innovations to the trade visitors from all around the world. In 2019, GIFA will once again be presenting almost the entire range of products available anywhere in the world in the following areas: foundry and melting plants, refractories technology, moulding and core making plants and equipment, moulding sands and moulding auxiliaries, sand preparation and reclamation, gating and feeding, casting machines, knockout, fettling and finishing, pattern and die making, process control technology and automation, environmental protection and waste removal as well as information technology.

METEC 2019: in Düsseldorf for the tenth time METEC, the International Metallurgical Trade Fair and Congresses, has been an established member of the four trade fairs since as long ago as 1979. The exhibits at the tenth trade fair will include plant and equipment for iron, steel or non-ferrous metal production, plant and equipment for casting, pouring and shaping steel, equipment for metallurgical plants and rolling mills or steel mills. With over 17,700 visitors (53 per cent of them from outside Germany) and 525 exhibitors from 35 different countries,

METEC again set records for the best performance in its roughly 40-year history last time.

THERMPROCESS: industrial furnace technology THERMPROCESS has an even longer tradition: the International Trade Fair and Symposium has been THE place to find innovative thermoprocess technology since as long ago as 1974. Information about state-of-the-art technological trends for solutions relating to the production and use of industrial furnaces and heat generation plants makes sure that visitors enjoy the best possible competitive edge. The exhibits include industrial furnaces, industrial heat treatment plants and thermal processes, equipment for special applications, components, equipment and other supplies, occupational safety and ergonomics. The trade fair at-

‹‹‹

31

tracted more than 7,100 trade visitors, every second one of whom came from outside Germany, and 314 exhibitors from 30 different countries.

NEWCAST – an immediate success NEWCAST, which joined the quartet of trade fairs as its fourth member in 2003, is the most recent addition to The Bright World of Metals. As the world’s leading trade fair for precision castings, it is the highlight of its industry every four years and has recorded excellent growth rates – like last time in 2015: (4,000 visitors, 66 per cent of them from outside Germany, and 434 exhibitors from 33 different countries). The application areas for castings range from vehicle manufacturing and the aerospace industry to machine and plant engineering and medical technology.

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Analysis starts with good sample preparation

MPT International 2 / 2018


32

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş IRONMAKING â&#x20AC;&#x201C; STEELMAKING

Sweden gears up for fossil-free steel production

SSAB AB, Stockholm, Sweden; HYBRIT â&#x20AC;&#x201C; a joint venture between SSAB, LKAB and Vattenfall, Stockholm, Sweden Contact: www.ssab.com www.hybritdevelopment.com E-mail: viktoria.karsberg@ssab.com

MPT International 2 / 2018

Total CO2-emission in Sweden & Finland, MT/ year

SSAB has developed a plan that involves a drastic cut in CO2 emissions even before a solution for fossil-free steel has been found. The goal is to be totally fossil-free by 2045. The transition in SSABâ&#x20AC;&#x2122;s business is a consequence of the SSAB, LKAB and Vattenfall initiative to find a solution for fossil-free steel production, HYBRIT. A study is currently under way to convert the blast furnace in OxelĂśsund (Sweden) into an electric arc furnace. This is the first step in adapting the process for the production of fossil-free steel. Conversion will take place in around 2025 and would mean that SSAB can cut its carbon dioxide emissions in Sweden by around 25%. SSAB announced that they are also planning to convert the blast furnaces in Raahe (Finland) and LuleĂĽ (Sweden) between 2030-2040 in order to eliminate most of the remaining CO2 emissions and reach the target to be fossil-free by 2045. â&#x20AC;&#x153;The transition to fossil-free steel production has already started, and weâ&#x20AC;&#x2122;re now detailing what the road ahead will be like. We believe that this is the right way to go and that it will create many exciting business opportunities for us as a company. SSAB wants to be part of the solution to climate change,â&#x20AC;? said Martin Lindqvist, President and CEO of SSAB. The transition in SSABâ&#x20AC;&#x2122;s business is a consequence of SSABâ&#x20AC;&#x2122;s, LKABâ&#x20AC;&#x2122;s and Vattenfallâ&#x20AC;&#x2122;s initiative to find a solution for fossil-free steel production,

Total electricity consumption, TWh / year

Nordic steel company SSAB has developed a road map for transition the business to fossilfree steel production. The transition in SSABâ&#x20AC;&#x2122;s business is a consequence of the Swedish LQLWLDWLYHWRĆ&#x201A;QGDVROXWLRQIRUIRVVLOIUHHVWHHOSURGXFWLRQ+<%5,77KHLQLWLDWLYHLVJRLQJWR EXLOGDJOREDOO\XQLTXHSLORWSODQWIRUIRVVLOIUHHVWHHOLQ/XOH§1RUWKHUQ6ZHGHQ

SSABâ&#x20AC;&#x2122;s roadmap to replace coal and coke by fossil-free electricity

HYBRIT. At present the coal and coke used to reduce iron ore into iron are shipped to Sweden from places including Australia. This is a process that generates large volumes of carbon dioxide. The idea behind HYBRIT is to use hydrogen, which has been produced with electricity from fossil-free sources. The emissions are then normal clean water.

Unique pilot plant for fossil-free steel A pre-feasibility study worked out by SSAB, LKAB and Vattenfall is giving the green light for the fossil-free steel initiative, HYBRIT. For the first time, there is an opportunity for a technology shift and, as early as this spring (2018), a globally-unique pilot plant for fossil-free steel is being planned for Northern Sweden. The initiative could reduce Swedenâ&#x20AC;&#x2122;s total carbon dioxide emissions by 10% and those in Finland by 7%. The reduction in Sweden has been described as being crucial if Sweden is to be able to meet the goals of the Paris Agreement on climate change. â&#x20AC;&#x153;It is with great pleasure that we can announce today that we are giving the green light to the initiative to proceed with the planning and de-

signing of a pilot plant for fossil-free steel in LuleĂĽ and the iron ore deposits in Norrbotten. We hope to be able to break the ground already before the summer. This spring weâ&#x20AC;&#x2122;ll also start investigating the possibilities of broadening the project to include Finland. We are also very pleased that the Energy Agency wants to support us in this project,â&#x20AC;? said MĂĽrten GĂśrnerup, CEO of HYBRIT. The aim is to develop a totally fossil-free process for steel production by 2035. The phases of the project are scheduled as following: â&#x2013;Ş 2016-2017 pre-feasibility study â&#x2013;Ş 2018-2020 pilot line design and construction â&#x2013;Ş 2021-2024 pilot line trials â&#x2013;Ş 2025-2035 demonstration plant trials The pre-feasibility study includes calculations and the potential in due course to be able to commercialize fossil-free steel. The conclusion is that fossil-free steel, given todayâ&#x20AC;&#x2122;s price of electricity, coal and carbon dioxide emissions, would be 20-30% more expensive. With declining prices in electricity from fossil-free sources and increasing costs for carbon dioxide emissions through the European Union Emissions Trading System (ETS), the pre-feasibility study con-


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5YGFKUJTGHGTGPEGƂIWTGUCEEQWPVHQT 1,600 kg of CO2 emissions per t of crude steel produced

siders that fossil-free steel will in future be able to compete in the market with traditional steel. This spring the planning and designing of the pilot plant will be initiated. The cost is estimated to be SEK 20 million (approx. US$ 2.44 million) and it was recently confirmed that the Swedish Energy Agency will finance half of this, while the other half will be covered by steel company SSAB, mining company LKAB and power company Vattenfall. The Swedish Energy Agency has earlier contributed SEK 60 million to the pre-feasibility study and a four-year-long research project. “HYBRIT is a significant part of the road towards SSAB’s goal of being fossil-free by 2045, and the report from the pre-feasibility study shows not only that is it possible to carry out this initiative, but it can also create exciting future opportunities for us as a company. We want to be part of the solution to climate change,” said Martin Lindqvist, President and CEO of SSAB. “Fossil-free steel production starts in the mine, and we’re currently working intensively on how the next generation of pellet plants will be designed, as well as how a future electrified and more highly automated mine should be designed. HYBRIT is an important driving force for LKAB,” said Jan Moström, President and CEO of LKAB “It’s very positive that we can take the next step with a unique pilot plant, for both the project and for our work on the climate challenge. The industrial electrification and climate-smart hydrogen will be crucial factors in lower emissions and a fossil-free society,” said Magnus Hall, President and CEO of Vattenfall. “With our commitment to the HYBRIT initiative, we are contributing to the long-term competitiveness of the Swedish steel industry and gearing up work on the unique green energy systems in Sweden. In addition, we help driving the transition to a fossil-free industry and a sustainable soci-

The HYBRIT route predicts 25 kg of CO2 from fossil energy sources with a huge portion of green energy


IRONMAKING – STEELMAKING

‹‹‹

35

fossil-free steel, with good access to climate-smart and fossil-free electrical power, Europe’s highest-quality iron ore and a specialized, innovative steel industry. To be able to carry out this project, however, significant national contributions are still required from the state, research institutions and universities. There has to be good access to fossil-free electricity, improved infrastructure and rapid expansion of high voltage networks, research initiatives, faster permit processes and the government’s active support for pilot and demonstration facilities and long term support at EU level. ety,” said Erik Brandsma, Director General at the Swedish Energy Agency.

The ambition of a unique contribution for future generations Steel is a significant element of modern society, and global demand for steel is expected to increase as the world’s population grows and urbanization increases. If a new process cannot be found for ore-based steel pro-

duction, carbon dioxide emissions from the steel industry will increase by up to 25% by 2050. Coal and coke, which are shipped to Sweden from places including Australia, are currently used to reduce iron ore into iron. The idea behind HYBRIT is to use hydrogen, which has been produced with electricity from fossil-free Swedish sources. The emissions would then be normal water. Sweden and Finland have a unique opportunity to drive an initiative for

Conclusion Sweden and Finland have a unique opportunity to drive an initiative for fossil-free steel, with good access to climate-smart and fossil-free electrical power, Europe’s highest-quality iron ore and a specialized, innovative steel industry. To complete this project, however, significant national contributions are still required from the state, research institutions, and universities.

GSM up to 350 t capacity

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MPT International 2 / 2018 glama.de

GFM up to 150 t capacity

GRM up to 25 t capacity


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››› RAW MATERIALS HANDLING

Newly developed hybrid feeder for spherical materials Nickel mattes is a raw material for crude nickel metal production. This material is H[WUHPHO\GLIƂFXOWWRKDQGOHDVLWFRQVLVWVRISDUWLFOHVZKLFKDUHDOPRVWSHUIHFWO\ spherical, creating challenges for the operator in its reception, interim storage and RQZDUGWUDQVSRUWDWLRQ$XPXQGWRJHWKHUZLWKD)UHQFKUHƂQHU\KDYHFRPHXSZLWKD new hybrid feeder for this application. The recent commissioning at Eramet Le Havre’s Sandouville Refinery in France has brought another Aumund project to a successful conclusion. Eramet is a French mining and metallurgical group with world leadership in alloying metals, particularly manganese and nickel, and in high-quality metallurgy. Eramet’s Nickel division currently comprises three companies, with the Sandouville refinery – a wholly owned subsidiary of the Group – forming the “Nickel salts and metal” business unit. At this refinery Nickel mattes are transformed into high purity nickel metal and salts. The raw material is extremely difficult to handle as it consists of particles which are almost perfectly spherical, creating challenges for the operator, in its reception, interim storage and onward transportation. To combat these challenges Aumund Fördertechnik GmbH, after discussions with the customer, came up with a new hybrid feeder for this application. The Aumund BPB-SLP hybrid feeder combines the technical characteristics of a Samson® material feeder and a heavy-duty Aumund BPB-SF arched plate conveyor. The combination of these machines was the key to achieving a spillage-free process. In developing this product Aumund engineers were able to draw on their experience gained in many previous reference projects, in ports and terminals as well as in the mining industry. Many operators in the ports and terminals sector already place their trust in the advantages of Aumund’s Samson® feeder, and the arched plate conveyor with its heavy-duty chains

Aumund Fördertechnik GmbH, Division Materials, Rheinberg, Germany Contact: www.aumund.com E-Mail: minerals@aumund.com

MPT International 2 / 2018

The new Aumund BPB-SLP hybrid feeder is a technical combination of Samson® material feeder and a heavy-duty Aumund BPB-SF arched plate conveyor (© Photos: Aumund)

has been relied upon for decades in mining and other industries internationally.

