SMS Group Newsletter 2018-2 EN

Welded Tubes_A4_e.indd 1 welded. or submergedarcwelded,longitudinallyspirally production – no matter whether high-frequency (HF) … inallprocessesforweldedtubeandpipe And weareyourpartner! and closerpipetolerances-theseareyourgoals. effective processes,more challengingdimensions Even betterquality, moreflexibleandcost- THE RIGHTPROCESSTOMEETEVERY REQUIREMENT a: +492161350-1851 [email protected] Fax: +49 2161350-1515 Phone: 41069 Mönchengladbach, Germany Ohlerkirchweg 66 SMS group GmbH LSAW -large-diameterpipe plants. AND PIPEPLANTS WELDED TUBE entire valuechain,together. your competitiveedge.Let’s addvaluealongthe application. Evenmore:allthissubstantiallyboosts narrow producttolerances,andabroadfieldof As aresult,youbenefitfromhighcost-effectiveness, Leading partnerintheworldofmetals ERW -weldedtubeplants. Spiral pipeplants. www.sms-group.com 15.02.18 09:39

newsletter THE SMS GROUP MAGAZINE ISSUE 02 / 2018 tube andwireindustry. big challengesofdigitalizationandIndustrie4.0in the Current trendsanddevelopmentshelptomasterthe THE FUTURE THE ALL SET FOR newsletter gear units. and productivity by modernized SSAB, Finland,enhancesquality IN FOCUS IN MODERNIZATION 74 steel stripforthe U.S.market. Stainless produce 95,000tons of Two American newplantsatNorth ISSUE 02 ISSUE THE SMSGROUPMAGAZINE COMMISSIONING

2018 80 forging lines. by innovativeportfolio pipe SMX SMS group expands plant INNOVATION 100 CONTENTS 02/2018

IN FOCUS PROCESS CHAIN

SMS group as a strong partner for wire ELECTRICAL AND AUTOMATION SYSTEMS METALLURGY AND ENVIRONMENTAL and tube producers: New concepts for plant automation TECHNOLOGY Holistic X-Pact® Process Guidance Successful implementation of world‘s first concept. 52 HD spray system Production start in Texas AcelorMittal Bremen banks on Tenaris produces the first Production excellence with X-Pact® Drive secondary cooling technology from seamless tubes on new high-tech Modular drive solution for integration SMS group. 64 PQF® plant. 10 into automation systems. 54 Japanese delegation visits SHARC furnace Smart coating IRONMAKING PLANTS Hellenic Halyvourgia welcomes visitors PERFECT spray® protects metal and Production start at BPSL to electric arc furnace plant built by non-metal surfaces against wear No. 2 blast furnace of Bhushan Power SMS group. 65 and corrosion. 20 & Steel Ltd. is up and running. 61 Much-sought after continuous casting On the road to a successful future Top technology first technology SMS group has upgraded existing Shandong Steel Rizhao commissions Saarstahl AG commissions SMS bar mill at Hyundai Steel Pohang. 32 blast furnace equipped with Paul Concast for supply of continuous Wurth systems. 62 casting plant. 66 The digital way to maximizing quality The PQA® quality assurance soft- FLAT ROLLING MILLS ware is a powerful tool adapted to High-quality production the needs of the metals industry. 46 Use of CVC®plus bending and shifting systems. 70

2 SMS group newsletter 02|2018 04

80 106

STANDARDS

Fast modernization of gear unit PRODUCTION Photo Highlight 04 Cooperation with SMS group improves Two new wheel sets for twin-drive gear unit product quality and reduces costs at The two output wheels supplied Retrospect – Outlook 06 SSAB. 74 by SMS group are the biggest case- hardened gears in the U.S.A. 106 Performance Modules 56 STRIP PROCESSING LINES AND FURNACE TECHNOLOGY TECHNICAL SERVICE News 58 Stainless steel strip for the U.S. market Early warning system against plant SMS group supplied cold rolling mill downtimes Events 115 and stainless steel bright-annealing Genius CM® monitors condition of line to NAS. 80 components prone to wearing. 109 Imprint 117

Investment in the future Successful partnership confirmed Ilsenburger Grobblech orders Mahshahr Pipe Mill Company signs heat treatment line with modernization contract. 110 MultiFlex-Quench®. 98

FORGING TECHNOLOGY Pipe forging line – Innovation from a single source SMS group expands plant portfolio. 100 Follow us on twitter @SMS_group_GmbH Expansion of recycling capacity Aludium Amorebieta orders multi chamber melting furnace from Hertwich. 104

02|2018 SMS group newsletter 3 RUBRIKPHOTO HIGHLIGHT

4 SMS group newsletter 02|2018 RUBRIK

GERMANY XXL WHEEL SET

On behalf of an American aluminum producer, the staff of SMS group manufactured ready-to-install wheel sets in its Hilchenbach workshop. Each wheel set has a diameter of four meters and a weight of 130 tons which corresponds to that of a full-grown blue whale. Since case-hardened gear wheels of that size cannot be manufactured in the U.S.A., both wheel sets were made in Germany and then shipped to the United States. Read more on page 106. ◆

Klaus Lazzaro [email protected]

02|2018 SMS group newsletter 5 RETROSPECT – OUTLOOK

WORLDWIDE TECHNOLOGIES FOR THE FUTURE Digitalization and Industrie 4.0 are the main focus of SMS group at this year’s Tube and wire.

6 SMS group newsletter 02|2018 • At this year’s Tube and wire SMS group introduces future- oriented solutions for the tube and wire industry. • In addition to additive manufacturing, this also includes automation technologies and smart service.

The topics digitalization and Industrie 4.0 are key challenges that are set to profoundly change the tube and wire industry in the years to come. At this year’s international trade fair for tube, wire and cable, SMS group is turning the spotlight on these key issues for the future and will be looking from a number of different angles at how digitalization is changing the whole value-added chain and enabling greater efficiency, higher quality, and more flexibility to plant operators.

ADDITIVE MANUFACTURING

The first impetus arising from digitalization and Industrie 4.0 concerns the design and manufacture of machines and components for the production of tube and wire itself. At the fair, SMS group will be demonstrating this using among others the example of a mill stand for a cold pilger mill, which is made with the aid of additive manufacturing processes. The component geometry of a mill stand, which up to now has been made by machining techniques, was optimized in terms of the stresses generated so that the number of strokes and thus the productivity can be enhanced significantly. Further exam- tected on the basis of the 3D models, generated by high res- ples of SMS group’s activities in the additive manufacturing olution cross-sectional measurements. The direct transfer of growth market, which are to be shown at the fair, are the the measurement readings to the mill stand control system competence center for 3D printing, which is being built in allows roll setting adjustments to be made during ongoing Mönchengladbach, as well as 3D printed components. These production and thus saves time and money by directly moni- components show an enhanced functionality, they weigh less toring the production process. and have shorter delivery periods. An example in this context is the successful development of additively manufactured SMART SERVICE SOLUTIONS spray heads for closed-die forging presses. Digitalization is also creating new opportunities for plant ser- PRECISE MEASUREMENT TECHNOLOGY vice. “Smart Maintenance Solutions” are aimed at enhancing the availability of the plant and the quality of the end prod- The second topic includes the possibilities that digitalization ucts on a long-term basis by combining software solutions. offers for the production process. The aim of the “smart mill” The creation of a digital plant structure will offer maintenance is to use data and the corresponding parameters as a basis teams centralized access to all the relevant parameters in fu- for business and process control-related decisions. A realistic ture. The information required will be provided, for example, mapping of the process with precise measurements is re- by the electronic parts catalog eDoc, the Genius CM® system quired for the collection of reliable process data. This type of (Condition Monitoring), or the IMMS® (Integrated Mainte- measuring system for tube, wire rod, bar, and section mills is nance Management System). to be displayed by SMS group at Tube & wire in cooperation with TBK Automatisierung und Messtechnik GmbH, an SMS Electronic parts catalog eDoc group company. During the rolling process the system meas- The electronic parts catalog maps the plant documenta- ures up to 5,000 contours per second with laser light-section tion of the entire project scope of supply as a cloud solu- sensors. Local atypical anomalies on the surface can be de- tion. For large-scale projects the data is based on a

02|2018 SMS group newsletter 7 Sensors generate data. For manufacturing tubes, wire and bars, up to 5,000 contours per second are detected by laser light-section sensors generating a high-resolution 3D model during ongoing production.

total of thousands and thousands of BOM items and delivery time can be checked and the required part be drawings, and single documents from SMS group Divisions procured. involved and from all other suppliers of individual parts or assemblies which now can be called up via just one tool by Genius CM® (Condition Monitoring) editing them in a consolidating and structural manner. In The Genius CM® (Condition Monitoring) system is a modu- this way, SMS group customers receive a tool enabling larly designed online monitoring system of the plant. The them to identify and request parts easily and quickly. The system controls and documents the current condition of data are continually updated and tedious searching for components subject to wear and failure. Compared to tra- the required information is now a thing of the past. Func- ditional inspection and maintenance methods the advan- tions such as displaying common parts across all plant ar- tage is the permanent monitoring of plant components. eas provide the plant operator with the desired transpar- Operators are permanently informed on the actual condi- ency, thus contributing to increasing efficiency and tion and warned in case of critical situations. Consequent- reduced inventory level. ly, Genius CM® opens up entirely new possibilities for opti- In addition to that, the electronic parts catalog forms the mizing quality and availability. basis for other digital products. As the virtual image of the Sensors are installed at critical plant components along plant it enables linking digital services to the purchasing the process chain, regularly transmitting measured data process. Technical information needed is immediately to Genius CM® such as torques, vibrations, temperatures, available for all applications and can be transferred di- forces, oil flow, particles and viscosity. rectly to the procurement process. When e.g. a component failure is predicted by means of Condition Monitor- IMMS ® - Integrated Maintenance Management System ing, information on common components, inventory and To allow its customers to focus fully on their core business

8 SMS group newsletter 02|2018 RETROSPECT – OUTLOOK

SMS group provides a customer-specific maintenance system to its customers. With the Integrated Maintenance Management System (IMMS®) SMS group combines computer-aided maintenance with valuable data and thus comes up with a plant- and customer-specific, all-encom- passing package.

DIGITAL PRODUCTS AND PLATFORMS

At the fair stand visitors will obtain an insight into “smart” training courses using augmented reality. Digital products and platforms will round off the range of presentations by SMS group at Tube & wire 2018. They form the basis for intelligent, digital services, and implement for example the secure, digital exchange of information between SMS group and its customers. One example is the platform for PQSC® piercer plugs for seamless tube rolling mills, through which you can process orders and check the status of each order 24 hours a day. Not only that, a comment function ensures easy communication, as notes referencing the relevant customer orders and the relevant SMS group employees can be entered. The The quality management system PQA® (Product Quality Analyzer) is option of order-based communication means the whole pro- another digital product to be presented at Tube & wire 2018. cess is more transparent, change requests are easier to follow, and orders can be split if different delivery times for par- tial deliveries are required.

QUALITY MANAGEMENT SYSTEM LEADING PARTNER

More and more SMS customers’ plants employ the PQA® sys- However, it is not just technological boundaries that will be tem (Product Quality Analyzer), a quality control system jointly redefined by digitalization. The way we work with customers developed with MET/Con Metallurgical Plant & Process Con- and other partners will change, with cooperation becoming sulting, a subsidiary of SMS group. The PQA® system collects even closer in future. As the “Leading Partner in the World of and assesses quality-relevant process parameters across the Metals” SMS group is getting together with customers to pres- entire process chain from steelmaking through to the final ent projects at this fair that highlight this successful way of product. Process parameters can be measured values and cooperating in the areas of new plant construction, revamps, events but also complex criteria applied for quality assess- and service. Some examples of these successful projects are ment. For further information, see Page 46. available on the following pages. ◆

X-PACT® MES 4.0

The holistic, modular solution for planning and controlling of all production plants is called X-Pact® MES 4.0. Due to its highly comprehensive and adaptable functionality for all plant types of the metallurgical process chain, the Manufacturing Executive System (MES) has a special position within the product portfolio of SMS group. This includes e.g. equipment in steelworks, continuous casters, flat rolling mills, tube plants, section mills and strip processing lines. Special characteristics of different types of material from simple carbon steels through to special steel and aluminum are also considered in this concept.

02|2018 SMS group newsletter 9 IN FOCUS

The new PQF® tube mill, erected by SMS group, is designed to produce 600,000 tons per year precision seamless tubes with diameters of up to 9 5/8 inches.

BENEFITS To this end, SMS group has equipped the new PQF® seamless tube plant with a wide range of automated, state-of-the-art technology. Norbert Theelen from SMS group: “Our advanced level of digitization 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. For example, we have installed a secure WiFi network throughout the whole plant. This gives the operating crew access to information they need via mobile panels and thus also creates completely new ways of working.” Complete traceability and monitoring offers optimal conditions for predictive maintenance. Tenaris is therefore a pioneer for modern digital plants.

10 SMS group newsletter 02|2018 IN FOCUS

U.S.A. PRODUCTION START IN TEXAS PQF® seamless tube production underway in advanced Texas plant.

® • The new PQF tube mill from Tenaris manufactures about 600,000 tons of tempered oil country tubular goods (OCTG) per year for natural gas and crude oil production. • Cutting-edge technology is employed in the plant. A high level of digitalization ensures complete traceability laying the foundation for Industrie 4.0 applications at the same time. • A recycling rate of 95 percent makes the seamless tube mill of Tenaris the most sustainable tube mill in the world and it has been awarded the label “Minor Source of Emissions” by the United States Environmental Protection Agency.

Tenaris has successfully started production at its seamless tube mill in Bay City, Texas, about 80 miles southwest of Houston. The company invested a total of 1.8 billion dollars in the plant, located near the most active shale plays in the United States. The plant manufactures tempered oil country tubular goods for use in the production of natural gas and crude oil. The new PQF® tube mill, erected by SMS group, is designed to produce 600,000 tons per year precision seamless tubes with diameters of up to 9 5/8 inches. The high-strength PQF® seamless tubes produced at the new mill are mainly used for casing applications as well as line pipes. With its Rig Direct® strategy, Tenaris is synchro- nizing its tube manufacturing with customer 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. “Our goal is to make the tube and pipe industry more effective and to drastically reduce imports for our market,” says Germán Curá, President of Tenaris North America.

02|2018 SMS group newsletter 11 IN FOCUS

Analysts and market experts see huge opportunities for the World of Metals” to life. The cooperation with Tenaris success in the strategy being pursued by Tenaris, which may was an example of this. also give the company a significant competitive advantage. SMS group supplied the plant technology and related SMS group has worked very closely with Tenaris on the engineering for its construction, and was responsible for installation of state-of-the-art production technology for the erection and commissioning supervision, including cus- seamless tubes that satisfies the challenging requirements tomer training. The main units of the PQF® plant include: concerning both quality and tolerances as per API stan- Billet preparation section and saws dards. Speaking of the new plant, Germán Curá goes on to Rotary hearth furnace say: “It is the most advanced production facility in our indus- Barrel-type piercing mill with Diescher disks, equipped try worldwide.” for the first time with a hydraulic adjustment system PQF® rolling mill of BCO design CLOSE PARTNERSHIP FOR WORLD’S MOST Extracting mill ADVANCED TUBE PLANT Induction furnace for shell reheating 24-stand stretch reducing mill In 2008, SMS group erected a PQF® seamless tube plant for Cooling bed and batch layer saws Tenaris at its mill in Mexico. Norbert Theelen, Head of Long Products at SMS group, adds: “We had already built a seven COST EFFICIENCY THANKS TO EXTENSIVE AUTOMATION inches PQF® plant for Tenaris in Veracruz, Mexico. Building AND MAINTENANCE-FRIENDLY DESIGN on our experience from this, our experts worked closely with the customer‘s teams to set out objectives for the new Compared to previous industry standards, the new Tenaris plant and had already agreed their planned course of action plant is twice as efficient when it comes to high-quality seam- during the engineering phase. There was intensive coopera- less tube production. This is made possible thanks to, among tion among all parties involved, that is, between Tenaris, our other things, the high degree of automation and the use of Tube and Pipe Plants Division in Mönchengladbach, SMS robots, which convey the steel from one station to the next in Innse in Milan, and SMS Elotherm in Remscheid. We got to- a fully automatic process. Most of the crew works in the con- gether for regular steering committee meetings to ensure trol room, in adjacent buildings, or below the production line, there was a continuous exchange of information and ideas. where they have easier access to the machine components It was this close partnership that enabled us to meet Tena- for maintenance purposes. “Our process is fully automatic”, ris’s precise requirements.” says Curá. In addition, every tube is given an identification During the construction phase, an average of 1,400 mark, similar to a barcode, meaning the customer can trace skilled specialists, fitters, technicians, and engineers were the precise specifications using a scanner or smartphone.” In deployed on site, which covers an area of 110,000 square view of the challenging conditions in oil or gas fields, this meters. The first tube was rolled in October 2017, and the smart means of tracing tube documentation is making a sig- plant was officially inaugurated in December. Thanks to the nificant contribution to total quality assurance. very close proximity to the customer and the cooperative To this end, SMS group has equipped the new PQF® development of new plants and processes for new materi- seamless tube plant with a wide range of automated, state- als, SMS group is bringing its motto of “Leading Partner in of-the-art technology. Norbert Theelen from SMS group: “Our advanced level of digitization allows Tenaris to make substantial time savings and achieve optimum transparency as regards the current plant and production status. This is further Technical Data enhanced by a host of other added value sources that boost efficiency levels. Tenaris is a trailblazer for modern plant and Annual capacity: 600,000 tons of seamless tubes equipment that combine the benefits of digitization. For ex- Tube diameter: between 4 ½″ (114.3 mm) and ample, we have installed a secure WiFi network throughout 9 5/8″ (244.5 mm) the whole plant. This gives the operating crew access to infor- Tube wall thickness: between 5.7 and 25.4 mm mation they need via mobile panels and to completely new ways of working.” Product range: OCTG tubes as per API, carbon steels, The basis for the automation used at Tenaris Bay City is low alloy and high-alloy steels with a provided by the Carta® (Computer-Aided Rolling Technology chromium content of up to 9 % and Application) technology system, which is used as a techno- 13 % respectively logical production planning and process control system for

12 SMS group newsletter 02|2018 IN FOCUS

The new PQF® seamless tube plant has been equipped with highly automated state-of-the-art technologies. The SMS group team after rolling the first tube.

the entire hot rolling section of the seamless tube mill. Carta® It is not just the tubes and production processes that are consists of three modules. The process-planning module continuously tracked, the tools are too, especially the mill prepares the rolling mill settings and the tool design. The stands and mandrels, and for this they are equipped with process management module controls the rolling process in around 850 chips and are monitored throughout with a fully real time, and saves and analyzes the process data. The tool automatic tool tracking system with RFID technology. In addi- management module is responsible for the precise and time- tion to this, Tenaris also has a comprehensive condition mon- ly use of the tools. So the benefits of Carta® are numerous. itoring system for the main drives, gears, motors, and saws. This technology system offers not only increased output but This online monitoring system is used in particular for moni- enhanced tube quality and optimized mill utilization, too. toring parts that optimize preventive maintenance, increase The measuring data used by Carta® to monitor the quality the plant’s availability, and reduce operating costs. are provided by systems such as CaliView®, which is supplied by SMS group. This is a newly developed inline system of MODERN, ECO-FRIENDLY WORKSTATIONS measuring rolls and passes which are installed in the mill. A camera is used to take fast, precise and non-contact mea- The building is eight stories higher than usual and this im- surements of the stands inline, and to align them perfectly. proves the airflow inside the building and creates a pleasant, Time-consuming, manual measurements are no longer re- climate-controlled working environment. Ninety-five percent quired. CaliView® ensures there is direct feedback to a mobile of the waste materials created during production are to be control device, meaning the rolls can be precisely adjusted recycled on site, according to Tenaris. And this makes Tenaris during the measurement. What’s more, the system detects not only one of the most advanced but also the most sustain- wear on the work rolls and logs the data for producing infor- able tube mills in the world. The United States Environmental mative statistics. Protection Agency has categorized the new Tenaris plant as a SMS group also implemented a holistic tracking solution “minor source of emissions”. ◆ 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 data- Contact base for developing production and process know-how. [email protected]

02|2018 SMS group newsletter 13 IN FOCUS

WORLDWIDE INDUCTION PLANT SETS NEW STANDARDS Inductive, highly dynamic inline reheating for the production of seamless pipes by means of cutting-edge control and inverter technology.

14 SMS group newsletter 02|2018 Materialdurchflussrichtung Inductor Transport direction Temperature measurement (optics, pyrometer)

Throughput speed approx. 1 -1.5 m/s

Layout of inductive reheating.

