Producing Efficiently 08.10.–10.10

40237 Düsseldorf, Germany E SMS group always meettheconstantlyrisingchallengesofmarket. From thermalpre-treatmenttoreshapingandrefining,we comprehensive offeringintheareaofaluminumproduction. around theworld,thismeansbeingabletocountona team member,isthefoundationforsuccess.Toourcustomers Being abletotrustintheexpertiseandperformanceofevery Trust... duard-Schloemann-Strasse 4 Solid competenceforthealuminumindustry

Fax: Phone:

+49 21 +49 21 1 881-4902 1 881-0

Internet: E-mail:

www.sms-group.com [email protected] Confidence throughperformance electrical engineeringandautomationsolutions. production cycle,includingtheintegrationoflatest our solidprocessknow-howencompassesthecomplete Whether innewplantconstructionorrevampprojects,

– D

Aluminium 2014 Aluminium

SMS group. üsseldorf, Germany üsseldorf,

October 7-9, 2014 2014 7-9, October

SMS group at group SMS

all 9 all

Bild tauschen 20

The MAGAZINE OF T HE SMS GROUP ISSUE 02 / 2014 e P be keptcompetitive. The SMSgroupshowshowalsoolder plants can 50 yearsisnotoldageforsteelmaking plants. ffi ro d c u i e c nt ing ISSUE 02 T he MAGAZINe ly

2014 OFT HE SMSGROUP Contents sms group newsletter 02 / 2014 Events

Anniversary

24 Salzgitter Flachstahl invests in new plant equipment. Metix celebrates tenth anniversary

Plant building experts from South Africa: Imprint SMS group Newsletter Metix. At the end of 2013, Metix celebrat- Issue 02 | 2014 ed its tenth anniversary with customers ISSN 00000000 Contents Publisher and staff members in Johannesburg, SMS group Corporate Communications, Eduard- South Africa. In his address held during Schloemann-Straße 4 the ceremony, Dr. Guido Kleinschmidt, 40237 Düsseldorf, Germany Phone +49 211 881-0 Starting on page six Member of the Managing Board of SMS E-mail: communications@ Siemag, emphasized that it was the right sms-group.com of this Newsletter, you www.sms-group.com decision to make Metix a member of the Responsible according to can read how older German press law SMS group. Metix is an expert in building Dr. Thomas Isajiw plants for the ferroalloys industry. The Printing and prepress production plants can processes company holds a leading market posi- Druckhaus Kay GmbH become competitive Hagener Straße 121 tion in southern Africa. 57223 Kreuztal, Germany

again through modern- Published on July 31, 2014 /© SMS izations. group / Circulation in German 6,200, in English 11,500 / Printed in Germany

The information provided in this magazine contains a general description of the i performance characteristics of the products con- In focus – Modernization Events 2014 cerned. The actual products may not always have the characteristics described and, in particular, these 01.09.–02.09. EPEC Conference – European Plant Engineering Committee | 04 In brief 08 Revamps made 20 Next generation may change as a result of Düsseldorf, Germany further developments of the products. The provision of 122 Events by SMS cold rolling mills this information is not in- 09.09.–11.09. The 7th European Oxygen Steelmaking Conference | Trˇ inec, Czech Republic tended to have and will not ® 125 Imprint Even plants as old as fifty The X-Roll 2.0 cold rolling have legal effect. An obliga- 11.09.–13.09. ANKIROS 2014 – 12th International Iron-Steel and Foundry Technology, tion to deliver products years are not ready for the technology offers convincing having particular character- Machinery and Products Trade Fair | Istanbul, Turkey istics shall only exist if ex- scrap heap yet, thanks solutions for plant upgrades pressly agreed in terms of the contract. to smart modernization and newly built plants. 15.09.–17.09. European Steel Environmental Congress 2014 | Teesside, UK concepts. 19.09.–26.09. metal Form China 2014 | Beijing, China 24 Almost like newly 21.09.–24.09. Euro PM 2014 | Salzburg, Austria 16 Fit for the future built 23.09.–26.09. International Trade Fair for Transport Technology | Berlin, Germany Paul Wurth and ArcelorMittal Salzgitter Flachstahl installs The SMS group newsletter app is Ghent set benchmarks when new converter vessels and a 24.09.–27.09. Tube China 2014 - The 6th All China International Tube and Pipe Industry now available on the App Store and Trade Fair | Shanghai, China it comes to increasing the ef- new ladle turret. More information on Google Play. ficiency of blast furnaces. 29.09.–03.10. 19th International Forgemasters Meeting | Tokyo, Japan about upcoming events is available 27 Towards a secure 06.10.–08.10. Furnaces North America Conference 2014 | Nashville, U.S.A. Trust...

THE MAGAZINE OF THE SMS GROUP at: www.sms-group. ISSUE 02 / 2014 2014

/ ISSUE 02 ISSUE future 07.10.–09.10. Aluminium 2014 | Düsseldorf, Germany com/conferences.php

SMS group at Aluminium 2014 OF THE SMS GROUP THE MAGAZINE At Aluminium Norf, SMS October 7-9, 2014 Düsseldorf, Germany Hall 9C20 PRODUCING EFFICIENTLY 08.10.–10.10. 34th SENAFOR | Porto Alegre, Brazil

Bild tauschen 50 years is not old age for steelmaking plants.

Solid competence for the aluminum industry The SMS group shows how also older plants can be kept competitive. Being able to trust in the expertise and performance of Whether in new plant construction or revamp projects, our Siemag is upgrading the every team member, is the foundation for success. To our solid process know-how encompasses the complete produc- customers around the world, this means being able to count tion cycle, including the integration of the latest electrical on a comprehensive offering in the area of aluminum produc- engineering and automation solutions. tion. From thermal pre-treatment to reshaping and reﬁ ning, we always meet the constantly rising challenges of the market. Conﬁ dence through performance – SMS group. 15.10.–17.10. AluExpo 2014 SMS group | Istanbul, Turkey Eduard-Schloemann-Strasse 4 Phone: +49 211 881-0 E-mail: [email protected] 40237 Düsseldorf, Germany Fax: +49 211 881-4902 Internet: www.sms-group.com roughing stand and the edger, 01_SMS_Umschlag_EN.indd 1 21.07.14 11:45 and extending the rolling mill 23.10.–24.10. Southern Africa Roll Users Conference 2014 | Vanderbijlpark, South Africa Cover photo Slabs in the new stainless steel plant of with an additional roll stand. Fuxin Special Steel in China. The works was supplied by 26.10.–28.10. The Arab Steel Summit 2014 | Dubai, United Arab Emirates SMS Siemag.

2 125 Contents

32 Severstal Columbus trusts in SMS. 82 Tulachermet orders steelworks. 114 Premiere of environmental concept.

Markets Projects Innovations

32 Fascination steel 42 sms Siemag Service In an interview, Madhu G. 44 Paul Wurth Ranade, Vice President of 46 metallurgical technology Ecoplants Severstal Columbus, speaks 51 steel refining 102 Precision in about the development of his 54 Continuous casting plants company and tells us why 58 Hot rolling mills perfection ® he trusts in technology from 63 Cold rolling mills The Morgoil bearing: SMS Siemag. 66 Aluminum plants A classic is turning 60. 70 strip processing lines and 36 service in the veins furnace technology 112 Center for cooling With 15 workshops and 100 80 Electrics and automation technology years of experience, SMS Cooling tests under real-life Millcraft are the number one 84 sms Meer conditions. service experts in the U.S.A. 84 Steelmaking/Continuous casting technology 114 Efficient production (long product mills) 84 Tube & pipe plants of stainless steel 88 Long products plants First implementation of an environmental concept at Fuxin 93 Forging plants Special Steel. 95 NF metals 98 Heat treatment technology

3 sms group newsletter 02 / 2014 in brief

SMS group SMS group N ew spokesman N wo in Japan

Since April 4, 2014, Burkhard Dahmen has been Spokesman of the Managing S ince April 1, 2014, Board of SMS Holding GmbH. Dahmen will remain President & CEO of sMS SMS group KK has been Siemag AG. Dr. Joachim schönbeck, present on the Japa- longstanding President & CEO of SMS Meer GmbH and previous Spokesman nese market. “Being the of the Managing Board of SMS Holding worldwide only full-range GmbH, left the sMS group on March 31, 2014. supplier of machinery and plants for the metals industry, we look forward to rendering

SMS Meer effective local support to our customers in Japan E xpanded production via our newly established company there,” said SMS Meer Engineering China (SMEC) nents for wire rod and tube plants, has increased its manufacturing ca- forging equipment and finishing Dr. Guido Kleinschmidt, pacity in shanghai, China. through plants. sMEC also provides services Member of the Manag- the expanded facilities, the company for everything to do with commission- can offer its customers an enhanced ing and site management services for ing Board of SMS Siemag portfolio. The new workshop covers a its customers. AG, at the opening cer- floor area of 12,500 square meters. The product range includes compo- www.sms-meer.com emony in Tokyo. With a production volume of 111 million tons in 2013, Japan is the third-largest steel market in the world after China and the Euro- pean Union (EU).

www.sms-group.jp

4 in brief

Paul Wurth acquires license SMS Mevac Construction of DRI plants N we at the top

In March 2014, Paul Wurth s.A. and process is the market leader in gas- The Management of SMS Mevac GmbH Kobe Steel of Japan signed a license based reduction processes. Under in essen underwent a reorganization agreement for the construction of this license agreement, the sMS as of April 1, 2014. Markus Hüllen (pho- Midrex® direct reduction plants. Ac- group is entitled to market, design to), previously Head of the technical counting for approximately 60 percent and erect Midrex plants around the Department, has assumed the position of global DRI production, the Midrex world. It will also provide the group of CEO. He will be assisted by the au- with access to new markets in which thorized representatives of the Manag- abundant, inexpensive natural gas ing Board, Markus Dietrich, also newly is available, such as in the Middle appointed as CFO, and Michael neu- East and South and Central America. mann, COO.

Shohei Manabe, Executive Officer, Kobe Steel, and Head of the Iron Unit Division, and Marc Solvi, Chief Executive Officer, Paul Wurth, shake hands after signing the construction license agreement.

SMS Meer N ew Board Member

With effect from April 1, 2014, Marcel Fasswald SMS India (photo) has been appointed Member of the Manag- ing Board of SMS Meer GmbH, Order Handling and Technology. Fasswald was previously Managing Di- N ew Head rector of SMS India Pvt. Ltd. The Board of Manage- ment of SMS Meer also includes Jens Barth, Sales, Effective April 1, 2014, Christian Klein and Torsten Heising, Commercial. assumed the position of Managing Di- rector of SMS India Pvt. Ltd. in Gurga- on. He succeeds Marcel Fasswald who is now a member of the Managing Board of SMS Meer in Mönchenglad- Drever International S.A. bach. Christian Klein, aged 48, has been with the company since 1993. Most recently, he was Head of Design NwOe CE Gas Cleaning Systems.

As of July 1, 2014, Dr. Fritz Brühl assumed the position of Chief Executive Officer at Drever International S.A. in Liège, Belgium. In parallel, he will retain the position of Executive Vice President of the Furnace Technology Di- vision. Effective July 1, 2014, Jean-Marc Raick will take over the function of CTO on the Managing Board of Drever.

5 InIn FocusFocus sms group newsletter 02 / 2014

PRODUCING EFFICIENTLY

Frequently enough, old plants cannot keep up with the young generation in terms of product variety, quality and economic efficiency. The SMS group offers plant operators concepts for comprehensive modernizations which boast individual solutions that even make plants as old as fifty years fit to keep pace with the competition.

6 InIn FocusFocus — ModernModerniizatzationion

Overview

Convincing: Revamps made by SMS 8 Refreshed: Blast furnaces now boast enhanced efficiency 16 Redefined: High-tech solutions for cold rolling mills 20 Completely overhauled: Continuous casting plant almost like newly built 24 Towards a secure future: Biggest aluminum rolling mill to be upgraded 27 In FocusFocus sms group newsletter 02 / 2014

A successful project implemented by NLMK DanSteel and SMS Siemag was the upgrade of the heavy-plate mill.

8 In Focus — Modernization

R EVAMPS MADE BY SMS

New production plants for steel or aluminum boast greater product variety, higher quality and, frequently enough, lower operating costs. Old plants are often not able to keep up with the young ones. However, smart modernization concepts may prevent machines as old as fifty years from being thrown on to the scrap heap.

ith the modernization of our heavy-plate mill, MP 1600 type closed-die forging press, we have set a milestone in terms of sustain- supplied by SMS Meer in 1987, was fit- able growth,” says Allan Thomasen of NLMK ted with a new main drive and a new DanSteel, Denmark. Thomasen, Project Man- automation system, resulting in higher W plant availability. “Since the plant ager at NLMK DanSteel in Fredericksvaerk, was the person in charge of the plant upgrade implemented in 2012. Having overhaul performed by SMS Meer, our run for more than 50 years, the mill received a new roll downtimes have markedly decreased,” stand, a new hot-plate leveler and new electrical and auto- says Stephan Baron, Project Manager mation equipment. “We are now able to produce plates of at Hirschvogel. Fewer plant down- Allan Thomasen greater widths and with a wider range of thickness. Through times are a key benefit provided by this, we can open up new markets,” adds Thomasen. Proj- modernizations. operators also often Project Manager at ect partner was SMS Siemag – with its experts experienced have their plants overhauled in order NLMK Dansteel in in everything to do with the modernization of steel and non- to improve the quality of their products Fredericksvaerk. ferrous metals plants. and expand the product range. “The requirements of the market, that is the A PLANT OVERHAUL REDUCES DOWNTIMES end users, have become increasingly Especially during the boom years from 2005 through 2010, exacting during the last few years,” ex- new plants were built in great numbers. “There are times in plains Burkhard Dahmen, Spokesman which the customers prefer to modernize and times in of the Managing Board of the sMS which they will rather decide in favor of a newly built plant. group. “At the same time, plant opera- Actually, we provide the customers with machines and tors aim to improve their profitabil- equipment perfectly tailored to their needs in terms of ity, for example by lowering quality and machine availability,“ explains Johannes the operating costs and Kahlen, executive Vice President service, sMS Meer. A reducing the mainte- plant upgrade is often the less expensive option compared nance effort.” the com- to a new investment, especially as an upgrade may be im- panies of the SMS group, plemented in various stages and initially tailored to current which build plants and ma- needs. With the right modernization measures implement- chinery for the steel and nF- ed, even older machines will continue to be able to com- metals industry, are experts not pete. The heavy-plate mill at NLMK DanSteel is just one out only in building brand new plants, but of many examples. Also Hirschvogel Umformtechnik GmbH particularly also in plant upgrades. in Denklingen, Germany, opted for a modernization. An During the last ten years, the SMS

9 In Focus sms group newsletter 02 / 2014

With the latest automation systems developed by the SMS group, plant operators are always one step ahead.

Siemag Business Area alone has successfully complet- i ed modernization projects at more than 250 plants. the FACTS + FIGURES corresponding figure for SMS Meer is barely lower. This is experience on which the plant operator can rely. When it Innovative X-Pact® products increase comes to revamps, the SMS group offers convincing solu- Product quality tions for the entire process chain of metallurgical plant en- IPQS® Integrated Product Quality System analyzes, gineering. From the blast furnace and continuous casting documents and optimizes the product quality plants all the way through to closed-die forging plants. “By offering the right modernization concept for each plant Productivity type, we improve our customers’ competitiveness,” says Plant Condition Advisor Dahmen. Michael Heupel, General Manager Repairs and monitors the plant condition in order to support the maintenance management Modernizations, SMS Meer Service Europe, adds: “We offer plant operators customized repair and modernization con- PPS®-Level 3 (Production Planning & Scheduling) cepts and implement these concepts together with our plans and schedules the production from the customer order all the way through to the dispatch order customers until the plant is up and running again. Espe- cially in the fields of closed-die forging, extrusion, and wire Ladle Management System and tube welding, we can build on a wealth of project expe- optimizes ladle logistics and ladle utilization rience accumulated by our employees.” Energy efficiency Energy Advisor FOUR STEPS TO SUCCESS monitors, measures and optimizes energy consumption Four points are critical to a successful plant modernization: on a plant-wide level a detailed analysis of the present plant status, an intelligent FEOS® (Furnace Energy Optimization System) modernization strategy, good planning and preparation and provides energy-optimized control of the EAF operation top technologies aligned to the specific requirements of Gas Cleaning Assistant each individual customer. “Our experts have all these four controls and regulates the gas cleaning plant in an points in mind,” adds Dahmen. energy-optimized fashion First, the SMS engineers analyze the existing plant and review which areas should be renewed. “The basis for a successful modernization is to determine the status of the existing plant,” explains Stephan Krämer, Executive Vice President Hot-Rolling Mills, SMS Siemag. “We analyze the equipment, the product range and the technological processes against the future requirements. Quite often, we are able to reveal hidden potentials as early as in this first phase.” Following this survey, SMS draws up a moderniza-

10 In Focus — Modernization Most recent references

Three peeling plants 400-ton converter Dongbei Special Steel, China ThyssenKrupp Steel Europe, Germany Three peeling plants of types WDH50, Vessel, trunnion ring, lamella suspension WDH75 and DDH20 were overhauled in 2013. system, vessel supporting bearings, bearing Results: better surface quality and closer pedestals diameter tolerances. tion concept, taking into account the specific plant parameters and customer wishes. the plant downtime during the reconstruction phase is planned with utmost scrutiny together with the customer. Like in the case of newly built plants, the SMS group uses Virtual engineering for this purpose. Individual measures become visually perceptible to all parties involved and complex processes can be assessed, ensuring that the customer’s requirements are met. Blast furnace relinings Hot strip mill Arcelormittal Temirtau, Kazakhstan SSAB, Sweden WORKING DURING RUNNING OPERATION Paul Wurth modernized blast furnaces 2 and Modernization of the plant from the laminar 3. The project included new cooling systems cooling system through to the coil transport One central objective always is to keep and plant technology from charging through including electrical and automation equipment the downtimes as short as possible. To to tapping. for the production of high-strength grades. this end, SMS Siemag and SMS Meer preassemble and test the replacement equipment in their workshops. this also happened to the roll stand and the hot-plate leveler for the heavy-plate mill modernization at NLMK DanSteel, which were both assembled and tested in SMS Siemag’s workshops. “In order to minimize production losses, we plan to perform as many on-site activities as possible with the plant still in operation. At the same time, we must see to it that all safety precautions are taken,” states Krämer. At salzgitter Screw press Hot strip mill Flachstahl, for example, SMS Siemag’s Wuxi Turbine Blade, China ThyssenKrupp Steel Europe, Germany experts exchanged the ladle turret of a SMS Meer replaced the screw and the tie Installation of a new edger and crop shear, rods on the SPKA 11200 screw press. modernization of the finishing mill and the continuous slab caster in no more laminar cooling system, new X-Pact® electri- than six hours. This does not mean cal and automation systems.