External chains and belted surface As they are on the arched plate conveyor, the chains on the hybrid feeder are not underneath the conveyor but lateral, so that the conveyor sections are on the same level as the mid-point of the chain bolts. This was the technical solution that fulfilled the requirement of a fixed belted surface. This Aumund design results in a lower overall height and a slightly wider machine, with a centre distance of 7.2 m, chain width of 3 m and belt width of 2.6 m. It is surrounded by a dust cover and has a top-mounted filter, as well as a slewing grate, cleaning brushes and catching strips, for the fine, spherical bulk material. It was essential that no spillage of the fine material could find its way into the production area, so effective sealing was paramount. The hybrid feeder also has a waterproof belt surface, and robust tractor-type chains are required due to the high densities of the material (2.8 to 4.3 t/m³). The hopper has a hydraulically swivelling grate for the purpose of intercepting and removing any pollutants which may have infiltrated into the material delivery containers.

Mobile handling devices deliver full containers of material onto a hydraulic tipping mechanism. The entire content of the container are then tipped into the hopper, but the Aumund design limits the volume of material that can enter the feed chute at the same time to a maximum of 33 t. As the ongoing process works at a volume of only 10 to 12 t/h, the hybrid feeder is set at a range of conveying speeds of only 0.001 to 0.006 m/s.

Request also from the Americas New hybrid feeders have since been sold by Aumund, four of them by Aumund USA, to M3 Engineering & Technology Corporation, which bought them for the Continental Gold Buriticá Project. Three of these four feeders are identical, with centre distances of 21 m, and will be located underneath the filter press. The fourth unit will receive tailings from a front-end loader via a lateral hopper, and unlike the other three has a hydraulic drive. The purpose of this machine is to feed the tailings into buckets on a cable-car, which takes the material up the mountain to be backfilled into the mine. The machines will be supplied this year and are expected to be commissioned by mid-2019.


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38

››› CONTINUOUS CASTING

voestalpine to upgrade bloom casting mill in Austria making it compatible with Industry 4.0 voestalpine Group has decided to invest more than EUR 100 million in future-oriented projects at its Donawitz site in Austria. One of the projects 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 highly automated production line with an annual capacity of up to 950,000 t is scheduled to start up operation in 2019. The voestalpine Group’s Metal Engineering Division is headquartered in Donawitz, Austria. With its innovative steel solutions, it 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. “This major investment in a continuous casting line will enable us to produce even higher quality pre-material for our products and further expand our technology leadership in our key customer segments. This investment will

voestalpine AG and Head of the Metal Engineering Division. The new line, 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.

New continuous bloom caster to be supplied by Primetals Technologies

voestalpine has awarded Primetals Technologies the order to supply a four-strand continuous bloom caster for its Leoben steel works. The “CC4” plant will replace the existing “CC2” continuous bloom caster at the Leoben steel works. In four-strand operation, it is designed to produce 950,000 t of highest quality blooms per annum. A fifth strand can be added to increase the production capacity if needed at a The new four-strand continuous bloom caster will replace a later date. The new similar, but timeworn plant at the same site plant is scheduled to be brought into also serve to secure the Group’s Dona- operation at the end of 2019, when it witz site,” comments Franz Kainersdorf- will become the world’s most modern er, Member of the Management Board of caster of its type. The plant is also Industry 4.0 compatible. Primetals Technologies is responsible for the basic and detailed engiPrimetals Technologies, Ltd. – a joint neering, the supply and construction venture of Siemens, Mitsubishi Heavy of the plant, and will supervise the Industries and Partners, London, UK commissioning. The continuous castContact: www.primetals.com er will produce round blooms with a E-mail: rainer.schulze@primetals.com diameter of 230 mm and rectangular MPT International 2 / 2018

blooms with a cross-section of 270 mm x 360 mm, and it is designed so that it can also produce a format of 440 mm x 330 mm. The range of products comprises rail steels, case-hardening steels, machining steels, steels for seamless tubes, heat-treated steels, spring steels, cold headed and cold extrusion steels, tire cord steels, cold work steels, bearing steels and welding electrode steels. The continuous bloom caster will be equipped with the DynaFlex hydraulic mold oscillator and the LevCon mold level control. The combination of the Dynacs 3D secondary cooling system and the fully automated casting clearance DynaGap 3D with dynamic soft reduction in the strand-guiding system ensure cast blooms of a consistently high quality. The plant also has an online traversing strand stirrer, with a traversing range controlled by Dynacs 3D. For loading and unloading the heat retaining boxes, a fully automatic crane is planned with a connection to a production planning system for stockkeeping. The scope of delivery also includes special mechatronic packages and an integrated automation solution.

Conclusion At its Donawitz steel works in Austria, voestalpine is focusing on the production of producing blooms with perfect soundness as a pre-material for premium rails, qualiy wire rod and special seamless tubes. The new continuous bloom caster for four-strand operation is designed to produce 950,000 t per annum with the option to add a fifth strand to further expand production. The new state-of-the-art casting plant is Industry 4.0 compatible.


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AUMUND Foerdertechnik GmbH • Saalhoffer Str. 17 • 47495 Rheinberg • Germany metallurgy@aumund.de · www.aumund.com


New technology for classifying the homogeneity of cast products SMS group has developed the “HD scan” testing solution for centreline segregations of slabs and blooms that overcomes the draw-backs of visual inspection of etched samples. HD scan is a reliable, automated inspection technology that provides impartial testing results. The quality – particularly the internal quality – of cast products such as slabs and blooms is a crucial commercial factor, first and foremost for the steel producers and steel traders, but also for the processing companies and users of the final product. However, when it comes to assessing the quality, questions about the criteria to MPT International 2 / 2018

be used to evaluate the internal quality will have to be answered. Are there impartial testing methods available and can any dimensional characteristics be used? “We found a perfect solution for testing the internal quality: HD scan,” says Dr. Tamara Gusarova, development engineer at SMS group. “We apply ultra-

sonic testing – a proven method generally used for technological analysis and medical examination and have developed a new software tool to analyze the measured data. This tool generates objective, valuable reports on the internal quality of cast products.” HD scan is easy to operate. It is a reliable method providing reproducible re-


QUALITY ASSURANCE

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41

Ultrasonic head carrying two sensors immersed in the basin accommodating the samples

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sults. In addition, HD scan is absolutely safe. It does not involve any handling of acids and does not require a special testing laboratory. The HD scan ultrasonic testing unit comprises a water basin (where the samples are placed), ultrasonic sensors and a computer-controlled manipulator to perform the testing. The basin can be dimensioned as required, for example a basin of 1.5 square meters is suited for nine flat samples, 400 mm square.

The usual macro-etching method inspects a single randomized section which is to represent the whole product. However, the test results may indicate to good or too poor a quality â&#x20AC;&#x201C; which is anything but a total quality test of the sample. By contrast, HD scan provides three-dimensional information about the whole sample. Quality conclusions can be drawn based on several sections inspected in a very short time and representative results comparable to those provided by the macro-etching method. However, with traditional macro-etching, such multi-sample testing would require much more time and additional effort. While macro-etching always shows a specific segregation (HCl etching shows only C-type segregations), HD scan is suitable for all types of segregation. Also, HD scan does not need a specially prepared surface, as it is the case with macro-etching. A roughly milled surface is sufficient. Not even rust interferes with the measurement. HD scan can be used to classify centreline segregations, detect cracks (including the type and length of the crack and its position in the sample), and to assess the sample geometry, including eccentricity, trapezoidal form, and bulging. The macrostructure is also shown. HD scan offers the possibility of neutral and impartial comparison of products from different sources. There is no need for visual inspecting and classifying an etched sample with a catalogue. Instead, HD scan provides impartial values determined in an automated inspection process. Quality parameters detected can be documented and archived to classify the product.

'CU[VQWUGCPFTGCF[HQT FKIKVK\CVKQP The testing procedure is simple. The operator loads the samples into the basin. Once the loading process has been confirmed, the test procedure is performed fully automatically, right up to classification of the centreline segregation.

The section of the sample to be analyzed can be chosen randomly. With other test methods the term â&#x20AC;&#x153;sectionâ&#x20AC;? always implies a two-dimensional surface. With HD scan, however, section implies three-dimensional volume information on the sample. HD scan gathers measurement data over a depth of 20 mm. This information is displayed using 100 individual layer images. To achieve the same result using the macro-etching technique, the sample would need to be finely ground and etched 100 times. HD scan is designed for the automatic classification of centreline segregation. The system can make dimensionally accurate distinctions between internal defects at a resolution of 0.5 mm. The choice of ultrasonic head and frequency has been optimized for the automatic classification of centreline segregation. It can also detect other internal defects, such as fine cracks for example. The existing etching photographs are digitized and archived. Therefore the archive is not started from scratch, and comparability is maintained over longer periods of time. What is more, the photographs can be automatically evaluated using the HD scan software. For better comparability, the same evaluation algorithms as used for ultrasound data are applied here. The HD scan data can be stored as low-volume data in a long-term archive. The digital evaluations can also be linked with existing process data, meaning processes can be optimized quickly and reliably.

%QPENWUKQP SMS group has developed a testing solution that involves no economic or health-related risks. The procurement and operating costs are low, as are the manpower resources required. It offers a short return on investment (ROI). The information volume is high, the evaluation software is easy to use, and the results are factual and objective. HD scan is a reliable and state-of-the-art technology that provides visibly successful quality results.

