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Metals Magazine Innovation and Technology for the Metals Industry Issue 03 | November 2014 Metals Magazine Innovation and technology for the metals industry Tapping the Hearth Of Innovation World’s Largest HBI Plant under Construction in Texas Five Arvedi ESP Lines for China Mechatronics – A Key Factor for Optimized Plant Performance On course to a bright future. Innovation Publisher: Siemens VAI Metals Technologies GmbH · Metals Magazine is published quarterly. The real challenge is not Turmstrasse 44 · 4031 Linz, Austria © 2014 by Siemens Aktiengesellschaft Metals Magazine Team: Dr. Lawrence Gould, Managing Editor; Munich and Berlin. to create something new, Alexander Chavez, Freelance Editor ([email protected]); All rights reserved by the publisher. Allison Chisolm, Freelance Editor ([email protected]); List of registered products: Monika Gollasch, Art Director, Agentur Feedback; ChatterBlock, Connect & Cast, COREX, CTC Caster Technology Consulting, Tina Putzmann-Thoms, Graphic Designer, Agentur Feedback DSR, DYNACS, DynaGap SoftReduction, FAPLAC, FINEX, Gimbal Top, idRHa+, but to create something Publishing house: Agentur Feedback, Munich, IMGS, IT4Metals, KL, KLX, LIQUIROB, LOMAS, MEROS, MORGOIL, MORSHOR, www.agentur-feedback.de NO-TWIST, PLANICIM, SIAS, Si-Filter, SIMELT, SIMETAL, Simetal EAF FAST DRI, Publication date: November 2014 Simetal EAF Quantum, Simetal ­­Gimbal Top, SIMETAL SILOC, SIROLL, SIROLL extraordinary. ChatterBlock, SMART, SmartCrown, SR SERIES, STELMOR, TCOptimizer/ Circulation: 10,000 TCOPTIMIZER, WinLink, X-HI, Xline are registered trademarks of Siemens AG Order No.: E10001-M10-A21-V1-7600 and Siemens VAI Metals Technologies GmbH and/or affiliated companies in ISSN 2194-5381 certain countries. Dispo No.: 21661 HYQST is a trademark of Siemens Industry, Inc. K. No.: 28105 MIDREX is a registered trademark of Midrex Technologies, Inc. Photo credits: Corbis, page 2; Getty Images pages 97, MULPIC is a registered trademark of Centre de Recherches Metallurgiques ASBL 101 lower photo, 102 lower photo SCR is a registered trademark of Southwire Company, LLC Qupik, pages 1, 4, 5, 16, 17, 18, 19, 20, 21, 28 and 106 All figures and values cited in this issue of Metals Magazine ([email protected], www.qupik.com) are in metric units unless otherwise indicated. Photos pages 6 and 105: Copyright Mitsubishi Aircraft Corporation Contact address for all reader inquiries: Laser torch used for All other photos: Siemens VAI, unless otherwise indicated [email protected] cutting steel strip 105 Editorial | Metals Magazine 3/2014 Dear Reader, Dr. Lawrence Gould Apart from recognizing how to ignite The serendipitous nature of innovation is frequently and utilize fire, perhaps one of the underrated in the industry. Emphasis is usually placed on greatest discoveries of ancient times collecting and processing Big Data rather than on enhancing the perceptive skills of people. Decisive, however, for initiat­ was when man learned how to make ing the concatenation of steps that may lead to an invention and subsequent innovation is the awareness and capability of individuals to link together knowledge, facts and circum­ hay. This is because by properly drying moist grass, the stance. This must be done with a sagacious mindset and resulting product known as hay can be kept and stored in such a way that when a favorable chance event does throughout the winter months to feed domestic animals. occur, its potential is recognized and acted upon. In the This changed the course of history because it allowed vast words of Louis Pasteur, the famous French chemist and areas of the northern hemisphere to be settled, which microbiologist, “Chance favors the prepared mind.” otherwise would have remained the sole domain of hunt­ Innovation is thus the product of a systematic approach ers and gatherers. and serendipity – backed, of course, by painstaking hard Innovation, particularly in the metals industry, is the work. The real challenge, however, is not to create some­ result of systematic, scientific and tedious incremental thing new but to create something extraordinary. This is steps that usually lead to a eureka moment, that is, the ultimately the foundation for all progress in history and in manifestation of a new idea that can be further developed our society today. and applied to become a marketable commodity. More of­ Readers of this magazine are well aware of the impact ten, however, innovation is the product of serendipity – a that technological innovations have had on advances in totally unexpected revelation or event that sometimes leads the iron and steel industry. Many of these were introduced to an extraordinary innovation with global implications. by the researchers and engineers of Siemens VAI, who, The discovery of stainless