11 In Focus sms group newsletter 02 / 2014

that it is not possible to flexibly react to changing requirements, as was necessary when we revamped the slide, slide guide and pressure rod of the eccentric press in the precision forging shop of Sona BLW in Remscheid, Germa- ny. Damaged parts had been hidden in the old plant and only became visible when we were installing the new equipment. “We are very satisfied with the result,” says Stefan Schäfer-Kuhl, Maintenance Manager at sona BLW. “De- spite all difficulties, the SMS Meer team complied with the tight time schedule.” Beside the mapping of the status quo and a smart strategy, diligent preparation is another essential factor. For example, new electrical and automation systems are tested and preoptimized in the SMS Siemag test fields in Hilchen- bach. The Plug & Work procedure has proved successful in both newly built plants and modernization projects. This approach also provides the opportunity to train the customers’ operating staff and make them familiar with the new automation system. “The testing takes away a great deal of pressure which we would otherwise have to cope with during our on-site activities,” says Frederic Schultheis, Electrical Engi- neering Manager at Ma’aden-Alcoa. For Ma’aden-Alcoa, SMS Siemag is currently building several aluminum plants in Saudi Arabia. During migration to a new automation sys- 178 projects tem, operation in changeover mode minimizes the risk of failure. The changeover mode involves the successive test- Approximately every third continuous caster project is a moderni ing and optimization of new functions with the possibility of zation. Recently, the CSP® plant at Nucor Berkeley (U.S.A.) was switching back to the old system whenever necessary. modernized; in early 2014, JSW Dolvi (India) placed an order for the modernization of the CSP® continuous caster and of the automation and drive system of the CSP® plant. HIGH-END EQUIPMENT CONVINCES When all systems are running smoothly, the old automation system is switched off. “We applied the procedure successfully during the commissioning of the automation system of the existing heavy-plate mill at Dongkuk steel in South Korea,” states stephan Krämer. Also at Dongkuk 90 plants Steel, SMS Siemag for the very first time equipped an exist- ® ing heavy-plate roll stand with CVC plus technology. This Since 1949, Paul Wurth has modernized 90 blast furnace plants provides the possibility of rolling with greater reductions worldwide, including 20 in the last 15 years. In the future, moderniza- especially in the last passes, increasing production and tion projects will become even more important. complying with tighter shape and flatness tolerances. Also the quality of the new equipment is crucial to the success of a modernization. Because only if well-engineered and proven equipment and systems are used, will plant operators benefit from a modernization. “We supply high-quality equipment designed for around-the- 34 percent clock operation of metallurgical plants and guar- Worldwide, 34 percent of all hot strip mills are older than 30 years. anteeing a very high On the other hand, 30 percent of all hot strip mills are younger than level of availability ten years. for the operators,” says Krämer.

12 In Focus — Modernization

The right experts are the be-all and end-all of every modernization.

AUTOMATION safeguards THE FUTURE ing unit,” says Lothar Hartwich, Project Especially in older plants, major potential can be tapped by Manager at SMS Meer. upgrading the automation equipment. “In metallurgical Modernization solutions developed plants, modern electrical and automation systems make by the SMS group help plant operators production safe and reliable, and ensure a high product to prolong the life cycles of their equip- quality,” says Detlef Ehlert, Executive Vice President Elec- ment. “Customers benefit from solu- trics and Automation at SMS Siemag. SMS Siemag also of- tions coming from a single supplier. fers pure automation solutions for plant expansions. “From Expertise, know-how, high-tech equip- the meltshop through to the caster, from the rolling mill ment and constructive and trustful col- through to the strip processing line: Under our X-Pact® laboration are the keys to success,” brand, customers are provided with solutions that all come says Dahmen. Also customers seem to from a single source,” continues Ehlert. “We also provide be convinced of this approach: “During automation solutions for plants designed by third-party the implementation phase, the collab- suppliers.” A most recent example is a Steckel rolling mill oration with sMs siemag was very at the Shandong Taishan Steel Group in China. The auto- good. The SMS team is highly profes- mation experts from sMS boast the necessary in-depth sional. Cooperation was extremely un- knowledge to analyze existing legacy automation functions. complicated. For NLMK DanSteel, this modernization project was a big fu- INDIVIDUAL SOLUTIONS FOR EVERY MODERNIZATION ture-oriented leap ahead,” summariz- SMS group – We The X-Pact® products consist of modules, enabling the re- es Thomasen. modernize any plant newal of individual components without having to replace Like many other upgraded produc- type. Watch our the entire system. “Several projects currently underway tion plants, the heavy-plate mill in video on moderniza- concern plants which we supplied 15 years ago. While we Frederiksvaerk, Denmark, is definitely tions via the follow- are upgrading the hardware to the latest state of the art, the not ready to be thrown on to the scrap ing link or scan the proven and continuously optimized application software heap. below QR code. can be retained unchanged,” explains Ehlert. Based on ex- www.sms-group. perience from several decades, the companies of the SMS www.sms-group.com com/qr/ group can draw on a great number of proven techniques. modernization Nevertheless, every revamp will also bring about individual solutions. Sometimes, these may even result in joint development projects, as in case of a peeling plant project carried out by SMS Meer at Steeltec in Switzerland. “We originally offered a conversion from manual to motorized mode and are now developing together with the customer an automation solution involving light barriers and a small process-

13 sms group newsletter 02 / 2014 in brief Wuhan Iron & Steel, China

CSR Sifang, China N ew assembling line

grade and automation of a bogie assembling line. the order scope also includes supervision of the installation activities. With this project, CSR sifang, one of the biggest high-speed train manufacturers in China, intends Coiler reels to increase to ten the number of bo- gies produced per shift. Automated class X100 handling systems, like overhead carri- ers designed by CTI systems, a subsidiary of Paul Wurth, and automated S MS Siemag is modern- guided vehicles (AGVs), ensure a nearly fully automatic material flow of the izing a coiler in hot strip various bogie components in all as- mill No. 2 at Wuhan Paul Wurth received an order from sembly stages. CSR Sifang Co. Ltd., China, to engineer Iron & Steel, China. After and supply key components for the up- www.paulwurth.com the upgrade which will be completed in spring Wuxi Turbine Blade, China 2015, coiler 3 will be able to reel hot strip of high- Modernized screw press est strengths and with

Wuxi Turbine Blade (WTB) in Wuxi, Ji- great thicknesses such angsu Province, China, has commis- as tube grades of sioned an sPKA 11200 screw press upgraded by sMS Meer, Germany, in strength class X100 and just seven months. After erection at up to 20 millimeters the new location, the spindle and the tie-rods were replaced. Wuxi can now gage. The project range reliably and safely produce workpieces covers the adaptation of for the manufacture of high-quality turbine blades on the machine again. the coiler, mounting of “Following the revamp, the press is new core components, now state-of-the-art,” says Mo Jianq- iang, Deputy Director and senior en demanded quality within the agreed extension of the automa- gineer Forging equipment at WTB. time.” tion system and installa- “When we order something from SMS Meer, we can be sure of receiving the www.sms-meer.com/en/service tion of new drives.

14 In Focus — in brief

Hadeed, Saudi Arabia E nvironmental technology meets expectations

HADEED (Saudi Iron and Steel Com- pany), Saudi Arabia, and SMS Siemag have successfully completed the modifications to the existing ladle furnaces No. 1 and No. 2. HADEED is an affiliated company of SABIC (Sau- di Basic Industries Corporation). The close collaboration between sMS Siemag and HADEED contributed to the on-schedule installation of the fume extraction systems on the ladle furnaces. All parties involved attached highest priority to the objec- stallation of the new ladle roofs and mental conditions, both inside and tive of performing the construction the fume extraction equipment, SMS outside the steelworks. work without interruptions to the Siemag has successfully fulfilled the running production. Through the in- objective of improving the environ- www.sms-siemag.com

Logan Aluminum, U.S.A. Acciaierie Valbruna, Italy Fresh air for Logan Close Since 2013, the U.S. company Logan tolerances Aluminum Inc. has been operating a new AirwashTM system supplied by Acciaierie Valbruna from Vicenza, Ita- SMS Siemag for efficient cleaning of ly, has commissioned four mill stands the exhaust air emitted by two alu- for the intermediate train supplied by minum cold rolling mills. In the SMS Meer. This state-of the-art roll- course of the modernization of two ing mill enables Acciaierie Valbruna aluminum cold rolling mills, and to fulfil different requirements of the with a view to saving operating and customer: Bars can be produced in a maintenance costs, the American diameter range from 20 to 73 milli- company Logan Aluminum Inc., meters (round bars), rebars in a range resident in Russelville, Kentucky, from 14 to 50 millimeters and hexag- entrusted sMs siemag with the onal material in a range from 20 to supply of an AirwashTM exhaust air 57 millimeters. Further products are cleaning system which replaced the wire rod with diameters from 5.5 to existing system on the basis of acti- 12 millimeters and bar-in-coil from vated carbon. operating to the ab- 12.5 to 32 millimeters. sorption and rectification method, Acciaierie Valbruna has found a re- the AirwashTM system recovers roll- liable partner in SMS Meer – for the ing oil from the exhaust air. This re- supply of technological equipment covered oil can be returned to the and for services. rolling mill and re-used there. www.sms-meer.com www.logan-aluminum.com

15 In FocusFocus sms group newsletter 02 / 2014

Relining of blast furnace A at ArcelorMittal Ghent: new steel jacket, new cooling system, enlarged furnace shell.

16 In Focus — Modernization

FIT FOR THE FUTURE

ArcelorMittal Ghent and Paul Wurth set benchmarks when it comes to increasing the efficiency of blast furnaces. The revamping of the PCI systems, which was completed in 2013, allows improved process control, savings on coke and nitrogen, and a corresponding decrease in hot metal costs.

aul Wurth has modernized the blast furnaces at In terms of operating stability and ArcelorMittal Ghent. Increased productivity and equipment performance, this tech- improved overall flow-rate control were two of the nology has meanwhile become widely i P project objectives. The revamp will enable the cus- established as the to date most reli- tomer to benefit from higher plant availability. ArcelorMittal´s able pneumatic conveying method for Paul Wurth integrated iron and steelworks on the Ghent-Terneuzen Ca- pulverized coal. the introduction of nal in Belgium is rather young. Founded in 1962 with the the new equipment at the Ghent Paul Wurth is as support of the european Coal and steel Community and works marked the beginning of a a self-standing constructed between 1964 and 1968, Sidmar was the first gradual learning process in PCI appli- corporation within coastal steelworks of the Luxembourg-based ARBED group. cation, conducted over many years the SMS group. With The steelworks has always been both strongly committed to and intended to tap the economic more than 1,600 quality and efficiency and open to new technologies in all benefits provided by the technology’s employees and 27 stages of the production chain – from primary metallurgy process intensifying potential. Entire- subsidiaries, it ranks through to the final product (cold strip, mainly for the auto- ly new knowledge was gained con- among the world’s motive industry). Thanks to its own solutions, the steelworks cerning the control of the blast fur- leading suppliers has been a pioneer in the steel industry. nace process. Ways had to be found of of blast furnaces, The ironmaking plant, consisting of two blast furnaces how to implement this knowledge coking plants and commissioned in 1967/68, produces more than four mil- through suitable operational and green technology for lion tons of hot metal for steelmaking. The complete hot plant engineering measures, such as metallurgical plants. metal output is used in the works’ converter steel plant. optimization and modification of the The blast furnaces were – and are – equipped with the full cooling systems of the blast furnaces, line of modern technologies and plant features. For many optimization of the burden quality, ex- years, their operating results have been a benchmark of pansion of the instrumentation, appli- efficient hot-metal making in Europe and within the Arce- cation of new process control equip- lorMittal group. ment, and adaptation of the burden preparation and charging practice. In Pioneering achievements in Ghent the course of the years, this approach In the wake of the oil crisis in the 1970’s, the technique of has led to the situation that the blast pulverized coal injection started to be widely introduced at furnaces at Ghent operate with maxi- blast furnaces around the world as a means to intensify the mal injection rates and lowest overall process and reduce the coke rates. The conversion from reducing agent consumption. When, heavy oil to pulverized coal injection at Sidmar in the mid- after the year 2000, injection rates of 1980’s was another item on the list of pioneering achieve- more than 200 kilograms of pulver- ments realized at the Ghent steelworks. It was the first ized coal per ton of hot metal were works for which Paul Wurth designed the complete injec- reached, the injection plant built in tion plants of the blast furnaces ready for introducing the the 1980’s came close to its capacity then latest technology of dense-phase conveying. limits.

17 In Focus sms group newsletter 02 / 2014

Above: Static distributor, also called “The spider”.

Below: The pre assembled distri bution and regulating equipment.

Bild in höherer Auflösung anfordern

18 In Focus — Modernization

The objective of achieving stable injection rates the injection pipes) and fewer incidents As a first remedy, the capacity of the coal grinding and dry- of manual intervention by operators. ing plant was increased. Following this measure, Paul Wurth received the order to modernize the pneumatic con- Improved accuracy of distribution veying system and the injection equipment during the years However, the main benefit achieved is 2010 through 2013. the objective of these modernization the distinct improvement in the accu- measures was to guarantee stable injection rates of at least racy of coal distribution via the tuy- 240 kilograms per ton of hot metal for both blast furnaces. eres: With the dynamic distribution Higher availability of the injection lines, improved overall system in place, Paul Wurth guaran- flow-rate control and higher accuracy of the coal distribu- tees maximum deviations of ±2.5 per- tion via the tuyeres were further objectives of the modern- cent between the individual injection ization project. Another relevant criterion of the project was lines, versus the at best ±5 percent the minimization of periods requiring “coke-only” operation achievable by static systems. of the blast furnaces as a result of the necessity to tempo- The uniform distribution thus rarily completely cut the transfer of injection coal to the achieved has a direct positive effect on blast furnaces during the construction work. the stability of the blast furnace opera- The technological solution proposed by Paul Wurth and tion, making it a key factor for the effi- accepted by ArcelorMittal Ghent mainly consisted of en- cient use of pulverized coal at high in- larging the diameters of the coal conveying and injection jection rates. At ArcelorMittal Ghent, lines as well as revamping the injection equipment by re- the mean deviations in the distribution placing the static coal distribution system with a dynamic have meanwhile been reduced to even one. To this end, in each injection line, the subcritical coal below one percent. Moreover, the in- nozzles were replaced by Paul Wurth’s GRITZKO® control jection rates have been raised to up to valves which, in combination with Cabloc flow rate mea- 245 kilograms per ton, while fulfilling surements, guarantee that the volumetric flows to the tuy- the specified values for the overall eres can be individually regulated. consumption of reducing agents. Thanks to the dynamic distribution Markedly accelerated ramp-up curve technique, combined with dense-phase Also in the planning of the equipment supplies and of the conveying equipment and high-preci- installation work, special consideration was attached to the sion regulation of the overall flow rate, customer’s wishes. Blast furnace A, which was the first to a technology has become available receive the new injection equipment, required a total of 150 which not only provides a rapid return “coke-only” operating hours. In the subsequent ramp-up of on investment but also makes it pos- the injection rate – always a rather sensitive phase – the sible for effective injection rates of level of 160 kilograms per ton of hot metal was reached in more than 230 kilograms per ton of hot three days. The lessons learned from the first blast furnace metal to become the state of the art – were of great use for the second one. Blast furnace B was even when being retrofitted to existing without coal supply for only 93 hours and the ramp-up blast furnace plants. curve could be accelerated: after 72 hours, the coal injection rate had already reached a level of 180 kilograms per www.paulwurth.com ton of hot metal. The upgrade with technology of the latest state of the art did not only achieve a higher capacity but also a substantial increase in plant availability (less frequent and shorter interruptions of the coal transfer to the tuyeres), reduced nitrogen consumption (thanks to lower pressure gradients in

19 In Focus sms group newsletter 02 / 2014

NE W GEneRATION OF COLD ROLLING MILLS

SMS Siemag redefined the technology for cold rolling mills and, with the “X Roll® 2.0“, offers their operators convincing solutions for modernizations and new plants.

lant operators are under high competitive pres- roll drive to be maintained for significantly smaller work sure. They have to take action and make their pro- rolls or high rolling torques. With this new drive spindle, duction process as flexible and efficient as possi- coupled with design modifications at the work roll drive P ble. SMS Siemag satisfies these requirements by necks, SMS Siemag succeeded in extending the operational permanently advancing the proven rolling technology which is known under the name of X-Roll®. The new generation of X-Roll® cold rolling mills presents numerous plant technological advancements and innovations. One example is the new compact tandem mill with four-high CVC® plus mill stands. This compact tandem mill helps plant users save operating costs amounting to millions as compared to conventional concepts. X-Roll® 2.0 cold rolling mills impress by further solutions, also for existing plants.

EXTENDED APPLICATION LIMITS The preferred type of drive is the work roll drive. It ensures the highest degree of process reliability and is normally cheaper than intermediate or backup roll drives. Howev- er, there are limits to the work roll drive since in the case of thinner work rolls the correspondingly thin roll necks and drive spindles cannot transmit the required rolling torque. The Sieflex® HT spindle by SMS Siemag allows the advantages of the work

20 In Focus — Modernization

limits of the efficient work roll drive and managed to more this sealing effect is attained by means of a high-speed air than double the capability of the rolls and drive spindles. flow using the Coanda˘ effect, the so-called Coanda˘ nozzle. Thus it is possible to roll a broad range of materials from For this purpose, a considerable amount of compressed air soft to high-strength steels on one facility. If the material is applied. A seal of completely new design operates with a strengths remain unchanged, thinner final gages can be subsonic flow that required the tip of the nozzle to be mod- achieved. Sieflex® HT drive spindles are of interest for modified. The changed contour provides for an improved flow ernizations, too, as they help enhance the product mix and behavior, deflecting the drop-loaded air and sealing the roll the capacity of the cold rolling mill at low capital expendi- reliably. The new contour permits the gap between Coanda˘ ture. nozzle and rolls to be enlarged and hence to obtain a higher suction effect between strip top side and nozzle. In this way, COST-EFFICIENT STRIP BLOW-OFF SYSTEM a higher drying effect on the strip surface is achieved. The In the exit section of cold rolling mills the DS (Dry Strip) nozzles in the marginal area can be switched off to cut com- system frees the strip surface from excess coolant resi- pressed air consumption and lower the operating costs. dues. The efficiency of SMS Siemag’s DS systems is defined by a combination of stationary and moving partition ele- TWIN REEL: COMPACT AND STURDY ments as well as targeted blowing-off and exhausting of SMs siemag has given the continuous exit section of specified areas. Wear-free and contactless sealing of the tandem mills a new design and offers, apart from the roll crown is a core component of the DS system. To date, known and proven double and carrousel reels, the newly

Cold rolling mill featuring the new twin-reel concept.

21 In Focus sms group newsletter 02 / 2014

developed twin reel. The twin reel combines the advan- i tages of both conventional reel concepts and is even supe- ADVANTAGES rior to them because of its intelligent, very sturdy and economical design. It permits winding to be started at high The twin reel not only stands for a simplified drive that saves operation costs. strip tensions, further improves the winding quality and allows the plant to be ramped up quickly. When using the Finished strip winding at high strip tension right from the start conventional coiler types, the classical method is to remove Reproducible reeling accuracy even for wide strips the finished coils on the operator side. The new twin reel deviates from this principle. The two reel drives are no lon- Continuously high strip tension favorable for high-strength grades ger arranged on the drive side but placed on the drive and operator sites. In between, in the middle, the strip is coiled. Careful handling of sensitive strip surfaces through very The reel mandrels are solid and supported in any position short initial winding courses on both bearing sides. If a reel mandrel is in its top position, Reeling of “jumbo coils” with a maximum weight of 60 tons winding of a new coil is started. In the bottom position, the Reel mandrels with smaller diameters (508 and 610 millim- finished coil is removed and carried away underneath floor eters respectively) level. Compared to the carrousel reel, the drive technology Easy and space-saving coil removal has been simplified. the twin reel can do with just one Simple construction and clear arrangement of foundations gear stage. The new twin reel is not only suited for use in new plants, Fast ramp-up of the plant but also for installation in existing tandem mills, for example in the course of a revamp from discontinuous to continuous operation.