MPT International 2 / 2018


42

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

Rail and section mill started up operations in Kazakhstan 7KHĆ&#x201A;UVWUDLOVZHUHSURGXFHGDWQHZ$NWREH5DLODQG6HFWLRQ:RUNVĹ?WKHĆ&#x201A;UVWDQG RQO\UDLOPDQXIDFWXULQJSODQWLQ.D]DNKVWDQ,QOLQHKDUGHQLQJWHFKQRORJ\KDVEHHQ LPSOHPHQWHGIRUWKHWUHDWPHQWRIKHDY\GXW\UDLOVZLWKOHQJWKVXSWRPHWHUV7KH UDLOVSURGXFHGDUHSUHFHUWLĆ&#x201A;HGSHU*267VWDQGDUGDQGEHVLGHVVDWXUDWLQJWKHGRPHVWLF PDUNHWDUHH[SRUWHGWRWKH5XVVLDQ)HGHUDWLRQDQG&,6FRXQWULHV

Rail and section mill of Aktobe Rail and Section Works LLP in Kazakhstan (Photo by courtesy of ARBZ)

Primetals Technologies was granted the plant acceptance certificate for the new rail and section mill supplied to Aktobe Rail and Section Works LLP (ARBZ), Kazakhstan. The new rolling mill was installed in the town of Aktobe under the auspices of Kazakhstan Temir Zholy JSC, the national railway company, and is the first and only rail manufacturing plant in Kazakhstan. Since the commissioning of the mill in 2015, the rails produced here meet the fast grow-

Primetals Technologies, Ltd. â&#x20AC;&#x201C; a joint venture of Siemens, Mitsubishi Heavy Industries and Partners, London, UK Contact: www.primetals.com E-mail: rainer.schulze@primetals.com

MPT International 2 / 2018

ing demand for railway equipment in Kazakhstan and other CIS states. Contracted to Primetals Technologies in 2013, the combined rail and section mill in Aktobe is able to produce around 200,000 t of rails per annum in lengths of up to 120 meters, as well as 230,000 metric tons of angles, U and I-sections. Primetals Technologies supplied the complete rolling line, including a walking-beam furnace with a capacity of 90 metric tons per hour, a 2-Hi reversing blooming stand with a maximum working roll centerline of 1,050 millimeters, and a reversing universal mill train consisting of four Red Ring stands arranged in universal-edging-universal-universal configuration. The scope of supply also included a 125 meter cooling bed, equipment for a

horizontal-vertical straightening, cutting saws, and machines for bundling and handling the final products. The fluid systems for the rolling mill and a water treatment plant were also be part of the scope of supply. Primetals Technologies handled the engineering of its own equipment as well as that provided on site by the customer, and was also responsible for supervising installation and commissioning. In addition to the mechanical equipment for the rolling line, Primetals Technologies supplied the basic and process automation, all the main and auxiliary drives, the medium-voltage supply and distribution systems, as well as an uninterruptible power supply. Also a test laboratory and a workshop for roll maintenance was built.


HOT ROLLING

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Inline rail head-hardening system from at the ARBZ rolling mill (Picture by courtesy of Primetals Technologies)

Dual-phase rail hardening technology In order to produce rails with a high contact fatigue and wearing resistance, the rolling mill was equipped with the Injector Dual-phase Rail Hardening (IdRHa+®) system. This system is an advanced technology available for inline hardening of heavy-duty rails with lengths up to 120 m. Jointly developed by Primetals Technologies and the Italian technical center, Centro Sviluppo Materiali SpA RINA-CSM, IdRHa+® enables rails to be produced with improved resistance to contact fatigue and wear. Through a very flexible and reliable process, the rail product performances are optimized according to the different grades of steel. The current rail production is 100% Idrha-treated, and it consists of highstrength pearlitic rails P65 DT350 for high-speed applications. The design of IdRHa+® is based on thermomechanical and metallurgical process models, and validated by experimental trials in pilot plants. The system allows the simulation of various cooling strategies for different grades of rail steel prior to the start of production. This enables run-up times to be reduced, nominal capacity to be attained more quickly and relevant performance parameters to be fulfilled consistently and reliably. The plant features also an inline, fully-equipped non-destructive testing station to assure quality. After obtaining the national certification, ARBZ entered the multi-year certification process according to the Russian standards GOST, and a pre-certification was obtained in November 2016 after a rigorous six-month testing protocol at the

All Russian Railway Research Institute (VNIIZhT). Outside Moscow, Russia, VNIIZhT operates a railway loop where the rails under testing are subjected to a variety of operating conditions (train composition, load distribution, time, acceleration, speed, braking, gradient, etc.). The conditions of the rails are examined during and after the test, so that a thorough investigation of all the occurrences of wear and damage may be completed. Besides saturating the domestic market, ARBZ rails are exported to Russian Federation and CIS states.

Unique spare parts management system to follow soon In November 2017 the company awarded Primetals Technologies the order to implement its new spare parts management concept at the new rail and section mill. This new concept delivers ARBZ a comprehensive selection of spare parts with fixed pricing as well as a two years warehousing contract. The new system simplifies time-totime inquiries, leaving the whole supply chain activities to Primetals Technologies – including subcontractors. In addition, permanent technical support on site enables immediate response and continuous improvement in operation. The new warehousing system makes available a variety of spare parts for predictable defects that may occur at the mill as well as for unexpected needs. It makes a plant more efficient within its maintenance and has full interchangeability with installed parts and commercial commodities, so steel producers can rely on the warehouse management

IdRHa+® allows the simulation of various cooling strategies for different steel grades

system and be less likely to have a shutdown, bringing the safety and trustworthiness necessary to a successful business partnership. The service package includes a dedicated Primetals Technologies team at the customer’s premise, granting safekeeping of parts by delivering proper storage and classification. The costumer can also order parts on demand from a comprehensive list, centralizing management or any warranty aspects, making picking parts up from warehouse fast and precise. Another major advantage is the engineering support on site, on a daily basis for any request of technical expertise about maintenance and operational aspects. Also, a Primetals Technologies advisor is available for any reference visit to the plant and also a consultant for the customer loyalty program, building solid, long term relationships. Such assistance provides follow-up on continuous improvements, bringing in new solutions and technology, pursuing best practices to improve the design and features of Primetals Technologies equipment. MPT International 2 / 2018


44

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş TUBE MAKING

Tenaris starts advanced seamless pipe production for the demanding US oil and gas industry Tenaris has successfully started production at its new pipe mill in Bay City, Texas, USA. 7KHFRPSDQ\LQYHVWHGDWRWDORIELOOLRQ86GROODUVLQWKH*UHHQĆ&#x201A;HOGSURMHFWORFDWHG near the most active shale plays in the United States. Using the PQFÂŽ technology from SMS group, Tenaris is able to produce 600,000 t/year of precision seamless tubes with diameters of up to 9 5/8 inches for use in the oil and gas industries.

Tenaris built the new pipe mill in Bay City, Texas, about 80 miles southwest of Houston (Picture by courtesy of Tenaris)

The high-strength PQFÂŽ seamless tubes produced at the new Tenaris mill in Texas are mainly used for casing applications as well as line pipe. With its Rig DirectÂŽ strategy, Tenaris is synchronizing its pipe manufacturing activities with their customersâ&#x20AC;&#x2122; drilling operations to reduce storage, maintenance and inspection costs. In the past, the U.S. had to import a significant portion of the tubes required for shale gas production from Asia and other parts of the world. â&#x20AC;&#x153;Our goal is to make the tube and pipe industry more effective and to drastically reduce imports for our market,â&#x20AC;?

Michael Wilms, Vice President Seamless Tube Plants, SMS group, MĂśnchengladbach, Germany Contact: www.sms-group.com E-mail: michael.wilms@sms-group.com

MPT International 2 / 2018

says GermĂĄn CurĂĄ, President of Tenaris North America. Analysts and market experts see huge opportunities for success in the strategy being pursued by Tenaris, which may also give the company a significant competitive advantage. SMS group has worked very closely with Tenaris on the installation of state-of-the-art production technology for seamless tubes that satisfies the challenging requirements concerning both quality and tolerances as per API standards. Speaking of the new plant, GermĂĄn CurĂĄ goes on to say: â&#x20AC;&#x153;It is the most advanced production facility in our industry worldwide.â&#x20AC;?

High-quality tubes for the U.S. oil and gas industry For the new Texas pipe mill, Tenaris relies on the experiences gained during an earlier project. In 2008, SMS group erected a PQFÂŽ seamless tube

plant for Tenaris at its mill in Mexico. Norbert Theelen, Head of Long Products Plants at SMS group, adds: â&#x20AC;&#x153;We had already built a seven inches PQFÂŽ plant for Tenaris in Veracruz, Mexico. Building on our experience from this, our experts worked closely with the customerâ&#x20AC;&#x2122;s teams to set out objectives for the new plant and had already agreed their planned course of action during the engineering phase. There was intensive cooperation among all parties involved, that is, between Tenaris, our Tube and Pipe Plants division in Germany, SMS Innse in Italy, and SMS Elotherm, also Germany. The steering committee met regularly for a continuous exchange of information and ideas in order to precisely meet Tenarisâ&#x20AC;&#x2122; requirements.â&#x20AC;? During the construction phase, an average of 1,400 skilled specialists, fitters, technicians, and engineers were deployed on site, which covers an area of 110,000 square meters. The first


TUBE MAKING pipe was rolled in October 2017, and the plant was officially inaugurated in December. Thanks to the very close proximity to the customer and the cooperative development of new plants and processes for new materials, SMS group is bringing its motto of “Leading Partner in the World of Metals” to life. The cooperation with Tenaris was an example of this. SMS group supplied the plant technology and related engineering for its construction, and was responsible for the erection and commissioning supervision, including customer training. The main units of the PQF® plant include: ▪ billet preparation section and saws, ▪ rotary hearth furnace, ▪ barrel-type piercing mill with Diescher disks, equipped for the first time with a hydraulic adjustment system, ▪ PQF® rolling mill of BCO design, ▪ extracting mill, ▪ induction furnace for shell reheating, ▪ 24-stand stretch reducing mill, ▪ cooling bed and batch layer saws. The plant is designed for an annual capacity of 600,000 t of seamless tubes with diameter between 4 ½ inch (114.3 mm) and 9 5/8 inch (244.5 mm). Tube final wall thickness is ranging between 5.7 and 25.4 mm. The plant produces OCTG tubes as per API made of various steel grades (carbon steels, low-alloy and high-alloy steels with a chromium content of up to 9% and 13% respectively).

Extensive automation, maintenance-friendly plant design Compared to previous industry standards, the new Tenaris pipe plant is twice as efficient when it comes to high-quality seamless tube production. This is made possible thanks to, among other things, the high degree of automation and the use of robots, which convey the steel from one station to the next in a fully automatic process. The operating personnel work most of the time in the control room or in adjacent buildings. Below the production line, they have easy access to the machine components for maintenance purposes. “Our production process is fully automatic”, says Curá. “In

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45

The plant manufactures precision seamless tubes with diameters up to 9 5/8 inches (Picture by courtesy of Tenaris)

addition, every tube is given an identification mark, similar to a barcode, meaning the customer can trace the precise specifications using a scanner or smartphone.” In view of the challenging conditions in oil or gas fields, this smart means of tracing tube documentation is making a significant contribution to total quality assurance. To this end, SMS group has equipped the new PQF® seamless tube plant with a wide range of automated, state-ofthe-art technology. Norbert Theelen from SMS group: “Our advanced level of digitalization allows Tenaris to make substantial time savings and achieve optimum transparency as regards the current plant and production status. This is further enhanced by a host of other added value sources that boost efficiency levels. Tenaris is a trailblazer for modern plant and equipment that combine the benefits of digitalization. For example, we have installed a secure WiFi network

throughout the whole plant. This provides the operators access to information they need via mobile panels and to completely new ways of working.”