• Different runtimes produce temperature differences from INDUCTION ESTABLISHED AS EFFICIENT pipe to pipe. The consequence: Products of inferior quality REHEATING METHOD and production stop in the worst case. • Through inductive reheating the temperature level can be in- Raising the temperature level and compensating the tem- dividually raised and the axial temperature profile can be perature profile inline in the ongoing process are desirable. compensated during the ongoing process. Due to its high power densities (up to ten times compared to • A modular reheating system examines the individual conventional furnace installations) and dynamic control be- pipe sections pyrometrically and adapts the temperature havior, the inductive heating offers a solution. However, high as needed. throughput speed and flow rates in pipe production also place the highest requirements on sensor systems, control and inverter technology. Thanks to developments in these areas over the past few years, induction has established itself During the production of seamlessly rolled pipes, different not only as powerful reheating method in pipe production runtimes from the furnace up to the final production step but also in other fields such as hot rolling mills. lead to temperature differences between the workpieces. Each delay in the production chain is immediately notice- INDUCTION PLANT ILLUSTRATES able in a blank or pipe temperature drop which may entail a NEW DEVELOPMENTS production stop in addition to products of inferior quality. Depending on the respective production step, runtime In the following example, an induction plant is introduced variations may also result in an unfavorable temperature which has been integrated in a seamless pipe mill for reheat- profile or undesired temperature gradient across the blank ing between roughing and finishing mill at a throughput speed or pipe length. of one meter per second. Consequently, these new develop- Another challenge in producing seamlessly rolled pipes ments provide a solution for the above-described problems in is uneven workpiece cooling. Depending on the geometry, the rolling mills. in particular the relation between length and wall thickness, The result is a modularly designed reheating system com- the ends cool down more quickly than the rest of the blank prising eight individual modules. Each module consists of an or pipe. inverter with a nominal capacity of 1,400 kW and a reso-

02|2018 SMS group newsletter 15 IN FOCUS

nant circuit designed and made of a condenser battery and sure that high resolution and thus optimal adaptation of the inductor. Each module output can be freely controlled up to actual and target temperature profile is achieved. the rated inverter capacity and independently of other mod- The temperature of each pipe section is measured in ules. For maintenance work or in case of a fault individual mod- front of the inductor at approx. 1.40 meters, thus calculating ules can be removed from service. The control system is capa- an individual heating profile for this section. After each sec- ble of compensating a failure of individual modules. In this ond inductor the temperature reached is checked und com- case, the output of the remaining modules is automatically pared with the target profile. Deviations are included in the adapted. power control of inductors still remaining so that a given target temperature is exactly reached when exiting inductor 8. COMPACT PLANT The control system is capable of monitoring and managing even two pipes independently. Each pipe receives a dataset The illustration on the previous page illustrates the layout of with measured temperatures and performances and is the compact plant with its most important sensors. The ma- therefore optimally documented as regards quality assur- terial flow direction is from right to left according to the in- ance.External influences are considered automatically in a ductor numbering. For calculating the power distribution short- and long-term calculation correction with different across the pipe length each pipe is first of all divided into weightings. A lower weighting of short-term changes of exter- sections of equal length. Based on temperature values mea- nal influences ensures the stability of the control system. sured in front of the plant, the amount of energy to be induced for each pipe section and inductor is calculated in a WARNING SYSTEM SUPPORTS OPERATOR forward-looking way. After each inductor the heating prog- ress is checked pyrometrically and the measured value com- The figure below illustrates a typical temperature profile pared with the calculated value. In case of deviations the pre- and shows calculated forward-looking temperatures of in- viously calculated amount of energy to be induced is line control in an exemplary fashion. Already after the sec- recalculated and adapted automatically up to the pipe outlet ond inductor an approximation to the desired final state is for the then remaining modules on the basis of reheating. shown. After the eighth inductor an absolutely even profile At a speed of one meter per second each pipe section is attained. runs through an inductor in less than one second, while a When the forward-looking calculation of the required total run of a pipe section through the plant is just over ten energy recognizes that the installed power of the plant is seconds. In terms of the control system the length of an indi- insufficient due to a pipe with too low a temperature level to vidual pipe section was selected as short as possible to make bring it to the required temperature at a given speed an

980

Simulation of chronological temperature 960 profile.

940

final profile 920 after 6th inductor

Temperature (°C) Temperature after 4th inductor after 2nd inductor input profile

900

length of of tubetube (m)

880 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

16 SMS group newsletter 02|2018 Entry and exit temperatures Operating Data. Temperature (°C) Temperature ~ 15 Sec. ~ 45 Sec.

Temperature In 1 Temperature In 2 Temperature Out 1 Temperature Out 2

Time (S)

alarm is released by the operator. The maximum speed is obvious measurement errors of individual pyrometers due to calculated such that the set temperature level and profile steam and scale. Measurements of pipe speed at the in- and can be reached. The operator then has the choice to decide outlet ensure that safe transport monitoring is available and either for a set temperature level or profile at the expense overheating of pipes is ruled out if feed problems occur. of the speed or to choose the other way around or to out- feed the pipe. SUPERIOR QUALITY OF END PRODUCT

DETAILED MEASUREMENTS As regards control dynamics the induction plant for reheating described herein sets new standards in the production The above illustration shows the behavior of the exampled of seamless pipes and places highest demands on inverter plant during operation. The pipe reaches the inductive re- technology and control. The inductive heating plant is an in- heating section with a temperature gradient and at the entry tegral part of a pipe mill newly built by SMS group. Offline section it is at that time subjected to a temperature measure- simulation of sequences and processes made customer ment. Then, an inline comparison of process model and actu- training possible already prior to commissioning, in which al temperature is started before the head end of the pipe future operating staff could familiarize itself with the func- leaves the heating section again 15 seconds later. The mea- tioning of the plant. As a result, the commissioning phase suring signal of the exit pyrometer indicates a successful tem- was significantly reduced and all pipes were within close perature lift and compensation. temperature tolerances already at the beginning of the In the upper part of the figure the temperature gradient is ramp-up curve. clearly visible when the pipe is entering the reheating section The dynamic control of inductive heating allows a target- (blue, red graph) which has been fully compensated at the ed increase and homogenization of the pipe temperature. outlet at simultaneously increased temperature level (light Advantageous to follow-up processes are particularly opti- and dark green graph). mal, reproducible running-in conditions demonstrated by The dynamic control of the inverter voltage and thus the higher product quality of the end product. By reducing scrap heat output are illustrated in the lower part of the figure. The and recycled material energy savings can also be realized tail end of the pipe leaves the inductor plant at an even tem- with simultaneously increased productivity of the whole perature profile after a little more than 45 seconds. The devi- plant. Other process and quality improvements are possible ation measured reaches 25 K and includes e.g. also measur- by setting specific, optimized temperature profiles.◆ ing errors caused by scale. In this case, a total capacity of about 6,000 kW is only required while the output is not evenly distributed among all modules. To check the measured values for plausibility and reduce malfunctions of the plant to a minimum the temperature measurement is redundant on all positions required for power calculation and control.

By redundant and permanently updated correction values Further information the plant can be operated safely even in the case of failure or www.sms-elotherm.com

02|2018 SMS group newsletter 17 IN FOCUS

WORLDWIDE NEW DESIGN FOR EXPANDER LUBRICATION RINGS A special combination: combining conventional and additive design.

Conventional steel

Lubricating ring of hybrid design.

AM-Area

Lubricating ring with dual-line distributors.

Conventional manufacture of fluid holes.

18 SMS group newsletter 02|2018 IN FOCUS

Lube oil supply for common rail.

For manufacturing large-diameter pipes the pipes are cali- surrounding components. With the help of additive manu- brated by means of a mechanical expander with regard to facturing technology, the channels can be manufactured their concentricity and dimensional accuracy following outer completely independently of the contour of the manufactur- and inner seam welding. During each expansion process, ing tools and can be designed in a highly compact manner in high surface pressure and thus friction between segment small assembly spaces. surfaces and wedge occurs. Friction decreases by defined lubrication. To direct the lubricant to the respective points the NEW DESIGN REDUCES NUMBER OF lubricating ring serves as lubricant distributor and forwarder. POSSIBLE LEAKAGE POINTS In particular for expander tools with small pipe diameters (e.g. 14 inches or smaller) the conventional manufacture The SMS group design is characterized by the two surround- comes to its limits. This is due to the small space in the lubri- ing common rails (cf. the above illustration). The rails supply cating ring, making positioning and manufacture of fluid the individual channels to the dual-line distributors where a holes difficult. precisely defined quantity of lubricant is then ejected. Lube oil supply for the two common rails only takes place via two NEW POSSIBILITIES THANKS TO ADDITIVE channels which is highly advantageous to the number of nec- MANUFACTURING TECHNOLOGY essary seals or possible leakage points, reducing it by 17 percent. Consequently, the need for special seals is also eliminat- Additive Manufacturing (AM) technology opens up new posed. Lubricant supply via merely two channels additionally sibilities, however, the often filigree structures associated simplifies the construction of adjacent components such as with additive manufacture are hardly ever applied particular- the conventionally manufactured disc. Designing with Additive ly in heavy engineering. The reason for this is that very rough Manufacturing is defined such that the expenditure for sub- operating conditions often prevail and high forces are re- sequent post-processing is kept as low as possible. To achieve quired for plastic deformation resulting in solid construction this, all angles in Z direction are selected in such a way that the of the components. need for support structures is eliminated. Solid design has also been considered during the prod- Hybrid design provides a solution for expander tools when uct development process when a new lubricating ring with calibrating small longitudinally welded large-diameter pipes. In hybrid design was created combining conventional and ad- future, the hybrid will be tested in a plant for practical use in ditive manufacturing. The layered application is based on a cooperation with a customer as part of a development project. steel ring where holes are manufactured with conventional The combination of conventional and additive technolo- means for forwarding fluids to the wedge. The ring is aligned gies convinces not only from a technical aspect but also eco- and installed in the printer’s assembly space. Then, the nomically and will play an important role in heavy engineering structure is created by additive manufacturing technology. in the future. ◆ Owing to a compact arrangement of the fluid channels, the applicable level of coating is merely 70 millimeters. Com- pared to the original construction, the maximum dimensions of the outer diameter have been reduced by ten percent and they have been decreased by almost 30 percent in the Contact overall component height which also results in downsized [email protected]

02|2018 SMS group newsletter 19 WORLDWIDE SMART COATING WITH PERFECT SPRAY® The SMS group develops innovative coating solutions for functionalization of metal and non-metal surfaces.

20 SMS group newsletter 02|2018 IN FOCUS

• Pipelines transporting oil, gas or drinking water are partly ex- WIRE ARC SPRAYING posed to extreme conditions. Proper corrosion protection is Wire arc spraying involves feeding thus essential. two metallic wires into a spray gun at ® With the new thermal spraying system PERFECT spray metal a controlled feed rate. Electric current • is applied via copper, conductive and non-metal surfaces can be treated such that they are pro- wires. Once the wire feed starts, the tected against wear and corrosion. two spray wires move forward until Coating is almost pore-free. Moreover, the materials of differ- they touch each other. At the touch • ent melting temperatures can be conveyed homogeneously point, the wires are heated due to a high short-circuit current. This melts enabling constant arc resistance to be set. the coating material. A gas jet, usually consisting of compressed air, atomizes the molten material, acceler- ates the particles, and deposits them onto the surface to be coated. About 1.8 million kilometers of oil and gas pipelines are rout- ed underwater or overland across the whole of Europe. At 4,700 kilometers, the longest pipeline worldwide transports oil from Siberia up to the Pacific coast. The global network of long-distance pipelines includes more than three million kilometers and it is growing each year by approx. 25,000 kilometers. Pipelines which are lifelines supplying the whole world with vital natural resources are indispensable for transporting oil, gas or drinking water over long distances and they are partly subject to extreme conditions. Whether laid on above- ground pipelines, underground or underwater – proper corrosion protection is the essential thing with regard to longevity and resistance of the pipes. Here, the wire arc spraying is used – a method characterized by high deposition rates and low energy consumption.

WIRE ARC SPRAYING SYSTEMS OF THE LATEST GENERATION

The welding technology experts of SMS group have taken a closer look at it bringing together two promising technologies: wire arc spraying and the fully digital current-voltage source PERFECT arc® developed by SMS group coordinating the control of all electric-arc processes for welding and coating methods without changing the hardware. As a result, the new thermal spraying system PERFECT spray® came into being for treating metal and non-metal surfaces. With the new wire arc spraying system for thermal spraying acc. to DIN EN 657, SMS group opens up entirely new markets in the areas of corrosion and wear protection as well as for maintenance. Due to control-oriented or design-relat- SMS wire arc spray ed disadvantages of the wire arc systems available on the system in practical market today, end users had to previously accept major re- application during robot-controlled strictions with regard to the attainable coating quality and coating of turbine process efficiency. Through new approaches in electric-arc blade. control, a new open linear construction type and the development of a new SMS-own burner concept with pressure-loss-optimized, turbulence-reduced and high-ex-

02|2018 SMS group newsletter 21 IN FOCUS

panding nozzle system significant improvements can be addition, these coatings are post-treated with a specific Sol- achieved in process efficiency and coating quality. Gel-based sealing method ensuring corrosion protection for The new wire arc system is of modular design and fea- more than 20 years according to current standard specifica- tures ceramic internal flow contours, adapted to the relevant tions even with heavy seawater exposure depending on coat- coating task, which were designed to take account of the gas ing thickness. dynamics and can be adapted to the desired gas volume or Wire arc sprayed coatings can also be found in numerous mass flow rate. There is the option of directing the flow on other industrial sectors, such as in automotive industry for the wire ends well within the supersonic range (gas flow coating interior cylinder walls, especially lightweight-con- speeds greater than Mach 1) or of decelerating the gas - de- struction crankcases in combustion engines, in turbine con- pending on the material or application - to subsonic speeds. struction for the application of adhesive primer coats for Almost all metal materials available in wire form can be pro- plasma coating, for repair and maintenance tasks (e.g. for cessed. Through the option of separately controlled wire reconditioning shafts and bearing seats), for coating polymer feed rates it is also possible to process different materials on or fiber-reinforced materials (e.g. for improving shielding at- the cathode and anode sides to generate alloys or pseudo-al- tenuation characteristics acc. to EMC), in medical technology loys during the process (e.g. steel/nickel or aluminum/copper (among others for antibacterial surfaces), in the aerospace combinations). industry (e.g. for wear protection of leading edges), for the polymer industry (heat-conductor layers for local extruder THE MORE HOMOGENEOUS THE SPRAYING PROCESS, temperature control), in the field of energy production THE BETTER THE COATING QUALITY (high-temperature corrosion protection of incineration plants) and in generative manufacturing (coating and func- PERFECT spray® offers: tionalization of 3D printed light metals & polymers). an innovative nozzle concept for generating a The future-oriented PERFECT spray® predestines the high-speed gas jet, spraying plant not only for applications in the industrial envi- a wear-resistant and reliable wire contacting concept, ronment but qualifies the plant also for science and research precise and ultrafast process control, to open up new resource-saving applications and markets. At full parameter control of power supply for processing the largest specialist conference in the field of thermal different wire materials and diameters as well as, spraying (International Thermal Spray Conference ITSC-2017) maintenance-friendly burner and durable highly the inverter technology of SMS group and different coating functional materials for all system components. burners were presented to an international expert audience. The highlight of the PERFECT spray® system is the active pro- A specialist lecture in the so-called Industry Forum rounded cess control by means of fully parameterizable current-volt- off this successful event and established SMS group asfu- age source in connection with active adjustment of the char- ture-oriented plant manufacturer with innovative products. ◆ acteristics, depending on each corresponding wire-shaped, metallic filler material.

THERMAL SPRAYING METHOD CONQUERS NEW MARKETS

Current questions and problem definitions of a politically mo- tivated energy turnaround bring coating methods such as wire arc spraying to the fore of such technologies which can ensure a cost-, energy- and material-efficient long-term corrosion protection. Material systems suited for this task definition are alloys based on aluminum-zinc (Al-Zn) which can be processed as pre-alloyed Al-Zn wire or by using different wires (anodic: zinc; cathodic: aluminum). PERFECT spray®, the coating system of SMS group applies a virtually pore-free coating. Due to the possibility of controlling wire feed velocities of cathode and anode separately, materials of different melting temperatures can be conveyed homogeneously, thus setting Frank Lichtenthäler a constant electric-arc resistance (minimal length variation). In [email protected]

22 SMS group newsletter 02|2018 THERMAL SPRAYING During thermal spraying the wire-shaped filler metals are always fully molten. Due to its cost-effectiveness and relatively safe handling this method has become well-established in many industrial branches for corrosion and wear protection. Process-typical applications are repair coatings for example after wear damage to plungers and gearcases. In the offshore area these applications serve for corrosion protection e.g. of pipelines or boiler walls.

CAD representation of optimized wire arc burner PERFECT GUN (open linear construction type; image below) compared to classical standard spray burner LD/U2 with closed design and high pressure loss (image top).

02|2018 SMS group newsletter 23 ELEKTRIKIN UNDFOCUS AUTOMATION

INTERVIEW LONG-TERM EXPERIENCE ON BOTH SIDES voestalpine Tubulars GmbH & Co KG based in Styria, Austria, has placed an order with SMS group for the supply of a new heat treatment line and a hot tube straightening machine in 2015. After successful commissioning Reinhold Reisner and Helmut Jungbauer talk about the project.

DIVERSE SOLUTIONS

voestalpine Tubulars supplies seamless tubular products with an outside diameter of up to 193.7 millimeters (7 5/8 inches). In addition to the seamless tubular products used in the drilling and completion of oil and gas wells, voestalpine Tubulars produces hollows for redraw, mechanical tubing, boiler and heat exchanger tubes, pressure tubing and line pipe. These pipes are used in the automotive, petrochemical, construction, mining, tunneling and fluid transportation Industries.

REINHOLD REISNER, HELMUT JUNGBAUER, VOESTALPINE TUBULARS VOESTALPINE TUBULARS

Mr. Reisner: How has your company devel- So what made you decide right now, during oped in recent years and which products do the current times, to invest into your new you chiefly manufacture? equipment? Reinhold Reisner: voestalpine Tubulars produces Reinhold Reisner: Oil and gas exploration and pro- seamless steel pipes for the oil and gas industry as duction have become increasingly challenging and well as other industries – such as automotive, me- critical, changing the requirements of our custom- chanical engineering, construction and petrochem- ers. These requirements drove the need for pipes ical. There have been a number of R&D projects with unique properties and new steel grades, which together with our customers for tailor-made solu- require state-of-the-art heat treatment processes. tions, which resulted in new materials and thread The heat treatment expansion enables us to meet connections to better meet our customers’ needs. these requirements.

24 SMS group newsletter 02|2018 Top and bottom right: The cross-roll straightener with ten individually controlled rolls has a very sturdy design and allows rapid roll changing for minimum standstill times. The line is controlled fully automatically.

Bottom left: The heat treatment line supplied by SMS group consists of a walking beam type austenitizing furnace, an SMS Quenching Head, a cooling table for normalizing, a tempering furnace, also of walking beam design, a cooling bed and two sawing stations for sample cutting.

Thanks to the investment you are now in a po- ship with SMS and we have seen that they deliver sition to offer an extended range of products. us with proven quality and machinery. Further- What made SMS group the right partner for more has the cooperation with SMS group been your investment? always very structured and based on long-term Helmut Jungbauer: More than 35 years ago experience on both sides. And it is very import- SMS built a large part of our hot rolling mill, with ant for us, that SMS group has always met the many other parts having been added over the agreed delivery dates. ◆ years, such as two straighteners and now SMS was invited to provide us an offer also for the heat treatment mill expansion. For us it is very Contact important that we have a long-lasting relation- [email protected]

02|2018 SMS group newsletter 25 200 t/h walking Beam Furnace.

WORLDWIDE INNOVATION IN COMBUSTION PROCESS The SMS-ZeroFlame burner reduces emissions and boosts the performance of heating furnaces.

Flame vs. flameless combustion, process conditions.

26 SMS group newsletter 02|2018 IN FOCUS

• Strict environmental regulations call for innovative solutions The dilution of oxygen in the air jet is obtained by “entrain- to reduce the contamination caused by furnaces. For this rea- ment”, that is the phenomenon that occurs when a free jet is son, SMS is going to market low-emission burners under the developing in a gas volume: the free jet sucks particles of the brand name SMS-ZeroFlame. external gas because of a momentum exchange with the still • The ZeroFlame burner is an effective tool for furnace opera- gas. The overall entrainment is called recirculation. tors to manage the combustion process with tremendous Theory and experiments both show that an effective re- flexibility and excellent performance. circulation depends on the diameter of the jet nozzle, once that the temperatures of the two gases (the jet and the flue gas inside the furnace chamber) are set. However, the flame- SMS group offers the tube and wire industry a broad range of less burners have some limitations, i.e.: reheating and heat treatment furnaces. The portfolio in- there is an upper limit to the power that can be supplied cludes pusher furnaces for small billets as well as large walk- by the burner. ing beam furnaces for reheating of big size blooms or slab. the flames produced by the burner are very long. Furthermore, SMS group also delivers a broad variety of ro- the turn down of the burner is limited. tary hearth furnaces for seamless pipe mills or forge shops, as well as provides a strong know-how in combustion tech- SMS-ZEROFLAME BURNER nology. Most of these reheating furnaces make use of direct flame burners having typically a rating from 500 to 3,000 kW. The SMS-ZeroFlame burner was developed specially to over- With ever stricter environmental regulation and increas- come the limitations of the flameless burners available on the ing need for environmental protection SMS group is always market, providing the following performances: seeking to contribute by researching innovative technologies stable low NOx flame at low furnace temperature. for containing the pollution generated by its furnaces. flameless condition with ultra-low NOx emissions for fur- One of its efforts in this direction is the designing, proto- nace temperature above 750 degrees celsius. typing, testing and patenting of a remarkable new type of low booster function: increasing of the rating without increas- emission burner, now commercialized under the product ing the flame length keeping the NOx emissions low. name of SMS-ZeroFlame. This burner follows the steps of a flame length modulation: limitation of the flame length at long line of flameless burners present in the market since the any rating keeping the NOx emissions low. last 20 years, but boldly surpasses the performances of any increasing of turn down range. akin by offering unprecedented features. Flameless combustion occurs when fuel and comburent The result is obtained by the integration of two different jets mix in the following conditions (referred to as natural gas flames (see illustration below) having the following character- combustion): istics: Oxygen concentration in comburent jet is less than an inner flame, swirled, visible and stable, produced in un- 13 volume percent. der-stoichiometric conditions. Temperature of the mixed jet is above 670 degrees an external flame, over-stoichiometric, not visible and celsius. diluted.