ECU: SAVING SPACE AND ENERGY i How can you improve a good conventional emulsion sys- ADVANTAGES tem? The answer SMS Siemag has found to this question is “Emulsion Compact Unit” (ECU). The ECU compact emul- The compact emulsion system ECU requires up to sion unit stands out due to its extremely space-saving de- 45 percent less operating energy. sign. Compared to a conventional emulsion system, the ECU needs up to 45 percent less energy for operation. 35 Use of waste heat for temperature setting of oil and water percent thereof are saved through emulsion supply in line tanks with demand and approx. 10 percent through clever use of Heating and cooling units in smaller dimensions waste heat from the rolling mill. The main components of Control of operating temperature by sensors an emulsion system are pipelines to the rolling mill, media Use of speed-controlled pumps to convey emulsion tanks and containers, cleaning equipment, stirrer, cooling volumes just as required and heating systems and pumps. A conventional design needs a ground area of about 300 square meters. The com- Smaller-dimensioned water treatment system ponents of the ECU are no longer arranged separately and Less maintenance due to lower number of components connected via complex pipeline systems, but combined in Shorter installation and commissioning periods thanks to one compact unit. Depending on the plant size, an ECU will modular design and reduced piping work take less than half the ground area. This saving is attained by arranging the components on two levels. Pumps and containers are placed on the base plate whereas heat ex- changers, filters, and magnetic separators are installed on top of the containers or tanks. For maintenance purposes all units are easily accessible.

FAST ROLLING START WITH TRC® SMS Siemag launched the Total Roll Gap Control (TRC®) system. this rolling assistance system reduces rolling risks and improves the yield. An example of a critical roll-

22 In Focus — Modernization

energy potentials that may subsequently serve as an important basis for decisions with respect to operational measures.

X-ROLL 2.0 SOLUTIONS – ALSO FOR EXISTING PLANTS In addition to the well-known and proven systems that characterize sMs siemag’s plants, such as modularized mill stand piping, highly dynamic adjustment systems and CVC® plus, the technical advancements and innovations permit a compact plant design without making concessions to the performance, and ensure economic and cost-efficient plant operation. All of the technology examples presented in this report are components of new plants, but can be reinstalled in existing facilities as well.

www.sms-siemag.com/cold-rolling-mills

The Emulsion Compact Unit is designed in a very space-saving way.

ing task is the threading and unthreading of strips. TRC® supports this threading and unthreading process so that the strip can be rolled to the defined thickness and desired quality as early and for as long as possible. This way, the off-gage lengths at the strip head and strip tail can be significantly reduced. TRC® was first installed in a tandem mill at Bilstein GmbH & Co. KG within the frame of a modernization. The experience made in daily operation shows that TRC® has considerably accelerated the threading and unthreading process and made it more secure. Off-gage lengths could be reduced by around 50 percent. In the meantime, SMS Siemag has also installed the system in an alumi- i num tandem cold mill. ADVANTAGES X-Roll® 2.0 cold rolling mills convince by their ECO-MODE AND ENERGY ADVISOR solutions, also for existing plants: New assistant and monitoring systems from SMS Siemag are an important contribution to efficient and resource- Sieflex®-HT drive spindle for transmitting high rolling saving operation of cold rolling mills. ECO-Mode is the torques, even when small work roll diameters are used new assistant that helps save energy. It takes care of a Cost-efficient strip blow-off system more energy-saving mode of operation of cold rolling Twin Reel - the compact coiler concept meeting highest mills by automatically switching off electrical consumers demands in the exit section of a continuous tandem mill or reducing them to minimum performance, for instance ECU – the new space- and energy-saving compact emulsion during a roll change or other operational downtimes. Ex- system perience shows that up to 10 percent of the average en- TRC® – assistant for threading and unthreading to permit ergy consumption of the selected units can be saved. The fast rolling start and shorter off-gage lengths X-Pact® Energy Advisor is an energy management system ECO-Mode and Energy Advisor provide the necessary trans- that helps reduce energy costs in rolling mills and keep parency for more effective plant and machine operation them stable. This is achieved by continuous monitoring of all energy-relevant data. This way it is possible to identify

23 In FocusFOcUS sms group newsletter 02 / 2014

ALM OstLIKE NEWLY BUILT

In order to fulfill the growing requirements on its products, Salzgitter Flachstahl is investing in an upgrade of its converters and in a new ladle turret. SMS Siemag already modernized two converters for Salzgitter Flachstahl and has now received a new order for another converter upgrade.

24 In FocusFOcUS — ModernModernizatzation

The third converter fitted with a lamella suspension system during an upgrade carried out by SMS Siemag.

he revamp of converter A at steel and slabs was permitted. In order and the availability of the converter,” the Salzgitter works was one to achieve a more stable and productive explains Berghöfer. The first heat in the of the most extensive that process, the specific volume of convert- upgraded converter A was produced in T SMS Siemag has carried out. er A was increased by approximately 25 September 2013. Converter B had al- “That was almost like building a com- percent. The deployment of the lamella ready been revamped in 2007. Now, the pletely new plant. A converter upgrade suspension system developed by sMS upgrade of converter C is pending. of such scale is definitely not daily busi- Siemag makes more efficient use of the For this project, salzgitter Flach ness,” says Dr. Andreas Berghöfer, installation space. The lamella system stahl GmbH has ordered a new convert- Manager BOF Shop at Salzgitter Flach- is a maintenance-free solution which er vessel from SMS Siemag. For better stahl. “Plant operation must go on” was enables the converter vessel to be sus- control of the metallurgical process, the motto throughout the comprehen- pended in the trunnion ring in an unre- this converter vessel will also have a sive project activities – no interruption stricted manner. “Altogether, we in- larger specific volume, in this case by to the continuous production of crude crease the quality, metallic yield, safety 18 percent. SMS Siemag will supply

25 In Focus sms group newsletter 02 / 2014

»CONSIDERING THE COMPLEXITY AND SPECIAL REQUIREMENTS OF THIS PROJECT, THE UPGRADE WENT EXCELLENTLY«

Thomas Müller, Director Steelworks Operations , Salzgitter Flachstahl GmbH

the converter vessel, the trunnion of which were supplied by SMS Siemag. Caster No. 2 was ring complete with drive unit, the vessel built by SMS Siemag in 1973. suspension system using the lamella system developed by SMS Siemag, the Jan Bader trunnion bearings and the bearing ped- [email protected] estals. Commissioning is scheduled for the end of 2015.

INDIVIDUALIZED INSTALLATION CONCEPT The new ladle turret of salzgitter Flachstahl’s continuous caster No. 2 is up and running. The conversion measures had been planned in such a manner that running production was not disturbed. Thanks to a specific assembly concept developed by sMS Siemag, the ongoing operation of the adjoining plants was not affected during the construction activities. The new ladle turret for continuous caster No. 2 had been completely Space-related and logistical condi- preassembled and replaced in one piece. tions called for the turret to be completely preassembled at the shop floor level. The ladle turret, which had a to- i tal weight of 340 tons, was exchanged FACTS + FIGURES in one piece. With the sMs siemag- developed assembly concept, it was The economic benefits for steel production in the thus possible to complete the revamp modernized converter* successfully and in a timely manner. Much smoother blowing process. SMS Siemag supplied all mechanical, Shorter blowing time. hydraulic and electrical components Longer refractory lining life. and implemented the complete instal- Extended service life of the blowing lances. lation and commissioning within a very

small time window. At Salzgitter, SZFG * Paper presented by Ralf Kromarek, Salzgitter Flachstahl GmbH, at EOSC 2011 operates four continuous casters – all

26 In Focus — Revamps

T owARDs a secure future

Aluminium Norf GmbH selected SMS Siemag to modernize its Aluminum Hot Mill 1. The first stage comprising the modernization of the roughing stand has already been completed. At present, SMS Siemag is renewing the edger. The order package furthermore includes the extension of the finishing mill by one stand.

luminium Norf GmbH (ALUNORF), Germany, op- most urgent goal of the modernization which is implement- erates the biggest integrated aluminum rolling ed in several stages is to boost production capacity. and remelt plant worldwide. It fabricates prod- A ucts for challenging aluminum applications STAGE 1: MODERNIZATION OF ROUGHING STAND which are used, for instance to make bodies and covers of In November 2012, ALUNORF entrusted SMS Siemag with beverage cans, foil materials, lithographic sheet for offset the modernization of the roughing stand, comprising the printing purposes and, to an increasing extent, automotive extension by a new mechanical/hydraulic adjustment sys- plates. At its Neuss location, ALUNORF is implementing a tem, a new backup roll balancing system including new comprehensive modernization project for Hot Mill 1 in co- backup roll chocks as well as the renewal of stand platform operation with SMS Siemag. The hot rolling mill originally and exhaust hoods. Apart from the mechanical scope of supplied by Siemag has been in operation since 1967. The supplies and the media system modifications, sMS

The presentation shows the roughing stand. In Focus sms group newsletter 02 / 2014

»IN JUST THREE PROJECT STAGES WITH SHORT DOWNTIMES WE ARE UPGRADING THE NEARLY 50-YEAR-OLD ALUMINUM HOT MILL TO THE LATEST STATE OF THE ART.«

Guido Fick, Project Manager SMS Siemag

Siemag was responsible for instal- order comprises the supply of the new edger with entry- lation. After the revamp had been suc- side roller table and side guides, extension of the media cessfully completed, the first ingot systems and their installation, which requires substantial could be rolled already during the foundation work to be done. the edger will be manufac- “Christmas break” 2013, on January 3, tured and pre-assembled in the SMS Siemag workshop in 2014. Only a few days later, production Hilchenbach, Germany. performance was in line with the ex- Thereafter, it will be transported to neuss and posi- pectations of ALUNORF. Due to a dras- tioned in its location by means of a heavy-load lifting frame. tic increase in adjustment speed by This work is scheduled to be carried out during the “Christ- almost 100 percent it was possible to mas break” 2014. Installation of the new edger will boost shorten rolling cycle times and raise the annual capacity of the hot mill by a further seven per- production by up to 4.5 percent per cent, approximately. year. Final acceptance for the roughing stand revamp was granted on January STAGE 3: EXTENSION OF FINISHING MILL 31, 2014. In the third project stage, ALUNORF will adapt the finishing mill to the higher capacity of the roughing mill. In February STAGE 2: RENEWAL OF EDGER 2014, the company commissioned SMS Siemag to extend i In April 2013, SMS Siemag was award- the three-stand finishing mill by another mill stand of four- ed a contract for the second stage of high design. the modernization and is now renew- The scope of supplies will comprise all mechanical SMS Siemag ing the edger in the roughing mill. The equipment of the new mill stand, including the pertaining As a systems sup- distance between the existing edger drive technology as well as the modification of the existing plier SMS Siemag and the roughing stand is about eleven mill stand gear units to be able to attain higher rolling offers aluminum meters. this is an unfavorable situa- speeds. The extension of the existing media systems and producers complete tion due to the long reversing distanc- filter equipment will also be part of the supply package. solutions from pro- es between roughing mill and edger, Through the installation of a new stand and the rise in roll- duction planning to especially with a view to the aspired ing speed, ALUNORF expects to enhance capacity by an- design and manu- increase in production performance. other 9.5 percent. facture and further In addition, the rolling force of the “With just three project stages and short production- to installation and existing edger has reached its limits. compatible downtimes at the turn of the year, SMS Siemag commissioning, in- SMS Siemag is installing a new edger will have succeeded in upgrading the almost fifty-year-old cluding subsequent only four meters away from the rough- aluminum hot rolling mill to the latest state of the art and after-sales service. ing stand to reduce transport distanc- thus making it fit for future challenges,” says Markus Neu- es and shorten throughput times. The hausen, Project Manager at ALUNORF, and continues:

28 In Focus — Modernization

The roughing stand was modernized in the first one of three project stages.

Milestones of the first modernization stage: Roughing stand revamp “ALUNORF not only benefits from the capacity increase, but also from a 2012 2013 2014 higher flexibility in production plan- Nov Dec Jan Feb March April May June July Aug Sept Oct Nov Dec Jan Feb ning.” Main downtime Start: Dec 25, 2013, 12:00 h CAPACITY INCREASE BY 25 PERCENT End: Jan 02, 2014, 14:00 h Commissioning Final installation media system Final installation media system FAC Order placement for time-critical Project start third-party components Products that have been rolled on the more recent Hot Rolling Mill 2, established and commissioned by sMS Siemag in the nineties, can now also be processed on the modernized Hot Rolling Mill 1, if so required. The SMS Siemag Project Manager Guido Fick concludes: “Subject to further optimization of the process parameters in conjunction with the envisaged exten- The tight project schedule for the roughing stand revamp. sion of the preheating capacity, it will be possible to attain a total capacity increase of more than 25 percent per year.”

www.sms-siemag.com/en/aluminium i FACTS + FIGURES

ROUGHING STAND Ingot thickness max. 610 mm Exit thickness min. 12 mm Pass reduction max. 50 mm (per pass)

Rolling force 45 MN Adjusting speed 56 mm/sec.

29 MARKETS sms group newsletter 02 / 2014

U.S.a. STEEL MARKET

The U.S.A. is an important steelmaking location. Severstal relies on convincing plant technology made by SMS Siemag. Also the service solutions provided by SMS Millcraft are highly valued by North American steel companies.

30 RubMARKrikETS — Unterrubrik

Ovvi er ew

The fascinating world of steel Madhu G. Ranade relies on technology from SMS Siemag. 33 Steel and service in the veins SMS Millcraft – The maintenance specialist in the U.S.A. 36 Markets sms group newsletter 02 / 2014

Above: Mahdu G. Ranade, Vice Pres- ident and Gener- al Manager, Sever- stal Columbus, is a passionately committed steel manager: “To see how steel is boiled, cast and rolled – that is simply fascinating.”

Right: The horizontal hot-dip galvanizing line commissioned in 2012 anneals and galvanizes cold and hot strip.

More information and photos are available in our app.

32 Markets — U.S.A.

Interview AIThe F SC NATING W ORLD OF STEEL

Madhu G. Ranade, Vice President of Seven years ago, Severstal Columbus started production. Severstal Columbus, illuminates his How would you describe the development of the company since then? passion for steel and why he relies on The start-up in the years 2007 and 2008 went extremely ® technology from SMS Siemag. well. The CSP caster, for example, had one of the steepest ramp-up curves of all CSP® plants in North America. How- ever, the recession in 2009 struck our company, too, and as a result slowed down our development and the implementation of Phase II. It was restarted in 2011, and since that time the plant has improved very quickly and we are just beginning to hit our stride. With its new works in the U.S. state of Mississippi, Sever- stal Columbus succeeded in establishing itself in the The plants of Phase II were put on stream in 2012. Which highly competitive U.S. market. the company relied al- additional possibilities does the equipment offer to Sever- most exclusively on the expertise of SMS Siemag, from the stal Columbus? electric steelworks, secondary metallurgy, CSP® plant, Commissioning of the Phase II extension balanced the whole push-pull pickling line and combined pickling line/tan- plant nicely. By starting the second strand in the CSP® plant dem mill to the two galvanizing lines. Many of the plants we were able to maximize the throughput. With just a 20 per- supplied by SMS Siemag are equipped with its self-devel- cent increase in our manpower we could achieve a 100-per- oped X-Pact® electrical and automation systems. Having cent increase in production. The additional push-pull pickling started on a green-field site in 2007, the works reached its line helped us to enhance the throughput in our pickling plant final construction phase in 2011. seven years after the and also expand our market position. The second galvanizing first coil, Madhu G. Ranade, Vice President and General line gave us the capability of making construction market and Manager of Severstal Columbus, looks back on the coop- other hot-dip galvanized products. so, we basically estab- eration with SMS Siemag, gives insight into the company’s lished an additional market and boosted product sales. development and outlines its plans for the future. The new hot-dip galvanizing line is designed for galvaniz- Mr. Ranade, you have been working in the steel industry ing hot strip up to a thickness of 2.52 millimeters. Which your entire career. What makes the material steel so fas- market are you targeting with this product? cinating for you personally? Hot-dip galvanized strip from this line was initially des- Steel is definitely a building block of our modern civilization. tined for the construction industry. In the U.S.A., this sec- Cars, furniture, buildings, streets, bridges, wind turbines, tor has been suffering since the recession and not yet re- ships, and nuclear power plants – steel is in everything we covered, but as the market starts to develop we will take use. Daily life, in its present form, would be inconceivable full advantage of that line. In addition, we are processing without steel. To see how steel is boiled, cast and rolled – hot strip for the automotive industry in this line which that is simply fascinating. turned out to be a great advantage for our company.

33 Markets sms group newsletter 02 / 2014

»THE SMS TECHNOLOGY HAS BEEN EXCELLENT AND EXTREMELY RELIABLE: WE HAVE BEEN ABLE TO ACHIEVE VERY HIGH UP-TIMES AND PRODUCTIVITY.«

Madhu G. Ranade; Vice President and General Manager, Severstal Columbus

What are the prime markets of tinuous pickling/tandem operation. Severstal Columbus? With this technology we can provide Our products go to customers in very products with excellent geometrical different markets. We supply the auto- tolerances to our customers – and this motive industry, the heavy machinery holds true for the hot strip from the sector and service centers. Our steel CSP® plant as well. is furthermore used in the container Our products are really unrivaled in business, for building agricultural ma- the market. We are able to provide chinery, in the air-conditioning branch coils with a weight of up to 40 tons, and and irrigation business. As you can that is exactly what our customers see, it’s a very diverse and very solid prefer. With our secondary metallurgy customer base. equipment we can furthermore pro- In the automotive market we supply duce ultra-low carbon and low sulfur BMW, Mercedes, Ford, Chrysler, steels. Nissan and Volkswagen. We supply On the whole, we have a very flexible primarily unexposed deep-drawn “We supply products with excellent geometric system. It is highly automated and, as a steels, mild and HSLA (High Strength tolerances to our customers.” result, productivity is very high. We are Low Alloy) steels. Currently, we have able to basically go from scrap to hot several products under development which would expand strip in less than four hours, so we can supply our custom- the range we are offering to the automotive industry. ers very rapidly. to many customers we are a so-called “one-stop-shop”, which means they can get all steel prod- The works of Severstal Columbus are based on a process ucts they want through our own facility. route with steelmaking in an electric arc furnace and a CSP® plant. What advantages do you see in this set-up? Nearly all of your production plants are made by SMS It provides a great deal of flexibility for operation. For ex- Siemag. What is your experience with our technology? ample, as the demand ebbs we can adjust our production The sMS technology has been excellent. It has been ex- very quickly. This is also the only mini-mill that has a con- tremely reliable, and we have been able to achieve very high

34 Markets — USA

“By commissioning of the second CSP® strand we were able to achieve a 100-percent increase in production.”

up-times and productivity. Additionally, the technology is in-depth knowledge of their chosen specialty. The Ameri- very energy-efficient and cost-effective. can engineers tend to be more of generalists and have many additional talents. That turns out to be a very good and Severstal Columbus recently awarded SMS Siemag the successful combination. modernization of its CSP® plant. What goals are you striv- ing for? If you looked three years ahead, what would you like to The goals of the modernization of the CSP® rolling mill are read about Severstal Columbus? multi-faceted. the new side guides will support a stable I would like to read that Severstal Columbus is a very safe, and smooth strip flow and help improve edge quality. By customer-preferred plant with highly motivated and en- reinforcing the laminar cooling system we will save alloying gaged employees, with sustained profitability and a good, elements. We are considering the installation of a compact valued citizen of our community in Columbus, Mississippi. strip cooling system installed in the cooling section, which would allow us to again expand our product offering. www.severstalna.com

How important is the after-sales service of SMS Siemag to you? The service of SMS Siemag offers the great advantage of hav- Production record for CSP® plant ing always competent contact persons available on site to At the beginning of May 2014, Severstal assist us in steadily improving our plants. The SMS Siemag Columbus communicated that its CSP® plant experts furthermore help us to minimize downtimes and had produced more than 3 million short tons soon to proceed with our operation at full capacity. (i.e. 2.72 million metric tons) in the past twelve months, from May 2013 to April 2014. In recent years, you have been working together with SMS For the first time since commissioning of ® Siemag very closely. What differences do you see between the second CSP strand in the second quarter of 2011, the plant exceeded this mark and German and American engineers? is hence one of the most productive CSP® (Laughs) That’s quite an interesting question. German en- plants in North America. gineers are real experts, highly specialized and have a very

35 MarketsMarkets sms group newsletter 02 / 2014

Steel in his blood. George Born, SMS Millcraft.