Sophisticated management of product and quality data The basis for the automation used at Tenaris Bay City is provided by the CARTA® (Computer-Aided Rolling Technology Application) technology system, which is used as a technological production planning and process control system for the entire hot rolling section of the seamless tube mill. CARTA® consists of three modules. The process-planning module prepares the rolling mill settings and the tool design. The process management module controls the rolling process in real time, and saves and analyzes the process data. The tool management module is responsible for the precise and timely use of the tools. So the benefits MPT International 2 / 2018


46

››› TUBE MAKING The barrel-type piercing mill is equipped with a hydraulic adjustment system (Picture by courtesy of Tenaris)

of CARTA® are numerous. This technology system offers not only increased output but enhanced tube quality and optimized mill utilization, too. The measuring data used by CARTA® to monitor the quality are provided by systems such as CaliView®, which

is supplied by SMS group. This is a newly developed inline system of measuring rolls and passes which are installed in the mill. A camera is used to take fast, precise and non-contact measurements of the stands inline, and to align them perfectly. Time-consuming,

manual measurements are no longer required. CaliView® ensures there is direct feedback to a mobile control device, meaning the rolls can be precisely adjusted during the measurement. What’s more, the system detects wear on the work rolls and logs the data for producing informative statistics. SMS group also implemented a holistic tracking solution for material and individual tube tracking. Production and quality-related tube parameters are measured at every machine during this process. The Identification Database software tool uses data gathering terminals (DGT) to collect the relevant information at each specified station and assigns this automatically to the tube number. The system provides production and quality reports in real time, statistical reports for identifying quality-related problems or production bottlenecks, and a comprehensive database for developing production and process know-how.

Competence in Shot Blast Technology We offer a complete service in surface preparation technology, not just as machine designers and manufacturers. Our emphasis is on providing reliable service on:

• Wear and Spare Parts • Repair and (remote) maintenance • Inspection and process advice • Machine upgrades and performance enhancement • Upgraded used machines

AGTOS Gutenbergstraße 14 · D-48282 Emsdetten Tel. +49(0)2572 96026-0 · info@agtos.de

www.agtos.com MPT International 2 / 2018

171-11/13-4c-GB

Gesellschaft für technische Oberflächensysteme mbH


It is not just the tubes and production processes that are continuously tracked, the tools are too, especially the mill stands and mandrels, and for this they are equipped with around 850 chips and monitored throughout

Cokemaking Services

Coal blend optimization

The PQF® mill is equipped with a wide range of automated technology including the computer-aided rolling technology application CARTA® (Picture by courtesy of Tenaris)

with a fully automatic tool tracking system with RFID technology. In addition to this, Tenaris also has a comprehensive condition monitoring system for the main drives, gears, motors, and saws. This online monitoring system is used in particular for monitoring parts that optimize preventive maintenance, increase the plant’s availability, and reduce operating costs.

Environmental design of the whole production site The building is eight stories higher than usual. This improves the airflow inside the building and creates a pleasant, climate-controlled working environment. Ninety-five percent of the waste materials created during production are to be recycled on site, according to Tenaris. And this makes Tenaris not only one of the most advanced but also the most sustainable tube mills in the world. The United States Environmental Protection Agency has categorized the new Tenaris plant as a “minor source of emissions”.

We are indeed proud to look back upon more than sixty years of research and development in the field of cokemaking. DMT providing state-of-the-art investigation methods for stamp and top charging supported by Pilot-scale testing in a 10kg-retort Semi-industrial movable coke oven 60-year experience of coal blending Generation of coal blends with coals from different origin to perform reference tests Coal & Coke quality DMT use international standards to determine coal properties and coke qualities DMT assists coal merchants and assess their product for the marketing DMT supports coke plants in their continuous quality control of the used coal and the produced coke

www.dmt-group.com

Earth. Insight. Values.

http://www.dmt-group.com/en/services/consulting/coke-making-services.html


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››› HEAT TREATMENT

The BILSTEIN bell-type annealing plant was expanded

Cold-rolled steel manufacturer BILSTEIN expands fully automatic batch annealing plant With the latest expansion of its batch annealing plant, BILSTEIN has strengthened its reputation as one of the most innovative companies in the industry and doubled the original quantity of annealing bases. This batch annealing plant stands out by being the only fully automatic batch annealing plant in the world. Moreover, it is the strongestSHUIRUPLQJDQGPRVWHQHUJ\HIƂFLHQWIXUQDFHSODQWRIWKLVW\SH In December 2017, BILSTEIN, a coldrolled steel manufacturer based in Hagen-Hohenlimburg, Germany, placed a further contract with LOI Thermprocess GmbH for the expansion of the world’s first fully automatic batch annealing plant. The idea of fully automated operation for a batch-type annealing plant was developed by BILSTEIN and implemented together with several German companies. The contract for stage I was placed in 2011 and consisted of MPT International 2 / 2018

twelve annealing bases with six heating hoods and six cooling hoods. The plant started fully automatic operation in November 2012. After a successful test phase, the plant was expanded by four annealing bases in 2015 (stage II). In December 2017, the contract for stage III, consisting of eight further annealing bases was awarded. Production is scheduled to start in November 2018. Until now, the plants have been used for annealing medium strip. In the future,

The QR-code links to a video on YouTube showing the fully automatic crane operation (youtu.be/808Go_9eeqY)


HEAT TREATMENT

Dr. Peter Wendt, Tenova LOI Thermprocess GmbH, Helmut Mühlnickel, BILSTEIN, Christian Hagenkord, BILSTEIN, Heiner Witke, Kranbau Köthen GmbH, Dieter Winkens, Ludwig Bönnhoff GmbH (all Germany) Contact: www.tenova.com E-mail: Peter.Wendt@tenova.com

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Furnace plant type

HUGF 200-560 HPH BYPASS + JET

Outside coil diameter, max.

2,000 mm

Inside coil diameter

508 / 610 mm

Coil width, max.

1,350 mm

Coil weight, max.

30 t

Stacking height, max.

5,600 mm

Stacking weight (net), max.

125 t

Annealing temperature (material), max.

850°C

Furnace temperature, max.

950°C

Heating hood connected load

1,800 kW

Type of cooling

BYPASS+JET

Main technical data of the bell-type annealing plant at BILSTEIN

Automatic Coil Storage

Convector Plate Handling Unit

Automatic Crane

wide strips with a max. width of 1,350 mm will also be annealed. As shown in a video on YouTube (see QR code), fully automatic operation includes, among other functions, the following: ▪ automatic crane operation (unmanned), ▪ automatic charging/discharging of coils or “coil + convector” units, ▪ automatic charging/discharging of intermediate convectors, ▪ automatic charging/discharging of inner covers, heating hoods and cooling hoods, ▪ automatic connection/disconnection of all media (natural gas, hydrogen, electricity), ▪ automatic program guidance and data archiving, ▪ automatic condensate minimisation and condensate collection system, ▪ automatic heating and cooling programs, ▪ automatic purging program optimisation, ▪ automatic operation, archiving and visualisation, ▪ automatic coil storage management for complete material tracking, ▪ automatic communication between operational data acquisition system, crane control (including grippers) and bell-type annealing plant. To meet the requirements for fully automatic operation of the bell-type annealing plant, a series of adaptations and new developments were essential for the batch annealing technology itself. In automatic operation, the operating personnel does not have access to the plant. The entire plant is surrounded by protective fences including nine protective doors. The hall features various safety zones to ensure that regular maintenance work does not interfere with automatic operation in other areas of the annealing plant. Nevertheless, the systems must be set up in such a way that the visual check previously

‹‹‹

Automatic Cross Transfer System

General plant layout

Automatic coil transfer system MPT International 2 / 2018


50

››› HEAT TREATMENT

required is no longer necessary. Key design modifications were made to almost all parts of the plant as e.g. the annealing bases, the base locations, the heating hoods, the multimedia couplings, the inner covers, the instruments, etc. Now that the furnace plant has been operated in fully automatic mode for more than five years, it is justified to speak of a successful project. All the targets set were achieved or even outperformed. Not least because of this fact, BILSTEIN decided in favour of further enhancements and the implementation of plant expansions.

Crane type

Double bridge crane

Span width

32.8 m

Net weight of crane

approximately 135 t

Main hoist/auxiliary hoist

50 t / 28 t

Positioning accuracy

± 15 mm

Lifting speed

15 m/min at nominal load

Lifting height

up to 20.0 m

Design in accordance with EN 14492-2

redundant hoists as loads are carried over pressurised gas lines

Use of main hoist

for wide strip coils

for the transportation of hoods and medium strip Characteristics of the fully automatic crane Use of auxiliary hoist

Fully automatic handling of coils, hoods and convectors From an automatic coil storage warehouse located in the neighbouring hall, the coils are transported into the hall with the bell-type annealing plant via an automatic cross transfer system. The conveyor line (cross transfer system) between the coil storage hall and the annealing hall comprises four positions, each of which is indicated by the coil tracking system. The requested coil is automatically lifted by the coil warehouse crane by use of electro-permanent magnets, then transported to the conveyor line in the horizontal coil axis and placed on the fixed point on the tilting device. In the next step, the coil is tilted into the vertical coil axis. The transfer system moves the coil into the working area of the crane. It is equipped with an intermediate convector gripper below the actual control station, which places an intermediate convector on the coil. This “coil + convector” unit is used for charging onto the annealing bases. Following annealing, the annealed coils are returned to the neighbouring automatic storage hall via a second conveyor line on which the coils and convector no longer form a unit. The crane of the second transfer system positions the convectors in three fixed locations between the two transfer systems. A second tilting device is used to tilt the coils into the horizontal coil axis. In the last step, the annealed coil is either stored or directly forwarded for further processing. The automatic crane supplied by Kranbau Köthen GmbH for the annealing hall has a number of safety functions and an automatic anti-swing control system that perfectly compensates for the very different loads and centres of gravity of the coils and MPT International 2 / 2018

Fully automatic handling of hoods and convectors

plant parts to be transported. On both sides of the crane and trolley track, position sensors and “safe sensors” are installed in order to take the tilt of the crane into consideration in positioning. The crane positioning accuracy is less than ± 15 mm for all operation modes. A centring process is then carried out in the bell-type annealing plant to ensure safe “hydrogen-tight” connection of the media couplings. The double bridge crane system is designed as an 8-wheel crane with swing

drives. The lower blocks are equipped with a motor-powered rotating gripper arrangement and forged eyes for clearance-free rotation of the multi-functional gripper used. The crane is equipped with fire extinguishers for the switchgear room and dust extraction units at the crane tracks. The switchgear room air conditioning system on the crane features a redundant design. The plant features a multi-functional gripper developed by BILSTEIN together with Ludwig Bönnhoff GmbH


HEAT TREATMENT and also used at one of the companyâ&#x20AC;&#x2122;s other annealing plants. It was optimised significantly for use in automatic operation. This gripper can be used for the charging of coils, convectors, coils with convectors, inner covers, heating hoods and cooling hoods. The gripper, which is designed as a dual vertical gripper, mechanically generates the closing force for the coil and convector transportation at four points. Coils and conveyors which are dry or coated with rolling emulsion are held in position by friction. Hydraulically operated holding-down clamps are used for picking up and transporting the hoods. These clamps are also used as supports and spacers for individual convector transportation. In spite of the protruding convector, the transportation in combination of intermediate convectors on coils reduces the number of crane movements required, allowing a considerable time saving in the charging/discharging of the annealing bases. Hydraulically operated side guidance flaps allow precise positioning of the gripper, the annealing base positions and the charging/ discharging locations. A complex set of monitoring sensors was integrated for fully automatic operation. Proximity switches, limit switches, load measuring gauges and laser-measuring systems poll the actual operation status for the positioning and control of the gripper including its functional components as well as the load identification. The queries and communication with the crane system ensure the â&#x20AC;&#x153;safeâ&#x20AC;? pick up and holding of the load so that it is now ready for being transported. Wireless camera systems are an additional control tool used for automatic operation. The use of failsafe controls in the crane system and in the bell-type annealing plant as well as a state-of-theart ProViewÂŽ process control system supplied by LOI Thermprocess complete the automation concept. The measured data acquisition system developed by BILSTEIN and installed at the plant records and archives practically all measured data as well as performance and consumption data and evaluates this information on the basis of various criteria. This means that the company is a leader in the industry and ensures full transparency of all processes at the plant.