Integration of the two flames in the ZeroFlame burner.

02|2018 SMS group newsletter 27 IN FOCUS

Effect of transition between flame flameless mode in NOx generation.

20 100 O2 [%] NOx [ppm] 18 90

16 80

14 70

12 60

10 50 O2 [% DFG]

8 40 NOx (real) [ppmNOx (real) DFG]

6 30

4 20

2 10

0 0 09.50.24 10.04.48 10.19.12 10.33.36 10.48.00 11.02.24 11.16.48 Time

Due to the swirl, the inner flame is shorter than the external air burners, but in that case the short flame, produced by a one so, also if it supplies the same rating, the total length of strong swirled external air, produced very high NOx emis- the flames is defined only by the flameless condition. sions because, in any configuration, a stable flame was pro- The SMS-ZeroFlame flameless design allows integrating duced. The turndown can reach up to 25 percent of the total these two flames having different characteristics and at the available rating by acting on the distribution of the flames, same time leaving the overall NOx production unchanged. always favouring the flameless condition to minimize NOx This feature allows the burner to supply an overboost with- emissions. out increasing the flame length, by adding the inner flame to The new ZeroFlame burner of SMS group provides fur- the flameless working mode. The flexibility of the burner al- nace operators with an effective tool for managing the com- lows a finer control with respect to a usual flameless burner bustion process with tremendous flexibility and outstanding that has a limited turndown. performance. ◆ Another innovation the SMS-ZeroFlame burner brings to the users is the possibility to control the flame length, making possible the installation of large-size burners even in small furnace chambers, and to supply more power without increasing the flame length. By a precise modulation of the combustion air and fuel distribution between the two sub-burners it is possible to modify and control the flame length at the same rating (figure Contact on the right). In the past, this feature was obtained by double [email protected]

28 SMS group newsletter 02|2018 DerThe Hubbalkenofenwalking beam furnace von Sidenorat Sidenor Basauri Basauri, in Spanien Spain, hathas einea capacity Leistung of 85von tons 85 Tonnenper hour pro and Stunde is the firstund istfurnace der erste, entirely der equipped mit SMS-ZeroFlamewith SMS-ZeroFlame Brennern ausgestattetburners. wurde.

Improvements in rating control provided by SMS ZeroFlame.

150 % (external und internal) The usual turndown of a flameless burner is in the range from 50 to 100 percent, because below the 50-percent limit flames start to emerge and then NO emissions will increase. 100 % (external und internal) 100 % (external) x 100 % The new integrated version allows the lower limit of the turndown range to be extended up to 25 percent, in fact 50 percent can be supplied by the inner burner that has a range 50 % 50 % (external) 50 % (external) from 0 to 100 percent, while the other 50 percent are supplied by 25 % (external) the outer, flameless burner that has a range between 50 and 100 percent. So, the total turndown of the burner is 25

to 100 percent leaving NOx emissions untouched. Usual flameless burner SMS-ZeroFlame SMS-ZeroFlame Shorting mode Booster mode

02|2018 SMS group newsletter 29 IN FOCUS

Among others, SMS group will supply to Jianlong Beiman a loop layer for its high-speed wire rod mill.

CHINA NEW HIGH-SPEED WIRE ROD MILL FOR JIANLONG BEIMAN Jianlong Beiman commissions SMS group to supply core components for high-speed wire rod mill.

Jianlong Beiman Special Steel Co., Ltd., based in Qiqihar, Chi- 115 meters per second. In addition to the wire rod finishing na, has awarded SMS group an order to supply core compo- block, the scope of supply includes two cantilever compact nents for a high-speed wire rod mill for quality steel. roughing stands, the shear group upstream of the block, The centerpiece of the new wire rod mill, which has an and the loop laying head including pinch roll unit. What’s annual capacity of 500,000 tons, is the ten-stand wire rod more, SMS group will also supply the design for the LCC® finishing block. To comply with the high metallurgical re- (Loop Cooling Conveyor) with three-fan technology, as well quirements of the finished products, the wire rod mill has as the coil handling system. been designed for low-temperature rolling. To allow the plant to be extended at a later date, space has also been set aside for further water boxes and ACCURATE ROLLING a MEERdrive®PLUS block, ensuring the plant is equipped to handle closer tolerances. Commissioning will take place in Low-temperature rolling is achieved by installing a cooling spring 2019. ◆ and equalizing loop upstream of the block. The rolling schedule includes wire rod with diameters between 5.5 and

25 millimeters, and rebar with diameters ranging from 6 to Contact 16 millimeters, which are finish-rolled at speeds of up to [email protected]

30 SMS group newsletter 02|2018 IN FOCUS

U.S.A. HIGH-QUALITY BAR PRODUCTS FOR THE US MARKET Nucor Steel Kankakee, Inc. selects SMS group for new merchant bar mill.

sive or metallic blades. Maximized flexibility will be reached thanks to an 80 foot automatic magnetic stacker with four independent 20 foot sections. 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.

LESS DOWNTIME, MORE EFFICIENCY

A high degree of efficiency is also guaranteed thanks to the technology systems and quick-changing equipment: Size changes and adjustments to the product lengths can be performed quickly, while downtimes are reduced to a minimum. Besides the mechanical equipment, SMS group will supply the entire electrical and automation system. „This new MBQ mill is right in line with our long-term strategy for profitable growth. It builds on our market lead- Nucor Steel Kankakee Inc., based in Illinois, U.S.A., has cho- ership position by further enhancing our product offerings sen SMS group as the primary technology supplier for its new of merchant bar, light shapes and structural angle and 500,000 tons per year merchant bar mill. The new facility will channel in markets in the central U.S.,“ said John Ferriola, be installed at its existing bar mill located in Bourbonnais, Illi- Chairman, CEO & President of Nucor. The American Mid- nois, with production scheduled to commence in 2019. west region is one of the largest markets for merchant bar This plant will be designed to produce a wide range of mill products. With this new modern merchant bar mill, merchant bar products to complement the existing line, in- Nucor Steel Kankakee, Inc. is ideally positioned to offer its cluding equal and unequal angles in a range from 3 to 7 inch- customers a full range of the highest quality bar products. ◆ es, channels from 3 to 10 inches, flats up to 12 inches, rounds up to 3 5/8 inches and rebar from #14 to #18. The roll pass design developed by SMS group will allow the mill to use a wide variety of starting billet sizes, ranging from 6.25 inches square to 5.5 inches x 11.5 inches. The new merchant bar mill supplied by SMS group will consist of 16 total stands, including five dual-drive convertible stands, all equipped with quick-changing device. It will also be equipped with three shears along the mill, with provisions for automatic sampling collection, and an automatic sampling area at the cooling bed. Additional highlights will be a multi-line straightening machine with automatic bar positioning and feeding device and automatic roll changing system, as well as a 700 tons cold Contact shear. Two cold saws will have a capability to use either abra- [email protected]

02|2018 SMS group newsletter 31 The five-stand 3-roll PSM® sizing block (Precision Sizing Mill).

32 SMS group newsletter 02|2018 MODERNIZATION IN FOCUSIM FOKUS

SOUTH KOREA ON THE ROAD TO A SUCCESSFUL FUTURE SMS group has upgraded the existing bar mill for Hyundai Steel Pohang with a five-stand PSM®. This is an impressive evidence of how old technology can be used efficiently by targeted supplementation of hightech components.

• The automotive industry demands ever closer tol- Since the eighties, Hyundai Steel has originally erances from steel producers such as Hyundai produced only rebars in its Pohang plant. In the Steel. To satisfy the requirements the company re- course of time, the product range has been en- cently started relying on a five-stand PSM® from larged by SBQ grades. In order to meet the latest SMS group. requirements of the automotive industry with re- • The hydraulic adjustment features the technology gard to close tolerances, place has been created at Hyundai Steel. The rolling gap can be changed for the five-stand PSM® by shifting four stands in during the rolling process within milliseconds and the intermediate train. With this relatively small the result is a considerably more precise diameter extent of conversion work, Hyundai Steel was tolerance. able to make the plant fit and profitable for the automotive sector. With the PSM® many different SBQ grades in the diameter range from 25 to 83 millimeters can be rolled economically on the existing cooling bed in small batch sizes and with high precision.

A view of the five-stand 3-roll PSM® (Precision Sizing Mill).

33 The existing roughing and intermediate train.

PSM® with downstream rebar mill stands.

34 SMS group newsletter 02|2018 MODERNIZATION IN FOCUS

MORE PRECISE THAN REQUIRED BY automation systems. A fully automated rolling DIN STANDARDS process is monitored and controlled by electrical and automation systems of SMS group. The A particular feature of PSM® is the hydraulic ad- core element is the performance module TCS – justment under load enabling the rolling gap to Technological Control System, controlling the hy- be changed during the rolling process within mil- draulic roll adjustment. A clearly structured user liseconds. The 3-roll PSM® achieves a diameter interface graphically visualizes all parameters. tolerance which is six to ten times more precise The automation system of SMS group is de- than requested by the DIN standard, namely signed in such a way that existing measuring temperature-independent over the total length equipment of Hyundai Steel could be seamlessly of the bar. The requirement for near-net-shape integrated. rolling is thus fully satisfied. Another advantage is the rolling in free-size mode also enabling all ROLL CHANGE AND intermediate sizes to be produced. Consequent- ROLL SHOP ly, Hyundai Steel is able to consider e.g. the peel- ing dimension of a bar, reducing it to a minimum. For a roll change the prepared PSM® mill stands are transported on a change car from the roll ELECTRICAL AND AUTOMATION SYSTEMS shop equipped by SMS group to the change position. As soon as the stands are available in ex- In addition to mechanical equipment, the scope change position the change procedure can be- of supply of PSM® also included electrical and gin. In the event of minor dimension changes,

View of rake-type cooling bed.

02|2018 SMS group newsletter 35 View into the control stand.

Exchange unit ready for replacement.

36 SMS group newsletter 02|2018 MODERNIZATION IN FOCUS

not all five stands have to be exchanged reducing work and expenses. Extension and retrac- tion of the stands is fully automatic. What’s PSM® during more, automation is already properly preset assembly in SMS group workshop. A film on the since the position of the roll rings has been topic of conver- transmitted from the roll shop in advance. A di- sion can be mension change or exchange of used stands can found under therefore be completely finished within a few www.sms- minutes. group.com/ nl2018-video- ASSEMBLY hyundai- steel-pohang The conversion work at Hyundai could be performed in a short period of time because each PSM® had been completely manufactured and already assembled in the SMS group workshop in Mönchengladbach. In just two large portions, the mill was transported directly to the construction site. Consequently, on-site assembly could take place quickly, reducing downtimes specifically for modernization projects to a minimum as in the case of Hyundai Steel. ◆

Contact [email protected]

Worldwide references New Year Company equipment Modernization 2016 Jiangyin XingCheng Special Steel Works Co., Ltd., China PSM® 450/4 ✔ 2016 Lech-Stahlwerke GmbH, Germany PSM® 380/4 ✔ 2015 OEMK, Russia PSM® 380/4 ✔ 2014 Hyundai Steel Pohang, South Korea PSM® 380/5 ✔ 2013 Qingdao Iron & Steel Co., Ltd., China PSM® 380/5 ✔ 2013 Kardemir A.S., Turkey PSM® 380/4 ✔ 2013 Jiangsu YongGang Group Co., Ltd., China PSM® 380/4 ✔ 2012 SDI Pittsboro, U.S.A. PSM® 380/4 ✔ 2011 Xining Special Steel Co., Ltd., China PSM® 380/4 ✔ 2011 Fujian WuHang Stainless Steel Products Co., Ltd., China PSM® 320/4 ✔ 2009 Timken - Harrison Rolling Mill, U.S.A. PSM® 480/5 ✔ 2006 Deutsche Edelstahlwerke, Germany PSM® 420/6 ✔

02|2018 SMS group newsletter 37 IM FOKUSIN FOCUS

WORLDWIDE NEW GENERATION OF MEERDRIVE®PLUS WIRE-ROD FINISHING BLOCK With the successful installation of the new MEERdrive®PLUS wire-rod finishing block at the Neunkirchen plant of Saarstahl AG, another step towards rolling of wire-rod diameters with close tolerances has been implemented.

In comparison with the first generation which has Together with the modified roll pass design ap- been successfully assembled for the first time at proach, the first bundle at Saarstahl Neunkirchen Further informa- ArcelorMittal Ruhrort, Germany, the new genera- achieved a tolerance of ±0.05 millimeters at a dition on this topic tion of four-stand MEERdrive®PLUS wire-rod finish- ameter of 16 millimeters. is provided by this ing blocks has been extended by a quick-change Thanks to horizontal positioning of the four film. stand, special stands and speed adjustment for drive motors on one side, a quick-change stand tension control. could be realized by means of a change car.

38 SMS group newsletter 02|2018 MEERDRIVE®PLUS-BLOCK Thanks to REDUCES DOWNTIMES horizontal positioning of the four drive motors The MEERdrive®PLUS block is designed for spring on one side, a steels with an inlet temperature of 750 degrees quick-change stand could be realized by Celsius. The fist two stands are of the CL 230 UHD means of a change type, characterized by high load-bearing capacity. car. For the special roll pass design in this block where the two final passes are executed as „round – round“ it is important to arrange the two last stands as close as possible to each other to make sure that twisting is prevented. To achieve this, stands of the CL 160S type were developed and no guide is required between the mill stands. Consequently, static guides are only needed in front of stands 1 and 3 and a roller guide is required in front of stand 2. On demand, remote ad- MEERdrive®PLUS justment under load can be integrated in all stands. block during stand change. Since all finished sizes in the MEERdrive®PLUS block are finish-rolled a so-called “one-family rolling“ can be realized in the rolling mill reducing the required downtimes in the mill. ◆

Contact [email protected]

Arrangement of TWO MORE stands 3 and 4 with CUSTOMERS RELIED MEERdrive®PLUS. ON MEERDRIVE®PLUS TECHNOLOGY With Arlenico S.p.a. (formerly Caleotto) and Feralpi Siderurgica S.p.a., two of the most important Italian wire-rod producers, ordered a four-stand MEERdrive®PLUS block from SMS group. Both blocks are integrated in the existing plants. At Arlenico, the focus is on much better tolerances and thermome- chanical rolling, whereas Feralpi emphasizes on a possible expansion of and increase in production and on the mechanical properties of the material.

The opportunity of “one-family rolling“ generates additional cost savings for both plant operators.

02|2018 SMS group newsletter 39 MODERNIZATION IN FOCUS

MEDIUM SECTION MILL

The semi-continuous medium section mill comprises furnace, high-pressure descaler and downstream breakdown mill stand. During reversing rolling, the positioning of rolled material into various roll grooves is realized by a dis- placement and bloom reversing device.

40 SMS group newsletter 02|2018 SOUTH KOREA FIT FOR THE FUTURE Modernized medium section mill for Hyundai Steel – precision products for the automotive industry.

After having been in operation for more than 25 years, SMS group upgraded the existing medium section mill at Hyundai Steel at the Pohang site to make sure that the old plant also meets today’s requirements – particularly the high standards of Hyundai Motor regarding quality and precision. To achieve this, the intermediate and finishing stand group has been equipped and rebuilt with four new hydraulically adjusted stands and associated automation and control system. In addition to that, the profile measuring device PROGAUGE has been integrated and new roll changing units were installed. ◆

Contact [email protected]

02|2018 SMS group newsletter 41 LANGPRODUKTE

HCS-STANDS

Modernization experts of SMS group have analyzed the entire process and developed an investment-friendly solution for Hyundai. Only the last four of the twelve finishing stands had to be replaced by HCS stands (Hydraulic Compact Stand) with hydraulic adjustment to assure that the required tolerance values of Hyundai Motor are attained. Due to customized engineering the base plates could be reused to keep foundation costs as small as possible.

42 SMS group newsletter 02|2018 MODERNIZATION INLANGPRODUKTE FOCUS

INTERMEDIATE AND FINISHING STAND GROUP

The intermediate and finishing stand group in operation for more than 25 years consists of a total of twelve stands. For maximum flexibility, stands in UD design – i.e. usable as universal and two-high stands – as well as tilting stands are employed.

FIVE ROLLING MODES FOR PRODUCTION

With four new and eight remaining stands Hyundai Steel operates the plant in five rolling modes for the production of H-beams, unequal and equal-sided angles, tank-track elements and precision round bars. After the upgrade, especially the rounds reveal a dimensional accuracy corresponding to one fourth of the specified DIN tolerance range.

LASER LIGHT CUT MEASURING

Compliance with the tolerances and the surface quality is scanned completely by means of non-contact PROGAUGE laser technology. Up to 500 scans per second are done. PROGAUGE controls the hydraulic adjustments of stands 11 and 12 in closed loops fully automatically to compensate deviations in the rolled material within fractions of a second. In addition to that, PROGAUGE provides a system for surface flaw detection called SURFTEC.

02|2018 SMS group newsletter 43 MODERNIZATION LANGPRODUKTEIN FOCUS

ROLL WORKSHOP

The roll workshop was also structured more efficiently with new techniques. The withdrawal device of the universal stands simplifies roll changes significantly.

44 SHORT DELIVERY TIME

It took SMS group a delivery period of only about eight months and downtimes of approx. four weeks to equip the plant with the latest technologies.

RELIABLE High reliability and longevity of SMS group equipment: the rolling mill was first assembled in Belgium in 1969 and then relocated to Korea in 1994.

45 IN FOCUS

WORLDWIDE THE DIGITAL WAY TO MAXIMIZING QUALITY PQA® (Product Quality Analyzer) perfectly combines the comprehensive process know-how of MET/Con and an efficient quality assurance software particularly adapted to the needs of the metallurgical sector to form a powerful solution for the metal industry.

MET/CON MET/Con offers advisory services based on vast metallurgical and oera- tional expertise. Employing more than 230 industry experts, MET/Con is the right partner for all advisory services in the fields of production and further processing of steel, aluminum and other NF metals.

46 SMS group newsletter 02|2018 • Expertise is usually transferred in writing or verbally, but this involves the risk of getting lost in many places. ADVANTAGES OF PRODUCT QUALITY ® ® • PQA serves to transfer the knowledge online and related to ANALYZERS (PQA ) the respective application, for example in the form of quality rules or production information, thus providing first-class de- Quality is not a matter of the last process step, but is generat- cision support paired with clear recommendations to act for ed along the entire production route. ® production. PQA reveals its full potential when used along the entire production and process chain. Nevertheless, the system will ® • The PQA rules can be adapted to the individual needs of the come with benefits and savings, if just parts of the process customer. Responsibility for that task is with the experts of chain or individual lines like galvanizing or annealing lines are MET/Con, a company of SMS group. analyzed. Saving production costs Since critical quality deviations are identified early, the further processing of substandard materials is blocked. This saves energy, resources, manpower and time. In addition, the sys- Traditional advisory services in the fields of know-how, pro- tematical support helps reduce the workload of the staff. cess and quality are based on the transfer of expertise to Increased yield and improved quality at every process stage customers on site either in writing or verbally. However, this Early reallocation of substandard material or provision of re- method has the disadvantage that knowledge may get lost pair recommendations increases the yield and the quality level at every process step. in many places, for example, when an employee leaves the company or the knowledge does not reach all of the staff Transparent production process Consistent material tracking and remote access to the system members needing it in their daily routine. through web-based reports make the production process more PQA® solves this problem by providing the knowledge transparent and speed up optimization processes. Moreover, online and related to the respective application, in the form long-term storage of process-relevant data helps understand and trace the origin of quality problems. of quality rules and production information, and by present- ing professional advice directly during the production pro- Creating confidence The transparent and quality-oriented production process cess. PQA® thus offers first-class decision support and gives makes sure the material supplied to the customers will be of clear recommendations to act for production and along the constant quality, and it creates confidence that for each pro- whole process chain. cess step all quality-relevant data are documented and stored. PQA® was developed by MET/Con Metallurgical Plant & Process Consulting GmbH, a company of SMS group. The MET/Con team prepares the PQA® rules in cooperation with the customer, based on empirical values and the vast expertise of the MET/Con specialists. is a freely configurable quality report for all product key pa- RULE-BASED INSTRUCTIONS rameters, which may be set against the order data. The product purchasers thus benefit from a continuously con- PQA® supervises, documents and safeguards process and trolled quality standard and a consistently documented product quality over the entire processing chain from steel- production process. making up to the refined cold strip or other intermediate and finished products. To that end, all relevant production REPUTED PRODUCERS RELY ON PQA® and process data are recorded and continuously analyzed according to preset rules. In the case of quality deviations, The PQA® know-how, quality assurance and software tech- the system will provide clear instructions permitting possi- nology have been developed over the past five years and ble defects during the production process to be indicated applied in the plants of reputed steel producers worldwide. and corrective action to be initiated in due time. For that The PQA® system is the centerpiece of the new CSP® purpose, the products are checked after each process step minimill at Big River Steel, U.S.A. Here, quality is controlled to see whether they are suitable for the next process step to this approach from steelmaking to the finished hot or and for achieving the desired final quality. cold rolled and galvanized product. After an implementa- PQA® effectively supports the user in making up his de- tion period of eight weeks, the system presented Big River cision on the quality of a pre-, intermediate or finished Steel considerable cost savings and quality improvements. product and to block or release it for the next processing Furthermore, PQA® is used in the new flat steel complex step respectively for supply. A further result of this analysis of Shandong Iron and Steel in Rizhao, China. In this

02|2018 SMS group newsletter 47 greenfield project, production of automotive grades is will be applied to produce engineering steel and bright controlled throughout the complete process. In addition, steel products (for further information please refer to PQA® is integrated in the company’s new heavy-plate and page 50). ◆ Steckel mills. In China, PQA® was also implemented in the new high- performance hot-dip galvanizing line at Benxi Steel. Moreover, the system will be installed in Indonesia at PT Krakatau Steel’s new hot strip mill in the near future. Recently, long product producer Swiss Steel at Emmen- brücke, Switzerland, awarded an order to MET/Con cov- ® ering the supply of a PQA system for quality manage- Thomas Hüper ment along the complete production chain. The system [email protected]

48 SMS group newsletter 02|2018 IN FOCUS

Experienced experts help determine the quality rules to be ® integrated in the PQA® for each PQA system modules quality-relevant process step and and their functions to be applied whenever required.