steel, for example, was by acci­ in response to the requirements of producers, combined dent. In 1912, during attempts by Harry Brearly to find a methodology and brilliant insight to achieve milestone suitable steel alloy that could be used to increase the wear accomplishments. resistance of rifle barrels, he noticed that when 12% chromi­ This edition of Metals Magazine is therefore devoted to um was included in the alloy mixture, the steel samples innovation. Various examples of Siemens VAI technological maintained their luster and did not rust. The steel reacted developments are presented that noticeably contribute with oxygen and formed a thin protective film, even when to more efficient production processes, improved quality, it was scratched. This was the birth of stainless steel. greater energy efficiency and, most importantly, to the Unplanned incidents outside of the metals industry also benefit of our customers. underline the importance of luck in research activities. Alexander Fleming’s discovery of penicillin in 1928 is such Yours sincerely, an example. John Pemberton’s search for a headache cure and his accidental mixing of coca leaves and cola nuts in carbonated water resulted in the world’s first Coca­Cola. The idea for the microwave oven arose when someone’s chocolate bar melted in his pocket as he passed by a large laboratory vacuum tube that emitted microwaves. And, of course, everyone knows the story about the proverbial Dr. Lawrence Gould apple that fell on Isaac Newton’s head, which eventually Managing Editor led to his monumental theory of gravitation. Siemens VAI Metals Technologies GmbH 3 Contents 28 36 03 Editorial Technology, Automation, 06 Executive Column 08 Project Review Mechatronics 32 Go West! Construction of the world’s largest HBI plant in Corpus Panorama Christi, Texas, now in full swing 16 Tapping the Hearth of Innovation 36 Mastering the Realm of Fire Siemens VAI offers a broad range of solutions Heatopt – an intelligent and holistic process-control to lower energy demand and environmental system from Siemens VAI for optimized electric emissions in steel mills steelmaking 28 Augmented Reality Is Here 42 U.S. Customers Profit from EAF Know-how View the EAF Quantum electric furnace in three Successfully commissioned electrode control systems dimensions on your Apple iPad at Steel Dynamics and Harrison Steel 46 The Jet Process An innovative solution to maximize scrap and HBI rates Metals Magazine is also in converter steelmaking available on the iPad For selected magazine topics 50 Keeping Pace with the Market readers can access additional Improved caster performance throughout Europe with content with the new iPad innovative technology from Siemens VAI magazine application. The app, an interactive alternative to the print 56 A Jumbo Solution for Quality version of Metals Magazine, can Start-up of the new heavy-section bloom caster at be downloaded at the Siemens magazine newsstand. Zenith Steel, China 4 Executive Column | Metals Magazine 2/2014 The EAF Quantum: Dawn of a new era in electric steelmaking As an example of an energy-saving innovation, the Simetal EAF Quantum allows steel producers to reduce their electric energy consumption by 20% through the preheating of scrap in a shaft. Other striking examples of groundbreaking innovations for each step of the iron and steel production route are presented in this issue. Producers benefit not only from improved process effi- ciency and environmental compatibility, but also from 16 impressive cost savings. 4062 7886 58 Five Arvedi ESP Lines for China 84 Flatter Strip A Chinese steel producer chooses the Arvedi ESP Even the most severe strip shape defects are no match process to excel in the market for the Siemens VAI MTL21L multiroll tension leveler 62 Customized Standardization 86 A Superb Team Effort Modernization of the drive systems at three hot­rolling A Siemens VAI consortium demonstrates proven mills of ArcelorMittal in Europe competence in implementing two Chinese strip­ processing lines 68 Armenia’s First Modern Bar Mill A new rebar mill from Siemens VAI rejuvenates 90 From Waste Heat to Profit Armenia’s construction industry Siemens VAI performs energy efficiency study for CSN to reduce waste­heat losses 70 Capacity Boost for the Middle East A continuous cast aluminum mill in Oman produces 94 Optimized Storage Logistics electrical conductor grade and aluminum alloys ArcelorMittal Eisenhüttenstadt profits from the Simetal Siloc logistics system 72 Breathing New Life into an Existing Mill Siemens VAI solutions help Novelis Korea expand 96 Mechatronics: Access to Precision production of automotive aluminum sheet Mechatronic solutions serve as the basis for optimized plant performance 76 A Long-term Partnership Continuous modernization of two
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