Only one person per shift works in the area of the coil storage hall, the cross transfer system and the batch annealing plant. The workplace is accommodated in the control room eight metres above shop floor level.

*KIJN[GPGTI[GHĆ&#x201A;EKGPV annealing technology

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

51

in active cooperation with BILSTEIN. The bell-type annealing plant features state-of-the-art JET cooling hoods and a BYPASS cooling system. All fans in the waste gas system, on the heating hoods, annealing bases and in the BYPASS system are fitted with frequency converters. Two externally arranged five-line recuperators ensure extremely high combustion air pre-heating up to approximately 600°C at the heating hoods. The BYPASS cooling system is a twophase cooling system. A few minutes after the start of the cooling phase, the

In addition to the automation concept which is unique throughout the world, this batch annealing plant is also the highest-performance annealing plant of its type with an annealing Gripper type Type 610 vertical gripper base capacity of approximately 2.82 Load capacity 15 t, 18 t t/h (reference stack Gripper net weight 8.6 t with approximateTransportation of ly 90 t and at Î&#x201D;T = coils 14 t, ø 2,000â&#x20AC;&#x201C;1,350 mm 35 K). A high-perintermediate convectors 1 t, ø 2,050mm formance recirculation system with convectors on coil 15 t impellers specificalheating hoods 18 t ly designed for this cooling hoods/inner covers 4t customer as well as a high-performance Main characteristics of the fully multi-functional gripper BYPASS cooling system are used. A frequency-controlled â&#x20AC;&#x153;gas/thermal oilâ&#x20AC;? cooler is switched on BYPASS fan allows this cooling system at approx. 700°C. A circulation system to be activated at considerably high- feeds the thermo-oil which was heater annealing temperatures without in- ed to more than 250°C to a subsequent creasing the risk of sticking strips. ORC process (ORC = Organic Rankine In addition, this bell-type annealing Cycle); electrical power is generated by plant features the most advanced energy a piston expander. In order to increase efficiency concept in the world, which the relatively low efficiency of the ORC was developed by LOI Thermprocess process, hot water â&#x20AC;&#x201C; in addition to the

Multi-functional gripper MPT International 2 / 2018


52

››› HEAT TREATMENT

Design scheme of the oil and water circuits for the heat recovery system

electrical power - is generated in this ORC process and fed to a hot-water circuit. As soon as a gas temperature lower than 300 – 350°C has been reached in the BYPASS system, the cooling system is switched to a second gas/water cooler. Hot water with a temperature of approx. 80°C is extracted and fed to a

hot water circuit. This second circuit is connected to a system of ring pipes supplying the high-bay storage warehouse and the air curtains at the hall doors as well as the emulsion tanks to be kept at a constant temperature of about 50°C, which allows recycling of more than 50% of the energy required for the heating of the coils and auxiliary masses. This hot water can only be extracted from BYPASS cooling systems with external coolers. The innovative feature is that, in contrast to the past, the energy used for heating is no longer completely dissipated during the cooling process and discharged via cooling water. In the past, additional energy was required for re-cooling this cooling water. With the new solution, up to 58% of the energy used can be recycled provided that that hot water at a temperature of 70 – 80°C can be used at the plant.

The QR-code links to a video on YouTube showing the fully automatic gripper operation mode (youtu.be/8K681pV8jX4)

As a result, this bell-type annealing plant has a specific gas consumption of approximately 140 kWh/t instead of the usual 180 kWh/t, which corresponds to a real and proven energy saving of more 22%. For each annealing batch, the ORC system generates up to 400 kWh of electricity; up to 5,300 kWh of heat energy is generated by heat extraction. To summarize, the BILSTEIN bell-type annealing plant of is not only the only fully automatic batch annealing plant in the world but also the highest-performance, most energy-efficient furnace plant of this type.

References BILSTEIN

[1] Wendt, Peter et al: The world’s first batch annealing plant with fully automatic crane operation ensures optimal use of energy. MPT International, 3/2015 (June), 136-141

Most of the energy captured in the hot stack can be recovered MPT International 2 / 2018

[2] Wendt, Peter et al: Modernization of existing industrial furnace plants. Heat processing, 02/2015, 81-90


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54

››› COLD ROLLING

BILSTEIN relies on advanced plant concept for reduction and skinpass operations of steel strip Cold-rolled steel manufacturer BILSTEIN placed a contract with SMS group for the supply of a complete 4-high reversing cold mill. This high-performance plant is designed for reduction and skin-pass (RCM/SPM) operations particularly of demanding steel grades. In July 2017, BILSTEIN Cold Rolling Mill in Hagen, Germany, awarded SMS group the order for the supply of a complete 4-high reversing cold mill. This high-performance plant is designed for reduction and skin-pass (RCM/ SPM) operations. Its design combines powerful, robust mechanical systems with intelligent, future-oriented process control. BILSTEIN has decided to invest in a high-performance reversing cold mill of the proven CVC® plus design featuring the well-established X-Pact® electrical and automation system. The RCM/SPM is designed to roll and skinpass a wide range of demanding materials in widths between 600 and 1,350 millimeters and minimal final thicknesses of up to 0.20 millimeters. This new cold mill will be able to roll and skin-pass 290,000 t of cold strip annually. In order to achieve the required performance as well as reliable and efficient rolling, the 4-high stand will be equipped with small-diameter work rolls. The Sieflex® HT drive spindle, designed to transmit extremely high torques via small-diameter work rolls in order to achieve great pass reductions, even with higher-strength materials, is among the system’s many highlights. Another feature of the plant will be the X-Shape flatness measuring and control system, which plays a crucial role in achieving outstanding flatness results. Special characteristics of the plant include its upgradability, allowing, for example, innovative rolling assistance

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

MPT International 2 / 2018

Illustration of the new combined reversing cold rolling and skin-pass mill for BILSTEIN

systems to be integrated or the degree of automation to be increased in the future. Process reliability and output will be further enhanced as a result. Alongside the cold rolling mill and its auxiliary equipment, the peripheral equipment, such as the demineralized water unit, fire extinguishing system, closed cooling water circuit and air treatment systems for balanced shop air management, including preheating and heat recovery, is part of SMS group’s scope of supply.

Ambitious project schedule SMS group is also responsible for final erection and commissioning of the new plant. BILSTEIN will benefit from the extensive pre-erection work and tests performed in the SMS group’s Hilchenbach facility. This also includes the full assembly of the mill stands as well as testing of the hydraulic valve stand and the hydraulic positioning system. Only previously tested units will be delivered to the customer’s site.

All automation hardware and software will be commissioned in advance in the SMS group test field. As part of these Plug & Work tests, BILSTEIN’s personnel will also receive prior training in the operation of the plant. All these measures will ensure quick and smooth assembly and commissioning and a fast plant startup, and guarantee that BILSTEIN will be able to produce marketable material on the new RCM/ SPM from September 2019. The cooperation between SMS group and BILSTEIN will extend beyond the equipment installation. Both partners aim to establish a long-term partnership based on process-oriented service engineering. The objective of this cooperation is to drive forward the systematic refinement of the plant and related processes towards greater system integration. Performance, process efficiency and sustainability are features characterizing BILSTEIN’s new combined reversing cold rolling and skin-pass mill and making it one of the most advanced plants of its kind worldwide.


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56

››› STRIP PROCESSING

New-generation wiping system for more uniform and thinner zinc coatings The new CXJ wiping system from Danieli Kohler has obliterated the old boundaries for line speed and coating weight while delivering superior quality coated strip products for the automotive industries. The overall space required is drastically reduced, so installing the system on an existing hot-dip galvanizing line with a narrow pot area is easier than ever. In hot-dip galvanizing lines, the wiping system meters the molten coating on the strip coming out of the pot after it has been surface-treated in the furnace. The new Compact X-JET (CXJ) wiping system ensures precise coating weights and a high-quality surface appearance in combination with a compact design. Submerged rolls hold the strip in the pot and work together to maintain flatness. The CXJ Air Knife Rigs create a uniform jet of wiping gas across the nozzle width by having the gas pass through a series of separate chambers with successively smaller flow passages. The size and shape of the last chamber creates the optimal shape of the jet at the exit of the lips. This precisely shaped and directed jet of pressurized gas leaves a uniform coating of the correct thickness on the strip. Dross is the by-product of the wiping process in hot-dip galvanizing. Skimming is the removal of top dross and slag from the pot surface. Q-Robot Zinc executes the skimming activities previously performed by a human operator, with important health and safety benefits for the line operators, and with positive economic effects. The heart of the wiping equipment is the state-of-the-art CXJ nozzle. An advanced R&D project achieved a major breakthrough compared to previous technology. Each nozzle is equipped with an automatic lip cleaner and optional gap width adjustment to save on wiping gas, minimizing skimming and reducing noise. Elevator/positioners precisely and repeatably position each

Danieli & C. S.p.A., Buttrio, Italy Contact: www.danieli.com E-mail: info@danieli.com

MPT International 2 / 2018

3D engineering study of the Compact X-JET wiping system for continuous hot-dip galvanizing lines

X-Jet for the appropriate height and distance to strip. Non-contact edge baffles are automatically centered between the jets, while each baffle plate follows the strip edge via a special sensor. Submerged roll rigs are available with 2- or 3-roll arrangements, special bearings and optional sink roll and rear stabilizing roll scrapers. The automation and control system is supplied by Danieli Automation, including the optional coating weight closed-loop control (Q-Zinc CLC™). Q-Robot Zinc™ is an industrial, heavy-duty 6-axis anthropomorphic robot, with a specially designed tool and control system, typically located at the back of the pot. The CXJ wiping system provides considerable benefits as following: ▪ It delivers the same high performance as the standard X-Jet, up to 10% more uniform coating, in a smaller physical package. ▪ The minimum zinc coating weight can be as low as 30 g/m² per side. ▪ It can be easily installed in narrow pot areas of existing lines.

▪ It operates at 20-25% higher line speed with the same coating weight. ▪ There is reduced downtime required for installation while minimizing design requirements. ▪ Fast return on investment (ROI): less than two years (documented cases of four months).

Conclusion The CXJ technology incorporates an identical laminar flow chamber and lip design as the standard X-JET, with the same jet efficiency, focus and sharpness. Auxiliary functions such as jet angle adjustment, automatic lip cleaning and jet gap width adjustment have been simplified and optimized, incorporating the latest feedback from over 20 operating lines. The new design is more modular, which facilitates customization for revamp installations and provides for easy addition of advanced features. Danieli has demonstrated the superiority of the X-JET on both new galvanizing lines and revamps.