The PQA® is of modular design with the flexible software structure suited to group various modules depending on the respective application. In addition to the functions required for quality control, supplementary modules also cover applications in the field of Big Data analysis and Artificial Intelligence (AI). This makes it possible to show previously unknown, new correlations with the aid of various intelligent, mathematical evaluation methods including pattern recognition options.

DIS – Data Integration Studio DIS is the foundation of PQA®. It serves to structure the collected data and keep them ready for further processing.

PDW – Production Data Warehouse PDW is a database for intelligent structuring of information from different plants to facilitate the analysis of fault causes along the entire process chain.

LD – LogicDesigner LD is used to concentrate and combine to PQA® quality rules all the knowledge spread over several automation levels, written on paper, or existing inside the heads of employees and at MET/Con.

QM – QualityMonitor The QM serves to continuously assess the product on the basis of rules at constant quality.

WR&A – Web Reporting & Analysis The WR&A module creates freely configurable reports and makes them available in a browser application.

SPC – Statistical Process Control SPC is the traditional, statistical analyzing tool for quality and process evaluation.

DC – DataCorrelator DC is an advanced analyzing tool to perform a fault cause analysis in a process chain and, on the basis of the results thereof, to create new intelligent rules to improve quality.

PPS – Proactive Process Supervision Learn more about The PPS continuously supervises the condition of the plant. It identifies devi- PQA® in the new, ations and provides clear instructions to the staff to prevent any quality is- comprehensive sues and unplanned downtimes. brochure. www.sms-group. com/pqa

02|2018 SMS group newsletter 49 IM FOKUSIN FOCUS

SWITZERLAND ORDER FOR QUALITY MANAGEMENT SYSTEM Swiss Steel Emmenbrücke implements PQA®.

level along the entire production chain, achieve more stability in the production process, further improve ontime delivery performance and optimize the company’s competetiveness in the long run. MET/Con, a company of SMS group, was commissioned to supply an integrated IT solution operating on knowledge- based expert rules. Use will be made of an advanced software and database solution from Aachen-based QuinLogic, an SMS group company. Solutions based on this approach have been successfully implemented at selected flat steel producers with a great variety of downstream processes. The PQA® system carries out online analyses of process, production and quality data from steelmaking, casting and rolling, right down to the drawing processes. The PQA® expert quality rules, which can be freely configured and fed with specific knowhow, take into account customer- and order-specific information in the quality assessment process and for the block-or-release decisions for the next downstream processing step. The modular software consists of a LogicDesigner for flexible rule adaptation, a quality assessment module and web- The PQA® quality management system from MET/Con is designed to based reporting. The centerpiece of the quality management enhance the quality level, stabilize the production process, improve system is the DataCorrelator software module, which covers on-time delivery performance and secure competitiveness. latest features such as “Big Data” analyses and artificial intelligence (AI). Various intelligent mathematical evaluation methods, including pattern recognition options, identify and indi- cate correlations that can be directly used for process optimization. Swiss Steel, member of the SCHMOLZ + BICKENBACH Group, With this project, Swiss Steel, Steeltec and MET/Con want produces about 600,000 tons per year of engineering steel at to set a milestone showing how the performance, efficiency Emmenbrücke, part of which is further processed within the and quality level of the mill can be further improved by gaining Group at bright steel manufacturer Steeltec. These special total process and production transparency. ◆ steels are used in sectors such as automotive and mechanical engineering. The new PQA® Product Quality Analyzer from MET/Con is going to be implemented at Emmenbrücke as a pilot for a group-wide Industrie 4.0 initiative. With this quality manage- Mirko Jurkovic ment system, Swiss Steel aims to further enhance the quality [email protected]

50 SMS group newsletter 02|2018 ELECTRICAL AND AUTOMATION IMSYSTEMS FOKUS

X-Pact® MES 4.0 is an important component in the transformation Production planning for Industrie 4.0 with the X-Pact® MES 4.0 to a learning factory. system from SMS group.

U.S.A. PRODUCTION PLANNING IN LINE WITH INDUSTRIE 4.0

Nucor Steel Gallatin places supplementary order with SMS group for X-Pact® MES 4.0 production planning system.

Nucor Steel Gallatin in Ghent, Kentucky, U.S.A., has commis- Technical Order Generation, used to generate the relevant pro- sioned SMS group to supply an X-Pact® MES 4.0 production duction orders from the customer orders; the Plant Sequenc- planning system for the pickling and galvanizing line it or- ing System, used to determine the optimal sequence for the dered recently. strips to be produced; and the Business Intelligence Reporting Nucor Steel Gallatin chose the MES (Manufacturing Exe- system, which offers interactive, web-based reporting for ob- cution System) from SMS group as this production planning taining information from the production data. system features a state-of-the-art software architecture and The equipment will undergo an integration test and also be modular, extendable structures that offer economic bene- commissioned together with the previously ordered X-Pact® fits to a modern, highly productive company at a time of automation system from SMS group. growing digitization. Commissioning of the new system with its unique “Heat-to- Nucor also chose SMS group as its supplier because the Coat” technology supplied by SMS group is scheduled for X-Pact® MES 4.0 can be seamlessly integrated in the X-Pact® 2019. The “Heat-to-Coat” technology is characterized by its automation solution it has already ordered for its strip pro- compact, user-friendly U-shape design, its turbulence tank cessing line. The scope of integration ranges from basic auto- pickling line, high-performance induction heating system, mation (level 1), through process automation (level 2), right FOEN® galvanizing equipment, and the Drever cooling system. up to the production planning system (level 3). At the same With a high production rate of 180 tons per hour and a large time, X-Pact® MES 4.0 is an extremely important component strip section (up to 6.35 millimeters thick and up to 1,854 milli- in the successful transformation to a learning factory along meters wide), the line is setting a global standard in hot strip the lines of Industrie 4.0. galvanizing lines. The pickling and galvanizing line has an annu- In addition to the basic system for recording and storing the al capacity of 500,000 tons. ◆ production data, the scope of supply includes the connection to the automation systems, such as level 2 for example, and to Wilfried Runde the customer’s ERP system, as well as the following modules: [email protected]

02|2018 SMS group newsletter 51 ELECTRICAL AND AUTOMATION SYSTEMS

WORLDWIDE SETTING NEW STANDARDS IN PLANT AUTOMATION Introduction of the holistic X-Pact® Process Guidance concept.

Production processes in the steel industry have situations, even if they occur extremely seldom. been and are becoming increasingly challenging, The new plant automation concept X-Pact® the reasons being the growing flexibility in pro- Process Guidance has been designed to cope duction, the ever smaller batch sizes that are with this kind of challenges. The previous separa- possible as a result of this flexibility and the in- tion between level 2 and level 1 has been com- creasingly wider production mixes. Besides bined into a process guidance oriented approach. these factors, the continuing further develop- Thanks to the modular structure, classic modules, ment of automation technology is an indispensi- such as reporting, tracking or material handling, ble requirement to stay competitive and to sup- and metallurgical models can be easily integrated. port the staff in production with the latest The Realtime Private Data Cloud, which supports available automation solutions. all common Industrie 4.0 communication stan- Along with the increasing degree of automa- dards such as OPC UA and MQTT, makes it possi- tion in the works, it is becoming more and more ble to connect new sensors in virtually no time or important to have systems capable of providing conveniently transfer data between authorized support in case of out-of-the-normal scenarios. systems, such as energy management, plant con- Such support has to be designed in a way that dition monitoring, etc. every operator, no matter how experienced he As well as the modularity of the system and may be, will be able to handle such extraordinary the Realtime Private Data Cloud, X-Pact® Process

SPECIALTY: PROCESS SLIDER The Process Slider is the plant operator’s central HMI unit. This unique operating screen provides intelligent, process-oriented and situation-specific operator guidance. The process is chronologically displayed from left to right. When the system is in a process phase, the sequence of steps within this phase is worked off one after the other from the top to the bottom. This guidance ensures that the operator receives only information needed for a particular process step. Besides the main sequence path, the operator is also provided with a full list of out-of-the-normal scenarios commonly associated with each individual process step.

52 SMS group newsletter 02|2018 ELECTRICAL AND AUTOMATION SYSTEMS

Guidance comes with a wide range of virtualiza- text of activities. X-Pact® Vision also provides a tion features. Virtualization supports the cre- multitude of tools, such as Breadcrumbs, Wizards ation of redundancies to increase plant availabil- or context-sensitive help tools. ity and provides independence from the system hardware. A PROVEN CONCEPT

VISUALIZATION X-Pact® Process Guidance has already been implemented in various metallurgy projects. Elec- Operation and visualization are based on the tric and BOF steelmaking shops as well as reduc- X-Pact® Vision concept, which always places the tion plants have been equipped according to this operator in the focus of interaction. Specific dia- concept. ◆ logs have been developed for specific categories of users, for example line operators, metallur- gists, maintenance personnel, production man- Paul-Christian Hopp agers, etc., while focusing on their individual con- [email protected]

GENERAL X-PACT® PROCESS GUIDANCE MODULES

Examples of general modules Tracking module This module displays the current status of the plant. Which product is being produced, in which quality and under which conditions?

Reporting module This module captures all data necessary to produce detailed reports. As well as the acquisition of data, the editing of data is another key feature of this module. Data editing is aligned to the system visualization. Additionally, prepared PDF files are provided for data editing purposes.

Example Casting Machine In this case, the Main Module tracks the material flow and transformation (molten metal, strand, slab) and guides the operator along the entire casting process (from the preparation (set-up) of the machine down to the end of the sequence (dis- charging). In doing so, it generates a twin of the product-related tracking data in the data cloud.

02|2018 SMS group newsletter 53 ELECTRICAL AND AUTOMATION SYSTEMS

WORLDWIDE SUCCESSFUL PRODUCTION WITH X-PACT® DRIVE

The modular drive solution X-Pact® Drive for low-voltage frequency converters has been integrated in the automation systems of numerous plants.

X-Pact® Drive solution for the pickling line/tandem cold mill at the customer Big River Steel in the U.S.A.

Many plants have been successfully com- coiler mandrel drive of the CSP® plant at the missioned with the X-Pact® Drive module, a customer Big River Steel in the U.S.A. With a new module added to the range of X-Pact® REFERENCES IN power rating of 1,000 kW and 200 percent products. The modularity of the concept FIGURES: overload, this unit is one of the higher-ca- has proved very successful during the com- 59 line-ups (total length of pacity motors in the low-voltage range. missioning activities. the control cabinets: For coilers that handle thin-gage strip, it Also during running operation, the sys- approx. 1,300 meters) is very important to use synchronous mo- tem has performed excellently, last but not 1,418 drive units tors because they have much lower inertia least due to its robust design. More than 3,019 motors than asynchronous motors. This avoids 99.5 percent availability of the drives over a necking of the strip head at the start of wind- installed motor power period of more than a year speaks for itself. rating from 1 to 2,500 kW ing. For a synchronous motor, the frequency A milestone achievement was the commis- converter only needs to feed the pure active sioning of the synchronous motor for the current. Thus, the frequency converter can

54 SMS group newsletter 02|2018 Power inverter module for the coiler. The coiler of the CSP® plant at Big River Steel in the U.S.A.

achieve correspondingly higher power ratings. Currently, the same solution is being implemented at MMPZ-group (Miorskij Metalloprokatnyi Zavod). In this case, it is for 2,500 kW coiler drives with 150 percent overload. Unlike a synchronous motor, an asynchronous motor has to be fed with ap- parent current. Accordingly, a higher-dimensioned frequency ADVANTAGES OF X-PACT® converter is required. DRIVE AT A GLANCE:

QUICK SPARE PARTS SERVICE AND High power density of 5 MW per converter system EFFECTIVE CUSTOMER TRAINING Cost-efficient solution through standardized cabinet design

Short commissioning time, resulting in a faster ramp-up Customers highly appreciate the spare parts service and the operator training provided by SMS group. Courses on mainte- One common application software for all plant types nance and repair take place under hands-on conditions in Easy maintenance due to cartridge system SMS group’s modern test and training center in Hilchenbach. Optimized spare parts inventory Here frequency converters can be flexibly coupled with differ- AC and DC bus systems ent motors. In the same facilities, also tests of more complex Synchronous motor and asynchronous motor applications and drive-related control systems are performed. By linking the frequency converters with a central control system, it is UL or CE certified guaranteed that each drive can be separately controlled. ◆

Volker Paersch [email protected]

02|2018 SMS group newsletter 55 RUBRIK

WORLDWIDE PERFORMANCE MODULES Improving competitiveness with affordable investments.

SMS group is continuously developing a multitude of solutions to substantially improve the competitiveness of plants at moderate investment costs. These technologies, components, automation solutions or services are classified as Performance Modules. Each individual module helps customers improve the performance of their plants in one or several dimensions and hence achieve a competitive edge in a tough market environment. This means the modules will not only increase plant productivity and product quality, but also reduce operating costs and permit new, high-margin products to be introduced. Every production line experiences minimal anomalies that are caused by the ingoing material, minute damage to the rolls or roller guides, or incorrect pass settings among other things. All this has an influence on the product quality and productivity. Produc- ers are facing two challenges: firstly, the defects on the hot surface need to be detected and located; secondly, the cause of the defects needs to be identified and eliminated. Whether it’s tube, rail, bar, wire rod, beam, channel or other sections: SMS group offers the right measuring system for all rolled metal products. ◆

Contact [email protected]

Q 4.0 P E

Quality Industrie 4.0 Production Efficiency

Section mills Seamless tube plants, bar and wire rod mills

P Q P Q Performance Performance PROGAUGE Checkbox MEERGAUGE® Checkbox IN-LINE MEASUREMENT OF SECTIONS PRECISE MEASUREMENT OF TUBES, AND RAILS Quality BARS AND WIRE ROD Quality - Reduction of out- - Short exposure time Challenges of-tolerance rolling Challenges and absolute syn- Real cross-section measurement for - Stable measurement Demand for higher dimensional accura- chronicity of the in-line control of the finishing section result cy of the rolling stock and continuous measuring heads monitoring of the rolling process - Corrective roll adjust- Solution Productivity ment during running The gage consists of 4-8 “laser section” - Increase of available Solution production sensors capable of performing up to rolling time up to 2 % Online measuring system based on 5,000 scans per second. A true-shape - Time and cost laser light cut technology Productivity cross-section is generated by up to benefits through Synchronous, contact-free measure- - Increasing available 4,000 synchronous measured points. optimization of ments over the entire cross-section rolling time up to 2 % Technical advantages production by four sensors - Time and cost Static system, no oscillation Measuring equipment in the immediate benefits through Synchronic scanning vicinity of the roll stands optimization of Recording of total cross-section production Shared coordinate system Technical advantages High measuring speed Transfer of measured values to roll stand Measurement of various contours control system (closed-loop control) High density of measured data: up to 20 million measured points per second

56 SMS group newsletter 02|2018 PERFORMANCE MODULES

Seamless tube plants, Seamless tube plants bar and wire rod mills

4.0 P Q Q Performance Performance SURFTEC Checkbox CALIVIEW® Checkbox DIAMETER MEASURING SYSTEM FOR INLINE MEASURING AND POSITIONING SURFACE DEFECT DETECTION Productivity OF CALIBERS Quality - Online surface - Perfect alignment Challenges detection with reduc- Challenges of the mill Detecting surface defects on the basis ing of “bad” products Incorrect pass alignments and - Exact roll wear of cross-section measurements - Reduction of after- misalignment of stands measurement treatment costs - Optimized mainte- Solution Solution nance and production Measurement with higher data rate Quality Precise contact-free inline measurement - Consistent tube (up to 5,000 cross sections/second) - Overfills & seams and alignment of rolls and passes in mills quality Reconstruction of entire product can be recognized Flexible solution for PQF® / MPM mills, surface immediately at the stretch reducing mills, sizing mills, piercer hot bar with exact and the toolshop Technical advantages location and size of Classification of the defect enables the defect Technical advantages an immediate intervention by the Visibility of the alignment of the rolls operating personnel to the passline Direct feedback via the mobile Control Device for the adjustment of the rolls during the measurement Wear of the rolls can be shown

02|2018 SMS group newsletter 57 NEWS

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

U.S.A. TRAINING CENTER FOR STEEL TECHNOLOGY Arkansas Northeastern College (ANC) and SMS group sign agreement creating the Arkansas Steelmaking Academy (ASA).

Officials from SMS group in North America and partnership announcement was made during a Arkansas Northeastern College administrators met visit to ANC by Arkansas Governor Asa Hutchinson. to finalize and sign an agreement creating the With the opening of Big River Steel, northeast- Arkansas Steelmaking Academy which will begin of- ern Arkansas has one of the highest regional con- ferings in 2019. Doug Dunworth, President and centrations of steelmaking in the United States. CEO of SMS group’s North American operations, SMS group, in 2017, opened a new local workshop met with Arkansas Northeastern College president in Osceola, Arkansas. This new facility allows the Dr. James Shemwell to finalize an agreement creat- local customers, in many cases, to save on trans- ing the Arkansas Steelmaking Academy (ASA). The portation costs as SMS brings maintenance ser-

58 SMS group newsletter 02|2018 8,500 square meters will be the footprint of the Center for Allied Techology of Arkansas Northeastern College. The new facility will also house the Arkansas Steelmaking Academy’s seminar classrooms.

vices utilized by these customers closer to them. ments “We are both pleased and excited about The Osceola workshop is housed in what was a this partnership between ANC and SMS group. vacated but fairly new 5,000-square-meter indus- Not only will this help our customer base in North trial building. SMS group prides itself on being a America, but the ASA can be a launching point in leading partner in the world of metals not only in training the future generations of steelworkers North America but throughout the world. SMS’s with knowledge in the latest technology in steel- largest market is the steelmaking and processing making and processing.” industry. The company provides world-class new The Arkansas Steelmaking Academy will be equipment and actively supports operators by de- housed in the College’s 8,500 square meter Center vising solutions throughout the process from for Allied Technology currently under construction. melting and casting to rolling and finishing. With By utilizing the new facility, the ASA will be located SMS servicing clients such as Nucor Steel, Big River in a world-class complex featuring technologi Steel, Tenaris, and TMK-IPSCO locally as well as cally-equipped seminar classrooms and hands-on many other manufacturers across the country, it training laboratories for steel technology. made sense for the company to consider a pro- The Center for Allied Technology is slated to posal by ANC to offer North American-based train- open in August with ASA offerings anticipated to ing centrally located in Arkansas. begin in 2019. Arkansas Northeastern College is currently one of very few colleges in the U.S.A. of- SMS TECADEMY BRANCH FOR THE fering Steel Industry Technology programs and NORTH AMERICAN MARKET the only one in the state of Arkansas. Shemwell noted, “We were proud to have Governor Hutchin- “Before now, the state-of-the-art steel technology son, a champion for economic development in training offered through the SMS TECademy has Arkansas, present for today’s unveiling of ASA. only been available in Germany,” said Shemwell. The agreement with our SMS colleagues an- “By partnering with SMS group, the Arkansas nounced today will advance ANC’s capacity as Northeastern College can become a satellite train- providers of steel technology training to the next ing hub for North America as a cost-effective way level, a global level.” ◆ to gain knowledge of cutting-edge techniques in steelmaking and processing.” The agreement between ANC and SMS group will allow companies to save the costs of overseas travel by providing a local option for the renowned Karsten Weiss TECademy training. Dunworth echoes these senti- [email protected]

02|2018 SMS group newsletter 59 NEWS

Dmitry N. Makarov, Director General at RUSAL ETC LLC, on the right side, and Patrick Schneider, SMS group, after signing the agreement.

RUSSIA COOPERATION WITH RUSAL The agreement covers the establishment of a manufacturing facility for innovative equipment to produce wire rod.