36 Markets — U.S.A.

S erVICe in the veins

The U.S.A. is one of the largest crude steel producers in the world. Their steelworks produce steel grades for all kinds of applications. In order to keep these plants running smoothly, outsourced maintenance services are particularly sought after and valued. SMS Millcraft is an important partner at the side of several North American steel companies.

“Steel – it is in my blood,” says George some instances sMS Millcraft work- Born. Since 1973, he has been working shop employees have received training in the steel sector just like his father in Germany and visits to Germany for did. For the past 14 years, he has been technical exchanges among manage- employed with sMS Millcraft and is ment employees have occurred. the presently responsible for Business primary source of training for the glob- 1,000 Development and Marketing as Vice al network of sMs siemag service President. SMS Millcraft, too, has been workshops has been sMS Millcraft heats for slab production thanks to Uni- Guard®, which markedly reduces the mainte- focusing on steel and offers the North with employees coming from all over nance effort for steel producers. American steel producers world class the world to learn caster mold copper maintenance services to ensure they plate repair, caster roll segment clad- can meet the continuously rising chal- ding, and cold mill work roll recondi- lenges of the steel market. tioning and plating. viders is experience. Together with its SMS Millcraft is headquartered in predecessor companies, SMS Millcraft Pittsburgh, Pennsylvania and includes MORE THAN 100 YEARS OF EXPERIENCE has locations that have been active in a total of 15 workshops spread through- Intensive exchange does not only take manufacturing and service for over out the United states with many of place between the continents but also 100 years. these locations often being located within Pittsburgh. the sMS Group This is most obvious in the Oil City, close to their customers. The company building, located on sandusky street Pennsylvania workshop of sMS Mill- is part of SMS group’s Service Division, along Pittsburgh’s North Shore not far craft. At the end of the 19th century the and its experts render repair and main- from the ballpark of the Pirates, is also Oil City area served as a birthplace of tenance services for metallurgical and the location of the offices of sMS the modern oil industry, with U.S. Steel continuous casting plants, hot and cold Siemag, sMS Concast and Drever in opening a plant and foundry at the be- rolling mills as well as strip processing addition to SMS Millcraft. “Every week, ginning of the 20th century to support lines. “Thanks to the close connection we organize meetings and discuss this industry, these buildings are what to the plant manufacturer, sMS current projects in order to be able to currently house the oil City opera- Siemag, we enjoy advantages that ma- act jointly and better satisfy our cus- tions. In 1989 U.S. Steel closed the fa- ny of our competitors do not have,” tomers’ wishes.” this local network cility, but a small group of engineers says Born. “When core components and the exchange within the sMS with know-how in metallurgical plant are concerned, for example, we col- group are not the only factors benefit- technology and continuous casting laborate with the Hilchenbach working the north American steelmakers plant design and maintenance re- shop, exchanging information and when relying on the know-how of SMS mained on-site there and specialized technical innovations with our German Millcraft. A primary advantage sMS in the machining and coating of copper colleagues at regular intervals.” In Millcraft has over similar service pro- molds. today, this sMS Millcraft

37 Markets sms group newsletter 02 / 2014

location is unique. “Our workshop born, Michigan, offers comprehensive BANDZINK, a sister service company reflects the entire history of molds in maintenance services for cold mill inside the SMS group. In Hogansville, the United States. All kinds of continu- work rolls. one of the sophisticated Georgia, a workshop exists whose pri- ous caster designs can be found here,” technologies used is the EDT (Electro- mary product line focus is hot mill, explains Chad Donovan, General Man- Discharge texturing) method which cold mill and strip processing line ager of Sales and Innovation, at SMS provides a uniformly textured surface rolls. this sMS Millcraft workshop Millcraft. for the cold mill work rolls which in- provides specialized roll cladding pro- creases roll service life and allows the cess such as sub-merged arc strip and HIGHLY SPECIalized AND EXCLUSIVE customer to produce value added steel electro-slag welding which are valued- To steelworks operators in north grades. “Our experts provide roll coat- added products for north American America the workshop in Oil City offers ing solutions allowing for longer ser- metals producers. the full range of repair services to sig- vice lives aiding the profitability of the While steel is being poured in North nificantly enhance the life of their cast- customers operations,” says Born and American steelworks, sMS Millcraft ing molds. Be it the box-plating meth- continues: “We pass on our expertise continues to develop new service so- od for electroplating or thermal spray and knowledge within the SMS group.” lutions for steelmakers to keep their coating, UniGuard® process – Millcraft This is to the benefit not only of US plants running profitably over an even has the experts and machinery avail- steelmakers but of the global steel in- longer time period than before. SMS able in Oil City. “Investing in sophisti- dustry as well. the eDT process, for Millcraft has not only steel but also cated CNC machining centers and fo- example, has recently been launched and especially service in its veins. cusing on developing value added in the SMS Siemag workshop in Tian- services for our customers is what has jin, China. www.sms-millcraft.com made us successful,” says Donovan. Over the past several years, growth Caster maintenance develops such as of SMS Millcraft has been focused on NanoGuard® and UniGuard® mold adding technology advanced products coatings, and internal powder coating to better service customer equipment of water jackets are all specialized and in some cases even enter new products offered solely by sMS Mill- product markets. For example in the craft, and they help to reduce mainte- southern United States, in Calvert, Al- nance costs for steel producers. abama, sMS Millcraft specializes in “Understanding the customers’ main- the reconditioning and repair of zinc tenance issues and then responding to bath equipment for hot dip galvanizing their needs is the service business, in lines. this product line has been de- the case of high speed casting ma- veloped around sophisticated thermal chine copper plates for example, these spray technology supported by DUMA- molds are often machined, coated and returned to the customer within one week to meet the customer’s needs for mold spares,” adds Donovan. But the coating of molds is not the i only service offered by SMS Millcraft. SERVICES “Each location has its core competen- Selected portfolio offered in the U.S.A. cy and in this way we can avoid redun- dancies,” says Born. The SMS Millcraft Repair and reconditioning of zinc pot Precision CNC grinding with automatic workshop in Washington, Pennsylva- equipment ultrasound and eddy current roll in- nia, for example primarily repairs plant Machining of roll bodies and of macro spection components from hot and cold rolling and micro grooves on sink rolls Electro- Discharge Texturing (EDT) of mills. One of the latest developments H VOF/Plasma thermal-sprayed zinc work rolls, work roll chrome plating for this workshop is a test stand for pot roll coatings Repair and reconditioning of caster high-pressure testing of large hydrau- Roll maintenance segments and oscillators lic cylinders such as AGC cylinders or shifting blocks. The location in Dear-

38 Markets — USA

Convincing: The know-how of the Close cooperation characterizes the SMS Millcraft service experts. companies of the SMS group.

The workshop in Washington, Pennsylvania, has a test stand for HGC cylinders.

39 RubProjreikc ts sms group newsletter 02 / 2014

ACV TI E WORLDWIDE

The companies of the SMS group are presently handling a great number of projects, ranging from the commissioning of a coke oven in Indonesia and the supply of a heat treatment line to Slovenia through to the commissioning of two wire rod mills in China.

40 RubProjreikc ts— Unterrubrik

Ovvi er ew

SMS Siemag Paul Wurth 44 Metallurgical technology 46 Steel refining 51 Continuous casting plants 54 Hot rolling mills 58 Cold rolling mills 63 Aluminum plants 66 Strip processing lines and furnace technology 70 Electrics and automation 80

SMS Meer Steelmaking/Continuous casting technology (long product mills) 84 Tube & pipe plants 84 Long products plants 88 Forging plants 93 NF metals 95 Heat treatment technology 98 sms group newsletter 02 / 2014 in brief

MAHLE Engine Systems, United Kingdom P roprietary camera system

top and bottom strip surfaces by means of a proprietary camera system. the unit was carefully designed to fit the existing space. thanks to pre-assembly, the shutdown time could be kept to a ArcelorMittal Galati, Romania minimum. The design also recognised the importance of providing precise camera positions and a stable strip sur- W heel sets face. The success in achieving this was reflected by the very short startup time for Romania for the camera system. “Parkegate‘s MAHLe engine systems, United King- flexibility, communication and detail ac- dom, put on stream a new strip inspec- curacy were essential factors in achiev- ArcelorMittal Galati tion unit supplied by Parkegate. the ing this success,“ says Robbie Sinclair, unit, which was installed in an existing MAHLE Engine Systems. selected SMS Siemag inspection line, had been engineered by to supply wheel sets for Parkegate to allow for the inspection of www.parkegate.co.uk three roughing stands from its hot rolling mill U.S. Steel Košice, Slovakia in Galati, Romania. By 350 tons of hot metal the end of 2014, SMS Siemag is to provide two U.S. steel Košice, slovakia, awarded pinion shafts, interme- SMs siemag the order to supply two torpedo ladle cars for its integrated iron diate shafts and spur and steelworks in Košice. The torpedo gears, respectively. The ladle cars will have a capacity of 350 tons of hot metal each and are sched- larger one of the two uled to be operational in September and spur wheels with double November 2015, respectively. U. S. Steel Košice, one of the biggest iron and helical gearing has a steelmakers in the region, already has a diameter of more than new annealing and coating line from SMS Siemag. Since 1967, SMS Siemag 3,700 millimeters and a has supplied more than 400 torpedo la- weight of about 40 tons. dle transfer cars worldwide.

www.usske.sk [email protected]

42 Projects — in Brief

Tata Steel, India T po quality at Tata Steel

converters and secondary metallurgical plants; Paul Wurth erected a blast furnace. one example of the perfect harmonization and quality of all components of the CSP® plant is the fact that after just 45 days the guaranteed minimum strip thickness of 1.2 millimeters was achieved. Still in the commissioning period, Tata Steel produced strips of merely 1.0 millimeter thickness. evaluations of ongoing production showed that in 98 percent of the In December 2013, tata steel Ltd. March 2012 and is completely operat- measured values the deviations in strip granted sMs siemag the final accep- ing with sMs siemag’s X-Pact® elec- thickness were just ± 10 µm and in strip tance certificate for its CSP® plant in trics and automation systems. sMS flatness just ± 10 i-units. Jamshedpur, India. the two-strand Siemag additionally supplied Tata Steel CSP® plant was commissioned in an X-Melt® steelworks with two BOF www.tatasteel.com

Hussey Copper, USA S uccessful acceptance

At the end of 2013, Parkegate, an affiliate of SMS Siemag, rendered inspection services at Hussey Copper in Leetsdale, Pittsburgh, USA, and started operation of the new side guides it had supplied for an existing copper hot rolling mill. The order included the design, supply and commissioning of the new side guides. Shougang Qian’an, China

Ruukki Metals Oy, Finland Very satisfied

Recently, sMs siemag has put on N we gear unit ordered stream seven lines for the production of grain-oriented silicon strip (Si steel) Ruukki Metals Oy, Finland, awarded for the Chinese customer shougang SMs siemag an order to supply a Qian’an. the mechanical equipment mill pinion gear unit and a Sieflex® plus X-Pact® electrical and automa- coupling for finishing stand F6 of its tion systems for all lines were sup- hot strip mill in Raahe. The compo- plied by sMs siemag. the customer nents are manufactured and pre- expressed his satisfaction: “The auto- assembled in the sMs siemag mation solutions are perfectly tailored workshop and will be delivered and to our requirements. All diagnostic integrated in the plant in summer systems work at high speed and pro- 2014. vide our staff easy operation.”

www.sms-siemag.com www.sms-siemag.com

43 PROJEcts – PAUL WURTH sms group newsletter 02 / 2014

In a donesi ’s First Coke Oven Plant

PT Krakatau Posco in Cilegon, Indonesia, has successfully commissioned its new coke oven plant – just 30 months after placement of the order. With this project, Paul Wurth adds another strategic reference to its portfolio of coke making plants.

In spring 2011, the Korean-Indonesian joint venture com- the coke side. In line with environmental regulations, the pany PT Krakatau Posco placed an order with a consortium equipment has been designed with the objective of reduc- consisting of Paul Wurth Italia, Paul Wurth International ing NOx emissions, for example by waste gas recirculation, Site services, Posco engineering & Construction, PT three-stage air inlet, underjet-type underfiring, etc. Addi- Krakatau Engineering and PT Posco E&C Indonesia to pro- tionally, both batteries have been equipped with sUPRA- vide the engineering, equipment supply, installation and COKTM level-2 automation, a flexible, powerful, accurate supervision of commissioning for the new coke oven, which and easy-to-use support tool, helping to increase the oper- is part of the integrated greenfield steel complex at Cilegon ating efficiency of the plant. Provision has been made for in Indonesia. Being the competence center in the field of retrofitting the soPRECO® single oven Pressure Control coke oven technology within the Paul Wurth Group, Paul system at a later stage. Wurth Italia was entrusted with the complete engineering and the supply of key components for two new coke oven QUENChING TOWER ACHIEVES LOW DUST EMISSIONS batteries of the top-charging type, one coal and one The quenching tower is of the Paul Wurth low-moisture quenching tower, a coke wharf and a complete by-product type. With a height of 45 meters, the inside of the RCC (roll- plant. the latter was designed in cooperation with DMT er-compacted concrete) construction is lined with acid-re- GmbH Deutschland. Additionally, Paul Wurth International sistant clinker bricks and fitted with a wide steam outlet Site Services supervised the on-site installation and com- area, so as to reach low steam outlet velocity and a low dust missioning of the batteries and the by-product plant. output. In order to wash the water steam generated during the process and to capture the coke particles in the steam, PREMIERE FOR LARGE-SIZE BATTERIES FROM PAUL WURTH the quenching tower is equipped with dust capture systems Heating up of the first battery started on June 11, 2013. The and a steam washing system. The settling basin features a first coke was successfully pushed on October 9, 2013. The grab crane for removal of the sedimented coke dust and second battery was commissioned two months later. The coke boxes for filtration of the quench water. two batteries, each consisting of 42 ovens, will achieve an annual production of 1.3 million tons of coke. The two bat- Gas treatment plant for a gas rate of 88,000 Nm3/h teries represent latest coke-oven technology and are world- The plant for cleaning the coke oven gas and recovering by- wide the first implementation of Paul Wurth’s “Jumbo Oven products is designed for a gas flow of 88,000 Nm3/h.- It in Batteries”. These batteries minimize daily pushing, conse- cludes among others primary gas coolers, tar decanters, quently leading to a reduction of emissions. The technology coal water gravel filters, electrostatic tar precipitators, gas is based on a twin-flue design with 38 heating flues for each exhausters, H2S / NH3 scrubbers, benzol scrubber, distilla- heating wall and features an asymmetrical configuration tion plant, benzol stripper as well as a Claus plant for sul- with mixed gas and air on the pusher side and waste gas on phur recovery.

44 Rubrik — Unterrubrik

Above: New coke oven battery No. 1 at PT Posco Krakatau, Indonesia. Left: Gas treatment plant at PT Posco Krakatau, Indonesia. Center: View of the coke oven battery.

Below: Part of the gas treatment plant.

i FACTS + FIGURES

BATTERIES Annual coke production 1,321,000 tons/year Coke oven batteries 2 Number of ovens per battery 42 Sets of coke oven machines 2 (1 stand-by) Pushing per day 82,3 Coke per oven 44 tons

OVEN DIMENSIONS Length 20 m Width 0.55 m Height 7.6 m Useful volume: 78.92 m3

BY-PRODUCT PLANT Coke oven gas production 78,000 Nm3/h Low heating value 4,185 Kcal/Nm3 Tar production 79,000 t/y BTX production 21,000 t/y Solid sulfur productionl 4,400 t/y

4545 ProjeCtS sms group newsletter 02 / 2014

TUNING FOR ELECTRIC ARC FURNACES

Value-added parts from SMS Siemag for electric arc furnaces provide plant operators measurable benefits. These additional benefits range from reduced maintenance costs, longer lifetimes and improved processes, all the way through to increased plant efficiency.

By means of the Furnace energy optimization system (FEOS®), electric arc furnace operation becomes more con- stant and more cost-efficient. The plant operator can increase the overall economy of the EAF by increasing the specific melting capacity and lowering energy consumption. FEOS® makes this possible by achieving optimal furnace utilization, while avoiding thermal losses and over- heating of the vessel. The system monitors the process on a continuous basis, with the result of an overall optimization of the electrical, chemical and thermal energy inputs. FEOS® can be added to an existing level-1 automation system and acts as a complement to the level-2 process models. the system consists of hardware and software components and features a simple and easy-to-use structure. Based on the process input values measured in real time and the functions set as default in the control basis; Power Control, Reactor Control, Burner Control and Foam- ing Slag Control, the system controls the actuating signals for the process-determining output parameters. precise and risk-free process control In EAF steelmaking, it is extremely helpful to have continuous measurements of the waste-gas composition and use these measurements to improve the efficiency of the process control. By a waste-gas analysis, it is possible to determine the ratio between sensible and chemical heat in the waste gas. If the process is controlled taking into account this ratio, it is possible to use the input energy more efficiently and optimize the process control on a continuous basis. Value-added parts from SMS Siemag for the electric arc furnace The waste-gas analysis system, jointly developed by improve plant efficiency and reduce operating costs.

4646 ProjeCtS — Metallurgical technology

SMS Siemag and SMS Concast, measures the waste-gas composition directly at the furnace elbow, without any in- terfering air flows. The employed measuring probes are as close as possible to the melting process. Consequently, the process control tasks can be fulfilled with high precision and without any risk for the operator. The sturdy twin-probe equipment for the waste-gas measurements is currently demonstrating its longevity in practical operation. The equipment is suitable for any electric arc furnace and can easily be retrofitted, as required. sis burner reduces energy input For a high steel quality, it is indispensible that all processes in the EAF – from scrap melting via decarburizing of the melt through to tapping – are perfectly harmonized. This is supported by oxygen injectors. SIS injectors in operation. The SMS Siemag Injection System (SIS) combines the burner and injector technology. It accelerates scrap melting and the decarburization of the steel bath, while minimizing the consumption of expensive resources, such as oxygen. The SIS can be integrated into new EAFs or retrofitted to More information existing ones. Plant operators installing SIS equipment re- i on value added alize savings on every ton of steel produced, achieving a Advantages parts for the EAF short return-on-investment period. Furnace Energy Optimization is available at Temperature measurements of the cooling water by System (FEOS®) www.sms-group. com/qr/value- wired systems regularly confront EAF operators with highly Highly transparent melting process challenging situations. Splashing steel and slag cause reg- and regulating strategies added-parts-eaf ularly recurring damage to the cables and sensors. SMS Avoidance of standstills Siemag’s wireless solution – X-Melt® Wireless Temp – re- Higher productivity duces the resulting cost- and time-intensive repairs. A protected transmitter sends the measured data by radio SMS Siemag Injection System (SIS) transmission to a receiver outside the danger zone. This Maximized oxygen efficiency technique ensures reliable operation of the system. through optimized nozzle design High plant availability through fewer downtimes and re- Efficiency increase by up to 40 percent through optimal shroud duced maintenance. gas jet The absence of wired connections is a major benefit of Cost savings of up to 70 percent this equipment. Additionally, operator safety increases as ® risky repairs in the high-temperature zone due to defective X-Melt cables will no longer be necessary. Higher reliability Shorter replacement time Alexander Bergs [email protected] T win probe Can be easily retrofitted to existing furnaces Sturdy probes and measuring equipment Long service life

47 ProjeCtS sms group newsletter 02 / 2014

Look into a calcium carbide furnace during standstill. Two out of six

Guodian has commissioned the two largest calcium carbide furnaces in China. SMS Siemag is supplying a further four.

i Two of the total of six submerged arc furnaces ordered from The calcium carbide produced is con- SMS Siemag have been successfully put into operation at verted into acetylene in a newly erected the Guodian-Sinopec ningxia energy Chemicals Co., Ltd. works complex. Acetylene is an impor- Submerged arc furnaces works of Guodian International Economics & Trade Co. Ltd. tant prime material for the plastics and The submerged arc furnaces produce calcium carbide for foam-rubber industry. In the process of Since 1960, SMS the local market. With a power rating of 46.5 MW tons producing acetylene from calcium car- Siemag has world- each, the furnaces are currently the largest furnaces of this bide, crude oil is substituted for locally wide installed 27 type in China. occurring raw materials. The province SAFs for the pro- The entire plant is to be used for producing around of Ningxia and neighboring Inner Mon- duction of calcium 750,000 t each year of high-quality calcium carbide for the golia possess extensive coal and limes- carbide. Especially local market. tone deposits that are suitable for car- in China, small The customer issued the acceptance for furnaces No. 1 bide production. furnaces are being and No. 2. In February and March, furnaces No. 3 and No. 4 increasingly replaced commenced production successfully. Furnaces No. 5 and www.sms-siemag.com/en/saf by larger units. No. 6 will follow by the end of the year.