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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş STRIP PROCESSING

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

Coil strapping unit at the hot strip mill No. 3 at thyssenkrupp Steel Europe AG, Bochum works

The global demand for steel pipe and tube has been constantly on the rise. Steel material grades for welded pipe and tube may vary from soft low-strength to ultra-high-strength steels, with strip thicknesses of over 25 mm. Tube manufacturers are used to receiving perfect coils â&#x20AC;&#x201C; safely strapped and with certified quality. Before the coils can be shipped, sub-prime quality strip like head end and tail end have to be cropped. In addition, samples are taken from every coil for quality control and inspection. BWG Bergwerk- und Walzwerk-Maschinenbau GmbH, an engineering and equipment supplier headquartered in Duisburg, Germany, has developed an innovative and customiz-

9QNHICPI-CNDĆ&#x192;GKUEJ$9)$GTIYGTM WPF9CN\YGTM/CUEJKPGPDCW)OD* &WKUDWTI)GTOCP[ %QPVCEVYYYDYIQPNKPGFG 'OCKNKPHQ"DYIQPNKPGFG

MPT International 2 / 2018

able solution to meet these particularly challenging technical requirements. In the design of both the manual and the automatic versions of its new coil strapping systems, BWG has focused on: â&#x2013;Ş ergonomics and occupational safety, â&#x2013;Ş safe cutting and sampling of the strip, â&#x2013;Ş coil tracking, â&#x2013;Ş identification of the taken samples, â&#x2013;Ş safe transport and delivery of the coil to the customer, â&#x2013;Ş improved productivity and quality. A usual method of sample taking and head and tail end cropping is manual or semi-automated torch cutting. For obvious reasons, this method has some disadvantages. It requires additional time, workforce and also material resources. Cycle times are long. The method is less environmental-friendly than a shear that does not need an exhaust system. BWG has designed such systems in the past and is still supplying them, but has recently come up with a much more efficient and safe solution that is operating in a fully automatic mode.

High-strength and ultra-highstrength steel coils have a strong tendency to re-open after coiling. This tendency makes these coils particularly challenging to handle. It must be ensured that these coils are securely positioned, guided and transported at each processing step â&#x20AC;&#x201C; particularly when samples have to be taken, i.e. before removing the straps, during the cutting process, and for re-strapping of the coil. Since coil weight matters, it is even more complicated for coils of smaller dimensions and less weight. In addition, occupational safety requirements for all operating conditions have to be addressed. BWGâ&#x20AC;&#x2122;s newly developed coil strapping line meets all these requirements. This new state-of-the-art coil handling system can operate in a fully automated mode and hence boasts a high level of automation. To increase production and yield through shorter cycle times, the design concept of the new line meets the following characteristics: â&#x2013;Ş interface to the existing material tracking system, â&#x2013;Ş possibility of transferring coils by the mill crane or â&#x20AC;&#x201C; alternatively direct connection to a coil transfer system, â&#x2013;Ş automatic centre line positioning of the coil, â&#x2013;Ş automatic measurement of the parameters of the incoming material (dimensions, temperature, etc.), â&#x2013;Ş automatic control of coil strap positions, â&#x2013;Ş automatic removal and disposal of existing coil straps, â&#x2013;Ş automatic uncoiling of the coil head end,


STRIP PROCESSING â&#x2013;Ş automatic cut-off and disposal of sub-prime quality head end scrap, â&#x2013;Ş automatic sample cutting, â&#x2013;Ş automatic identification and marking of the samples, â&#x2013;Ş automatic re-coiling, â&#x2013;Ş automatic circumferential coil strapping of high-strength steel coils or alternatively circumferential coil strapping using a normal strapping system for standard strength coils, â&#x2013;Ş automatic through-the-eye coil strapping, â&#x2013;Ş automatic coil weighing, â&#x2013;Ş coil take-over by mill crane or direct

coils. The new BWG coil strapping line was designed for fully automatic processing of high-strength steel grades for thick-walled welded steel pipe and tube. At the end of 2016 SZFG placed the order for this new line with BWG, which in the past had supplied major equipment to SZFG for processing lines and provided services such as installation and commissioning.

#PKPPQXCVKXGUVCVGQHVJG art concept BWG developed and supplied a line that can process both high-strength Sample handling

Cross cut shear

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

59

addition, the actual coil temperature is measured, as it is an important parameter for the further processing of the coil. The traversable uncoiler, developed and patented by BWG, ensures not only secure transport of the coil after the strap removal, but also controlled re-coiling at the sample station. The coil position is always secured by means of an expanding mandrel (in the coil eye) and by snubber rolls at the outer strip layer. Depending on the material characteristics of the coil, the snubber rolls can be adjusted to different positions during the uncoiling process. This design concept prevents unwanted plastic deformation (bends) of the strip Moveable uncoiler

Exit coil transport

Entry coil transport Conventional uncoiler and sampling

Design scheme of the fully automated coil strapping and sampling line at rolling mill

station operated in semi-automated mode

No. 3 of Salzgitter Flachstahl GmbH, Germany

connection to an existing coil transfer system. With the new coil strapping and sampling line, the steel producer is able to increase production in the sampling and packaging shop and to process orders â&#x20AC;&#x153;just in timeâ&#x20AC;&#x153;, while at the same time ensuring the safe transport and delivery of the coils to the end customer. German steel maker Salzgitter Flachstahl GmbH (SZFG) is highly convinced of the benefits provided by the new coil strapping and sampling system. The companyâ&#x20AC;&#x2122;s hot strip mill processes coiled strip, sometimes still in the hot condition. SZFG wanted new plant equipment to meet the increasing demand and growing requirements for finishing, sampling and safe strapping of such

and regular grades of steel for both large and smaller sized coils. The coil strapping and sampling line comprises important key components such as: â&#x2013;Ş fully automatic strap removal from the incoming coils, â&#x2013;Ş traversable uncoiler, â&#x2013;Ş high-performance sample shear with automatic sample and scrap removal systems, â&#x2013;Ş double-head strapping machine for regular and high-strength straps. The strap removal system consists of a robot with a strap detection device, a separating tool and a temperature measurement function. The positions of the straps are detected automatically, and the equipment is able to even cut through partially overlapping straps. In

despite the different product grades to be processed in the line. Depending on the material parameters, the traversable uncoiler pivots the coil into the optimum position in front of the shear. After passing the snubber roll, the strip moves freely, i.e. without a guiding device, avoiding surface damage. This technology functions reliably even with small diameter coils and should become the industry standard for this type of operation. The design of the traversable uncoiler does away with important disadvantages of conventional concepts. At a common spin-roll station the strip tension during uncoiling and re-coiling depends on the varying coil dimension (weight, outer diameter), i.e. the smaller the coil, the lower the strip tension, due to the limited press MPT International 2 / 2018


60

››› STRIP PROCESSING

forces and the friction value between spin rolls and coil OD. Actually, such conventional design limits the product range (in terms of tensile strength) that can be processed in such a coil strapping line. For safety reasons, a guiding basket is required, which, however, may damage the strip surface. Therefore, the onward transport of unstrapped coils upstream and downstream of the spin roll station by an adjacent coil transport system remains unsafe for certain high-strength steel grades. The newly developed traversable uncoiler meets all requirements for an automated and sustainable operation. The main advantages of the unit are: ▪ safe coil transport, ▪ controlled uncoiling and re-coiling with defined strip tension, ▪ constant strip tension despite variation of coil weight and outer diameter, ▪ no damages to the strip surface, ▪ minimum plastic deformation of the sample pieces. BWG has developed a new design for a high-efficiency shear that is already successfully in operation in a number of plants worldwide. The shear is de-

3D design scheme of the traversable un-coiler

signed to cut high-strength and ultrahigh-strength steel grades in a strip gauge range of 1.5 to 25.4 mm. (The new shear design also allows for the cutting of strip thicker than 25.4 mm.) The samples are automatically collected and tagged (marked and identified) in a separate container. Due to the flexibility of the traversable uncoiler, the high-efficiency sam-

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Expert for precise optical temperature measurement for process analysis and control Carl-Keller-Str. 2-10 · 49479 Ibbenbüren · Germany Phone +49 5451 850 · its@keller.de · www.keller.de/its

MPT International 2 / 2018

ple shear can be installed in its normal position. This facilitates sample collecting and scrap removal. No foundation pits are required. The scrap plates are automatically collected at low noise level and placed in a container that can be changed as required during production. The knives are easy to reach. A knife change is possible in less than 30 minutes time. The blade clearance is automatically adjusted to the actual strip thickness according to the data provided by the material tracking system and the warehouse management system. After the samples have been taken the strip is re-coiled. The traversable coiler conveys the new coil to the double-head circumferential strapping machine. Standard coils are strapped with standard strapping material. For highstrength grades, a second strapping head applies a specified number of highstrength straps around the coil, in order to ensure safe transport (for shipment and delivery to the final customer). The continuously operating material tracking system, which is connected to the warehouse management system, is a key component of the line automation. The coil data are updated with new information gathered from the coil strapping and sampling system. The actual coil data are subsequently analyzed and used for downstream machine settings. Using the innovative new coil strapping and sampling line designed by BWG, steel producers are able to optimize production and shipping processes. At the same time the system provides occupational safety and a safe coil transport by road, rail or sea.


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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş STRIP PROCESSING

Laura Metaal upgrades cut-tolength line at steel service centre The Dutch company Laura Metaal has successfully completed the ambitious and challenging project to modernize and upgrade their existing cut-to-length line. The plant was upgraded with new technological solutions from FIMI in order to be able to process heavier gauge materials, ultra-high strength steel strip and also abrasive hot rolled coils.

Strapped stack of heavy-gauge sheets at the exit of the cut-to-length line

Italian plant manufacturer FIMI is ranked among the leading manufacturers of metal strip cutting lines worldwide. The company is the parent firm of the FIMI Group which comprises the four companies FIMI, SACMA, ADDA FER and SVM â&#x20AC;&#x201C; all of which share the same vision of quality for highest customer satisfaction. This leadership position is based on the high quality of the products and high performing solutions provided by the group. Established in 1963, FIMI develops and manufactures complete strip processing lines for â&#x2013;Ş cutting to length, â&#x2013;Ş slitting of metal strip, â&#x2013;Ş re-coiling and strip inspection, â&#x2013;Ş slit coil packaging lines, â&#x2013;Ş stackers.

FIMI Spa â&#x20AC;&#x201C; Fabbrica Impianti Macchine Industriale, Viganò (Lc), Italy %QPVCEVYYYĆ&#x201A;OKITQWRKV 'OCKNKPHQ"Ć&#x201A;OKITQWRKV

MPT International 2 / 2018

The range of strip processing technologies from FIMI also includes packing solutions for sheets, slit coils and mother coils, electro-welded tube mills, tube finishing lines and handling and packing systems for tubes. A wide range of material, including ferrous and non-ferrous such as carbon steel, high strength steel, stainless steel, painted steel and aluminium, is processed by lines made by FIMI. The lines and equipment are mainly destined for steel service centres and companies in the steel processing sectors such as the automotive industry and the household appliances industry.

Modernization of the Laura Metaal cut-to-length line The Dutch company Laura Metaal selected FIMI was as supplier and technical partner for the development and implementation of the ambitious and challenging project to modernize and upgrade the existing cut-to-length (CTL) line at the Laura steel service centre in Maastricht, the Netherlands.