UC RUSAL announced the signing of a cooperation agree- and Russian intellectual development in general. I am sure ment with German company SMS group. The cooperation en- that cooperation with SMS group will become a powerful in- visages collaborative establishment of a manufacturing facility centive for the popularization of Russian technologies abroad,” for innovative equipment to produce wire rods, based upon commented RUSAL’s Technical Director Victor Mann. the unique technology of combined casting, rolling and extru- “Intellectual leadership has long been a guarantee of com- sion processes developed by RUSAL. The created technology petitiveness and business efficiency, so today’s event is aimed is RUSAL’s know-how, it provides an absolutely new approach at strengthening the company’s position in the global market. to wire rod production and enables to produce high-quality Developing its own technologies, SMS group is always focused products of special grades. According to the agreement, a on providing its customers with the most unique develop- joint enhancement of the production line installed at IrkAZ, ments, including in cooperation with our partners,” said Pat- Irkutsk, is planned for subsequent commercial sales of the rick Schneider, Head of Sales, SMS group. ◆ equipment worldwide on the base of SMS group capacities. “Partnership with one of the largest industrial companies in Europe is an important step for the development of the Patrick Schneider engineering and technological potential of both UC RUSAL [email protected]

60 SMS group newsletter 02|2018 IRONMAKING PLANTS

INDIA PRODUCTION START AT BPSL No.2 blast furnace of Bhushan Power & Steel Ltd. at Rengali, Odisha, commenced operations in November 2017.

Design and engineering for this completely new ironmaking sive package of BFXpert® models and modules including the unit have been executed by Paul Wurth. Orders for the equip- SACHEM® advisory system. ment supply were placed mainly in 2014. The furnace is de- The construction of the blast furnace and its auxiliaries was signed for a daily hot metal production of 4,450 tons. With a carried out by BPSL. The above mentioned technologies and hearth diameter of 9.6 meters, it has an inner volume of 2,015 systems and some other critical items like carbon blocks for cubic meters and is fitted with two tapholes and 25 tuyeres. the hearth have been delivered by the Paul Wurth group. Our Since this blast furnace is completely of Paul Wurth design, teams also provided continuous supervision services to en- it has a closed loop water cooling system with staves (both sure the quality of work in accordance with standards speci- copper and cast iron) over the entire height of the BF shell. It is fied by Paul Wurth. furthermore equipped with a Central Feed type Bell Less Top® After the furnace has been successfully built, tested and charging system, a modern gas cleaning plant with axial cy- blown in, Bhushan Power & Steel and Paul Wurth are now clone and annular gap scrubber, the company’s tuyere stocks jointly working on a fast and smooth production ramp-up. ◆ and TMT’s tapping machinery. Important sub-plants of Paul Wurth design are the INBA® slag granulation and the pulver- ized coal injection.

Big attention has been given to proper process control. Contact This is supported by a number of TMT’s probes and an exten- www.paulwurth.com

INTERNATIONAL COOPERATION The project involved services and Gas cleaning plant, supply executed by Paul Wurth furnace top teams coming from the company’s structure and hot subsidiaries in India, Luxembourg, blast stoves, BF 2, Italy, Germany, China, Russia and the BPSL. Czech Republic.

02|2018 SMS group newsletter 61 IRONMAKING PLANTS

CHINA TOP TECHNOLOGY FIRST Shandong Steel Rizhao commissions first Blast Furnace and applies Paul Wurth systems.

INBA® dewatering drum placed close to the casthouse.

In December 2017, Shandong Steel Group Rizhao blew in their The commissioning of BF2 is foreseen for summer this year. first Blast Furnace at a new production site which shall help to Paul Wurth also designed the coke batteries for this plant pro- phase out older ironmaking facilities in the group. Just a few ject and delivers the SOPRECO® single oven pressure control time later, the first hot metal has been tapped from the fur- valves and SUPRACOK™ L2 automation packages. ◆ nace for which Paul Wurth supplied top charging and slag granulation technology. The current phase of construction consists of two Blast Fur- naces with 5,100 cubic meters inner volume each. They become some of the largest BFs to be equipped with an original Central Feed type Bell Less Top® charging system. Furthermore, at each ® furnace, Paul Wurth’s INBA cold water systems with 2 dewater- Contact ing drums will ensure reliable slag sand production. www.paulwurth.com

62 SMS group newsletter 02|2018 METALLURGY AND ENVIRONMENTAL TECHNOLOGY

Poh Ming Koon, CEO of PMB Technology Berhad (center, standing), his team, and the SMS group team get together for the kick-off meeting.

MALAYSIA SILICON PRODUCTION PMB Silicon commissions SMS group to supply two submerged arc furnaces for the production of silicon.

PMB Silicon Sdn. Bhd., based in Sarawak, Malaysia, has A special feature is the rotating furnace vessels, which pre- awarded SMS group the contract to supply two submerged vent carbide precipitation in the furnace mix. With this plant arc furnaces for the production of silicon. The planned pro- PMB Silicon is securing its in-house silicon production. Silicon duction capacity is 32,000 tons of silicon per year. Commis- produced in this way is used as a main alloying element for sioning is scheduled for autumn 2018. the production of aluminum alloys in Press Metal Berhard SMS group‘s scope of supply includes the basic and de- machinery. ◆ tail engineering as well as the equipment for the 24-MW submerged arc furnaces, which essentially comprises two furnace-rotating gear units, the furnace vessels, gas hoods, the installation of a power supply and mains voltage compensation system, and the supervision of the erection and Martin Köneke [email protected] commissioning.

02|2018 SMS group newsletter 63 METALLURGY AND ENVIRONMENTAL TECHNOLOGY

The team of ArcelorMittal Bremen celebrated the successful retrofit together with SMS group.

GERMANY SUCCESSFUL IMPLEMENTATION OF WORLD’S FIRST HD SPRAY SYSTEM

SMS group successfully designs and installs the world’s first High Definition spray system at ArcelorMittal Bremen.

The new HD spray technology from SMS and deactivated is already being suc- group was implemented and successful- cessfully applied in a wide variety of sys- ly commissioned in the two-strand slab tems. caster at ArcelorMittal Bremen in No- Pneumatically operated pressure vember and December 2017. SMS group control valves and the related automa- retrofitted the two strands of the vertical tion system form the centerpiece of the bending caster one after the other and HD spray system. The secondary cooling put them back into operation within one water is distributed and controlled only month of one another. The goal of the just before the cooling nozzles. This retrofit was to improve secondary cool- makes negative influences such as long ing and slab quality. The continuous caster at ArcelorMittal control lines or pressure losses a thing Kai Küstner, Project Manager for the Bremen has been equipped with the new of the past. What‘s more, the use of HD HD spray technology. caster retrofit at ArcelorMittal Bremen: spray in combination with an air-water “We are very satisfied with the HD spray cooling system reduces process air con- technology. The SMS group team was very committed and sumption by 30 percent. SMS group’s scope of supply com- supported our trusting cooperation. This enabled smooth prised the entire basic and detail engineering, delivery and commissioning.” The HD spray system developed by SMS erection of the HD spray system and the new segment piping, group is a scalable water distribution and control system which as well as supervision of the commissioning. ◆ – compared to conventional solutions – requires far less space and pipework. The SMS group concept of control circuits Dirk Austermann across the width of the slab that can be individually activated [email protected]

64 SMS group newsletter 02|2018 METALLURGY AND ENVIRONMENTAL TECHNOLOGY

GREECE JAPANESE STEEL DELEGATION VISITS SHARC PLANT

Cost-effective steel production with low-grade scrap.

In December 2017 a delegation from the Iron and Steel Insti- tute of Japan visited the SHARC electric arc furnace plant (Shaft Arc - electric arc furnace with scrap preheating in the shaft) at Hellenic Halyvourgia (HLV) in Volos, Greece. The delegation comprised 19 representatives of eight Japanese electric steel producers. It was headed by Shigehiro Oi, Director, Member of the Board, Managing Executive Officer of Sanyo Special Steel. The delegation was welcomed by Andreas Metzen, Technical Director of Hellenic Halyvourgia. He and his team of engineers showed the delegation around the electric steel plant. The delegation was organized with the aim of exchanging ideas and information on the cost-effective production of steel, with special emphasis on steel production with low-grade scrap in the SHARC electric arc furnace. Delegation from the Iron and Steel Institute of Japan in front of the SHARC electric arc furnace at the Hellenic Halyvourgia plant. HOMOGENEOUS HEAT DISTRIBUTION IN THE FURNANCE SHELL tric arc furnace in the world operating with two shafts. Thus it can be charged with the least expensive scrap available in Greece, The SHARC at HLV is a 54-MW direct-current electric arc fur- currently at a purchase price of USD 15 per ton. The price advan- nace with a tapping weight of 100 tons. It features two symmet- tage varies depending on where in the world the scrap is pur- rically arranged preheating shafts for drying and preheating chased. In Turkey, for example, the same scrap grade costs the scrap. Other available scrap prehe ating systems are asym- around USD 30, in certain regions of China up to USD 50 per ton. metrical and have just one shaft. The design of the SHARC, Over the past ten years, in Greece the market volume for however, generates a fully symmetrical distribution of heat, long products has decreased from 2.2 million tons to 350,000 meaning that also in the furnace shell the heat distribution is tons annually. Nevertheless, Hellenic Halyvourgia has been homogeneous, producing minimum thermal load. able to maintain its profitability thanks to liquid steel produc- Especially the SHARC’s unique two-shaft design, which dou- tion in the SHARC furnace. The SHARC achieves maximum en- bles the available volume, allows the use of inexpensive, ergy savings compared to conventional electric arc furnaces - low-density scrap. The shafts with the built-in post-combustion without any coal in the charge. With less than 280 kilowatt systems make the furnace not only highly productive and effi- hours and an electrode consumption rate of 0.57 kilograms cient, but also easy on the environment. With a potential charge per ton of liquid steel, the SHARC process is a very cost-effec- of up to 65 percent of hot briquetted iron (HBI) in the shafts, tive steelmaking route. Not only that, due to the symmetrical the SHARC can also be used for the production of high-quality design of the SHARC, the coal rate for foaming slag is only nine long and flat products. kilograms per ton. Interested customers may coordinate a tour The delegation observed several heats using the SHARC pro- of Hellenic Halyvourgia with SMS group. ◆ cess with low-density scrap of 0.25 tons per cubic meter. The SHARC features the most economic and efficient scrap preheat- Jan Bader ing technology of all electric arc furnace types. It is the only elec- [email protected]

02|2018 SMS group newsletter 65 ELEKTRIK UND AUTOMATION

GERMANY MUCH SOUGHT-AFTER CONTINUOUS CASTING TECHNOLOGY Saarstahl AG commissions SMS Concast for supply of new continuous caster S1.

66 SMS group newsletter 02|2018 METALLURGY AND ENVIRONMENTAL TECHNOLOGY

• The soft reduction technology entails gentle forming of the strand shell in the final solidification stage, when the cast strand has reached a solidification ratio of approximately 0.3. • The resulting mixing effect has a positive influence on the segregation behavior and reduces the microporosity of the cast products. • Saarstahl AG has used solidification models developed yb SMS group ever since caster S0 was brought on stream.

Saarstahl AG, a world leading producer of wire rod, bar steel, lidification stage, when the cast strand has reached a solidifi- semi-finished products and forgings in a wide range of de- cation ratio of approximately 0.3. This forming effect has a manding grades, has chosen Zurich/Switzerland-based SMS positive influence on the segregation behavior of the cast Concast as suppliers for its new continuous casting plant S1. steel, as it presses the liquid steel in the final solidification This is the third continuous caster order in a row Saarstahl zone up against the casting direction, causing a mixing effect has placed with SMS group, after the casters S0 and S3. between the segregated steel of the sump and the less seg- Saarstahl holds a very prominent position among long regated liquid steel. Additionally, a harder reduction in the fi- product manufacturers. The company has been consistently nal solidification stage reduces the microporosity in the cast pursuing a clear-cut quality improvement strategy. At Völk- product. The success of soft reduction depends on how pre- lingen in Germany, Saarstahl produces 2.7 million tons of cisely the process controlled and tracked because the soft semi-finished products and 2.5 million of long products of reduction modules can only work properly if correctly adjust- sophisticated grades, including ball bearing, spring and ed relative to the solidification point. Therefore it is crucial to quench/tempered steels as well as cold-upsetting grades. know the exact position of the solidification point. For this, The company is world leading especially in the field of con- Saarstahl has used a solidification model developed by SMS tinuous casting technology. group ever since caster S0 was brought on stream.

SOFT REDUCTION TECHNOLOGY PLANT TECHNOLOGY OF CASTERS S0 AND S3

As early as in 2002, SMS group had supplied continuous cast- Caster S0 is designed to cast 150 x 150 millimeter and 180 x er S0 to Saarstahl. That plant was the first billet caster in the 180 millimeter billets in six strands, all of which feature soft world to consistently apply the technology of soft reduction. and hard reduction modules. The roller pairs (top and bot- This entails gentle forming of the strand shell in the final so- tom rollers) are combined in double modules of two pairs

CHRONOLOGY OF THE CONTINUOUS CASTERS

S0 S3 S1 Commissioning: 2004 2009 2019 Casting radius: 11 10.5 10.5 Number of strands: 6 5 5 Formats [mm]: 150 x 150 240 x 240 180 x 180 180 x 180 265 x 340 Casting speed [m/min]: 4.00 1.25 2.50 2.50 0.90 Hydraulic oscillation: yes yes yes Mold electromagnetic stirrer: yes yes yes Strand electromagnetic stirrer: yes yes yes Metallurgical soft reduction: yes yes yes Spray cooling: Air-mist cooling, 5 zones Air-mist cooling, 4 zones Air-mist cooling, 5 zones

02|2018 SMS group newsletter 67 METALLURGY AND ENVIRONMENTAL TECHNOLOGY

Continuous caster S3 in operation.

each. With the modules, each upper roller can be adjusted developed technology. The new caster will have the same separately. The double module design provides the advan- number of strands as S3. The machine head will come with tage that the distance between the rollers can be kept very the same proven design as caster S0: Convex molds with a small. This makes is possible to adjust the soft reduction pa- high-precision, spring-guided hydraulically actuated oscilla- rameters with utmost precision. After caster S0 was success- tion system. fully commissioned in 2004 and after introducing the soft The soft reduction modules will integrate the positive fea- reduction technology in billet casting, Saarstahl started to tures of previous designs. Particular emphasis will be placed use soft reduction also in bloom casting. on keeping the distance between the rollers small while In 2007, SMS Concast received the order for the con- achieving very high rigidity of the modules. This will be struction of a new casting plant S3 in place of an existing one achieved by arranging the rollers within reinforced double which was no longer needed. The number of strands was re- modules. Like the casters S0 and S3, also caster S1 will be duced from six to five because of the greater section sizes equipped with mold and strand stirrers. The automation and and for better accessibility. The new caster is designed to communication systems for the new caster will be consist- cast 240 x 240 millimeter and 265 x 340 millimeter blooms. ently in line with Industrie 4.0 standards. All strands are fitted with high-performance soft reduc- SMS group will also provide the complete discharge equip- tion modules. The greater section sizes require higher forces. ment, including the turn-over cooling bed, for the project. The Therefore the roller pairs are arranged in single modules. cooling bed will be designed to ensure that at the end of the bed the billets will have reached a temperature suitable for PLANT TECHNOLOGY OF CASTER S1 safe railway transport. The local space conditions called for the joint development of a suitable construction concept, includ- In 2017, Saarstahl ordered a third continuous casting plant, ing a solution to bridge caster S0. ◆ named S1, from SMS Concast, continuing the excellent cooperation that has existed between Saarstahl AG and SMS group for 15 years. The new caster will be designed to produce 180 x 180 millimeter billets in length between 6 and 13.5 meters. The annual production capacity will be 850,000 tons. Commissioning is planned to take place in the third quarter of 2019. It will also be erected in place of an existing older one and feature state-of-the-art technology. The plant concept will take into account the experience from the operation of the casters S0 and S3, resulting in a Dr. Stephan Feldhaus combination of existing operating know-how and further [email protected]

68 SMS group newsletter 02|2018 METALLURGY AND ENVIRONMENTAL TECHNOLOGY

Continuous casting plant S3, bow segment.

02|2018 SMS group newsletter 69 FLAT ROLLING MILLS

WORLDWIDE HIGH-QUALITY PRODUCTION The use of CVC®plus bending and shifting systems in finishing stands of hot flat rolling mills.

Manufacture of a CVC® system in the SMS group workshop.

70 FLAT ROLLING MILLS

® • The CVC system of SMS group combines a simple and efficient operating principle with robust and reliable mechanical equipment. • Over the years, manifold requirements paired with results from practical experience have led to constant advancement and increased lifetime.

The market for hot rolled strip is characterized by constantly growing demands on quality and a continuously rising share of newly developed, higher-strength steel grades. Coupled to the condition of having to produce flexibly and cost-effectively, this leads to ever higher requirements on equipment and Short-stroke CVC® system with integrated backup roll balancing process technologies. Ensuring high plant availability and system and a shifting stroke of ±150 millimeters. high stability of the rolling process are the prerequisites for economical production, in particular when high-strength, thin hot strip is concerned. The technology concept of SMS group, comprising various interlinked modules, offers a broad basis to satisfy all these requirements. Block operating side entry section Long-stroke shifting block Short-stroke shifting block CVC®PLUS

One example of such a technology module combining mechanical actuators, control systems and process models, is Bending the Profile, Contour and Flatness Control model PCFC®, with cylinder the patented CVC®plus work roll bending and shifting system being its most effective profile actuator. In 1980 already, the basic principle of CVC® (Continuously Variable Crown) was invented to perfectly supplement the established work roll bending system. It allowed work rolls Locking device with a special contour to be axially shifted and the resulting roll crown and hence the roll gap profile to be continuously Long-stroke and short-stroke CVC® systems. influenced. Parallel to the first use in practise, a pertaining technological process model (PFC) was developed on the basis of physical-mathematical approaches. This process model calculates, among others, the set values for the CVC® shifting and work roll bending systems. SUCCESSFUL PRODUCT The main mechanical components of this actuator are the CVC® bending and shifting blocks integrated in the finish- Within the next few years, the CVC® system was integrated in ing stands of hot flat rolling mills, CSP® plants and Steckel a large number of various types of hot rolling mills due to its mills. In addition to other products, such as hydraulic adjust- simple and efficient operating principle combined with ro- ing system, gear units, gear-type spindles, loopers and coiler bust and reliable mechanical equipment. As to the mechani- mandrels, CVC® blocks belong to the core products SMS cal systems, distinction is made between the so-called long- group manufactures in its own workshops. Following the stroke system with movable bending blocks and the invention of the CVC® basic principle in the 1980’s, SMS short-stroke systems with stationary bending blocks. The group equipped its own workshop with all mechanical ma- type of system to be used depends on the required shifting chine tools required for that purpose. stroke. Oval-shape pressure hulls allowed the cylindrical

02|2018 SMS group newsletter 71 FLAT ROLLING MILLS

100 ® plants worldwide have been equipped with the CVC system by SMS group since 1984.

bending cylinders so far employed for a shifting stroke of ance made the short-stroke CVC® system successful on the ±100 millimeters in the short-stroke system to be used for an market. Several plant operators conduct a first inspection adjustment range of ±150 millimeters, too. The new design, about five years after system installation. however, required the advancement of the manufacturing All process stages like design and accompanying mea- processes to make sure the new pressure hull contour was sures such as FEM analyses, manufacturing and installation provided with the necessary high surface quality and surface work as well as quality control were planned in-house, ad- properties. So, new manufacturing methods and processes, vanced and optimized to reach product maturity. Also includ- including pertaining machines and special tools, were imple- ed are, after-assembly in the workshop, all function tests on mented to meet these requirements. test facilities specially developed and built for that purpose. In addition to their different structures, the two CVC® systems come with different numbers of cylinders. Manifold re- CUSTOMERS SEE BENEFITS quirements in numerous implementations paired with results from practical experience have led to constant This led to an extremely reliable product ensuring high plant advancement and increased service life. Furthermore, the availability on the one hand and hot rolled strip of extraordi- short-stroke system offers the advantage of integrating the nary product quality and close tolerances on the other. And backup roll balancing unit in the fixed block. that is the reason why, over the last few years, SMS group has received a constantly rising number of inquiries and orders ESTABLISHED IN THE MARKET by customers who want to replace their work roll bending and shifting systems supplied by other suppliers with new Its robust design, the low number of individual parts and less short-stroke CVC® systems including the PCFC® Profile, Con- tolerance-related components impacting the window clear- tour and Flatness Control model.

FAST IMPLEMENTATION BY LOCAL PROXIMITY NUMBER OF CYLINDERS IN REFERENCE TO THE DIFFERENT CVC® SYSTEMS. To enable the experts of SMS group to quickly implement the customer-ordered modernizations and to ensure short deliv- Type of cylinder: Number of cylinders in Number of cylinders in ery times, all trades and processes involved in the product short-stroke system: long-stroke system: already start to coordinate and cooperate in the sales phase. Bending cylinders: 4 8 Apart from this organizational measures, it is the local pres- Locking cylinders: 4 8 ence and the cooperation of sales, order handling, development, design, production and service departments at all of OVERVIEW OF CVC® SYSTEMS SMS group’s locations that support the successful product DEPENDING ON THE SHIFTING STROKE. management of one of the most important actuators in the finishing stands of hot flat rolling mills.◆ Shifting stroke: CVC® system: ±100 – 150 mm Short-stroke system Ralf Setzer ±150 – 250 mm Long-stroke system [email protected]

72 SMS group newsletter 02|2018 MODERNIZATION FLAT ROLLING MILLS

The project teams after signing the contract (left to right): Konstantin Valuev (SMS group Liaison Office Director Magnitogorsk), Sergey German (Equipment and Services Purchasing MMK), Wolfgang Fuchs (Head of Hot Rolling Mills SMS group), Ralf Mackenbach (Electrical and Automation Systems SMS group), Marina Keller (Commercial Sales SMS group), Sergey Nenashev (Member of the Managing Board MMK) and Igor Gubanov (SMS group Moscow Liaison Office Director).