48 ProjeCtS — Metallurgical technology

Rotating furnace shells

SMS Siemag will supply two submerged arc furnaces to Mississippi Silicon, U.S.A. Convincing performance of primary dedusting equipment thanks to new bag cleaning system.

Mississippi Silicon LLC. placed an order with SMS Siemag kind in the world. It is scheduled to for the supply of two submerged arc furnaces (SAF) for the commence operation in July 2015. production of silicon. the two furnaces will have a com- This project is supported by KfW bined annual capacity of 33,000 tons. Interesting features IPEX Bank, which is providing the debt are the rotating furnace shells which avoid cold areas in the capital by way of a loan secured by melt and prevent carbide deposits on the furnace walls. Hermes. In addition to the SAFs proper, SMS Siemag is supplying Mississippi silicon is a strategic the electrode columns, the material handling and the hy- partnership between the Vicintin fami- draulic systems, the complete primary gas cleaning equip- ly from Brazil and the US-American ment and the X-Pact® electrical and automation systems. Clean tech LLC. the project was of- Also the cranes, the chemical laboratory and the stoking ficially kicked off on January 13, 2014, and charging machines are included in the scope of supply. in a ground breaking ceremony atten- The primary gas cleaning system supplied by sMS ded by Phil Bryant, Governor of the Siemag will be fitted with pulse-jet bags which guarantee state of Mississippi. dust contents ‹ 10 mg/Nm³, at a capital investment lower than that involved when using common reverse-air sys- www.sms-siemag.com/en/saf tems. The silo station will be designed for dust densities (›650 kg/m³). With these values, the equipment supplied by SMS Siemag fulfills all requirements on eco-friendly technology. The works is being built in Burnsville, Mississippi, U.S.A. It will be one of the most efficient silicon works of its

Ground breaking for the new works.

49 ProjeCtS sms group newsletter 02 / 2014

Scrap being charged into the converter. The new converter platform.

2.8 million tons of liquid steel are the target

Two of three converters have been put into operation at Visakhapatnam Steel Plant, India. SMS Siemag supplied the secondary-metallurgy equipment, environmental technology and automation systems.

The X-Melt® basic-oxygen steelworks being built at Vi- ates with the level-2 process models and the level-3 sakhapatnam Steel Plant (VSP) in India is growing towards production planning system from the X-Pact® electrical and its planned dimensions, eventually making possible an an- automation package. Level 3 provides the operators with all nual production of 2.8 million tons of liquid steel. The first of tools they need to plan and control the production process- three BOFs is up and running, and the customer has already es. This makes it possible to maximize the total through- issued the FAC. In March 2014, the second converter was put of the works and provides the basis for consistent, commissioned just as successfully. The delivery of the third plant-wide product-tracking and quality-control systems. converter is planned to take place in spring 2015. All three VSP is a leading Indian steelmaking company. converters are or will be equipped with primary and secondary dust extraction systems and a gas changeover station. www.sms-siemag.com/steelmaking

MAXIMIZATION OF THE TOTAL THROUGHPUT SMS Siemag also supplied two ladle furnaces and a 150- ton RH-TOP vacuum degasser (SMS Mevac) for the production of quality steel grades. The complete BOF shop oper-

50 Projects — Steel refining

ONM STREA

With an 80-ton Duplex RH-TOP plant, Shanxi Taigang Stainless Steel can produce a wide range of high-quality steel grades with low levels of hydrogen.

Taigang Group International Trade Co., Ltd., and the end user Shanxi Taigang Stainless Steel Co., Ltd., both located in taiyuan, China, have successfully put on stream a new 80-ton Duplex RH-TOP plant (Ruhrstahl Heraeus process) supplied by SMS Mevac and its consortium partner sMs siemag Technology (Beijing) Co., Ltd.

VACUUM PRODUCED IN FOUR STAGES 80 This 80-ton Duplex RH-TOP plant, No. Shanxi Taigang Stainless Steel uses the 2, makes it possible to produce a great 80-ton Duplex RH-TOP plant to treat steel for electric sheet production. variety of high-quality steel grades SMS Mevac supplied with low levels of hydrogen. The plant all key components for the Duplex RH-TOP is primarily used for the treatment of plant at TISCO. steel for electric sheet production. The vacuum is generated by a four-stage steam-ejector vacuum pump with splash control system (RH-SC®)- for re ducing the splashing of steel. Within this project, sMS Mevac’s supplies included nearly the complete basic engineering, the main part of the detail engineering, the delivery of key components of the mechanical, electrical and instrumentation equipment, the complete level-1 and level-2 www.xxxxxxxxxxx.de/ automation systems as well as supervision of installation and commissioning.

www.sms-mevac.com

51 Projects sms group newsletter 02 / 2014

O rders from South Korea

Hyundai Steel is planning to expand its electric steelmaking plant in Dangjin by installing an SMS Mevac fast vessel-exchange RH unit. Additionally, new furnaces from SMS Concast will make the expansion into the stainless-steel long product segment possible.

Hyundai steel Co., located in seoul, South Korea, has awarded SMS Mevac the contract for the supply of a fast vessel-exchange RH (Ruhrstahl Heraeus) unit for its secondary-metallurgy facilities in Dangjin. The RH plant will be designed to treat liquid steel in nominal heat sizes of 155 tons and will include a hydraulically actuated ladle lifting system, a burner lance and a vacuum alloying system for the addition of ferroalloys under vacuum.

ADVANCED PRESSURE REGULATION The vacuum will be generated by a four-stage steam-ejector vacuum pump system with advanced pressure regu- From the left: KM Chun (CTC Clover), Lucio Corsi and Matteo Crosti (SMS Concast), BS Kim (Hyun- lation for optimized process control. dai Steel), Michael Neumann (SMS Mevac), J Lee, TH Min, IH Kim and KH Ka (Hyundai Steel). The fast vessel-exchange RH plant will be part of the existing electric steelmaking shop. After treatment in as well as the supervision of installa- percent, the 150-ton EAF will be oper- the RH plant, the liquid steel will be tion and commissioning. ated with a charge mix of scrap and cast into blooms on a continuous From sMS Concast, Hyundai steel hot metal. This high degree of flexibil- casting machine. The blooms will be will receive an electric arc furnace and ity guarantees an optimal production used mainly for the production of au- a ladle furnace with an annual capacity process and minimized costs for dif- tomotive parts. the scope of supply of a total of 1.1 million tons of crude ferent quality requirements. the RH includes the main basic data, parts of steel. The ordered equipment will en- plant and the furnaces will be com- the basic and detail engineering, the able Hyundai Steel to expand into the missioned at the end of 2015. delivery of key components (e.g. stainless-steel long product segment burner lance, hydraulic system, etc., and complement the range of products www.sms-mevac.com while the existing steam-ejector vac- made in Dangjin with a special focus www.sms-concast.com uum pump system will be modified) on automotive applications. Up to 40

52 Projects — Steel refining

110-t RH plant at Tubos Reunidos. Short cycle time

Tubos Reunidos starts up 110-ton RH plant. Especially convincing performance features are the low level of inclusions and the very low hydrogen content.

Tubos Reunidos s.L.U., spain, has successfully put on is lifted out of the ladle car for the vacuum treatment. After stream its new RH plant supplied by SMS Mevac. The plant, the treatment, the second ladle car takes the ladle and with an annual production of 400,000 tons, produces steel brings it to the caster. Additional benefits of the ladle lifting with extremely low levels of inclusions and hydrogen con- concept are the short vacuum suction line and the direct tent for the manufacturing of seamless steel tube. access to the stationary vacuum vessel. With this plant, tubos Reunidos fulfills the increasing demands on steel cleanness. Via the LF–RH production CONSULTATION IMPROVES METALLURGICAL RESULTS route, Tubos Reunidos will make alloyed steel with low hy- SMS Mevac’s supplies for this project included engineering drogen content in its EAF steel plant in Amurrio, close to and supervision services, as well as the delivery of key Bilbao. A convincing feature is the short cycle time of the components such as the ladle lifting system, vacuum metallurgical treatments, which are executed in both the vessel, vessel transfer car, vacuum pump, toP-burner ladle furnace and the RH plant, with further treatment for lance, electrics, instrumentation and automation. Further, cleanness in a separate ladle treatment station. With an ar- Tubos Reunidos will receive comprehensive consultation by rangement of the plant components, specifically developed SMS Mevac to achieve significantly improved metallurgical for Tubos Reunidos, a short treatment cycle time of less results. than 60 minutes is achieved. The new RH plant is one of two plants recently put into www.sms-mevac.com operation that make use of the new RH-Rocker-Type® ladle lifting device developed by SMS Mevac, and the first to use two ladle transfer cars. With the new lifting device, the ladle

53 Projects sms group newsletter 02 / 2014

Coni v ncing technology: The STEC-Roll®

The exchange of experience with operators of continuous casting plants has led to a trendsetting roll concept developed by SMS Siemag: the STEC-Roll®. SSAB and ArcelorMittal take advantage of the new potential.

The steC-Roll® provides optimum The steC-Roll® design developed by i strand support thanks to a minimal SMS Siemag prevents undesired cohe- Advantages bearing window width. All roll bodies sion between the shaft and the roll. The STEC-Roll® are mechanically interlinked, also in The upgrade does not require the seg- the case of narrow slab formats. For ment frame to be adjusted. this de- Maintenance-friendly the STEC-Roll®, SMS Siemag has design feature makes it possible to bring Removal from a roller line in less veloped different cooling concepts. older plants to the state of art with lit- than 60 minutes The steC-Roll® is maintenance- tle effort. Reusable friendly, enabling a roll line to be dis- The rollers can be used several assembled in less than one hour and SSAB: Improved casting process times. reassembled in less than two hours. For the continuous slab casting Economic Unlike other systems, the steC- plant at its Montpelier works, ssAB Minimized maintenance effort Roll® does not require the use of any Iowa, U.S.A., has ordered twelve reduces costs. special tools. This aspect and the re- STEC-Roll® lines from sMs siemag Easy assembly usability of the rolls lead to a dramat- for use in the bow segment. Here, the Long service lives ic decrease in maintenance costs. rolls improve the casting process and The steC-Roll® can be used in any set new standards for efficient main- continuous casting plant for flat tenance. SSAB decided in favor of the products. Its maintenance friendli- STEC-Roll® because the internal roll ness is one of its most distinctive fea- cooling solution with revolver bore tures. provides the basis for a flexible secondary cooling concept as required SSAB MOBILE: LOW MAINTENANCE for the casting of demanding steel SSAB in Alabama, U.S.A., has or- grades. dered six STEC-Roll® lines from SMS The steC-Roll® will replace two Siemag for its slab caster in Mobile. A driven and ten non-driven rollers in key reason for ssAB to choose the one segment of the existing slab cast- STEC-Roll® design for driven rolls is er. The rollers to be replaced feature the fact that it requires little mainte- maintenance-intensive split bearings. nance and can be easily installed. SS- Nevertheless, the upgrade does not AB expects from the upgrade that it require the segment frame to be ad- will bring the high maintenance effort justed. As an additional service, the down to a minimized level. STEC-Roll® will receive a customized

54 Projects — continuous casting plants

»WE ARE UTTERLY CONVINCED OF THE STEC ROLLS®, DUE TO THEIR LONG SERVICE LIVES AND RELIABLE DESIGN. ROLLS OF THE STEC-ROLL® DESIGN BRING A LOT OF POSITIVE CHANGEs TO US.«

Axel Schulz, Mechanical Maintenance Specialist, ArcelorMittal Eisenhüttenstadt

ArcelorMittal Eisenhüttenstadt: STEC-Roll® with revolver bore for dry casting.

coating applied in the service work- lives are immensely important. the reuse the rolls. Rolls of the steC- shop of sMS Millcraft LLC, U.S.A. by rolls will optimize the casting process Roll® design bring a lot of positive build-up welding. This will further in- and set new standards for efficient changes to us.” crease the lifetime of the rolls. maintenance. SSAB makes heavy plate at several ArcelorMittal Eisenhüttenstadt has Stephan Six locations in the U.S.A. The plates are already had very good experience with [email protected] used in end products for a number of the steC-Roll® in a long-term test exacting applications such as offshore running over a period of 24 months, structures. during which the rolls provided im- pressive results. LONG SERVICE LIVES AT ARCELORMITTAL Axel schulz, mechanical mainte- ArcelorMittal Eisenhüttenstadt has or- nance specialist at the steelworks of dered 88 STEC-Roll® lines from SMS ArcelorMittal Eisenhüttenstadt: “We Siemag. The rolls will be used to up- are utterly convinced of the steC grade the first strand of a two-strand rolls, due to their long service lives, slab caster. The new rolls will be in- the reliable design and the incredibly stalled in eight segments of the easy and quick assembly and disas- straightening zone where long service sembly. What is more, it is possible to

55 Projects sms group newsletter 02 / 2014

Swift width changes

SMS Siemag has developed a process which makes it possible for slab widths to be adjusted efficiently and in a highly flexible way: Delta Speed Adjustment.

Slab width reduction of 200 millimeters – from 1,300 down to 1,100 millimeters over a length of 6.3 meters (LC).

56 Projects — continuous casting plants

With this intelligent process, sMS ment is going on. Especially for grades Siemag achieves shortest transition susceptive to cracking, it is important i lengths thanks to high adjustment to have a smooth transition. this ef- Advantages speeds. The newly gained plant flexi- fectively prevents breakouts. Delta Delta Speed Adjustment bility provides the operators various Speed Adjustment minimizes stress formation in the strand shell and im- benefits in addition to increased plant Faster slab width changes availability and higher yield. proves strand support during the ad- Minimized transition lengths Delta speed not only refers to the justment phase. As a result, narrow- high speed at which the narrow faces face adjustments of more than 400 Minimized risk of breakouts of the molds change their positions, millimeters are no longer problematic. Soft compression of the strand but also to the mathematical algo- shell rithm which controls the adjustment Consistent quality assurance Smaller gap between mold narrow process in the continuous casting The currently available systems for face and strand shell plant. Delta speed Adjustment sets adjusting the slab width during cast- Optimized for handling crack- the mold taper at the same time as the ing have a number of drawbacks. sensitive grades width change proper. This saves time During width reductions, the strand No need to reduce the casting and leads to shorter transition lengths. shell is too heavily compressed; dur- speed A further benefit of the system is that ing width increases, a gap occurs The casting speed can also be it is not necessary to reduce the cast- between the mold and the strand changed during width adjustment ing speed; in other words, the planned shell. With Delta Speed Adjustment, yield does not have to be reduced. The these problems no longer exist. Del- newly developed algorithm is depen- ta Speed Adjustment can be retrofit- dent on the casting length. ted to any existing plants and is also As the drive speed for actuating the suitable for curved molds. narrow-face adjustment adapts automatically, the casting speed may be Ronald Wilmes varied while the narrow face adjust- [email protected]

Delta Speed Adjustment

30 Taper and slab width 1,300 during narrow face adjustment from 1,300 down to 25 1,250 1,100 millimeters.

Source: SMS Siemag 20 1,200 15

1,150 10

5 1,100 width (mm) average narrow face speed (mm/m) 1,050 0 2,000 4,000 6,000 0 2,000 4,000 6,000 transition length (mm) transition length (mm)

57 Projects sms group newsletter 02 / 2014

Cold plate leveler for high-strength plates.

Each leveling roll is driven separately. X-Pact® automation from SMS Siemag.

58 Projects — Hot rolling mills

LEVELER FOR HIGH- PERFORMANCE MATERIALS

To VDM Metals GmbH in Altena, Germany, SMS Siemag is to supply a cold plate leveler. The machine is specifically designed for high-performance materials and equipped with eleven leveling rolls.

VDM Metals GmbH, Germany, has awarded sMs siemag Gerich, Plant Manager, Altena and the order to supply a new cold plate leveler. It will be in- Siegen. To obtain the best possible lev- stalled at the customer’s location in Altena and is intended eling results, the cold plate leveler will i to primarily level plates of nickel-based alloys, titanium al- be equipped, apart from the hydraulic loys and special stainless steels. These materials are used main adjusting system, with separate SMS Siemag for the production of highly stressed products for the chem- hydraulic adjustment for each roll and ical processing industry, the oil and gas industrial sectors, an individual roll drive. A hydraulic In the Altena works, or in the aerospace industry. “The new machine will help us bending compensation system will VDM Metals mainly to attain the flatness that clad grades need for further pro- compensate for the elastic deforma- processes plates that cessing to compound materials,” says Tobias te Kate who is tions during leveling inside the ma- have been rolled at responsible for the modernizing project at VDM Metals. For chine. thus it will be possible to set its Siegen-Geisweid leveling the special materials, the machine will be fitted the correct curvature for each individ- location. To this plant, with eleven leveling rolls. Since the rolls will be separately ual plate in co-action with the X-Pact® SMS Siemag had adjusted and driven, individual rolls may be retracted from automation system and hence to re- supplied a new 2.6-m the process and the leveler can be operated with just seven duce the residual inherent stress. mill stand in 2013. leveling rolls. This gives the machine an extended leveling range for plates having a thickness between 3 and 30 mil- Manfred Dingenotto limeters. “Changing of the operating modes is accom- [email protected] plished automatically and without time losses from one plate to the next,” explains Hemann Schwers, Plant Man- ager Plate Production in Altena.

IMPORTANT CONTRIBUTION TO SHORTENing THE THROUGHPUT TIME The supply package of sMs siemag comprises the mechanical equipment including roller tables and the X-Pact® electrical and automation systems including the leveling model (level 2) and the level-1 automation, drive technology, the operator’s desk with HMI (Human Machine Inter- face) as well as safety systems. Commissioning is scheduled for spring 2015. “The new leveler is an important contribution to reduce the throughput times of hard-to-level dimensional and material combinations”, says Hanno

59 Projects sms group newsletter 02 / 2014

HEAT TREATMENT WITH HIGH COOLING RATE

The Slovenian steelmaker Acroni has placed an order with SMS Siemag to deliver a heat treatment line and revamp a stainless-steel annealing and picking line. As part of the heat treatment line, SMS Siemag will install the newly developed MultiFlex-Quench® for the first time.