The existing line had to be upgraded with new technological solutions in order to be able to process heavier gauge materials, ultra-high strength steel strip and also abrasive hot rolled coils. The main goals were to achieve top product quality and a high productivity level i.e.: â&#x2013;Ş perfect sheet flatness and removal of internal stresses, particularly for the laser cutting processes, â&#x2013;Ş excellent sheet surface quality with complete removal of scale, wet and rust, â&#x2013;Ş high level of automation for the setup and control of the machines. Along with high productivity, Laura Metaal requested easy maintenance of the plant. The investment costs had to be in line with what is typically affordable for a service centre business. The existing cut-to-length line had been installed by FIMI in 2009. It was designed to handle: â&#x2013;Ş strip thicknesses from 5 to 20 mm â&#x2013;Ş a max. strip width of 2,100 mm â&#x2013;Ş max. yield strength values: 1,000 MPa up to 10 mm


STRIP PROCESSING 850 MPa up to 15 mm 550 MPa up to 20 mm The goals of the upgrade were to achieve: ▪ a strip thicknesses from 4 to 25 mm ▪ a max. strip width of 2,100 mm ▪ max. yield strength values: 1,250 MPa up to 8 mm 1,150 MPa up to 16 mm 800 MPa up to 20 mm 550 MPa up to 25 mm The upgrade of the existing cut-tolength line was completed and commissioned in July/August 2017 to the full satisfaction of Laura Metaal. All objectives of the investment have been fulfilled. Laura Metaal now operates one of the most powerful and best performing cut-to-length lines for heavygauge, ultra high-strength material in the world.

FIMI cut-to-length line at Laura Metaal (NL)

— Millmate Thickness Gauging systems Gapless gauging for aluminium strip

The Box Gauge measures aluminium strip thickness with a gapless sensor – excitation and receiver in one single unit. The compact and robust design, together with insensitivity to alloy variations and harsh rolling mill environments, enables accurate measurements in any position, even interstand in a tandem mill. Thus the MTG Box Gauge is ideal for use with all types of AGC, for control of thickness as well as for reducing thickness errors. abb.com/thicknessgauging

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››› TECHNICAL INNOVATIONS

Universal thickness measurement with extended measuring ranges FLAT PRODUCTS The thicknessSENSOR for universal thickness measurement of strip and plate material, offered by Micro-Epsilon, has been expanded by three measuring ranges and is therefore suitable for many other applications involving a material thickness up to 25 mm and measuring widths up to 400 mm. This high-performance system is suitable for thickness measurement of strip and plate material in the metals and plastics industries and for a diverse range of fabrics and composite materials. Two laser triangulation sensors are fixed opposite to each other on a stable frame and measure against the target from both sides. The material thickness is detected according to the difference principle. The evaluation unit integrated in the frame calculates the thickness values and outputs these analogically via tension and current or digitally via Ethernet. The thicknessSENSOR can be easily integrated into the processing line and in restricted spaces without requiring any complex sensor alignment. In addition, it also offers ease of use via an intuitive web interface, which enables the user to upload 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 meas-

Thickness measurement systems for different product sizes

urement task can be optimized using signal peak selection and freely adjustable signal averaging. Contact: www.micro-epsilon.com

Annealing simulator for product development and process optimization

Annealing simulator

HEAT TREATMENT Chinese steel producer Shandong Iron and Steel Group Rizhao has ordered a Multipas (multipurpose annealing simulator) from Primetals Technologies. The system will be installed in the research centre of the new iron and steel works under construction south of MPT International 2 / 2018

Rizhao. Multipas will be used there for product development and process optimization in heat treatment plants. Its use shortens the run-up phase of heat treatment plants and simplifies their optimization. Commissioning of the system is scheduled for September 2018. In a Multipas annealing simulator samples of cold-rolled plates with dimensions up to of 500 mm x 300 mm and a thickness of up to 3 mm are heated by conduction up to a temperature of 1,200°C by a maximum electric current of 8,000 A. Depending on the geometry of the sample, the heating rates are up to 100 k/s. The samples can then be cooled in very different ways. The two main forms of cooling are gas jet cooling with cooling rates of up to 100 k/s and water quenching. This method cools a sample with water at rates of up to 1,000 k/s, which enables the microstructure to be “frozen”. The sample is then examined in the laboratory. A Multipas is also equipped with spray water and mist jet nozzles, and fan cooling. The wide range of heating and cooling speeds is necessary in order to be able to simulate on a small scale all possible and future heat treatments in the large-scale plant. Contact: www.primetals.com


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››› TECHNICAL INNOVATIONS

Colour coating line technology

2018 LITMASH 29 MAY – 01 JUNE MOSCOW RUSSIA

STRIP COATING Bronx International provided the design, supply, supervision of installation, commissioning, transfer of production technology and full operator training for a new continuous colour coating line recently commissioned at Hoa Phat Steel

®

METALLURGY

®

INTERNATIONAL FOUNDRY TECHNOLOGY, SUPPLIES AND CASTINGS TRADE FAIR INTERNATIONAL METALLURGICAL TECHNOLOGY, PROCESSES AND METAL PRODUCTS TRADE FAIR

New colour coating line at Hoa Phat Group

Sheet in Vietnam. The single pass 120 m/min line is designed for strip thickness ranging from 0.15 mm to 0.8 mm and coil width up to 1,250 mm. The line will be capable of producing 120,000 t/year of prime yield colour coated coils with paints such as polyesters and PVDF. The colour coating line is equipped with energy saving technology. The prime and finish four zone gas-fired convection ovens include primary and tertiary heat recovery. All cleaning tanks are heated via the tertiary heat exchanger. A regenerative oxidizer completes the thermal package. The line comes complete with Bronx’s quick change U-wrap finish coater for quick colour change without stopping the line. Contact: www.bronxintl.com.au

worldwide

powered by The Bright World of Metals

www.litmash-russia.com www.metallurgy-russia.com www.tbwom.com

Wire rod cropping LONG PRODUCTS Head and tail cropping is a fundamental operation in wire rod production. The Danieli HSS-high speed wire rod cropping shear provides automatic on-line cropping of 4.5 to 32-mm-dia wire rod at production speeds of up to 120 m/s. Material yield is increased thanks to an optimized and repetitive cropping length (+ 0.3% average). Manpower requirements as well as operational and maintenance costs are reduced. It ensures a consistent high quality along the whole coil due to the elimination of un-cooled front and tail ends. Moreover, with an overall length of only 2,700 mm the machine is of a very compact design, facilitating the retrofit of existing plants. All these benefits make for a fast return on investment. Contact: www.danieli.com

MPT International 2 / 2018


Handheld vacuum gauge MEASURING EQUIPMENT A new hand-held vacuum measuring system has recently been introduced by Edwards. The easy-to-use P3 gauge is ideal for on-site service calls and in-situ pressure checking. It is battery powered with direct on-board display of measured pressure. The P3 can provide mobile and fixed pressure measurement for installations of all kinds, including service, maintenance, universities or laboratory applications. The Piezo Pirani sensor enables pressure measurement of all common gas types, in the range of 1,200 to 5 x 10 -4 mbar. Pressure gauge with case With the integrated battery, the device can be attached and operated at any pressure point. It can directly display or store up to 2,000 values. All data values stored can be exported via USB. Contact: www.edwardsvacuum.com

Pilot 3D positioning RXRSDLENQRGNO ×NNQ employees DIGITALIZATION Together with the Russian National Centre of Internet of Things (NCIT), the NLMK-SAP Innovations Lab have developed a pilot 3D positioning system for shopfloor employees of hot-dip galvanizing line No.1 at NLMK Group’s Lipetsk site. The system enables real-time tracking and analysis of equipment operating mode changes and employee positioning. The tracking information, amassed in a database, is later analyzed to enhance operational health and safety, human resource and contractor management practices. The system will notify about operational health and safety risks and eliminate them in advance. The pilot was developed on a fully featured line, used for production of steel products for automotive, construction industries, and white goods manufacturing. The next step of the project will be the full-scale roll-out of the system. Contact: www.nlmk.com

45 years of INTECO Symposium 2018 LEARN FROM THE PAST, LIVE FOR THE PRESENT AND PLAN FOR THE FUTURE Inspired by this slogan and on the occasion of INTECO’s 45th anniversary we have once again gathered the world experts on steelmaking and invite you to join us for a series of interesting talks. Our heroes made of steel from well-known universities and international companies will talk about challenges, research and trends that have moved the steel industry in the past as well as present and will lead it into an even brighter future.

HOTEL Böhlerstern, Kapfenberg, Austria July 4th & 5th 2018 REGISTER NOW: www.inteco.at/de/symposium2018

Wiener Strasse 25භ8600 Bruck an der Mur භAustria Tel.: +43 (0) 3862/53 110-0 භFax: +43 (0) 3862/53844 www.inteco.at


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SMS group supports college in USA creating the “Arkansas Steelmaking Academy” PROFESSIONAL TRAINING The Arkansas Northeastern College and SMS group agreed creating the “Arkansas Steelmaking Academy” which will begin offerings in 2019. The partnership announcement was made during a visit to the college by Arkansas Governor Asa Hutchinson. With the opening of Big River Steel, northeastern Arkansas has one of the highest regional concentrations of steel making in the United States. Steelmaking companies with operations in this area include Nucor Steel, Big River Steel, Tenaris, TMK-IPSCO and others. Before now, the qualified steel technology training offered by SMS group has only been available in Germany. “By partnering with SMS group, the Arkansas Northeastern College can become a satellite training hub for North America as a cost effective way to gain knowledge of cutting edge techniques in steelmaking and processing”, said James Shemwell, president of the college. The Arkansas Steelmaking Academy will be housed in the new 8,500 square meter Center for Allied Technology currently under construction at the main campus of the college in Blytheville, Mississippi County (Arkansas, USA). By utilizing the new facility, the steelmaking academy will be located in a world-class complex featuring technologically-equipped classrooms and hands-on training laboratories for steel tech-

From left to right: Dr. James Shemwell, President of the Arkansas Northeastern College; Asa Hutchinson, Governor of Arkansas and Doug Dunworth, President and CEO, SMS group North America

nology. The Center for Allied Technology is slated to open in August. Arkansas Northeastern College is currently one of very few colleges in the USA offering Steel Industry Technology programs and the only one in Arkansas. Contact: www.sms-group.com

@ > GD C6I=6JH<bW=

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

MPT International 2 / 2018

Münsterstr. 25 59348 Lüdinghausen

Tel: +49 25 91 / 98 03 40-0 Fax: +49 25 91 / 98 03 40-4

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


TECHNICAL INNOVATIONS

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69

Inline geometry measurement system pays off also for smaller capacity lines WIRE PRODUCTION In many forming stages of wire production, one-axis inline measurements of the diameter of the cold wire already help to achieve significant improvements in the quality of the finished product and in the ef-

One-axis inline

ficiency of production. Being a moderate investment and an easy-to-use system, Contour Check Wire introduced by LAP, is a highly attractive option for factories with lower throughputs. The systems measure the diameter and ovality with exactly the same precision as the systems of LAP’s proven Contour Check family, yet are smaller and, apart from power, need no other media supply. Contour Check Wire systems are designed for inline measurements of wire with diameters between 0.5 and 30 mm. They measure with a precision of ± 8 μm. If operated at temperatures not exceeding 40 °C, they do not require any cooling. The compactness of the hardware allows the sensor units to be easily integrated into existing lines or used as mobile units at several positions within a factory. The measured values are displayed both numerically and graphically on the touch screen of the Panel PC that comes with the system. Integration into the factory infrastructure is possible via optional interfaces.

