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01 2011 Cover Story Innovation metals&mining The magazine for the metals and mining industries www.siemens-vai.com Issue 1|2011 Innovation Creating the Future EDITORIAL > EDITORIAL Dear Readers, Technological innovation and development has always been a driving force in the metals and mining industries. The origin of Siemens – today the world’s largest engineering company – and the metallurgical plant builder Siemens VAI can be traced to spectacular inventions and their subsequent applications that have changed the industry forever. Our tradition and reputation as pioneers of innovation continue to this day. We aim to find answers to the present and future challenges confronting the steel industry. A major focus of our activities is therefore placed on the development of products and technologies that lower the consumption of natural resources and energy, reduce environmental emissions, improve the quality of steel and make the most of capital expenditures. Innovative services from Siemens VAI also provide opportunities to maximize the per formance and operational lifetime of the plants we supply. Our international centers of competence and our global setup ensure Werner Auer that we are close to the market. This allows us to better orient our research work both to regional requirements as well as to the individual needs of our customers. Siemens VAI researchers, specialists and process engineers work closely together with industrial partners, research institutes and universities to develop and implement state-of-the-art solutions. Our research activities are holistic in that all aspects of a product are taken into account that include technology, mechanical equipment, media supply, electrical and drive systems, all automation levels and environmental solutions. This issue of metals&mining presents examples of recent innovation high - lights across the entire value-added iron and steel production chain. Our innovation activities are not only limited to technologies and products, they also include innovative consulting, financing and maintenance services, examples of which are presented in this issue. Innovation is a fundamental pillar of the business activities of Siemens VAI. In this way we can ensure that a maximum of benefits are derived for our customers. Yours sincerely, Werner Auer CEO of Siemens VAI Metals Technologies metals&mining 1|2011 3 8 Siemens VAI works closely together with renowned steel producers to develop and implement benefit- oriented innovative solutions COVER STORY 8 Innovation: Creating the Future With Today’s Technologies Innovative solutions are decisive for providing producers with a competitive edge and for meeting the challenges of tomorrow COVER STORY 20 The Right Investment Decision Expert consultancy services from Siemens VAI help producers to determine which investment measures will lead to optimum technological and economical results COVER STORY > > CONTENTS COVER STORY 42 BLAST FURNACE: Bringing the Parts Together 24 FINANCING: Expert Financial Engineering Too VAiron Productivity Control System installed in Linz Innovative financing solutions for metals and mining projects 44 SMELTING REDUCTION: You Can Have It All Heat-recovery system for Finex plants MINING STEELMAKING 26 FLOTATION: The Same in Small Simine Laboratory Hybrid Flotation Cell for testing 46 ELECTRIC STEELMAKING: One Step Closer flotation behavior To Fully Automatic Steelmaking New technology modules for Siemens VAI electric 28 SERVICES: The Key to Sustainable Success arc furnaces Simine Services – life-cycle support for mining 50 LD (BOF) STEELMAKING: No Room for Error IRONMAKING Replacement of three LD (BOF) converters at voestalpine Stahl, Austria 32 COKEMAKING: The Coke-Oven Watchcat Pumas – improved productivity and safety in 54 LD (BOF) STEELMAKING: Highest Flexibility cokemaking In Steelmaking The future of steelmaking with bottom-blowing 36 SINTERING: Baptism by Fire techniques Start-up and one year of operation of a highly innovative sinter plant 56 ROBOTIC SOLUTION: LiquiRob: Simply Indis pensable An unusual helper CONTINUOUS CASTING 58 SLAB CASTING: Making Casting History COVER Advanced process models for 400 mm ultra-thick It is the development and application of innovative slab casters solutions today that is decisive for meeting and 60 TESTING EQUIPMENT: OsciBoy Gets the mastering the challenges Job Done that lie ahead. In the steel Siemens VAI tester for technological packages industry optimum usage of limited raw materials, cost pressures and urgent envi - ron mental demands are the key factors that drive innovative developments. 