RUSSIA COMPREHENSIVE REVAMP OF HOT STRIP MILL

Reconstruction of the finishing train to expand product mix, improve product quality, and reduce operating and maintenance costs.

Magnitogorsk Iron & Steel Works (MMK), Russia, has commis- renew the drive technology in the finishing train and will sioned SMS group to revamp hot strip mill 2500 at its plant in supply six main drives, including converters, two new spur Magnitogorsk. In particular, the order includes the extensive gear and six pinion gear units, as well as new drive spindles. modernization of the finishing train equipment and the in- SMS group will also install new work and backup roll chang- stallation of a new automation system. ing equipment and a new high-pressure hydraulic system Pavel Shilyaev, CEO of MMK PAO, summarizes the goals of for the finishing stands. the project: “The revamp of our hot strip mill 2500 is part of The plant automation system is also to be thoroughly our strategy for 2025. We will gain a number of advantages updated by SMS group. This includes the Level 1 systems, from this modernization: We will expand our product portfolio, process models such as the Pass Schedule Calculation (PSC) we will be able to reduce our production costs, and our rolling for the roughing and finishing stands, Profile and Flatness mill capacity will be increased by 500,000 tons.” Control (PCFC®), Cooling Section Control (CSC), a pacing system for the entire hot strip mill, the X-Pact® Vision operating CUSTOMIZED REVAMP CONCEPT and visualization system, and an extensive range of measuring equipment and technology. SMS group will perform a The customized revamp concept, on which MMK and SMS Plug & Work test on the automation system before the re- group worked closely, represents a further milestone in the vamp. At the same time, the automation system is to be in- mutual trust and cooperation between the two companies. stalled in a test center, then tested and pre-optimized un- The revamp strategy proposes to complete the revamp in der realistic conditions. ◆ four shutdown periods by mid-2020. Hot strip mill 2500 was built in the 1960s and supplied by a Soviet manufacturer. As part of the modernization, the finishing stands will be fitted with new hydraulic adjustment systems and work roll bending systems. These powerful adjustment actuators will enable MMK to produce strip within Ralf Mackenbach close geometrical tolerances. In addition, SMS group is to [email protected]

02|2018 SMS group newsletter 73 MODERNIZATION FLAT ROLLING MILLS

FINLAND FAST MODERNIZATION OF A GEAR UNIT Over the past few years, SMS group, together with its customer SSAB in Raahe, Finland, has made strong efforts in the fields of improving quality, increasing production and minimizing costs.

The gear unit was transported by truck and ship.

74 SMS group newsletter 02|2018 FLAT ROLLING MILLS

CONCEPT ENGINEERING Concept engineering has proven an efficient tool in developing the best-possible technical and cost-effective solution for the customers of SMS group on the basis of a systemat- ical holistic plant analysis. The examination includes equipment, production process as well as maintenance.

Optimized manufacture in the SMS group workshop.

A key success factor of the good cooperation with SSAB is tions did not permit the gear unit to be installed the usual continuously implemented concept engineering. This was way by means of bay crane. Despite the additional effort for applied also to SSAB’s gear units when preparing them for transportation, positioning and alignment, it was possible to future required performance. During the last downtime in manage installation ahead of schedule. November 2017, SMS group replaced main gear unit F1 and mill pinion gear unit F3, including pertaining couplings and MILL PINION GEAR UNIT IN ADVANCED GEAR DESIGN intermediate shafts. The results of the previously conducted concept engineering were implemented at the plant in par- The mill pinion gear unit in advanced gear design is a allel. SMS group completely revamped the first three mill cutting-edge mill pinion gear unit able to transmit substan- stands and partly equipped them with new components. tially higher torques at the same overall size. Using the Thanks to perfect preparation and close cooperation with same space and existing anchor bolts, this gear unit offers the customer, it was possible to substantially shorten the the customer a longer lifetime and more safety for the new given downtimes. drive elements. ◆

100-TON REDUCTION GEAR UNIT

All components were manufactured in the Hilchenbach workshop of SMS group in compliance with extremely high quality standards. The over 100-ton reduction gear unit is one of the heaviest, single-stage reduction gear units ever made by SMS group. This gear unit had to be designed to Karl-Friedrich Müller exactly fit in the former place. Unfortunately, local condi- [email protected]

02|2018 SMS group newsletter 75 MODERNIZATION FLAT ROLLING MILLS

SLOVENIA READY TO ROLL Upgraded cold rolling mill for aluminum strip successfully commissioned at Impol d.o.o., Slovenia.

76 SMS group newsletter 02|2018 FLAT ROLLING MILLS

On November 25, 2017, Impol d.o.o., Slovenia successfully rolled its first aluminum strip on the upgraded cold rolling mill at its site in Slovenska Bistrica, Slovenia. In summer 2016, Impol Slovenia awarded the contract for the upgrade of their over 40-year-old cold rolling mill to SMS group Technical Services (UK) Ltd.. With this upgrade Impol has invested in the future viability of the plant and has brought about significant improvements. The range of coil dimensions has been extended, including larger coil diameters and increased width, with maximum coil mass doubled. Higher strip tensions now allow thicker strip to be rolled. What’s more, the strip quality conditions, particularly the thickness and flatness control, have been improved. To top it off, the strip dryness system was also optimized. The first alumnum strip was successfully rolled on November 25, 2017. FLEXIBLE PRODUCTION

To attain all this, SMS group adapted the founda- rolled strip, and provide flexibility in operation for tion and completely replaced the entry and exit treadplate production. equipment. New mandrels complete with out- The ancillary equipment for the coil handling board bearing supports were provided on the and the utility systems were also part of the up- new uncoiler and coiler to ensure larger, heavier grade. This included the integration of new coil coils can be safely handled. New change-speed cars, a pallet conveyor system for coils, including a gear units on the uncoiler, coiler and main drive strapping machine, and media systems for the hy- mean thicker material can now be rolled with a draulics and pneumatics. For SMS group, a huge higher torque. challenge with this upgrade was integrating the New strip threading equipment was also in- design plans for new components and units into stalled. The uncoiler was equipped with a new the existing space, while at the same time assisting strip centering system by EMG Automation GmbH, Impol to ensure compliance of the upgraded a company of SMS group, for example, which equipment with the latest European machinery guides the strip through the mill in a centered po- safety standards. However, the close cooperation sition – a prerequisite for a stable, perfectly wound of all parties involved was a significant factor in coil and optimum process control. As part of the safeguarding the future viability of the aluminum reconfiguration of the exit end, a new belt wrap- cold rolling mill at Impol in Slovenia to such an ex- per, configured for over- and under-winding, was tent that it compares well with a new plant. ◆ integrated to enhance the coiling quality of the

The project team is delighted about the successful upgrade of the aluminum cold rolling mill, which is ready and able to meet the challenging rolling tasks ahead. Rüdiger Roger Wiechmann [email protected]

02|2018 SMS group newsletter 77 FLAT ROLLING MILLS

Entry side view to “CRM 4” (in the front) and “CRM 5” (in the background).

78 SMS group newsletter 02|2018 CHINA ACCEPTANCE GRANTED On December 21, 2017, Tianjin Zhongwang Aluminium Co., Ltd. granted FAC of two cold rolling mills from SMS group.

With fast steps the second construction phase of the aluminum production complex of Tianjin Zhongwang Aluminium Co., Ltd. was moving towards completion. At the end of 2017, Tianjin Zhongwang took the first cold rolling mills on own au- thority and granted SMS group, the supplier, the so-called final acceptance certificate (FAC). Tianjin Zhongwang can now expect the full performance of the two cold rolling mills “CRM 4” and “CRM 5”, corresponding to a total annual capacity of 528,000 tons per annum. Both single stands in six-high design with CVC®plus are processing a large scale of aluminum grades and aluminum alloys in widths of 1,000 up to 2,150 millimeters. In terms of rollable thickness range they differ from one another. “CRM 4” is capable of rolling strips with maximum incoming thickness of 10 millimeters. The minimum attainable final gauge is 0.2 millimeters. The maximum entry thickness of the “CRM 5” with 0.8 millimeters is slightly thinner. It realizes a minimum final thickness of 0.1 millimeters. Both cold rolling mills are equipped with all available state-of-the-art rolling technologies and the X-Pact® electrical and automation system AluControl® by SMS group, ensuring prime quality, high yield and efficient plant operation. Each of the mills is additionally provided with a Multi Plate® filter for the efficient cleaning of the used rolling oil. ◆

Klaus Siegert [email protected]

02|2018 SMS group newsletter 79 BANDANLAGEN

U.S.A. STAINLESS STEEL STRIP FOR THE U.S. MARKET SMS group has supplied a 20-high cold rolling mill and a stainless steel bright-annealing line to North American Stainless (NAS). The facilities have an annual capacity of 95,000 tons each of cold rolled and bright-annealed steel strip. So, NAS, a subsidiary of the Spanish Acerinox Group, has the most powerful plants in the U.S.A. producing such material.

The new, stainless steel bright-annealing line of NAS stands out for its high efficiency, flexibility and product quality.

80 SMS group newsletter 02|2018 The hydraulic valve stands arranged on the mill stand platform are easily accessible and greatly simplify maintenance work.

The mill stand is equipped with hydraulic roll gap control and crown adjustment for backup shafts B/C and F/G as well as with inner intermediate roll shifting.

20-HIGH COLD ROLLING MILL The 20-high cold rolling mill is a MonoBlock mill, type MB 22B-54“, and processes hot strip thicknesses of up to 6.2 millimeters. The compact and robust plant comes with high mill stand rigidity. Featuring a maximum rolling speed of 800 meters per minute and a maximum rolling force of 8,000 kilonewtons, it can achieve thickness reductions of up to 90 percent. Auxiliary and ancillary equipment is also included in the scope of supplies. A regenerative SUPAFINE® filter system makes sure the rolling oil is eco- friendly purified and cooled. Ecological plant operation is further supported by a fume exhaust system meeting most stringent environmental provisions of the local authorities. To reduce non-productive times, an uncoiling station, including flattener and crop shear, is integrated in addition to two reversing reels.

02|2018 SMS group newsletter 81 STRIP PROCESSING LINES AND FURNACE TECHNOLOGY

All process parameters in the furnace are automatically set for high production and low resource consumption by a mathematical model.

BRIGHT-ANNEALING LINE In the bright-annealing line the strip first runs through the cleaning section. This step is followed by recrystallizat ion annealing in an oxygen-free inert gas atmosphere with high hydrogen content, in an all-electric vertical furnace from Drever International, a company of SMS group. The annealing process is performed at a temperature of up to 1,250 degrees Celsius in an inert gas atmosphere (up to 90 percent hydrogen) under overpressure to thus generate a A four-high skin-pass mill stand is integrated in the perfect glossy surface. The exit section of the facility exit section of the facilities to improve surface and is equipped with a four-high skin-pass stand and a flatness as well as the metallurgical material tension leveler for strip post-treatment. A side properties. Strip flatness is then perfected by a trimmer serves for strip edge straightening and cuts downstream tension leveler. Thereafter, both strip the strip to the desired width. edges may be straightened by a side trimmer.

In a two-stage cleaning section, the cold rolled strip is efficiently freed from rolling oil and other dirt particles.

82 SMS group newsletter 02|2018 The technological highlight of the bright-annealing line is the all-electric vertical furnace from Drever International. Due to its high efficiency, the energy consumption of about 220 kilowatt hours per ton is 60 percent lower than that of a conventional line concept with muffle furnace.

02|2018 SMS group newsletter 83 STRIP PROCESSING LINES AND FURNACE TECHNOLOGY

The bright-annealed strip is characterized by a mirror-finish surface. Typical applications are household appliances and kitchen utensils, but the materials are used in many other fields demanding high-quality, glossy surfaces in addition to the material properties of stainless steel; for example in medical engineering or in the transport sector.

Dieter Gruchot [email protected]

84 SMS group newsletter 02|2018 In the entry and exit sections, maximum strip speed reaches 75 meters per minute, whereas in the process section the material goes through at maximum 50 meters per minute.

02|2018 SMS group newsletter 85 STRIP PROCESSING LINES AND FURNACE TECHNOLOGY

INTERVIEW “THE STRIP PROCESSING LINES MEET ALL REQUIREMENTS”

SMS group delivered seven lines for the production of silicon steel strip to Beijing Shougang Co., Ltd. in Qian‘an, China. Between 2011 and 2013 all lines went into operation. Qi Jiebin, Deputy Director and Metallurgical Equipment Engineer of the silicon steel business unit at Beijing Shougang Co., Ltd, on the cooperation with SMS group, the technology and the silicon steel market.

Mr. Qi, when you look back at 2011, how was ticulousness and exquisiteness. The team had the start-up of the new lines? rich work experience and strong ability of trou- On the whole, the commissioning process went bleshooting. Any problem during project execu- very smoothly. All parties worked hard and hand tion was solved in time. The project management in hand. Furthermore, the quality of commission- of both parties established effective communica- ing was ensured even in a very tight project tion mechanisms, ensuring consensus on major schedule. That was the basis for the later-on safe issues as soon as possible. In conclusion, I am and stable operation. Also the Plug & Work inte- very satisfied with our cooperation and it is an im- gration test was very beneficial; it is a very ad- pressive memory for me. vanced and convenient process. High-permeability grain-oriented material is When you look back, what was crucial for your for sure very difficult to produce. How much decision to select SMS group as supplier of time did it need to get into the market for the your new production facility? high-grain oriented material? First of all, SMS is for sure a metallurgical player The silicon steel production process is very long with long-standing experience and a large num- and difficult, but the processing lines by SMS meet ber of successful references. In addition, the ap- all requirements of high grain-oriented silicon propriate design concept and know-how of SMS steel production. Certain local optimizations and was recognized by us through the technical ex- adjustments have been carried out, based on the change meetings. We also appreciate the earnest fact production technology has been adjusted. attitude and pragmatic spirit. All these things The first coil of high grain-oriented strip was made us choose SMS eventually. successfully produced in March 2012. The first 500-kV-transformer was placed in network opera- What do you appreciate about the cooperation tion in 2014, and in 2015, the production line with SMS group? reached the design capacity of 150,000 tons. In Every team member took his job conscientiously. 2017, successful application in the first 1,000-kV- Everyone shared the typical German spirit of me- transformer was accomplished.

86 SMS group newsletter 02|2018 QI JIEBIN, DEPUTY DIRECTOR AND METALLURGICAL EQUIPMENT ENGINEER OF THE SILICON STEEL BUSINESS UNIT AT BEIJING SHOUGANG CO., LTD.

What kind of products are you producing like TBEA, ABB, Siemens and General Electric. The today? products are widely used in 500-kV, extra- and ul- Today, Shougang produces the full range of silicon tra-high voltage (EHV and UHV) transformer man- steel strip products. Non-grain-oriented silicon ufacturing, and there is a major breakthrough in steel has formed four series which cover 86 prod- the project of State Grid Corporation of China to ucts. In 2016, our output of non-oriented electrical develop and manufacture an AC transformer with steel strips reached 1.29 million tons. This made 1,000 MVA/1,000-kV. Shougang the biggest producer of non-grain-oriented silicon steel in China and worldwide. When it comes to grain-oriented grades, Shougang “I am very satisfied with our implemented low-temperature heating technology, which made us globally one of very few compa- cooperation, and it is an impressive nies applying this process. Our products cover the memory for me.” thickness range of 0.30, 0.27, 0.23, and 0.20 millimeters in the quality range from 20SQGD070 to 30SQG120 according to our product nomencla- What is approximately the percentage of high ture. Also, small batch production of materials grain-oriented material concerning your total with a thickness of 0.18 millimeter is possible. grain-oriented production? With our high grain-oriented products we rank We’re producing all of our materials with the “low- among the first-class suppliers for the transformer temperature plus nitriding” technology and we’re industry. Our products have gained the certification producing 100 percent high-grain oriented mate- of worldwide well-known transformer enterprises rial!

02|2018 SMS group newsletter 87 STRIP PROCESSING LINES AND FURNACE TECHNOLOGY

88 SMS group newsletter 02|2018 Left: In two flattening and coating lines the high grain-oriented material gets its final treatment.

Below: Entry section of one of three decarburizing and coating lines.

SMS delivered seven lines for the production of silicon steel strip to Shougang: Two annealing and pickling lines, three decarburizing and coating lines, and two flattening and coating lines.

GRAIN-ORIENTED AND NON-GRAIN-ORIENTED Which industrial sectors are provided with the SILICON STEEL STRIP silicon steel strip you’re producing right now? Shougang electrical steel products serve the Due to its magnetic properties, silicon steel strip, also called electrical steel complete life cycle of energy saving, emission re- strip, is widely used in electrical engineering. With its beneficial magnetic properties it contributes to improve the energy efficiency in electrical systems and duction and environmental protection. The prod- thus helps save resources. Differentiation is made between non-grain-oriented ucts are widely used in power generation motors, and grain-oriented strip. In non-grain-oriented strip, the grain distribution is ir- transformers, air conditioning compressors, re- regular so that the material features isotropic properties. It is therefore used in rotating machines such as electric motors and generators. In grain-oriented frigerator compressors, EI iron cores, small and strip, the grains are oriented in cold-rolling direction. Owing to the high per- medium-size micro motors, and so on. meability and the lower losses in the direction of magnetization grain-orient- At present, one of two domestic inverter air con- ed strip is used for static applications, for instance in transformers. ditioners is made of Shougang electrical steel. Grain-oriented strip is usually classified by its degree of orientation into conventional and high grain-oriented strip. The production route of grain-oriented These air conditioners are also exported to over material is highly complex and features several steps which require sophisti- 20 countries worldwide. cated treatment concepts.

How do you expect the market for non-grain- oriented material to develop? Do you feel an increased demand due to the e-mobility trend? With the rapid growth of electrical vehicles in China and worldwide, we expect that the demand world efforts focus on extending the power grid will further increase. Also, the growing air condi- and making it more efficient. Thus, the demand of tioning industry leads to an increased demand for grain-oriented electrical steel will gradually in- non-oriented electrical steel. crease; especially the market for high-magnetic thin products will grow. ◆ And how will the market for grain-oriented material develop? In China, the National Energy Administration issued the plan of construction and transformation of the distribution network, and put forward that the investment in the distribution network should be no less than two trillion yuan (approx. 250 billion Eu- ros) from 2015 to 2020. At the same time, the Inter- national Energy Agency disclosed in the world energy investment outlook from 2014 to 2035, that the investment in the global power field will reach 16.4 Michael Haentjes trillion U.S. dollars worldwide. In many areas in the [email protected]

02|2018 SMS group newsletter 89 The first coil produced by Tosyali Toyo on its new electrolytic tinning line.

TURKEY SUCCESSFUL TINPLATE PRODUCTION IN TURKEY

Tosyali Toyo produces with new electrolytic tinning line from SMS group and grants FAC.

The new electrolytic tinning line of Tosyali Toyo Çelik A.Ş. suc- The tinning line satisfies with high-performance equipment cessfully started production in the steel mill for the produc- units. In the entry section, a side trimming shear with scrap tion of packaging materials in Osmaniye, Turkey. Now, Tosyali baller is integrated. The strip is prepared for tinning in a Toyo granted SMS group the Final Acceptance Certificate cleaning, tension leveling and pickling section. The tin coating (FAC) for this line. SMS group supplied the complete line to section contains one preconditioning cell and six electroplat- the Turkish-Japanese joint venture between Tosyali Holding ing cells. The applied tin layer is then treated in a fully induc- and Toyo Kohan. The line is designed for the production of tive heating reflow system. Finally, the strip is passivated and 255,000 tons of tinplate per year. During the process, a very dried. Along the tinning line, various measuring units are in- thin steel strip is electrolytically coated with a fine layer of tin stalled to ensure constant process supervision and control. as corrosion protection. The final material is used for the pro- In combination with the tin layer thickness measurement, duction packaging for beverages, food or aerosols. this achieves the highest possible product quality and pro- SMS group delivered this line to Tosyali Toyo as a systems duction efficiency. supplier and was responsible for mechanical equipment and The line is designed for strips with a gauge of 0.12 to 0.60 process technology as well as electrical and automation sys- millimeters and widths ranging from 700 to 1,270 millime- tems. Furthermore, an advanced evaporation system for ters. The grades produced are T1 to T5 and DR6 to DR10 rinse water treatment and electrolyte recovery as well as an materials. ◆ anode caster complemented the supply scope. The line is equipped with the soluble-tin anode technology offering proven economic, ecological and process technology-related advantages. Highlight features of this technology are low tin consumption, stable tinning conditions for optimum product Stefan Klose quality and precise process control. [email protected]

90 SMS group newsletter 02|2018 STRIP PROCESSING LINES AND FURNACE TECHNOLOGY

U.S.A. NEW PRODUCTION CAPACITY FOR TUBES AND BARS IN THE U.S.A. Advanced quench-and-temper facility from SMS group at TimkenSteel in full swing.