measurement of wire

Contact: www.lap-laser.com

Setting The Standards For Highest Efficiency In Thermal Processing

EcoMelter©, 105t per day, content: 35t PulsReg® Medusa Regenerator

bitor: e exhi 18, r a e W 20 nium Alumi 1.10.18, 09. – 1 ldorf Düsse

JASPER Gesellschaft für Energiewirtschaft und Kybernetik mbH / Bönninghauser Str. 10 / D-59590 Geseke Telefon: +49 2942 9747 0 / Fax: +49 2942 9747 47 / www.jasper-gmbh.de / info@jasper-gmbh.de

MPT International 2 / 2018


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››› TECHNICAL INNOVATIONS

Expanded range of hot-rolled AHSS for automotive applications MATERIALS SSAB has introduced a range of hot-rolled advanced high strength steel (AHSS) grades to the Docol product portfolio of automotive steel, allowing for the development of new, innovative chassis components. The new Docol range of hot-rolled AHSS products brings increased strength to automotive components like torsion beams, control arms and chassis. It also provides manufacturers with an optimized microstructure that delivers excellent fatigue properties as well as easy forming of complex designs. Docol hot-rolled AHSS is available in strength levels up to 1,200 MPa, which is four times higher than high

strength aluminium. For chassis components, hot rolled steel is often the more suitable choice due to its larger interval in thickness. Docol hot-rolled AHSS products are available in thicknesses ranging from 2.0 up to 6.0 mm, which allows chassis components to benefit fully from the unique characteristics of the steel. The products are the result of an advanced cooling line at the SSAB hot rolling mill, which provides both cooling power and the accuracy to hit the exact properties desired. Contact: www.ssab.com

Integral solutions for conveyor belts SPECIAL EQUIPMENT With the introduction of an in-house developed transfer point seal for belt conveyors, Schulte Strathaus can now offer integral solutions for conveying systems. The unique design of the transfer point seal is based on the use of two different kinds of poly-

urethane. Hard polyurethane is used for guiding the material and softer polyurethane for the secondary dust seal. During conveying, the dust seal applies light pressure on the belt to prevent dust emissions. The relative softness of the material employed results in low wear on the

belt and thus increased belt lifespan. Furthermore, the seal can be adjusted when necessary. The company also re-engineers complete conveying systems, including sheet metal work on the chutes. Contact: www.schulte-strathaus.de

INDUSTRY 4.0 – THE CONTINUING STORY Future Steel Forum is returning to the Sheraton Warsaw Hotel, Poland on 6-7 June 2018. Expect lively conversation, animated discussion panels and plenty of networking opportunities.

REGISTRATION IS NOW OPEN: Register online to subscribe to the Future Steel Forum membership package which will include a subscription to Steel Times International, the Steel Times International Directory, relevant news alerts and admission to the Future Steel Forum, 6-7 June, Sheraton Warsaw Hotel, Warsaw, Poland. www.FutureSteelForum.com/register STANDARD RATE For more information: Sophie Wright, Delegate Sales sophiewright@quartzltd.com +44 (0) 1737 855022

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I wear out fans in a flash!

'HFG DEÖBHDMBXRSQHO wiping FLAT ROLLING In order to enhance the performance of rolling mills, Fives has developed the third generation of the DMS wiper system. The advanced system (DMS Wiper SCP 3.0) optimizes the rolling performance and increases the overall mill

But not our fans. They are protected against wear and long-lived. Strip wiping system Provision of effective wear protection on the fan impellers ensures a VLJQLÀFDQWLQFUHDVHLQ resistance to wear and service life.

productivity. The system features the latest advances in rolling technologies. It achieves 2B finish as well as ultimate BA quality (bright annealed mirror-like surface) thanks to its specific mark-free design. The wiper operates at speeds of up to 1,200 m/min, and has improved wiping efficiency in comparison to the conventional fleece-roll technology. The technology enables to achieve enhanced de-oiling, reducing oil consumption and the environmental impact due to the very low amount of oil remaining on the strip before degreasing. The wiping roll cassette can be replaced in less than 10 minutes.

„ Long service life „ High availability „ Extremely reliable

Come and see us at

Contact: www.steel.fivesgroup.com

IFAT Munich 14 – 18 May 2018 Hall B6, Stand 452

®

First coil-to-coil Flash bainite line

MATERIALS SFP Works LLC, the inventors of Flash® bainite, have selected SES® LLC to build the first coil-to-coil Flash® processing line. This compact line processes common steel grades like AISI 1020 to increase tensile strength up to 1,600 MPa. Sponsored by a US Department of Energy grant, the patented thermal cycle was developed initially with single sheets and requires less than ten seconds to make a very highstrength cold stampable steel. Dozens of auto OEM geometries have been cold stamped, folding almost like a sheet of paper. Mass reductions exceeding 50% have been proven over current stamped parts in auto OEM test facilities. The first SES® Flash® line will be capable of processing 1,220 mm x 1.8 mm. The future holds high volume production of 6.35 mm Flash® Armor, already proven in US Army testing to outperform titan. Contact: www.seseng.com

We make air work for you. Process and hot gas fans Process gas dust collection Process gas cleaning plants Secondary fuel technology Belt drying plants Vapour exhaust plants


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››› TECHNICAL INNOVATIONS

One roller mill for cement clinker and slag MATERIAL PROCESSING Almost 30 years ago Loesche introduced the first vertical roller mill to grind cement clinker and granulated blast furnace slag in one process.

In 1992, the concept of M- and S-rollers was established. Loesche has patented the concept which enables the production of cement with higher Blaine and effective grinding of blast furnace slag. More than 365 mills worldwide supplied by Loesche produce various types of cement such as OPC, PPC, composite cement, as per international standards. Loesche supplied an LM 35.2 +2 S cement mill to Sri Balaha Chemicals Pvt. Ltd in Hindupur, India. Since its commissioning in March 2017, the mill has been producing granulated ground blast furnace slag. It achieved the rated capacity of 4,000 cm²/gm at 50 t/h within two weeks from commissioning. Meanwhile production rates of 52 t/h have been achieved, with specific power consumption going down to 27.2 kWh/t; the guaranteed value is 35.1 kWh/t. Contact: www.loesche.com

Slag grinding mill at Sri Balaha Chemicals Pvt. Ltd, in Hindupur, India

© Utz Peter Greis, Düsseldorf

Cartoon

Protectionist measures: A new kind of globalization MPT International 2 / 2018


LITERATURE SERVICE

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73

Danieli Technology Book 200 pages, English Issued on the occasion of the Fourth Danieli Innovaction Meeting, held at the company’s headquarters in October 2017, this story book is a comprehensive and elaborate compilation of new solutions and processes to deal with a “new normal metals consumption period”. Contact: E-mail:

www.danieli.com info@danieli.com

Heat Treatment Guide Digital tool The app launched by Ovako helps choose the right steel for a specific application. Users will be able to predict how a steel of a specific composition will perform after heat treatment and alter the steel compositions to investigate the impact of different alloying elements. Contact: E-mail:

www.heattreatmentguide.com info@ovako.com

Seamless pipe inspection 8 pages, English

ShapeUT™ Technology

360 degrees of confidence

A brochure featuring Baker Hughes’ ShapeUTTM inspection system for seamless pipes and tubes. The system delivers 360-degree coverage with just a single probe setup, enabling operators to see oblique defects at any angle, regardless of orientation. The system works with GE’s Krautkramer GRP testing machines.

For Seamless Pipe Inspection

Contact:

www.bhge.com

bhge.com

Steel and powder level measurement in conti-casting 2 pages, English

CONGAUGE LB 6755 Radiometric Detector for Steel and Powder Level Measurement

Simultaneous steel and powder level measurement Measures the steel level and the powder level simultaneously. Ten individually controlled scintillators in an array configuration. Highly sensitive scintillation technology. State-of-the-art SiPM technology. Automatic calibration rig for steel and powder level supplied. Compatible with castXpert LB 452. Superior safety with automatic detection and compensation if a scintillation failure should occur.

Fully backward compatible with LB 6752, using mechanical adapter set

Detector powered through control unit

The Congauge LB 6755 radiometric detector offered by Berthold Technologies continuously measures both the liquid steel level and the thickness of the casting powder level, and can be set up to control the automatic casting powder feeders.

Same sensitivity as LB 6752

Connects to the castXpert LB 452

10 individually controlled scintillators

High level of redundancy. A scintillation module failure is automatically detected and compensated for.

Can be used with or without mounting flange

Contact: E-mail:

www.berthold.com info@berthold.com

in cooperation with

SMS Concast AG

Stainless steels and specialty alloys for pulp, paper and biomass conversion Reference book Nickel Institute has published a fully revised second edition of “Stainless Steels and Specialty Alloys for Pulp, Paper and Biomass Conversion”, a popular and practical guide for mill and project engineers within the pulp, paper and biomass sector. A main objective of this revision is to describe where newer alloys should be considered. Contact: E-mail:

www.nickelinstitute.com communications@nickelinstitute.com MPT International 2 / 2018


74

››› IN THE NEXT ISSUE…

Steelmaking Magnetic forces on electrodes and steel bath in the EAF The computation of the magnetic forces on EAF electrodes and the steel bath is complicated and has not been performed realistically to date. Simulations have to be based on a proper geometrical model and need to consider that the current density in the high current system and in the steel bath is extremely inhomogeneous. For the first time a realistic computation of the magnetic forces is presented in this article, applying the FNM computation system. Significant increase in converter availability and safety thanks to new torque support Italian stainless steel company Acciaierie Valbruna implemented a new torque support for the 70 t AOD converter vessel at its steelmaking plant in Vicenza. After installing the new electrohydraulic torque support a substantial reduction in uncontrolled vibrations of the gear unit and the converter vessel has been achieved. The measurements were performed in the presence of a specialist consultant from the University of Padua.

Hot rolling Modernization of the hot strip mill at Tata Steel Port Talbot works Tata Steel has invested more than £14 million in the modernization of its hot strip mill at Port Talbot, Wales (UK), allowing it to manufacture more higher-value steels for customers. The hot strip mill underwent 18 days of maintenance. Now, Tata Steel has installed the transfer bar cooling system to increase the volume capacity of the hot strip mill by more than 150,000 t/year.

Pipe making Pipe ID 4.0: comprehensive process control system for the manufacturing of large pipes A comprehensive process control system for the manufacturing of large-diameter spiral-welded pipes features a track and trace system, monitoring of the overall equipment efficiency (OEE), condition monitoring, smart diagnostics and power monitoring. The production data acquired includes all planned and unplanned downtimes including their causes, fault messages, target/actual production and the quality of the parts. In this way, the system operators gain a basis for calculating the OEE. This preview may be subject to change.

Metallurgical Plant and Technology

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Published by: jbd Gesellschaft für Medien und Kommunikation mbH Graf-Recke-Straße 82, 40239 Düsseldorf, Germany e-mail mpt@stahleisen.de Internet: www.mpt-international.com Editorial Staff: Chief Editor: Dipl.-Ing. Arnt Hannewald

+49 211 6707-568 e-mail mpt@stahleisen.de Publishing Staff: Managing Director: Joachim Berendt

MPT International 2 / 2018

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MPT International 2/2018 (Apr)  
MPT International 2/2018 (Apr)  
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