4 metals&mining 1|2011 64 90 Things are looking up in connection with The use of variable-speed drives in pump stations is one the latest improvements in Siemens VAI of many solutions offered by Siemens VAI to reduce coil-handling systems energy costs in the metals industries PANORAMA 82 COLD ROLLING: Slash Reprocessing Costs Siroll Off-Gauge Optimizer helps improve cost 62 INTERVIEW: An Island in the Caribic structures Interview with Dr. Karl Mörwald, “Siemens top innovator” 86 COLD ROLLING: Optimizing the Tension- Leveling Process ROLLING Advanced process models for the design of scale breakers and tension levelers 64 LONG-PRODUCT ROLLING: Going Vertical New vertical compactor for bar-in-coil and rod-coil BALANCE OF PLANT products 90 WATER MANAGEMENT: An Investment for a 68 PLATE MILLS: Investment Opens Doors to a Better Life-Cycle Balance New Market Variable-speed drives help improve energy efficiency Gerdau Açominas expands its portfolio with in water-pump stations technology from Siemens VAI 70 HOT-STRIP ROLLING: World’s Most Powerful ELECTRICS & AUTOMATION Hot-Strip Mill 92 ALUMINUM ROLLING: Advanced, Modular, The Siemens VAI next-generation hot-rolling mill is and Flexible the critical part of ATI’s new hot-rolling and pro cess - Siroll ALU TCS process automation for aluminum ing facility rolling mills 72 HOT-STRIP ROLLING: A New Generation of Downcoilers SERVICES Siroll Power Coiler – the ideal solution for the coil - 94 ROLLING MILLS: High Performance, Low Cost ing of high-strength and advanced steel grades Optimized mill maintenance ensures operation at full 76 HOT-STRIP ROLLING: Unified Temperature potential Control Comprehensive strip temperature and 96 MILESTONES & EVENTS microstructure control revolutionize hot-strip mill 98 PREVIEW automation DIALOGUE 80 PICKLING: Siroll Si-Filter Benefits Innovative filtering system for pickling lines 99 Contact metals&mining 1|2011 5 Start-up of New Steel Mill at TK CSA, Brazil hia Siderúrgica do Atlântico) steel mill located in the outskirts of Rio de Janeiro, Brazil. The first slab had already been cast on the first line in September. “The efficiency and safety of the plant configuration are im- pressive. Even the slabs produced immediately after commissioning were already of extraordinarily high quality,” said Dr. Herbert Eichelkraut, CEO of Thyssen- Krupp CSA. The steelworks is designed to produce some 5 million tons of slabs per annum. Siemens VAI supplied two basic oxygen furnace plants, secondary metallurgical facilities, primary and secondary dust- cleaning systems, two continuous slab casters, and the associated electrical and automation equipment. Slab removal from the run-out area of the slab caster Around 40% of the produced slabs are to be rolled at FACTS & FIGURESFACTS > In November 2010, Siemens VAI started up the LD (BOF) ThyssenKrupp locations in Germany. The remaining converter and continuous slab caster of the second 60% are foreseen for further processing at the new production line of the ThyssenKrupp CSA (Compan- U.S. ThyssenKrupp works in Calvert, Alabama. Modernization Project at Kennecott Mine The Kennecott Bingham Canyon Mine in Utah, U.S.A., tifier. The modernization ensures enhanced diagnos- operated by Rio Tinto, is one of the world’s largest cop- tic features as well as operational reliability and avail- per mines. Gold, silver and molybdenum are also ex- ability of the plant. Maintenance costs are also re- tracted at the mine. Three SAG (semi-autonomous duced. Retaining the power section of the rectifier is grinding) mills installed with twin-pinion DC motor the key feature of the modernization concept devel- systems in 1988 will be equipped with new control and oped by Siemens, a step that significantly reduces automation technology. The system is based on Simatic investment costs for the modernization. Commis- S7 for the general control of the mill and a Sinamics sioning will start in early 2011 and is scheduled for DCM converter for the drive-specific control of the rec- completion for all three mills by early 2012. Ore Mill Drive Modernization at Quadra FNX Quadra FNX Mining, one of North America’s leading copper producers, commissioned Siemens to mod- ernize the drive system in a SAG mill in its Robinson open-pit copper mine in Nevada, U.S.A. This will be the first time that an ore mill will be equipped with a Sinamics SL150 cycloconverter. The modernization concept for Simine Mill GD enables analogue or early digital control systems to be substituted without also having to replace existing electrical equipment such as the motor and transformers. This approach signif- icantly reduces conversion costs. Modernization work First installation of Sinamics SL150 cycloconverter control is scheduled to be finished in the summer of 2011. system in an ore mill 6 metals&mining 1|2011 Selected Start-ups and FACs (June 1 to Oct. 31, 2010) Company Country Project AG of Dillinger Hüttenwerke Germany Start-up secondary dedusting plant for 160-ton converter Baoshan Iron & Steel Co., Ltd China Upgrading of EAF No. 2 with RCB technology comprising three RCBs, valve stand, electrics and Level 1 automation Dragon Steel Corporation Taiwan FACs received for Sinter Plant No. 1, Blast Furnace No. 1, and Slab Casters Nos. 1 and 2 Hunan Valin Lianyuan Iron & Steel Co., Ltd. China Start-up of dry-type dedusting system for two 210-ton converters Hyundai Steel Co., Ltd Korea Start-up of 2-strand slab caster at Dangjin Works (CCP 2) Indian Steel Corporation Ltd. India Start-up of new 6-high reversing cold mill with a capacity of 450,000 t/a (Gandhidham works) Jiexiu Xintai Iron & Steel Co.
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