Handshakes after signing the contract. Front row, from left to right: Alberto Bregante (SMS Innse), Blaž Jasnicˇ (Acroni), Fritz Brühl (SMS Siemag). Back row, from left to right: Christian Sprung (SMS Siemag), Alberto Vaccani (SMS Innse), Burkhard Dahmen (SMS group), Andrey Zubitskiy (KOKS Group), Anton Chernykh (Slovenian Steel Group), Jens Barth (SMS Meer), Roman Robicˇ (Acroni), Vasilij Prešern (Slovenian Steel Group). Projects — Hot rolling mills

The innovative MultiFlex- Quench® has multiple nozzle systems that guarantees a wide range of cooling rates.

Acroni, a company of the Slovenian Steel Group (SIJ), is a can be tempered in an open-heated roller-hearth furnace highly specialized niche supplier focusing on plates and at temperatures between 400 and 800° Celsius. strips made of stainless grades, tool steels, abrasion-resis- tant steels and HSLA grades. This new heat treatment line ACRONI NOW MORE ENVIRONMENT-FRIENDLY will enable Acroni to further expand its product portfolio. The aim of the modernization of the annealing and pickling The line will be designed for plates with thicknesses line is to reduce the burden on the environment during the ranging from three to 100 millimeters; the range of mate- manufacture of strips made of non-grain oriented silicon rials includes high-strength carbon steels, stainless and grades (NGO, up to 2.4 % Si content), carbon steels and fer- tool steels as well as a range of special grades. For the ritic special steels. To achieve this, the chemical pickling new line, SMS Siemag will supply a roller-hearth furnace line will be replaced by a purely mechanical descaling sys- for hardening and normalizing, a quench of the MultiFlex tem in combination with a brushing section. Dispensing design and a roller-hearth furnace for tempering, as well with chemical descaling and the associated acid regenera- as all auxiliary facilities. These will include the complete tion by the spray roaster process will make the Acroni plate conveying equipment, all systems for the water sup- works much more environment-friendly. The revamping of ply and water treatment as well as the automation of the the annealing and pickling line will also comprise a new systems. automation system, new drives and the installation of strip centering control equipment, deflector rolls and supporting MultiFlex-Quench® for Heavy plate rollers. All activities are planned in such a way that only a The hardening furnace will be equipped with two chambers, minimum of construction work will be necessary, thus en- in which the plates will be annealed in a nitrogen-based suring short downtimes and rapid commissioning. inert gas atmosphere. Heating to up to 1,100° Celsius will The order is being carried out by SMS Siemag in Ger- be carried out indirectly using radiant heating tubes. many together with SMS Innse (Italy). Commissioning in the The innovative MultiFlex-Quench® is characterized by its Jesenice (Slovenia) plant is planned for 2016. In 2013, SMS exceptionally high degree of flexibility. It sets itself apart already delivered a new 2.6-m heavy-plate stand and a roll- from other quenches by the extremely wide range of cool- er quenching station to Acroni. ing rates, from abrupt water quenching right down to gen- tle cooling, achieved by multiple nozzle systems. As a re- www.sms-siemag.com/furnace-technology sult, flexible cooling patterns are possible for a wide range of different steel grades. squeezer rolls fix the plate in place and hence ensure good plate flatness, even at high cooling rates. Following the MultiFlex-Quench®, the plates

61 Projects sms group newsletter 02 / 2014

POWER PACK FOR NISCO

Nanjing Iron & Steel commissioned its new heavy-plate mill. With a rolling force of 120 MN the mill stand belongs to the strongest ones in China.

In 2013, Nanjing Iron & Steel Co. Ltd. (NISCO), put on ing roll adjustment and the drive stream, in the Chinese province of Jiangsu, a 4.7-m heavy- torques as a function of material prop- plate mill supplied by SMS Siemag. Only seven months erties and plate dimensions. The later, at the earliest stage ever for a mill in China, the shearing line includes a cropping company granted its final acceptance. The new plant is shear, a double-side trimmer and a di- designed for an annual capacity of 1.6 million tons and is viding shear. All shears are designed able to process slabs as well as blooms up to a thickness for cutting high-strength plates up to a of 600 millimeters. On its heavy-plate mill, NISCO produc- thickness of 50 millimeters. es plates with widths of up to 4,850 millimeters and thicknesses between 8 and 250 millimeters. For the new heavy- Frank Werner plate mill, SMS Siemag supplied the finishing stand, a [email protected] pre-leveler and a hot plate leveler as well as a shearing 9heavy-plate mills line. The package by SMS Siemag furthermore comprised have been supplied the X-Pact® electrical and automation system for profile to China by SMS and flatness control in the finishing stand and the leveling Siemag since 2005. models for both levelers.

CLOSE GEOMETRICAL TOLERANCES AND HIGH REDUCTIONS The finishing stand has a rolling force of 120 MN and is one of the strongest mill stands of its kind in China. It is equipped with hydraulic adjustment, work-roll bending and CVC® plus (Continuously Variable Crown) systems. Work roll bending and the position of the CVC® shifting system are adjusted by the profile and flatness control from pass to Watch a video on the pass. Thanks to the optimum setting of the roll gap for each Mill stand with CVC® plus technology. Nisco heavy-plate pass, higher reductions, the best possible number of pass- mill via the below es and very close geometrical tolerances can be attained. link or by scanning The pre-leveler upstream the plate cooling section is Facts + Figures the QR code. equipped with seven leveling rolls including roll pre-bend- Commissioning September 2013 www.sms-siemag. ing system. Thus, flatness deviations of the entering stock Annual production 1.6 million tons com/qr/nisco are remedied to ensure a homogenous cooling effect in the Plate width 1,800 to 4,850 mm downstream plate cooling section. The hot plate leveler is Plate thickness 8 to 250 mm designed as a nine-roll unit and has a maximum leveling Plate thickness ship-building steel, force of 44 MN. Adjustment of the leveling rolls is purely tube grades, pressure hydraulic. Both levelers operate with the SMS Siemag lev- vessel grades, structur- eling model, which is based on the mathematical-physical al steel, HSLA steels description of the leveling process and calculates the level-

62 Projects — HOT AND Cold Rolling mills

SMS Innse is the specialist for inline The cold rolling mill at ASA meets high Similar slab sizing press for slab width reduc- skin-pass mills. security standards. tion in one pass.

Extra High require- Reduced thick ments width

Skin-pass mills ASA now producing Xichang Steel receives a from SMS Innse. cold strip. slab sizing press.

25 inline skin-pass mills for galva- The six-high CVC® plus cold rolling PIETC Panzhihua Co. Ltd. has award- nizing lines, annealing lines, tin- mill at ASA Alüminyum Sanayive Ti- ed SMS Siemag the contract for ex- plate, combined annealing and caret A. in Akyazi, Turkey, success- panding the roughing mill in its hot galvanizing lines, have been sold fully started operation. Commission- strip mill in Xichang City, China, worldwide by SMS Innse in the last ing by SMS Siemag has brought ASA through the addition of a slab sizing ten years. Adding to this are two new Alüminyum a big step closer to its press. the aim of the revamp is to orders for particularly thick dimen- goal of establishing itself on the make the production process more sions. The first one was placed by a market also as producer of alumi- flexible. With an edging force of up to Turkish Service Center. The stand is num flats, especially of sheet panels 22,000 kN, the slab sizing press will presently under shipment and will and foil starting stock. SMS Siemag reduce the slab width to the required be installed in the course of 2014. supplied the complete rolling mill in- dimension, by up to 350 millimeters The second order was signed at the cluding the X-Pact® electrical and in one pass. By casting slabs with a beginning of March this year. In both automation system, coil preparation higher average width and a reduced orders, the strip width will be up to station, utility systems and fire extin- number of casting sizes, Xichang 2,100 millimeters. Both inline skin- guishing equipment. the Airwash™ Steel can increase the throughput pass mills will be equipped with bot- exhaust air cleaning system makes rate of its continuous casting ma- tom hydraulic roll force cylinders, the cold rolling mill satisfy even chine. The slab sizing press addition- positive and negative bending actua- highest requirements with respect to ally allows more flexibility in the tors, independent drives and top environmental compatibility. In addi- scheduling of the rolling programs. passline adjustment. Both projects tion to CVC® plus, the plant is equip Xichang steel produces carbon are on a turnkey basis. ped with all proven actuators and steels for pipelines as well as for the technological controls needed for construction of ships, bridges and rolling aluminum strips that are up to buildings, among other things. 2,200 millimeters wide to final thicknesses of minimum 0.1 millimeter.

www.sms-innse.com [email protected] www.sms-siemag.com/hot-rolling-mills

63 Projects sms group newsletter 02 / 2014

Pul s 40 percent

In February 2014, International Steels Limited (ISL), Pakistan, selected SMS Siemag to extend its Reversing Cold Mill (RCM). The two-stand Compact Cold Mill (CCM®) will increase the annual capacity by 40 percent.

The four-high RCM of CVC® -plus de sign by sMs siemag is the first cold rolling mill of its kind in Pakistan. Since 2011, ISL has been producing on this RCM high-quality cold strip with widths ranging from 700 to 1,250 millimeters and final thicknesses of minimum 0.25 millimeters. The annual capacity is 250,000 tons. Precautions were made already in the planning phase of the RCM to permit economical extension of the plant to a two- stand CCM® later on. These concerned The RCM at ISL will be supplemented by a second mill stand to come primarily the layout of the foundations as CCM®. The second mill stand will be established on the left side. and media systems. ISL recently exer- cised its option and awarded sMS Siemag the order for an extension second mill stand. torsten seeger, which will increase the annual capaci- Project Manager of sMs siemag, ty by 40 percent. comments: “The plant extension i schedule was made to keep the down- NO CAPACITY ADAPTATIONS time as short as possible. ISL will be CCM® SMs siemag will supply the second able to start production on the CCM® mill stand which is of identical design in mid 2015.” Compact Cold Mills to the existing one, as four-high stand Due to the geographical proximity to (CCM®) efficiently with hydraulic adjustment, CVC® plus ISL in Pakistan, esmech equipment close the capacity and work roll bending system. the Pvt. Ltd., sMs siemag’s Indian joint- gap between single- supply package of the second stand venture partner, will supply further stand reversing mills furthermore includes the X-Shape plant components, including equip- and tandem cold flatness measuring system. As the ment for roll changing, the interstand mills. In the range capacity of the emulsion system has area, enlargement of the mill stand up to 800,000 tons been designed for two-stand opera- platform and stand enclosures as well per year, they opti- tion right from the beginning, capacity as valve stands for the LP hydraulic mize investment and adaptation is not required. the only system. operational costs. thing to do is replace the exit-side equipment such as tension reel and www.sms-siemag.com/ coil car to permit installation of the cold-rolling-mills

64 ProjectsProjects — CCooldld RRoollinglling millsmills

Situated in Southwestern Vietnam, close to Ho Chi Minh City, is the province of Bình Du´o´ng, one of the centers of national industrial development. SEN CO D ORDER FROM VIETNAM in a YEAR

From Hoa Sen Group, Esmech Equipment Pvt. Ltd., the joint venture partner of SMS Siemag, in India, received an order to supply a single-stand reversing cold mill.

Hoa Sen Group

Hoa Sen Group was founded in 2001 and is domiciled in speed of 1,400 meters per minute. The main products the province of Bình Du´o´ng, an industrial center north of The CVC® plus technology by sMS of the group are gal- Ho Chi Minh City. The company ordered a six-high revers- Siemag together with other proven vanized and color- cean/Corbis O ing cold mill (RCM) with CVC® plus. For the second time rolling technologies will ensure pre- coated sheets. Until within one year, customers from Vietnam rely on the roll- mium strip quality. Commissioning of 2017, production is Instant/ an ing mill technology of the Indian joint venture partner of the plant is scheduled for August planned to rise from in

SMS Siemag. 2014. 650,000 tons (2013) ternity

E On this RCM, which will have an annual capacity of to one million tons. 2/ 200,000 tons, the Hoa Sen Group will produce strips with a www.sms-siemag.com/ page: minimum thickness of 0.11 millimeter. the plant is de- cold-rolling-mills signed to roll low-alloy carbon steel strips having widths

Photo right between 650 and 1,250 millimeters at a maximum rolling

65 PROJECTS sms group newsletter 02 / 2014

Latest visualization technologies: Infor- mation visualization shown for the integration of 2D plant drawings into the 3D plant model.

66 PROJECTS — Aluminum plants

VIRAL TU tour of ALUMINUM PLANTS

The Chinese company Tianjin Zhongwang is implementing the second stage of its mega production complex for aluminum flats. All facilities are supplied by SMS Siemag. In the Digital Workshop the customer gets to know the plant already before it is completed.

One of the largest production sites for When tianjin zhongwang started to aluminum flats in China to date is implement the second stage, it award- presently under construction in Tianjin. ed SMS Siemag a further order cover- The company Tianjin Zhongwang Alu- ing rolling mills primarily designed for 0.15/0.2 minium Co. Ltd. has planned an alumi- the production of material that is used num complex to be established in sev- to make beverage cans. the supply eral stages and awarded SMS Siemag package for the second stage includes millimeter is the final thickness of the flats Tianjin Zhongwang produces on its three-stand the complete supply of hot and cold a 1+5 hot rolling mill comprising one cold tandem mills after thickness reduction. rolling mills for the new production reversing roughing stand and one five- site. This order helps SMS Siemag to stand finishing mill of four-high design further extend its own market position for final thicknesses of minimum as systems supplier of mechanical, 2.00 millimeters. Adding up are two electrical and automation equipment single-stand cold rolling mills and two as well as media systems for turnkey three-stand cold tandem mills, each of aluminum production plants. In addi- six-high CVC® design, for thickness tion to the rolling mills, SMS Siemag is reductions down to a minimum final to supply a strip coating line. gage of 0.20 or 0.15 millimeters re- The first construction stage com- spectively. It is planned to complete prises one hot rolling mill and two cold the plant complex with a strip coating rolling mills for the production of hard line. In the final construction stage, aluminum grades. the facilities in- Tianjin Zhongwang will be able to sat- clude a 1+1+3 aluminum hot rolling isfy all market demands on high-grade mill consisting of two reversing rough- aluminum flats. ing stands, a three-stand finishing mill and all associated equipment units COMPREHENDING THE STRUCTURE needed for the production of aluminum The package supplied by SMS Siemag plates and strips. For further thickness to Tianjin Zhongwang is not restrict- reduction of the aluminum hot strip ed to plant equipment and machin- down to a final gage of 0.2 millimeters, ery; it also includes numerous train- Zhongwang’s plant comes with two ing measures providing know-how single-stand six-high aluminum cold for plant operation. From January 13 rolling mills with CVC® plus. to 17, 2014, seven members of the

67 PROJECTS sms group newsletter 02 / 2014

»The virtual training was a great help in better imparting the plant parameters.«

Klaus Siegert, Project Manager, SMS Siemag

customer’s staff, including the future shop managers of the cold roll- i ing and strip coating plants, attended a training course on the mechanical Tianjin Zhongwang and fluid-related equipment of the Tianjin Zhongwang aluminum cold rolling mills. The un- Aluminium Co. Ltd. derlying purpose of this training was is an affiliate of to provide a basis for comprehending China Zhongwang the rolling mill structure and opera- Holding Ltd. with tional processes as well as to en- headquarters in hance the knowledge on plant tech- Liaoning, a private nology. to this effect, sMs siemag enterprise belong- made use of future-oriented teaching ing to the leading and learning aids: The Digital Work- producers worldwide shop. of extruded aluminum products which FURTHER TRAINING planned are mainly used to Following a simulated plant tour in build rail and utility the Digital Workshop, the trainees vehicles and paid a visit to the mechanical work- in aviation. shop at the Hilchenbach location to inspect the equipment. On that occa- sion, they could recognize the virtual machines and functions they knew from the Digital Workshop and were especially and deeply impressed by the actual size of the mill stands. It is planned that the employees of Tianjin Zhongwang participate in further training courses in the Digital Workshop. Millstand of a finishing mill for aluminum hot strip.

68 PROJECTS — Aluminium plants

The advantages of virtual engineering have been used in a special projection room at the Düsseldorf location since 2006.

SIMULATED REALTIME-CAPABLE PLANT tour IN THE DIGITAL WORKSHOP

SMS Siemag’s Digital Workshop ap- sional by means of efficient 3D visu- 1,000 customers have visited the Dig- plies the most modern technologies alization. Data models and special ital Workshop. the integration of of virtual engineering. Even more: It software applications from the fields simulation tools and plant-specific is a communication and working of 3D CAD, simulation technology and information allowed the participants platform especially developed by SMS immersive, real-time-capable visu- from Tianjin to be presented a com- Siemag for its customers. alization methods are used and prehensive insight into the machines Virtual engineering will change combined to this effect. the Digital and operating functions of the cold plant design and construction in the Workshop supports, optimizes and rolling mills. The term “insight” can future as it provides methods and shortens all processes involved in the be taken quite literally, since the vi- digital tools for planning, design, construction of plants like in Tianjin sualization technology permits a view qualification and safe plant opera- – from the planning phase via imple- of plant components that are difficult tion. With its 3D plants and 3D pro- mentation up to training. to recognize on drawings or hard to cess simulations, virtual engineering Experience shows that training at access after the plants will have been offers real-time visual demonstra- interactive, virtual plants is more ef- installed. tions using virtual reality methods. ficient than training solely on the ba- In specially equipped projection sis of videos and manuals. Due to www.sms-siemag.com/en/aluminium rooms, digital models of plants, com- this experience, the Digital Workshop ponents or production processes are of sMs siemag has consistently presented to the viewer three-dimen- been expanded. Up to now, more than

69 Projects sms group newsletter 02 / 2014

EPX ERT IN ANNEALING LINES

China relies on annealing lines from SMS Siemag. This is proven by new orders for six high-strength steel plants.

During the past few months, a total of be equipped with a water-spray cool- and tested as a result of 25 orders for six orders have been awarded to SMS ing section in addition to gas cooling. continuous annealing lines since the Siemag covering the supply of continu- This water cooling technology per- year 2000, and is constantly being ous annealing lines. these lines are mits much higher cooling rates to be adapted to new challenges. This en- scheduled to go on stream in 2015 and attained and thus to produce dual- sures smooth and secure running of 2016 and will produce high-strength and complex-phase as well as mar- the high-strength strips through the and advanced high-strength steels tensitic grades. lines, even at high speeds. Electrical for the growing Chinese and interna- As the leading supplier worldwide and automation systems will be sup- tional automotive industry. Car makers of continuous annealing lines for plied from one source as well. As sys- are increasingly using high-strength high-strength steels, SMS Siemag of- tems supplier, SMS Siemag is able to grades to produce safe vehicles with a fers the complete equipment range perfectly harmonize all plant compo- low total weight and hence reduced and know-how for the installation and nents which will lead to high produc- energy consumption. operation of the lines. The mechani- tivity soon after start-up. cal and the process-related equip- EFFECTIVE COOLING SYSTEMS ment of the annealing lines is tried [email protected] The essential factor for obtaining such high-strength steel grades is sophisticated furnace technology with high cooling rates. together with Drever International, the market leader in the field of annealing furnaces, sMs siemag offers an eco- friendly radiant-tube furnace and highly efficient cooling systems. Cool- ing is an important process step, especially when high-strength material grades are concerned, as the material properties are set by a rapid cooling method. With its effective gas cooling the Drever ultra fast cooling system achieves cooling rates of up to 130 kelvins per second referred to a strip thickness of one millimeter. These cooling rates are necessary to produce high-strength dual-phase and TRIP steels with tensile strengths Annealing lines made by SMS Siemag with a Drever radiant-tube furnace are much asked for of up to 980 MPa. Two of the lines will in China.