The new AQTF (Advanced Quench-and-Temper Facility) OD/ID water sprayer, characterized by high-quench severity heat-treatment line supplied by SMS group to TimkenSteel and, at the same time, great flexibility to adapt to changing Corporation at its Gambrinus Steel Plant in Canton, Ohio, process conditions. U.S.A. has commenced full commercial production. Extensive During the commissioning period, a full array of intensive testing was successfully completed in November 2017, and testing was carried out, beginning with the certification of the TimkenSteel issued the FAC (Final Acceptance Certificate) to combustion heating furnaces in accordance to the SAE SMS group. Carolee Vanicek, director of tube manufacturing at ASM2750-E standard, which calls for extremely demanding Gambrinus, declares: “We found that SMS was able to bring temperature homogeneity inside the furnace chamber (± 3 de- the best technology to meet our needs and satisfy our custom- grees Celsius for furnaces of Class 1), as a requirement for pro- er demand. The commissioning effort went very well, and SMS ducing aerospace-quality material. group has met all the expectations we had on the AQTF.” The Different seamless mechanical tubes and SBQ (Special new line is able to treat 10 tons per hour of bars and heavy- Bar Quality) products have been processed by the AQTF, walled tubes, up to 13 inches in diameter. from six inches to 12 inches (out of a selectable range from four inches to 13 inches). These products are made up of a INNOVATIVE COOLING PROCESS variety of different steel grades that reflects TimkenSteel’s vast portfolio. The tests were performed with increasing The compact line is characterized by a combination of in- throughput to stress-test all the line components. ◆ duction preheaters and combustion furnaces for austenitizing and tempering processes. Subsequent cooling takes Contact place in the newly developed Quenching Shell, an advanced [email protected]

The new advanced quench-and-temper facility by SMS group at Timken- Steel has the capacity for 50,000 process-tons annually of 4-inch to 13-inch bars and tubes for the automotive, industrial and oil and gas industries.

02|2018 SMS group newsletter 91 BANDANLAGENSTRIP PROCESSING LINES AND FURNACE TECHNOLOGY

Basic representation of plate treatment in a heavy-plate treatment line with MultiFlex- Quench® technology.

High-temperature roller Shot blaster hearth furnace

Descaling Hardening and normalizing

WORLDWIDE NEW TECHNOLOGY FOR PLATE COOLING MultiFlex-Quench® – setting new standards for plate cooling in heavy-plate heat treatment lines.

92 SMS group newsletter 02|2018 Low-temperature roller MultiFlex-Quench® hearth furnace

Cooling Tempering

® • The MultiFlex-Quench is a new technology for plate cooling in heat treatment lines. • Depending on the customer’s needs and portfolio, the MultiFlex-Quench® concept provides for multiple options and expansion stages. • Flexible cooling options permit a wide product range to be implemented.

SMS group has been successful in establishing in the market At the beginning of 2020, the new heat treatment line of its MultiFlex-Quench®, a new technology for plate cooling in Ilsenburger Grobblech GmbH, a subsidiary of Salzgitter Group, heat treatment lines. Flexible cooling strategies allow stan- will start operation. The production capacity there will be dard and special materials to be produced as well as newly more than 200,000 tons per year. For that line, too, the inno- developed grades with high quality demands. In 2016 already, vative MultiFlex-Quench® technology was selected to make the new MultiFlex-Quench® at SIJ Acroni in Jesenice, Slovenia, sure heavy-plate production at the Ilsenburg location in Ger- processed the first heavy plate. To this customer, SMS group many satisfies future requirements (for further information supplied a complete, new heat treatment line designed for an please refer to page 98). This means the MultiFlex-Quench® annual production of 80,000 tons of heavy plate. technology is used in the two cutting-edge heavy-plate

02|2018 SMS group newsletter 93 STRIP PROCESSING LINES AND FURNACE TECHNOLOGY

In addition to an extensive product portfolio, the plates treated in a MultiFlex-Quench® convince with their excellent flatness.

heat treatment lines. From an economical point of view, the The key process to set material properties is cooling. Lami- production of heavy plate will be particularly efficient, if it can nar cooling systems with U-shaped pipes have been widely also serve the growing market of new special steels and quar- used in heavy-plate mills since the 1950s. But when mate- to plates. The high-strength and ultra-high-strength plates are rial advancement required ever higher cooling rates and used in the growth sectors of wind energy, power technology, more flexible cooling patterns, this prompted the develop- tubes and pipes, mechanical engineering and crane building ment of spray cooling systems with pinch rolls. At the begin- as well as the construction industry. ning of the new millenium, this technology, usually a combi- At the same time, these applications, demanding excellent nation of spray and laminar cooling, became state-of-the-art. ductility and good weldability combined with perfect flatness, Advanced materials, however, demand for the micro- push the advancement of the material steel. To produce structure to be precisely set, which can only be achieved in state-of-the-art heavy plates all process parameters, from a heat treatment line. Since the 1960s, roller-type quenches austenitization to targeted cooling at optimized cooling with separate high-pressure (HP) and low-pressure (LP) speeds and further to adapted tempering temperatures and sections have been installed in heat treatment lines for times, must be in perfect harmony in order to tap the full po- plate cooling. But this measure only covered a limited pro- tential of the material steel. cess window mainly comprising the abrupt quenching method. DEVELOPMENT OF NEW COOLING TECHNOLOGY SMS group picked up the vast experience gained from FOR HEAT TREATMENT LINES spray cooling systems in the heavy-plate sector and, on the basis thereof, developed a new flexible cooling system for High-quality heavy plates are produced in heavy-plate mills heat treatment lines. This advancement of a proven tech- setting the material properties in a thermo-mechanical roll- nology generated the MultiFlex-Quench® in 2015.The new ing process, or in special heavy-plate heat treatment lines cooling technology permits numerous cooling rates and where the rolled plates are reheated, precisely cooled and patterns to be applied in heavy-plate heat treatment lines then tempered. and ensures a high degree of flatness.

94 SMS group newsletter 02|2018 The first MultiFlex-Quench® was commissioned at SIJ Acroni, Slovenia, in 2016.

FLEXIBLE COOLING WITH NUMEROUS OPTIONS ed for special heat-treated steels of high wear resistance ac- companied by high ductility at low temperatures. The high degree of flexibility, the wide product portfolio and For the treatment of crack-sensitive tool steels, the the very good flatness results of the MultiFlex-Quench® are MultiFlex-Quench® may be equipped with a separate nozzle mainly due to a variety of options for plate cooling, hydraulic cooling system. Combined with the integrated cooling model, plate clamping by pinch rolls and due to subdividing of all the system is able to exactly implement cooling rates and pat- cooling headers into several zones over the entire width. terns. This helps substantially shorten the average period The MultiFlex-Quench® concept provides for multiple op- needed so far for cooling such materials in calm air or by com- tions and expansion stages depending on the customer’s pressed air. Several nozzle options permit a large cooling area needs and production program. to be covered and ensure maximum flexibility. All cooling In the basic expansion stage, cooling header groups ar- headers are able to act upon a large area and come with a fine ranged in segments are fed with water from an LP system. nozzle distribution and an optimized design. This method is preferred for high-alloy steels where carbide precipitation after a solution annealing treatment is to be sup- MODELS AND PROCESS DEVELOPMENT pressed and also for crack-sensitive tool steels. If necessary, it is possible to operate some of the cooling The technological centerpiece is complex, thermal online pro- headers at higher water volumes and hence pressures in a cess models for cooling strategies. They cover a broad range customer-requested arrangement. This mode can be applied for the targeted setting of most different mechanical property for wear-resistant steels with good ductility and for high- combinations in the heavy plates. The use of proven physical strength and ultra-high-strength structural steels. If surface Level-2 online models, such as the SMS cooling model, makes hardness or hardness depth are to satisfy extreme demands, sure the process is precisely controlled. SMS group also sup- it will be possible to install a so-called slotted nozzle (curtain ports its customers in the development of new material head) in the entry section of the quench. It provides the high- grades. The focus here is on new heat treatment cycles which est possible cooling rates. Such special applications are need- will be deposited in the model after successful testing.

02|2018 SMS group newsletter 95 STRIP PROCESSING LINES AND FURNACE TECHNOLOGY

High cooling range for maximized flexibility.

Several nozzle options permit a Soft cooling large cooling area to be covered and ensure maximum flexibility. tool steels

Low-pressure cooling Crack-sensitive

High-pressure cooling Wear-resistant and high-strength steels

Curtain head Wear-resistant steels

Specific water volume

OPERATING RESULTS

The results so far obtained from operating with the MultiFlex- At SIJ Acroni, all options for targeted setting of cooling strate- Quench® prove that a broad spectrum of steels with most dif- gies as integrated in the MultiFlex-Quench® are applied with ferent cooling requirements is feasible without neglecting ho- good results, including the model-based mode for interrupted mogeneous material properties or high flatness. cooling of crack-sensitive steels. Numerous tests revealed that the flatness results meet the Compared to conventional roller-type quenches, the respective requirements independent of the thickness range MultiFlex-Quench® offers a distinctly more flexible, uniform and the cooling strategy. In many tests with a minimum de- and efficient cooling technology for heavy-plate heat manded deviation of less than five millimeters per meter, for treatment lines. ◆ example, all measurements were below two millimeters per meter. Furthermore, the tests demonstrated that a narrow spread of surface hardness within ±5 percent is technically feasible. In addition to an extensive product portfolio, the plates ® treated in a MultiFlex-Quench convince with their excellent Ingo Schuster flatness. [email protected]

96 SMS group newsletter 02|2018 BANDANLAGEN

High-temperature furnaces from SMS group heat heavy plates up to 1,100 °C , depending on the material. This is followed by controlled cooling in the MultiFlex- Quench® implementing different cooling rates and cooling patterns. STRIP PROCESSING LINES AND FURNACE TECHNOLOGY

GERMANY INVESTMENT IN THE FUTURE Ilsenburger Grobblech orders future-oriented heat treatment line with MultiFlex-Quench® from SMS group.

Ilsenburger Grobblech GmbH, a wholly owned subsidiary of With this investment in innovative technologies, Salzgitter is the Salzgitter Group, has awarded SMS group an order for taking a decisive step to make the Ilsenburg location fit for the supply of a new heat treatment line, project name “Ad- future challenges. The new facilities to be built there are to justage II”. The line is the centerpiece of a project initiated by process more than 300,000 tons of heavy plate annually. Salzgitter to strengthen the heavy plate activities at its Ilsen- Commissioning is scheduled to take place early in 2020. burg site in Germany. The new heat treatment plant to be supplied by SMS SMS group will supply a highly energy-efficient heat group to Ilsenburger Grobblech GmbH will essentially consist treatment line capable of fulfilling the customer’s extremely of a shot-blaster, two roller hearth furnaces, the MultiFlex- exacting quality and flatness requirements. The flexible Quench®, a plate leveler, a cleaning and priming line, and a cooling strategies enabled by the integrated MultiFlex- water treatment plant. Quench® will make it possible to produce a very wide range SMS group is also going to supply the electrical and auto- of products, also in extremely challenging grades. mation systems and implement the material and process

Heat treatment line including plate leveler, cleaning and priming line and water treatment plant.

98 SMS group newsletter 02|2018 With the MultiFlex- Quench®, SMS group has established a new innovative cooling technology in the market. The highly flexible cooling strategies enabled by the new system form the basis for the production of a wide range of current and future grades. (The photo shows the first MultiFlex- Quench® installation at Acroni in Slovenia).

models. Also all the ancillary facilities such as the plate convey- in terms of cooling strategies. Switchable pressure ranges al- ing system, complete with the cooling beds and the plate feed- low any cooling patterns from extreme slow cooling through ing and centering equipment, are part of the supply package. to abrupt quenching with freely selectable cooling stop tem- Additionally, the project will involve the relocation of equip- peratures to be implemented. This flexibility provides the ment from the Salzgitter location to Ilsenburg. possibility of producing a much wider range of products than would be achievable with conventional quenches. Optimal THIRD SINGLE-SOURCE ORDER flatness, especially of thinner plates, is ensured by hydraulic clamping by roller guides. This project will be SMS group’s third single-source supply of A low-temperature furnace installed in the line will be used a complete heavy-plate heat treatment line to renowned Eu- to temper (warm up) the plates. In this open-flame roller hearth ropean steelmakers in quick succession. At the same time, furnace, the plates can be tempered at temperatures between SMS group has established the MultiFlex-Quench® in the 300 and 750 degrees centigrade. A specially designed waste market as a new, innovative cooling technology that provides gas system provides for optimal convection within the furnace much more potential and flexibility than conventional cooling chamber, resulting in maximized temperature uniformity. systems. After the Slovenian heavy-plate producer Acroni, The leveler will be designed to handle plates between 5 Ilsenburger Grobblech will be the second reference world- and 25 millimeters thick and up to 500 degrees centigrade hot. wide for this new technology. All leveling rollers can be separately adjusted. Thus it is possi- The new heat treatment line is to anneal and further pro- ble to apply different leveling strategies in order to minimize cess more than 200,000 tons of heavy plate per year. It will be the internal stresses of the plates and achieve plates of very designed to handle plate in thicknesses between 5 and 175 good flatness. Driving the rollers separately makes it possible millimeters and widths up to 3,500 millimeters. The between to distribute the torques and use different roller diameters 4 and 24-meters-long plates will weigh up to 28 tons. The within one set of rollers. material grades to be processed will include high-strength Ilsenburger Grobblech GmbH (ILG) is a subsidiary of carbon steels, highly wear-resistant steels, steels for offshore Salzgitter AG, one of Europe’s leading steel technology and pressure vessel applications as well as case-hardened groups. The about 750 employees of ILG produce approx. and quenched/tempered steels. 700,000 tons per year of heavy plate in about 350 steel grades for most diverse fields of application. This makes ILG MUCH WIDER RANGE OF PRODUCTS one of the leading heavy plate producers in Europe. ◆

For hardening and normalizing, the plates will be heated to temperatures of up to 950 degrees centigrade in a high-temperature roller hearth furnace. The furnace will feature two chambers with different temperatures. The plates will be heated by radiant tubes in a nitrogen-based inert gas atmosphere.

A large portion of the plates will be cooled in the downstream Contact MultiFlex-Quench®, which provides extremely great flexibility [email protected]

02|2018 SMS group newsletter 99 FORGING TECHNOLOGY

1 2 4 5 3

SMX forging line.

WORLDWIDE THE PIPE FORGING LINE – NOVELTY FROM ONE SOURCE Apart from the classic SMX forging lines, the plant portfolio of SMS group now includes pipe forging lines.

• The SMS radial forging machine is particularly suited for cus- The centerpiece of a pipe forging line is the SMX radial forging tomers who also produce pipes in different sizes and quali- machine. In addition to standard materials, sophisticated ma- ties in addition to massive semi-finished products. terials such as high-alloyed steels or nickel materials, titanium • The piercing process with inductive reheating is made inte- alloys or even composites made of centrifugal casting can be grated - unlike the classical lines. Mandrel changes along processed to forged pipes. with mandrel lubrication are automated. SMX PIPE FORGING LINE

The SMX pipe forging line of SMS group is particularly suitable for customers who want to produce pipes in different sizes and a variety of grades in addition to massive semi- finished products in their product mix. For a rare niche market with small or medium-sized batch sizes the classic SMX

100 SMS group newsletter 02|2018 FORGING TECHNOLOGY

SMX FORGING LINE 1 Rotary hearth furnace 2 Ent ry roller table 3 Loading manipulator 4 Hydraulic radial forging machine 5 Unloa ding manipulator 7 6 Exi t roller table 7 Tool changing device 8 Con trol stand

Inhomogeneous block temperature after piercing.

forging lines are better suited from an economic viewpoint. The technological difference is in the production of the hollow block. In a conventional SMX forging line the hollows are pierced outside the line in one separate heat on an open-die forming press or produced by the centrifugal casting method or the ESR process (Electro-Slag Remelting). In contrast, the piercing process in an SMX pipe forging line with subsequent reheating is integrated in the line. A vertical SMS piercing press pierces blocks made of steel or special metal in short cycle times. The used block present in the SMX pipe forging line is not After piercing the block loses heat energy, particularly at forged in one heat but is inductively reheated. The process both ends. The temperature of the block is inhomogeneous sequence selected can be compared with the extrusion of and for high-alloyed materials also below the optimal forging steel pipes. Another special feature of the SMX pipe forging temperature. Therefore, the pierced block must be induc- line is mandrel handling. The greater variety in pipe sizes tively reheated in a vertical furnace prior to forging. IAS, a requires a large number of mandrels. In an SMX pipe forg- company of SMS group, offers customized solutions. ing line mandrel change as well as mandrel lubrication

02|2018 SMS group newsletter 101 FORGING TECHNOLOGY

Forged pipes 352 x 28 millimeters, ratio of extension 2.6 made of UNS N 08028.

are automated. A mandrel manipulator is integrated in the inner pipe surface must be machined after forging. Even loading manipulator. Here, the mandrel is fixed to a pinlock large wall thickness tolerances of +/- 15 millimeters which serving as quick-change device enabling fast mandrel may occur on an open-die forging press during shell piercing change after each pipe forging. The used mandrel is cooled are reduced to much smaller eccentricities between 1.0 and with water and then sprayed with lubricant in a fixture. Af- 2.6 millimeters when pipes are forged on an SMX. terwards, the mandrel can be reused in the next forging. Demanding materials which cause problems during For an SMX 800/18MN the entire pipe portfolio includes seamless pipe rolling or which cannot be rolled during the pipes with manufacturing diameters from 150 to 500 millim- cross-rolling process due to defect formations can be forged eters and wall thicknesses between 27 and 100 millimeters perfectly on hydraulic radial forging machines of the SMX for manufacturing lengths of up to 10 meters. Even greater type. On the SMX, for example, pipes of nickel material UNS pipes can be produced on an SMX 1100/22 MN with a tool N 08028 were forged containing more than 30 percent nick- opening of 1,100 millimeters and a forging power of 22 meg- el. These pipes are employed in the chemical and petro- anewtons. Depending on the intended use, the outer and/or chemical industry as well as in oil and gas exploration in acid

Microstructure near inner surface, centrifugally cast shell 42CrMo4 Microstructure, centrifugally cast composite pipe, material after forging. transition after forging.

102 SMS group newsletter 02|2018 FORGING TECHNOLOGY

gas fields. Titanium pipes and ratios of extension up to 4.0 OUTLOOK can also be forged without problems at forging temperatures between 800 and 830 degrees Celsius. Due to rising energy costs, a continuous development of the Furthermore, pipes were forged from premachined cen- hydraulic radial forging machine SMX is currently focusing trifugally cast shells. The surface of the forged pipes is excel on a reduction in energy consumption. Corresponding con- lent and the microstructure after forging shows a fine cepts were developed. Whether temperature- and pres- bainite with grain size 8 to 9 (acc. to ASTM E 112). The former sure-resistant tubes and pipes for power plants, anticorro- cast structure has completely dissolved. High-alloyed cen- sive oilfield tubulars or wearproof mechanical tubing – the trifugally cast shells made of material 1.4404 also behave new SMX pipe forging line leaves nothing to be desired by similarly. Pipes made of centrifugal composite casting were the customer. ◆ forged for the first time. The outer shell consisted of low- alloyed steel 42CrMo4 and the inner part of high-alloyed austenitic steel 1.4404. The forged pipe 283 x 36 millimeters (ratio of extension 3.5) is characterized by a faultless material transition. The former cast structure has completely dissolved. With the so-called “step-forging“ it is possible to selec- tively vary the outer pipe diameter. For different inner diam- Dr. Hans Pelster eters within a pipe shaping mandrels can be used. [email protected]

Forged pipes 277 x 32 millimeters, 42CrMo4, ratio of extension 4 (left) and 302 x 42 millimeters, 1.4404, ratio of extension 2.5 made of centrifugally cast shells (right).

02|2018 SMS group newsletter 103 Multi chamber melting furnace Ecomelt-PS.

SPAIN RECYCLING CAPACITY EXPANDED Aludium Amorebieta orders multi chamber melting furnace from Hertwich Engineering.

104 SMS group newsletter 02|2018 FORGING TECHNOLOGY

The long-standing aluminum rolling mill in Amorebieta, Spain, pre-heated and decoated material is immersed in the melt which has been operating under the name Aludium since bath moved by a liquid metal pump and is melted instanta- 2015, has ordered an Ecomelt-PS275 multi chamber melting neously with minimal melt loss. furnace with preheating shaft for clean and contaminated As a further special feature, the melting furnace has a sepa- scrap from Hertwich Engineering, an SMS group company. rate feed for scalper chips, which are fed into the furnace This investment sees the plant adapting to the growing immediately after machining of rolling slabs and are also amount of recycled material available. The new multi cham- melted using the submersion melting process with the great- ber melting furnace will go into operation in spring 2019. est possible yield. To be able to process the growing amount of return scrap The rolling mill in Amorebieta started the production of effectively and economically in the casthouse, the melting ca- rolled aluminum products in 1961. The plant has been con- pacity is increased by investing in a modern multi chamber tinuously expanded and modernized, since 1985 initially as melting furnace of the type Ecomelt-PS275. The throughput part of the INESPAL group and since 1998 under the direc- is 275 tons per day. Loose and packaged strip or foil scrap, tion of Alcoa. Since 2015, the plants in Amorebieta and Ali- coils, wire, etc. are melted – each contaminated by oils, lac- cante (both Spain) as well as Castelsarrasin (France), along quers, plastic residues, rubber or other coatings. with the research site in Cindal, form the Aludium Group, a Depending on the type and composition of the scrap, fully integrated network specializing in the cutting, rolling Hertwich offers different furnace types within the Ecomelt se- and refining of aluminum. ries. The PS type furnace ordered by Aludium Amorebieta is The Amorebieta plant includes hot and cold rolling ca- suitable for scrap with the highest contamination rates. It pacities as well as strip processing and a casthouse for roll- comes with a preheating shaft into which the scrap is fed ing slabs. Contrary to the general market trend towards “Au- from above through a material lock. The hot gases flow tomotive” and “Aerospace”, the strategic focus here is on through the charged material in the shaft from the bottom the sectors “Building and Construction”, “Distribution” and upwards, and the pyrolysis gases produced thereby are com- “Specialities”. ◆ busted in the main chamber. By using pyrolysis gases (but also due to the advanced furnace design) the gas consumption can be reduced to some 300 kWh/ton (depending on the scrap input). This reduces operating costs and the minimum emissions (CO2, CO, NOX, dioxins, VOC, no salt) contribute to an environmentally friendly furnace operation.