70 PROJECTS – Strip processing lines and furnace technology

i FACTS + FIGURES

Six annealing lines for chinese customers CUO ST MER/LINE STRIP DIMENSIONS SPEED ANNUAL HIGHLIGHTS WIDTH THICKNESS ENTRY PROCESS EXIT CAPACITY Bengang 800–1,630 mm 0.30–2.3 mm 700 420 820 930,000 t Drever radiant-tube furnace with ultra Steel Plates fast cooling system, 6-high inline skin- CAL 1630 pass millstand with CVC®, and work- and intermediate roll bending, high Bengang 1,000–2,150 mm 0.50–2.5 mm 700 420 820 1,000,000 t process speed and capacity Steel Plates CAL 2150

Chinese 750–1,650 mm 0.50–2.5 mm 200 140 200 450,000 t X-Pact® electrical and automation system steelmaker, by SMS Siemag, Drever radiant-tube North China furnace with ultra fast cooling and water- spray cooling system, 4-high inline skin- pass millstand and tension leveler Angang Steel n.s. n.s. n.s. n.s. n.s. 600,000 t X-Pact® electrical and automation Company system from SMS Siemag, Drever Limited CAL radiant-tube furnace

71 Projects sms group newsletter 02 / 2014

Layout of a water-spray cooling system including circulation tank, pinch rolls and drying section.

QUICKLY COOLED

The water-spray fast cooling system from SMS Siemag is the right solution for ultra high-strength steels for the automotive industry.

Manufacturers of automobiles increasingly use ultra high- Within a very short strength steels in order to reduce weight and save fuel. time, the red heat strip is cooled by Beyond that, these steels help improve the accident behav- water-spray action. ior of vehicles. Cold strip processing lines with the water- spray fast cooling system are specifically designed to produce such high-strength steel strips for all internal parts of a vehicle. the water-spray cooling system of sMS Siemag is able to attain tensile strengths of partly more than 1,500 MPa. These high-strength dual- and complex-phase as well as martensitic grades are mainly used to produce crash- proof core components in the passenger compartment such as the A-pillar and B-pillar, door beams and roof bows. That’s the way steel products improve the safety of strengths. In the water-spray section, the strip immerses in modern automobiles and, at the same time, reduce their demineralized water and, during this immersion, both sides weight. Some components are up to 30 or even 40 percent are sprayed with water by special nozzles. This continuous lighter in weight. spraying action under high pressure creates turbulences that ensure fast dissipation of the heat energy. In the nozzle COOLING RATES OF MORE THAN 1,000 KELVINS PER SECOND chambers strips are cooled down from 700 degrees Cel- The water-spray system for fast cooling of steel strip down- sius, for example, to 60 degrees Celsius at a strip speed of stream of the recrystalization section of a continuous an- 140 meters per minute within a very short time. In other nealing line is able to achieve cooling rates that are dis- words, cooling by more than 600 kelvins is achieved within tinctly above those attainable by gas cooling sections. Due less than half a second. During this short period and over a to the high specific heat capacity of water, a large amount distance of just one meter the strip microstructure is com- of heat energy can be dissipated through spraying within a pletely transformed with the result of dimensional changes very short time. The cooling rates thus achieved are above of the steel strip. In co-action with a strip shape control, the 1,000 kelvins per second and millimeter strip thickness special nozzle configuration ensures a uniform cooling re- compared to at most 130 kelvins per second and millimeter sult over the entire strip width, preventing the formation of strip thickness attainable in advanced cooling systems distortions or flatness defects. The system has been in use based on gas. With the aid of such cooling systems it is pos- at an American company since 2013. Two orders were re- sible to produce steel grades with very high tensile cently awarded to SMS Siemag from China.

72 PROJECTS – Strip processing lines and furnace technology

The DUMA-BANDZINK air knife system can The evaporation systems at Shougang Jingtang With an entry-section trimming shear, be applied for the production of galvanized save operating costs and resources. Wuppermann will produce strip with and aluminized strip. galvanized edges.

Galvanized Conserving Precise strip strip resources trimming

Pangang orders Evaporation systems in Efficient production of galvanizing system. tinning lines. galvanized strip edges.

DUMA-BANDZINK was awarded an or- Through the commissioning of evapo- For the entry section of the hot strip der to supply an air knife system for the ration systems together with the new hot-dip galvanizing line of Wupper- new hot-dip galvanizing line of Pan- electrolytic tinning lines at Shougang mann staal in Moerdjik, nether- gang Group Chongqing Highstrength Jingtang, China, sMs siemag again lands, sMs siemag will supply a Galvanized Automobile Steel Sheet Co. demonstrated its engagement in con- 7-roll pre-leveler and a trimming Ltd. The line will be established in the serving resources. Reconditioning of shear unit. thus, Wuppermann will south of China for the joint venture of contaminated rinsing water in the be able to produce hot strip with gal- Angang steel Company and Pangang evaporation system is accomplished vanized edges in a single pass in the Group. About 450,000 tons of high- by separation into distillate and con- future. The so-called “silo sheet” is strength steel grades will be hot-dip centrate. The evaporators are heated often used in storage containers for galvanized or aluminized with the high- by means of steam from the process. bulk materials. est surface quality demands for the The resulting concentrate is reused in Both components will be supplied automotive industry. The air knife sys- the active bath whereas the distillate as network-capable package units tem can be operated in 3-roll mode is returned to the rinsing bath. Oper- including automation and control (galvanizing) and in 2-roll mode (alumi- ating costs are significantly reduced systems that can be easily integrated nizing). DUMA will supply the air knives by the closed-circuit design. Thus, up and put on stream. Integration will including sink roll, correction roll, to 250 tons of tin can be recovered per be accomplished by Wuppermann. stabilizing roll and pinch roll units, year. In the electrolysis as well as in For precise strip trimming it is first knife gap cleaning, contact-free edge the passivating process, 15 to 20 per- flattened by a 7-roll pre-leveler. The masks, cold gauging including closed- cent of the up to 3,800 liters of rinsing trimming shear is equipped with au- loop coating thickness control, electri- water fed per hour can be returned as tomatic adjustment and an integrat- cal and roll shop equipment. The DU- concentrate and the residual volume ed burr masher for smoothing burrs MA-BANDZINK air knife system can be as condensate. as well as a scrap chopper to ensure used for the production of galvanized trouble-free removal. and aluminized strip.

[email protected] [email protected] [email protected]

73 Projects sms group newsletter 02 / 2014

H OT-DIP GALVANIZING OF HIGH-ALLOY STEELS

Two hot-dip galvanizing lines will be supplied to China by SMS Siemag. Integrated Drever furnaces convince by their oxidation chamber.

The companies Angang Steel Company and Bengang Steel DREVER FURNACES WITH OXIDATION CHAMBER Plates Co., Ltd. (both China) awarded SMS Siemag one or- In both lines, the radiant-tube furnaces from Drever In- der each for the supply of a hot-dip galvanizing line. The ternational stand out by their high cooling rates (ultra lines will serve the rising demand for high-quality and fast cooling system) and an efficient and eco-friendly high-strength automobile sheets in China and will be mode of operation at high capacity. Particular units in equipped to produce galvanized or galvannealed steel strips these furnaces are the oxidation chambers serving for including deep-drawing steels and high-strength grades. targeted oxidation and later surface reduction of steels In addition to structural components, the plants will pro- which have a high manganese or silicon content in order duce strips for exterior car body parts. The lines will start to improve their wettability. operation at the end of 2015 and are both designed for the production of half a million tons. They come with low ex- ANGANG STEEL COMPANY penses for production, high quality and a wide portfolio. Angang’s line will be established in a new plant close to Convincing solutions from one source: Besides the hot- Guangzhou, a city in the province of Guandong. Integrated dip galvanizing line with furnaces and air knife system, in this line will be a premium-quality air knife system by SMs siemag will supply all further plant components DUMA-BANDZINK: thanks to a radial controller, auto- (cleaning section, tension leveler, skin-pass millstand, matic knife lip cleaning and nozzle gap width adjustment, roll coater, trimming shear, oiling machine, etc.). since among others, high surface qualities will be attained. the year 2000, SMS Siemag has sold a total of 28 hot-dip For this project, SMS Siemag will furthermore supply galvanizing lines. the complete electrical and automation systems.

The furnace by Drever International has an oxidation chamber to prevent wettability problems when processing high-alloy steels (Graphical representation of the Angang line).

74 PROJECTS – Strip processing lines and furnace technology

The line is designed to process strips with thicknesses from 0.4 to 2.5 millimeters and widths between 800 and 1,880 millimeters.

BENGANG STEEL PLATES CO., LTD. The line for Bengang is part of the new cold rolling mill No. 3 in the province of Liaoning in North China. For a galvanizing process with high surface qualities at low zinc consumption, a fully equipped FOEN air knife system including FOEN DEMCO® strip stabilization will be integrated. To produce automotive grades for interior and exterior parts, technical assistance and know-how will be provided by MET/Con for production and subsequent certification. The strips to be processed will be between 800 and 1,870 millimeters wide and from 0.4 to 2.5 millimeters thick.

75 Projects sms group newsletter 02 / 2014

Right: The new line at Shagang is designed to galvanize 320,000 tons of steel strip per year.

Below: Prior to annealing in the Drever furnace, the strip surfaces are freed from all dirt residues in a cleaning section.

Jiangsu

Jiangsu is a province in East China. It is situated at the mouth of the Yangtze and belongs to China’s most pros- perous and densely populated regions of the People’s Republic.

76 PROJECTS – Strip processing lines and furnace technology

S : HAGANG FIRST COIL GALVANIZED

Shagang, China, mainly uses its recently commissioned hot-dip galvanizing line, supplied by SMS Siemag, to produce steel strip for the household appliances and automotive industries.

At the end of December 2013, the Chinese company Sha- construction stage, one million tons of strip are planned to gang succeeded in galvanizing its first coil. since then, be produced in the Zhangjiagang Yangzi River Cold Rolling numerous further strips have been processed and strip Sheet works. Adding to the hot-dip galvanizing line, SMS quality has been continuously improved. The galvanizing Siemag will establish a tinplate annealing line as well as line serves to provide the cold strip with durable corrosion an electrolytic tinning line. The plant is located in Zhangjia- protection and an appealing look as well as an increased gang City in the Province of Jiangsu, East China. mechanical load capacity. For this purpose, the strip is annealed and then coated by means of zinc or aluminum/ www.sms-siemag.com/strip-processing-lines zinc. Shagang supplies the galvanized steel strips primarily to producers of high-grade household appliances and to the automotive industry. FAST CHANGE OF COATINGS i The line is equipped with a top-quality cleaning system for FACTS & FIGURES strip pre-treatment. In a Drever radiant-tube furnace, the strip is annealed and cooled down to the temperature re- HOT-DIP GALVANIZING LINE quired for galvanizing. To precisely set the thickness of the Annual production 320,000 t zinc layer for an unobjectionable surface quality, an air Strip thickness 0.25 – 2.0 mm knife system by Fontaine Engineering is integrated in the Strip width 750 – 1,300 mm Entry speed 270 m/min line. Two zinc pots and one pre-melt pot permit fast coat- Process speed 190 m/min ing changes. For post-treatment, the exit section of the Exit speed 270 m/min line is equipped with a skin-pass millstand, a tension leveler and a roll coater. Thus, it is possible to exactly set the STEEL GRADES surface roughness and flatness of the strip, and to protect CQ, DQ, DDQ, EDDQ, HSS and BH-IF the surfaces against white rust by means of a passivation layer. This was the first time SMS Siemag Processing Lines China had designed a complete line on its own and been responsible for order handling. In addition to the design and manufacture of core components, the order scope comprised supervision of installation and commissioning. Order transaction had been supported by further sMS Siemag companies in China and Europe. The lines are part of the first cold rolling mill for Shagang Group. In the initial

77 PROJECTS sms group newsletter 02 / 2014

L-EOW EN RGY COATING

Tianjin Zhongwang has ordered a color coating line for aluminum can material. In the seaport Tianjing, 82,000 tons of strip will be produced as of 2016.

All plant components for the new color sivating chemical. Two finish coaters coating line of tianjin zhongwang with premium control systems en- (Tianjin zhongwang Aluminum Co., sure a uniform and precise coating Ltd.), China, will be supplied by result in the layer thicknesses re- SMs siemag from one source. to be 82,000 quired at low media consumption. In mentioned in particular is the com- a flotation oven the solvents are out- pact coating process. the chemical tons per year of can material will be gassed without contacting the mate- strip pre-treatment, downstream color produced by Tianjin Zhongwang’s new color rial to make the color layer harden on coating equipment and the drying oven coating line as of 2016. the strip. Over the entire length of the are perfectly harmonized. For many oven, the strip is uniformly heated by products, the drying oven exclusively applying hot air and kept floating on uses energy recovered from the pro- an air cushion. This avoids mechani- cess. Hence, it is possible to achieve tion systems. Apart from design and cal contact inside the oven and safe- high product quality at low consump- manufacture, SMS Siemag will be re- guards a perfect surface free from tion of resources and energy. sponsible for the supervision of erec- defects. tion and commissioning. As of 2016, The out-gassed solvents are burned SUPERVISION AND COMMISSIONING the line will produce 82,000 tons of by a regenerative post-combustion INCLUDED color coated can material in the sea- system (RTO) with high thermal effi- In addition to the coating process fa- port Tianjin in North China. To attain ciency. Thus, strip heat treatment can cilities, the supply package will in- the surface properties required for be accomplished for a wide product clude all mechanical equipment and color coating, the strip is initially range without feeding external ener- the complete electrical and automa- cleaned and then covered with a pas- gy (autothermal operation). to pro-

78 PROJECTS – Strip processing lines and furnace technology

The color coating line at Tianjin Zhongwang, China, is 213 meters long. Entry and exit sections are located on the same side, which is advan- tageous for coil handling.

i FACTS + FIGURES

Technical Data: Commissioning 2016 Annual production 82,000 t Strip width 950 to 2,000 mm Strip thickness 0.15 to 0.5 mm Entry speed 300 m/min Process speed 250 m/min Exit speed 300 m/min Alloys aluminum alloys (3xxx series 5052 and 5182)

tect the color-coated strips and improve their properties for further processing, a wax layer can be applied by means of a heated vertical roll coater in the exit section of the line.

[email protected]

Color coating by finish coaters: One U-roll coater for the strip top side (above) and one S-roll coater for both strip sides (below).

79 Projects sms group newsletter 02 / 2014

From the new control pulpit, operators have a clear view of the production 200 process. or even more drive units are harmonized and tuned by SMS Siemag experts when designing the drive systems of coating lines. The result: highest strip quality and maximum productivity.

80 PROJECTS – Electrics and automation

E /a SYSteMS IN DEMAND IN CHINA

Recently, SMS Siemag has received a great number of new contracts from customers in China who are ordering strip processing lines including proprietary electrical and automation systems. This is because this way the customers will get everything from a single source.

One contact person of SMS Siemag fulfills this request from The high-precision closed-loop control of the coaters ensures many plant operators also in the field of strip processing that the aluminum strips are uniformly and accurately coat- lines. In addition to all mechanical, thermal and processed. Designing the drive system often involves the tuning of technological components, sMs siemag also provides the more than 200 drive units by the sMs siemag experts. An X-Pact® electrical and automation packages for these lines. optimal design of the drive equipment and control system is a Therefore, Tianjin Zhongwang and a further Chinese alu- precondition for best strip quality and maximized production. minum producer decided in favor of SMS Siemag as the full- SMS Siemag responds to the growing complexity of automat- range supplier for their new color coating lines. The inte- ed plants by innovative visualization concepts with a very grated concept, which includes the supply of the electrical strong operator focus. This particularly includes an improved and automation systems, also convinced two Chinese steel- ergonomic and user-friendly set-up of the work place. The makers who were both planning to build a new continuous new SMS Siemag HMI concept provides the operators with annealing line for ultra-high-strength steels. Also the cus- additional transparency and orientation, in other words with a tomer Angang decided in favor of SMS Siemag’s integrated clearer view of the production process. package for its new hot-dip galvanizing line project. HIGH PRODUCT QUALITY RIGHT FROM THE START PLUG & WORK SPEEDS UP COMMISSIONING The fact that there is just one project manager with overall The Plug & Work tests markedly cut the time needed for responsibility for all trades involved in the project, working commissioning the equipment. Also in China, namely at the closely with an interdisciplinary team, guarantees optimal facilities in Beijing, it is possible to perform realistic simu- solutions and short project handling periods. Consequent- lations of the equipment prior to the actual commissioning. ly, the plant can be ramped up quickly while making high- Firstly, the complete automation equipment of the custom- quality products from the very beginning. er’s plant is set up in the test fields. A simulation system then simulates the plant and the production process. This [email protected] allows the authentic automation equipment to be tested and optimized under realistic conditions, while the customer’s personnel is provided with intensive training. SMS Siemag also supplies a dedicated furnace modelling computer for the associated furnaces of the aluminum lines.

81 Projects sms group newsletter 02 / 2014 160 tons per hour is the capacity of the walking- beam furnaces, which will provide the feed stock for the two light-section mills supplied A continuous billet caster is part of the equipment by SMS Meer. supplied by SMS Concast to Tulachermet-Steel.

SMS Siemag will be responsible for the supply of the 160-ton converter shop.

82 Projects — Group

ODR ER FROM RUSSIA

Tulachermet-Steel orders complete steelworks with two connected light-section mills from the SMS group.

Tulachermet-Steel and sMS group CASTING OF SQUARE SECTIONS have concluded a contract for the sup- SMS Concast is supplying a ladle fur- ply of a complete steelworks with a nace, a twin-tank vacuum degassing connected continuous billet caster and facility for the secondary metallurgi- two connected light-section mills. The cal treatment and a six-strand billet order value comes to around EUR 180 caster. The continuous caster will be million. The contract was signed on the equipped with CONVEX technology® SMS Meer booth at the Tube & Wire fair and be able to produce square sec- in Düsseldorf, Germany, in the pres- tions in sizes from 150 x 150 to 180 x ence of the State Secretary of the Min- Back row from left to right: Ulrich Svejkovsky, 180 millimeters. SMS Meer is supply- istry of Economic Affairs of the Federal SMS Meer; Reinhard Reddel, SMS Siemag; ing two almost identical light-section Yevgeniy Shmagin, Consul General of the State of north Rhine-Westphalia, Dr. Russian Federation; Dr. Günther Horzetzky, mills, each of which will receive their Günther Horetzky, and the Consul Gen- State Secretary of the Ministry of Economic feed stock from a walking-beam fur- eral of the Russian Federation, Yevgeniy Affairs, Energy, Industry, Small and Medium- nace with a capacity of 160 tons per Shmagin. Sized and Craft Trades of the Federal State hour. One of these light-section mills of North Rhine-Westphalia; Jens Barth, SMS It was agreed to construct a convert- Meer; front row from left to right: Sergey will be equipped with a wire rod line er-based steel and rolling mill complex Frolov, Vice President, Strategy & Com- for the production of quality steel in in the immediate vicinity of the Tulach- munications KOKS Group; Konstantin Pitjul, the form of bar steel and wire rod. The Director General Tulachermet-Steel; Andrey ermet iron works located in tula, Zubitskiy, Senior Vice President KOKS Group; SMS group is also supplying the elec- around 200 km to the south of Moscow. Burkhard Dahmen, SMS group; Bernhard trical and automation systems for all Tulachermet-Steel will assume the Espendiller, SMS Siemag. production lines. tulachermet-Steel project management and the construc- is a Russian-based company estab- tion activities. the contracts for the gineering and automotive companies. lished by several investors with the construction and installation work will The steelmaking and rolling mill com- participation of shareholders of the be placed with Russian companies. plex will go into operation in 2016. SMS KOKS Group. the KOKS Group is a Siemag is supplying a 160-ton con- leading producer of merchant pig iron WITH ENERGY RECOVERY SYSTEM verter shop, equipped with a restraint- and coke. Furthermore, the group The rolling mills, which will make light free lamella suspension system and a possesses various assets for the pro- sections, bar steel and wire rod, will be dedusting plant. The latter will be fit- duction of high-quality coking coal designed for an annual capacity of 1.5 ted with electrostatic precipitators and the extraction and processing of million tons in the first phase, with the from SMS Elex. SMS Siemag will also iron ore. possibility of a later increase to two mil- be supplying an energy recovery sys- lion tons. The major part of the produc- tem. For the further optimization of www.sms-group.com tion will be supplied to Moscow and to energy efficiency, sMs siemag can other regions in Central Russia. Here, provide a converter-gas recovery and there is a demand for high-quality steel mixing plant for subsequent combus- products, above all from the construction of the gas in the existing Tulacher- tion industry and from mechanical en- met power station.