AFTERBURNING NOT REQUIRED Contact External afterburning is not necessary as all emerging py- www.hertwich.com rolysis gases are combusted in the main chamber in a con- Further information trolled manner. At the lower end of the shaft, the completely www.aludium.com

02|2018 SMS group newsletter 105 MODERNIZATION PRODUCTION

106 SMS group newsletter 02|2018 U.S.A. TWO NEW WHEEL SETS FOR TWIN-DRIVE GEAR UNIT The two output wheels supplied by SMS group are the biggest case-hardened gears on the American continent.

02|2018 SMS group newsletter MODERNIZATION PRODUCTION

• For its aluminum plate rolling mill with twin-drive gear unit, the U.S. customer ordered new, ready-to-install wheel sets from SMS group. • Gear wheels of four meters diameter and a weight of 130 tons cannot be manufactured in the U.S.A. so far. • The new wheel set will improve the gear unit’s efficiency - load capacity alone will be enhanced by approx. 30 percent.

Both wheel sets were manufactured in the Hilchenbach The twin-drive gear unit of SMS group. The work rolls are driven workshop of SMS group in Germany and have a diameter of by two separate gear units accommodated in one housing. four meters and a weight of 130 tons each. Until now, it has been impossible in the U.S.A. to manufacture case-hardened gear wheels of that size, since there is no equipment avail- stand distinctly higher loads to produce the future-planned able for heat-treatment of such components. higher-strength products for the automotive and aviation industries, the aluminum producer decided for the new wheel INCREASED PERFORMANCE set with case-hardened gearing. This enhances the load capacity of the gear unit by approx. 30 percent. In the year 2002 already, SMS group supplied for the customer’s aluminum plate rolling mill a twin-drive gear unit TWIN-DRIVE GEAR UNIT showing no visible damage until now. Also the examination of the gearing didn’t reveal any defects. However, statistics tell Work rolls of roughing stands and heavy-plate mills are often that the service life of several anti-friction bearings had ex- directly driven without using a gear unit. The drive train with pired. For that reason, the longtime customer contracted twin-drive gear unit installed at the customer’s plant offers SMS group to supply new, ready-to-install wheel sets al- the advantage of attaining comparatively high rolling torques though simple replacement of the anti-friction bearings even at very low speeds. In addition, the investment for this would have sufficed. But due to the high degree of plant utili- drive train is much lower as the motors used there are sig- zation, the customer could not afford, from an economical nificantly smaller, and stock-keeping of a spare motor, if so point of view, a plant downtime and possible installation risks desired, is cheaper for small motors. ◆ involved in replacing the bearings. Complete wheel sets can be exchanged faster and present lower risks. The new gears replace the existing wheel sets and thus increase the perfor- Klaus Lazzaro mance of the gear unit. As the rolling mill will have to with- [email protected]

Top motor Twin-drive gear unit Top motor

Drive shafts Drive shafts

Bottom motor

Work roll direct drive: Slow-running motors with high output torque. Work rolls driven by two gear units in one housing (twin-drive gear unit): Smaller motors make the overall system including gear units considerably more cost-effective.

108 SMS group newsletter 02|2018 TECHNICAL SERVICE

Online monitoring thanks to Genius CM®.

WORLDWIDE EARLY WARNING SYSTEM AGAINST PLANT DOWNTIMES

Genius CM® monitors the condition of wear-prone components.

The Chinese company Baosteel and the Italian warned in case of critical situations. Therefore, company ILVA S.p.A. relied on the know-how of Genius CM® opens up completely new dimen- SMS group for early warning systems against sions for optimizing quality and availability. plant downtimes and signed two contracts last Delivery of the early warning systems and on- Further information year for the supply of Genius Condition Monitor- site installation took place in 2017. Thanks to on the subject ing Systems (Genius CM®). Genius CM®, SMS group’s customers get results Genius CM® can be Genius CM® is a modular designed online quickly – even with complex applications. ◆ found in the plant monitoring system controlling and docu- brochure menting the current condition of plant compo- “Genius Condition nents subject to wear and failure. Compared with Monitoring Sys- traditional inspection and maintenance methods, tem – early warn- the advantage is permanent monitoring of plant ing system components. This enables operators to be con- Claus Wilk against failures“. stantly informed about the actual condition and [email protected]

02|2018 SMS group newsletter 109 MODERNIZATION TECHNICAL SERVICE

IRAN SUCCESSFUL PARTNERSHIP CONFIRMED SMS group‘s Technical Service receives follow-up order from Mahshahr Pipe Mill Company.

Mahshahr Pipe Mill Company (MPM) has signed a compre- er electronics and regulate the welding current by fully digital hensive service and modernization contract with SMS group means. As a result, the level of efficiency attained by the weld- for its large-diameter pipe mill in the Chuzestan Province in ing units is over 90 percent. Depending on the working point, Iran. With this contract, MPM and SMS group are continuing energy savings of up to 30 percent can be achieved com- their successful cooperation. pared to older welding techniques. What’s more, productivity In 2016, an interdisciplinary team of specialists from SMS can be increased by up to 20 percent, with process stability group and MPM conducted an audit aimed at inspecting the remaining at consistent levels throughout. current mainte-nance status of the large-diameter pipe mill As well as the welding equipment, both X-ray testing located in Mahshahr, not only in terms of compliance with ap- units are to be replaced, so as to ensure maximum pipe plicable standards but also against known benchmarks. Over- quality while boosting the output capacity of the overall all, the assessment included areas such as production, mainte- plant. Also the entire hydraulic control system is going to be nance, management, administration, and compliance with replaced. The aging MX4 hydraulic control system is being occupational health and safety regulations. A comprehensive replaced with a latest-generation Indra Motion MLC L75 service and modernization contract has now been agreed control system. based on the list of recommendations compiled by SMS group The plant will also be equipped with the new SHAPE au- following the audit. tomation system, which controls the forming process based on a continuous calculation of the optimum forming param- INCREASING PRODUCTIVITY eters. This minimizes any potential negative influences from

“The modernization and maintenance concept devised by SMS group will not only provide us with premium technology, but also with sustainable growth. This is a significant future-orient- PREVENTIVE MAINTENANCE ed step that will enable us to safeguard our competitiveness The IMMS® (Integrated Maintenance Management System) is and increase our production performance,” says Ehsan a package of proven software and valuable information. Shahrokhi, Purchasing & Procurement Manager of MPM. To establish a reliable basis for maintenance the system The service and modernization concept developed by maps the complete plant, including all components to be SMS group is tailored to MPM’s specific plant parameters and serviced, and integrates technical parameters. requirements and includes, for example, the overhaul of the Maintenance is exclusively target- and purpose-oriented. ® complete pipe welding equipment. Digital PERFECT arc This increases the economic efficiency and availability of the welding power sources are to be used for the welding units. plant as well as the final product quality. These work with insulated gate bipolar transistor (IGBT) pow-

110 SMS group newsletter 02|2018 TECHNICAL SERVICE

The service and modernization concept developed by SMS group is tailored to MPM’s specific plant parameters and requirements.

the starting material and will support the operator. The Each component subject to maintenance will be clearly SHAPE technology developed by SMS group provides our marked and coded (plant tree) in order to ensure targeted customers a competitive edge in terms of quality compared and purposeful maintenance approach as well as cost-ef- to conventional systems. fective management of the large-diameter pipe mill. As part of the technical assistance agreement, the entire “Once all the measures stipulated in the contract have large-diameter pipe mill in Khuzestan will be examined for been imple-mented, we will be in a position to guarantee the faults and disruptions, which will be eliminated successively. same level of plant performance as in case of a newly built This entails not only identifying the necessary spare parts but plant. With its willingness to invest, MPM is making a signifi- also optimizing production sequences. In order to achieve its cant contribution to the further development of the country. ambitious future goals, Mahshahr Pipe Mill Company is also With our service and modernization concept for MPM, we are investing in the know-how of its employees. SMS group is go- doing our bit to enable MPM to profitably produce and sup- ing to provide numerous on-site training courses. ply pipes and tubes of premium quality,” says Oleg Vilents, Over and above this, SMS group’s Technical Service Maintenance Consultant at SMS group. team will be assisting MPM with the deployment of an ef- Mahshahr Pipe Mill Company, a subsidiary of Sadid Indus- fective maintenance organization, aimed at improving trial Group, is a leading manufacturer of pipes, primarily in- preventive maintenance measures to improve the avail- tended for use in gas pipelines with diameters ranging be- ability of the plant and the quality of the finished products tween 24 and 56 inches and wall thicknesses of up to 35 in the long run. To this end SMS group is supplying IMMS®, millimeters. Thanks to the use of state-of-the-art technology, an integrated maintenance management system. IMMS® MPM is a well-established player not only in the domestic is a combination of tried and tested software and valuable market, but also in the Middle East and internationally. ◆ information, building on decades of maintenance experience. In order to create a reliable basis for an effective maintenance organization, the entire MPM plant will be Oleg Michael Vilents mapped and all technological parameters integrated. [email protected]

02|2018 SMS group newsletter 111 MODERNIZATION TECHNICAL SERVICE

Pendulum shear gearbox before the repair. Pendulum shear gearbox after the repair.

SOUTH KOREA LOGISTICS RIGHT ACROSS TWO CONTINENTS FOR A REPAIR Hyundai Steel, South Korea contacted SMS group for the repair of its pendulum shear gearbox.

After two sub-suppliers of Hyundai Steel had seen no possi- “I was deeply impressed when I bility to completely repair the gearbox, an expert of SMS group traveled to Dangjin-Si Chungnam, South Korea, to get saw the repaired gear - it looked an on-site impression of the condition of the gear. During the inspection one should determine the type of work required like a new one. All measures to reinstate the gearbox. However, the challenges were were explained in detail, so I was greater than initially assumed. The inspection revealed, among other things, that the housing was distorted. Since able to comprehend the repair.“ machine tools on the one hand and know-how for such re- Dae-Young Kim, Manager of Hyundai Steel Dangjin Steel Works pair measures on the other hand are available in the SMS group factory in Hilchenbach, it was immediately decided to transport the gearbox to Germany.

PENDULUM SHEAR GEARBOX AWAY ON TRAVEL SMS GROUP AS LEADING PARTNER

The gear was transported by ship from South Korea to Ger- The condition of the customer for the repair to happen in Ger- many. Customer’s wish was to additionally measure the many was that the gear had to be fully operational on site at whole gearbox three-dimensionally. For the 3D measure- the end of 2017 in any event. Here, SMS group proved to be a ment customer’s employees even traveled to Germany so competent and reliable partner. Despite unforeseeable nec- that the measurements could be jointly performed by staff essary new orders of individual parts the repaired gearbox members of Hyundai Steel and SMS group. was delivered to South Korea on time. Cooperation between After having consulted the customer, all measures were Hyundai Steel and SMS group turned out to be excellent. ◆ executed ensuring that the gearbox is again in a good condition both mechanically and qualitatively and is fully opera- Dr. Klaus Ginsberg tional also in future. Among others, the parting line of the [email protected] upper housing part was reground and the bearing bores Michael Wahl were enlarged. [email protected]

112 SMS group newsletter 02|2018 MODERNIZATION TECHNICAL SERVICE

INDONESIA MOTOR OPERATING WITH FULL POWER AGAIN Overhaul and repair of DC motor at SMS group’s Indonesian workshop.

For its Indonesian customer PT. Artas Energi Petrogas (Artas) helped to save time and money,” Mr. Rinaldi Santosa, Work- located in Cilegon, a complete repair and overhaul of a 2,000- shop Manager SMS Indonesia. kW DC motor was done by SMS group at its service workshop The SMS workshop in Indonesia was founded in 2014 in Indonesia. Artas’ DC motor is used for the production of and has a repair area of 2,200 square meters. The modern seamless steel pipes for the oil and gas industry in Indone- machine park normally offers repair services for spindles, sia’s first seamless tube plant. AGC cylinders and mandrels as well as refurbishments for The scope of work included the complete loading and un- caster rolls and mold plating. ◆ loading, disassembling, repair, overhaul and assembling. Af- ter the final acceptance test together with the customer, the motor was dispatched within the contracted delivery period Rinaldi Santosa and reinstalled right away. “A repair directly on the doorstep [email protected]

Heat treatment furnace for drying the motor.

02|2018 SMS group newsletter 113 TECHNICAL SERVICE

WORLDWIDE INTELLIGENT MANAGEMENT The copper plate 4.0 of SMS group informs the plant operator constantly on the current condition of the mold plates.

The sensor for sensor is well protected being attached to the mold sides out- copper plates side the casting area where lower temperatures exist and the developed by SMS group process itself is not affected. An enclosure protects the sensor records the against external influences such as contamination and water operating state vapor, while the data communications interface is safeguard- of the mold. ed via Near Field Communication (NFC). The sensor provides a microcontroller. A built-in NFC chip saves the captured data assigning them in a date-related manner. The sensor module saves the serial number of the copper plate, the manufacturer and other copper plate-related data at the factory. At a specific point in time and via an associated mold manager the plant operator receives a general overview on: Plate thickness, Operating time and History of individual plates. The data are prepared by means of the mold manager and An optimal mold condition and the correct maintenance in- displayed on the website in graphic and tabular form. In this terval are crucial for top strand quality and smooth opera- way, the plant operator receives a complete stock and status tion of continuous casters. However, there is no uniform overview of his copper plate fleet. Plate thickness is displayed rule for the wear of copper plates. Depending on the re- by means of coloring in the style of traffic lights. The sensor is spective process condition, mold plates wear out at differ- integrated in the copper plate requiring no cabling for opera- ent rates. This makes it all the more important that the re- tion. It may also be attached to competitor copper plates en- maining copper plate thickness of all plates in circulation is abling also such plates to be recorded by the plate manage- known to the plant operator. If needed, replacements can ment. thus be ordered by the customer in good time, the mold plate combination be precisely planned during mainte- CUSTOMER DATA ARE SAFE nance and the cooling characteristics be integrated due to a thinner wear layer and higher heat transition, particularly The system is only activated by express consent prior to its first when producing critical qualities. The copper plate sensor use via Android-based handheld device or Smartphone. Mea- developed by SMS group and the associated mold manager sured data are read out by means of handheld device, record- software enables plant operators to obtain an overview at a ed on an internal database and displayed accordingly. ◆ glance of the decision-relevant information concerning their entire copper plate fleet.

WEAR AND OPERATING TIME

A sensor integrated in the copper plate by SMS group measures plate thicknesses and utilization or operating times for Heiko Klose automated recording of the operating status of the mold. The [email protected]

114 SMS group newsletter 02|2018 EVENTS

JAPAN MARKET EXPANSION IN JAPAN The first HybrEx® symposium and the “Open House Day” at Yasuda Metal Industries Ltd. in Japan.

After Yasuda Metal Industries Ltd., based in Osaka, Japan, Industries demonstrated their installed extrusion plants in- had placed an order for a HybrEx®14 extrusion press in cluding the new HybrEx®14 that has been successfully in 2015, Japanese media introduced it as the first HybrEx® in- operation since 2016. stalled in Asia. It attracted the attention of other Japanese aluminum manufacturers confronted with the higher de- PARTICIPANTS SHOWED GREAT INTEREST mands for aluminum from the growing automotive industry. This offered SMS group a good opportunity to introduce its The day was concluded with a lively discussion and ex- HybrEx® and related technologies to other interested com- change of information headed by Mr. Tatsuaki Yasuda, Pres- panies. ident of Yasuda Metal Industries. All contributions clearly The HybrEx® symposium in Japan took place in Nagoya illustrated the high interest of the participants in HybrEx® city in October 2017. The selected aluminum companies technology and in its outstanding energy saving options and participated in the presentations and the factory tour at Ya- potential to increase productivity. ◆ suda Metal Industries afterward. The SMS group experts presented the highlights of HybrEx® technology and its latest developments as well as related equipment for the extrusion presses such as handling systems and heating tech- Dr. Hansjörg Hoppe nologies. At the factory tour, the specialists of Yasuda Metal [email protected]

First HybrEx® symposium and open house at Yasuda Metal Industries in Japan.

02|2018 SMS group newsletter 115 EVENTS

KENYA AFRICAN STEEL INDUSTRY IN THE SPOTLIGHT 3rd Cold Rolling & Processing Technology Day in Nairobi

Speakers, here Pieter Bezuidenhout from SMS group, received thank you badge from the organizer

On November 24th, 2017, the third “Cold Rolling ed by an own booth and in total three confer- & Processing Technology Day” presented by ence contributions, provided by the product Steel Group Association in cooperation with SMS divisions cold rolling mills, strip processing lines group took place in Nairobi, the capital of Kenya. and technical service. Steel Group Association was founded in 2010 in India and offers to representatives of the steel NUMEROUS GREENFIELD PLANTS industry a successful platform for communica- IMPLEMENTED tion and networking. And yet Steel Group especially looks after new, maturing markets. Torsten Seeger, Project Director in the Business Attended by approximately 130 participants, Division Flat Rolling Plants of SMS group, pre- the third “Cold Rolling & Processing Technology sented the reversing cold mill type of plant in sin- Day” took place in the Kenyan capital of Nairobi. gle-stand or twin-stand construction, featuring The conference was themed “Empowering steel optimized design for moderate investment and industry in Africa“. Among the participants were low operation cost. Thanks to its flexibility and high-level decision makers and executive man- upgradability, this type of mill is especially conve- agers from the local cold strip industry, suppliers nient to emerging, developing and reorganizing of rolling mill technologies as well as consultants, markets. In recent years, SMS group was capable looking for new investment opportunities for in- of implementing numerous greenfield installa- vestors. SMS group was prominently represent- tions in emerging markets, offering guidance to

116 SMS group newsletter 02|2018 Torsten Seeger, SMS group, at the Lamp Lighting Ceremony, performed during the opening of the conference. Imprint SMS group newsletter Issue 02 /2018

Publisher SMS group SMS group booth at the Corporate Communications, 3rd Cold Rolling & Eduard-Schloemann-Straße 4 40237 Düsseldorf, Germany Processing Technology Editing: Jan Euler Day in Nairobi, Kenya. Phone +49 211 881-0 E-mail: communications@ sms-group.com www.sms-group.com

Printing and prepress processes Druckhaus Kay GmbH Hagener Straße 121 57223 Kreuztal, Germany

African cold strip producers for particular invest- Published on ment decisions. March 29, 2018 © SMS group Esmech Equipment Private Limited, a company Circulation: German 4,000, English 12,000, of SMS group, was represented by Vijay Pitale, Chinese 1,000, Technical Director Strip Processing Lines. He Russian 1,000 presented a paper about the V-JET Air Knife Sys- The information provided in this tem as an advanced solution for zinc coating magazine contains a general description of the performance weight control and coating surface appearance. characteristics of the products concerned. The actual products The third paper presented by SMS group, may not always have the charac- Pieter Bezuidenhout, Managing Director SMS teristics described and, in particular, these may change as a group Technical Services South Africa (Pty) Ltd., result of further developments of the products. The provision of completed the proposal by offering the current this information is not intended and future movers and shakers of the African to have, and will not have, legal effect. An obligation to deliver steel industry a comprehensive technology part- products having particular char- nership for innovation, including supply support acteristics shall only exist if expressly agreed in the terms of and services. ◆ the contract.

Torsten Seeger [email protected]

02|2018 SMS group newsletter 117 Welded Tubes_A4_e.indd 1 welded. or submergedarcwelded,longitudinallyspirally production – no matter whether high-frequency (HF) … inallprocessesforweldedtubeandpipe And weareyourpartner! and closerpipetolerances-theseareyourgoals. effective processes,more challengingdimensions Even betterquality, moreflexibleandcost- THE RIGHTPROCESSTOMEETEVERY REQUIREMENT a: +492161350-1851 [email protected] Fax: +49 2161350-1515 Phone: 41069 Mönchengladbach, Germany Ohlerkirchweg 66 SMS group GmbH LSAW -large-diameterpipe plants. AND PIPEPLANTS WELDED TUBE entire valuechain,together. your competitiveedge.Let’s addvaluealongthe application. Evenmore:allthissubstantiallyboosts narrow producttolerances,andabroadfieldof As aresult,youbenefitfromhighcost-effectiveness, Leading partnerintheworldofmetals ERW -weldedtubeplants. Spiral pipeplants. www.sms-group.com 15.02.18 09:39

2018 80 forging lines. by innovativeportfolio pipe SMX SMS group expands plant INNOVATION 100