83 Projects sms group newsletter 02 / 2014

The project team from Štore Steel and SMS The cutting length of the billets will be between Satisfied: Zenon Górniak (right), Managing Direc- Concast after the contract signing. eight and twelve meters. tor from Huta Łabe,dy and Frank Lüth from SMS Meer.

High-alloy Order from Quick spring steel New Zealand change

Štore Steel orders billet SMS Concast to supply HF tube welding line for caster. billet caster. Huta Łabe,dy.

Štore Steel from Štore, Slovenia, has New zealand steel Ltd., based in For its works in Gliwice, Poland, Hu- ordered a new two-strand continu- Glenbrook, new zealand, awarded ta Łabe,dy has ordered an HF tube ous caster for billets from SMS Con- SMS Concast the order to supply a welding line with API finishing facility cast, switzerland. It will allow the 75-ton ladle furnace and a four- from SMS Meer Germany. SMS Meer company to cast high-alloy steel and strand continuous caster for the pro- is the single-source supplier of all spring steel grades of high quality in duction of square billets. technical equipment and is also re- future. With this investment, Štore “Besides evaluating technical and sponsible for installation and com- Steel will improve the quality of its commercial criteria, the short delivery missioning. Thanks to the horizontal products. time and the fact that we have known quick-change system, Huta Łabe,dy The new continuous caster will SMS Concast for many years as a reli- will be able to increase its productiv- produce sBQ billets (Special Bar able partner were decisive factors for ity by 30 percent in comparison with Quality) measuring 180 millimeters x placing this order with SMS Concast,” conventional quick-change systems. 180 millimeters. With the new caster says Craig Dixon, Manager strategic “SMS Meer will be supplying a from SMS Concast, the customer will Projects at new zealand steel. the tailor-made all-inclusive package. increase its production capacity from casting plant will have a radius of This approach has convinced us“, 150,000 tons to 300,000 tons per year. eight meters. The cutting length of the says Grzegorz Lukas from Huta Štore steel is one of the leading billets will be between eight and Łabe,dy. producers of flat spring steel in Eu- twelve meters. The hydraulic oscilla- The new line has an annual ca- rope. The company produces steel in tion of the molds will enhance the pacity of 270,000 tons and can pro- particular for the automotive indus- quality of the billets. Stroke, frequency duce tubes with diameters from 4 ½ try. Commissioning is scheduled for and negative strip time will be adjust- to 12 ¾”, wall thicknesses from 3.0 to the fourth quarter of 2014 ed online. the cartridge molds de- 12.7 millimeters, and lengths of up to ployed will be equipped with the CON- 18 meters. Commissioning is sched- VEX-Technology®, providing for a high uled for the third quarter of 2015. quality of the products.

www.sms-concast.com www.sms.concast.com www.sms-meer.com/tube-pipe-plants

84 Projects tube & pipe plants

It took just three months to erect and com- Axis Pipe and Tube has ordered a comparable Graphics of reeler from the operating side with mission the new GCP® gap closing press. transport unit from SMS Meer. arrangement of main drive motors.

Fast commis- R eaching new Heavy sioning customers shells

GCP® gap closing press Axis Pipe and Tube New tube reeler for for ITZ, Russia. award order. voestalpine Tubulars.

Izhorsky Trubny Zavod (ITZ), based in Axis Pipe and Tube, based in Houston, Seamless tube manufacturer voes- Kolpino near St. Petersburg, Russia, Texas, U.S.A., has ordered a heat talpine tubulars, based in Austria, has commissioned a new 25 MN treatment facility and pipe threading has commissioned a tube reeler GCP® gap closing press supplied by line from SMS Meer, Germany, for its from sMS Meer, Germany, and is SMS Meer. The plant was integrated Bryan works. With the two plants the thus upgrading its existing CPE mill into the existing 18m JCOE® large- company is capable of producing in Kindberg. the new reeler allows diameter pipe mill which SMS Meer OCTG tubes (Oil Country tubular voestalpine to process larger diame- supplied in 2006. It took just three Goods) used for natural gas and ters and wall thicknesses. months to erect and commission the crude oil production. Axis Pipe and “We already had positive experi- new press. Tube is thereby extending its product ences with the previous reeler from With this new gap closing press range and will be able to open up SMS Meer. However, the demands in the company, part of the severstal new customer segments. terms of quality and material have Group, is now able to produce pipes The heat treatment line includes a grown over the years. So we are again with small diameters and large wall hardening and tempering furnace, a banking on sMS Meer quality with thicknesses. ITZ uses the plant to water quenching unit and a hot the replacement of this plant sec- produce high-quality pipes for the straightener. Axis Pipe and tube is tion,” said Heinz teuschl, Head of long-distance trunk lines typically using the heat treatment line to pro- Seamless Tubes at voestalpine Tubu- used in Russia. Challenging offshore duce tube grades of up to HCP110. lars. Just one week was needed to sizes can also now be produced on The pipe threading line features set up the tube reeler. With its tube this new gap closing press. Control two threading machines which oper- reeler voestalpine is able to roll far of the forming process is handled by ate on the principle of stationary tool greater shell weights. The reeler is of the “SHAPE” software developed by and rotating tube. A hydrostatic pipe a welded frame design and compris- SMS Meer. tester with a maximum test pressure es additional guides for the roll ad- of 15,000 psi, is also supplied by SMS justment systems. All work rolls are Meer. driven and have a hyperbolic form.

www.sms-meer.com/tube-pipe-plants www.sms-meer.com/tube-pipe-plants www.sms-meer.com/tube-pipe-plants

85 Projects sms group newsletter 02 / 2014

range from 26.7 to 114.3 millimeters. Changzhou ChangBao has also re- Ro lLIng mill ceived a KR III 25 CNC groove dressing i machine from SMS Meer for machining the rolls of the new stretch-reduc- CARTA® in operation ing mill. The grooves in the rolls can be machined fully automatically on this CARTA® is the tech- machine. the machine is equipped nological production with a measuring device which records planning and pro- Changzhou ChangBao has commis- the stand and roll data under automat- cess control system sioned a stretch-reducing mill and ic program control. for the hot rolling Machining of the rolls from the front section of seamless a groove dressing machine. SMS Meer side of the stand allows any desired tube manufacturing. delivered the plants. groove form to be produced and the It convinces with edge radii to be machined in a single higher yield, im- pass. Changes to the groove forms are proved tube quality easily possible by quick reprogram- and optimized mill ming of the machine. Linking to the utilization. works databases and control systems, Changzhou ChangBao from Changzhou, Jiangsu Province, for example to the CARTA® technology China, has commissioned a new stretch-reducing mill in- system from SMS Meer, is also possi- cluding automation system from SMS Meer, Germany. The ble. sMS Meer has trained the cus- scope of supply includes the CARTA® technology package tomer’s personnel intensively so that (Computer Aided Rolling Technology Application) and a ful- they can operate the machine effi- ly automated groove dressing machine of type KR III 25 ciently. CNC. It will enable Changzhou ChangBao to produce heavy- walled tubes with small diameters from high-alloy steels. www.sms-meer.com/ tube-pipe-plants The stretch-reducing mill is equipped with the SMS Meer single universal drive. Each roll shaft is driven individually by an electric motor. Groove dressing Proper grooves quickly available machine of type KR III 25 CNC. By contrast with conventional stretch-reducing mills, the undesirable internal polygonization does not occur here. An internal polygon is a wall thickness irregularity of hexago- nal shape that occurs particularly in tubes with large wall thicknesses and small diameters. “With the stretch-reducing mill from SMS Meer we can produce more flexibly and improve the product quality. CARTA® ensures a very good tube quality and uniform wall thicknesses. With the new groove dressing machine, we also have the right groove for every diameter quickly and easily at hand,” says Wang Kui, Technical Director at Chang- zhou ChangBao. The mill has an annual capacity of around 100,000 tons of seamless tubes in the diameter

86 Projects tube & pipe plants

The new groove dressing machine from SMS Meer.

S hort changing times are convincing

BHEL has put into service a groove dressing machine from SMS Meer. It operates fully automatically – two passes in less than 30 minutes.

Bharat Heavy electricals Limited (BHEL), based in new 30 minutes. Changes to the groove shape can be made easily Delhi, India, has commissioned a new groove dressing ma- by quickly re-programming the system. The machine is also chine of type KR I 30/38 CNC, supplied by SMS Meer, Ger- linked to works databases and control systems, such as the many. With the new machine and the push bench plant up- CARTA® technology system (Computer Aided Rolling Tech- graded by SMS Meer, the roll stands of the stretch reducing nology Application, see also Page 86) from SMS Meer. mill will be fitted by BHEL with the latest roll pass technology in future. the groove dressing machine supplied by www.sms-meer.com/tube-pipe-plants SMS Meer machines the grooves in the rolls fully automatically. The roll diameters to be machined are 300 millimeters and 380 millimeters. automatic sensing of stand and roll data i The machine is equipped with a measuring system which Advantages senses stand and roll measurements automatically. the rolls are machined at the front end of the stand; therefore Groove dressing machine KR I 30/38 CNC any groove design can be produced. The technology from SMS Meer enables the edge radii to be dressed in one pass. Any groove form possible The ceramic cutting tools in the holder system enable good milling conditions and short changing times. the Quick re-programming grooves are machined automatically in two passes with a Automatic data acquisition high degree of precision. The whole process takes less than

87 Projects sms group newsletter 02 / 2014

PQSC® piercer plugs ensure improved inner Three high-speed wire mills from SMS Meer Formosa Hà T nh Steel will produce 160 mil- surface of tubes and pipes. went on stream at Rizhao. limeters and 180 millimeters square billets on the new mill.

Gaining cost 3.2 mill. tons High-quality advantages of wire rod SBQ steel

Baosteel orders PQSC® Four wire rod mills at Formosa Ha` T nh Steel piercer plugs. Rizhao Steel. orders new mill.

Baosteel, based in Shanghai, China, Rizhao Steel from Rizhao City, Shan- For its new integrated steel plant in has ordered PQSC® piercer plugs dong Province, China, has commis- Ha` T nh Province, Vietnam, Formosa from SMS Meer. The plugs are to be sioned three high-speed wire rod Ha Ha` T nh has placed an order with delivered in several sizes. Baosteel mills from SMS Meer. All three new SMS Meer, Germany, for a semi- plans to use them to produce a vari- mills have been installed at the Ying continuous billet mill. The produced ety of tube dimensions. They will be Kou City location in the Province of billets will be used within the For- installed in a cone-type piercer deliv- Liaoning. With the three wire mills mosa Group as starting material for ered by SMS Meer some years ago. Rizhao is able to produce different the production of wire rod and bars. Baosteel uses these piercer plugs for steel grades and offer more quality With the mill, Formosa Ha` T nhS teel the production of seamless tubes products on the market. The startup will be able to use continuously with chromium alloy. In making this of the first mill took place already casted billets as well as rolled bil- investment the company aims to im- nine months after the contract came lets for the downstream process. prove its process stability. Further- into force. Another, fourth wire rod Thereby, Formosa Ha` T nhS teel is more, Baosteel is looking to gain cost mill is to be installed at the same lo- gaining quality and flexibility in pro- advantages due to the long service cation. All four wire rod mills will ducing high-quality SBQ steel prod- life of the PQSC® plugs. achieve a total capacity of 3.2 million ucts. Formosa Ha` T nhS teel will PQSC® stands for “Premium Qual- tons per year. produce 160 millimeters and 180 ity surface Coating”. the PQSC® This wire rod mill concept devel- millimeters square billets on the piercer plugs have a special ceramic oped by sMS Meer with a six- and new mill. The maximum production coating to ensure high service lives four-stand wire rod block in the wire capacity is one million tons per year. for improved inside tube surfaces. rod finishing line allows grades of It is possible to increase the produc- carbon up to spring steels to be tion capacity up to two million tons rolled. in a second expansion phase.

www.sms-meer.com/ www.sms-meer.com/ www.sms-meer.com/tube-pipe-plants long-products-plants long-products-plants

88 Projects long products plants

An important detail: The wire rod finishing With the PSM® technology Xining produces also The laser measurement system MEERgauge® block with MEERdrive® technology. small lot sizes economically. is employed at Timken, U.S.A.

Cutting-edge First PSM® Precisely and core in China automatically

Fujian Wuhang takes 3-roll sizing block in op- MEERgauge® system plant into service. eration at Xining. commissioned.

Together with sMS Meer, the Chi- Xining special steel from Qinghai Timken from Canton, ohio, USA, nese company Fujian Wuhang Stain- Province, China, has commissioned a has successfully commissioned the less steel Products Co. Ltd. from 3-roll sizing block (PSM®, Precision MEERgauge® laser-based precision ChangLe City, Fujian Province, has Sizing Mill) supplied by sMS Meer, measuring system supplied by sMS successfully commissioned one of thus operating the first PSM® in Chi- Meer. The system displays the com- the most modern stainless steel na. With the PSM® Xining rolls all fi- plete product cross-section on the rolling mills for the production of nal sizes from diameter 16 to 100 basis of the light section method. wire rod and bar in coils. The rolling millimeters. Thanks to the hydraulic With the new measurement technol- mill achieves an annual production roll adjustment performed under ogy, Timken can reduce tolerance de- capacity of more than 300,000 tons load, the company produces any deviations fully automatically during the and rolls high-grade special steels. sired size from a single-pass family. rolling process. “The results pro- The core facilities include a state- Depending on customer require- duced by the MEERgauge® made a of-the-art 3-roll sizing block (PSM®) ments, Xining is hence also produc- lasting impression on us. We can fur- with hydraulic roll adjustment per- ing small lot sizes economically. ther improve our already very good formed under load which finish-rolls “The concept and the technical rolling tolerances, particularly with all final sizes for bars from diameter know-how from SMS Meer have con- the single-pass system running un- 13 to 38 millimeters from a single- vinced us from the very beginning. With der load,” says Perry Petrullo, Plant pass family. In addition, the PSM® this special rolling mill we will be able Manager at Timken. Up to 500 mea- also provides all the required initial to further expand our leading market surement points around the cross- cross-sections for the wire rod position,“ says Dang Fufei from the section are recorded simultaneously block. All the finished products of Xining Special Steel Group. The PSM® in a coordinate system displaying the the sizing block are coiled on a new- package also comprises an automatic actual cross-sectional form. MEER- ly designed coiler. stand changing system, a stand work- gauge® was completely installed and shop and a software system. integrated in just one week.

www.sms-meer.com/ www.sms-meer.com/ www.sms-meer.com/ long-products-plants long-products-plants long-products-plants

89 Projekte sms group newsletter 02 / 2014

PSM® cassettes in the Mönchengladbach workshop. i ADVANTAGES MEERdrive® compared to conventional wire rod technology: Conventional MEERdrive® Fixed gear ratios defined Great flexibility in roll pass design Fixed reduction ratios between the stands Free choice of reduction conditions between indi- Narrow limits for roll ad- vidual stands justments to compensate wear or varying spread Free adjustment range

Improved dimensional tolerances and metallurgical properties Highest mill flexibility

90 Projects long products plants

AO STR NG COMBINATION FOR KARDEMIR

Karabük Demir Celik (Kardemir), Turkey, has ordered a combined rolling mill for quality steel from SMS Meer. The plant, designed for a broad quality and dimension range, is able to produce bars and wire rod. Consequently, Kardemir can produce at low cost even small lot sizes.

The core is a 3-roll precision sizing reheating furnace with a capacity of block (PSM®) offering the possibility 150 tons per hour, 18 up-to-date to adjust the rolls even under load. In housingless two-high stands in H/V addition to that, the advantages in- arrangement, shears, cooling lines, a 700,000 clude a close tolerance range for roll- cooling bed with finishing lines and a ® ing. From the roll pass of a precision laying head, LCC , coil handling tons is the annual capacity of the rolling mill size greater and smaller infinitely equipment and two coil compactors. in the first stage. In a second stage, this can variable dimensions are generated A coiling line with two coilers and be expanded to 1.4 million tons. (”Free Size Rolling“). Quick program cooling devices allows the production changes are also possible. With the of coils. It was particularly designed control system TCS (Technological for scratch-free handling of the fin- supplies a self-developed CCT® sys- Control System) differences for ex- ished products. In the first stage, the tem (Controlled Cooling Technology). ample due to various cross-sections rolling mill achieves an annual capac- With this system, the process param- of the starting material or other entry ity of 700,000 tons which can be in- eters can be set for attaining the conditions can be compensated. creased in the second expansion desired mechanical properties and Moreover, differences in temperature stage to 1.4 million tons. microstructures. Commissioning is can be balanced out. scheduled for the first quarter of Surface-QUENCHED REBARS 2015. FEWER ROLLING RINGS THANKS TO PRODUCED AS BARS FLEXIBLE ROLL PASS DESIGN The plant contains three outlets: bars www.sms-meer.com/ long-products-plants The wire rod line is equipped with a in the 20- to 100-millimeter diameter MEERdrive® wire rod finishing block. range are directly rolled from the Here, each mill stand is driven by an PSM® on the cooling bed and bars in individual motor resulting in reduced the 20- to 55-millimeter diameter energy consumption and mainte- range are coiled via the coiling line. nance effort. Besides, roll passes are Wire rod can be produced in the 5.5- highly flexible. As a result, Kardemir to 25-millimeter diameter range via requires fewer rolling rings. The mill the wire rod line. In addition, quenched is designed for a maximum speed of rebars in the 8- to 40-millimeter di- 120 meters per second for wire rod ameter range can be produced as and 16.5 meters per second for bars. bars by means of a high-speed deliv- The plant consists of a walking-beam ery system (HSD®). SMS Meer also

91 Projekte sms group newsletter 02 / 2014

In December 1932, the first rail was produced.

A long runner becomes a monument

80 years after commissioning a rail rolling mill, the roughing stand becomes a monument of a partnership that has lasted for several decades. EVRAZ ZSMK from Novokuznetsk, Russia, is setting up a part of the plant on the works premises.

Within the last 80 years, up to 1.1 million tons of steel were processed year- ly on the old rail rolling mill. In April i 2012, the last rail was produced. After that, the plant was closed down. Now, SMS Meer the roughing stand is positioned on the works premises, directly in front of the SMS Meer is the production facilities. expert for section “It is amazing to see how respect- and semi-product fully an old plant from us is treated by mills. The plants are the customer,“ says Ulf Höltge, Proj- designed for a wide ect Manager from sMS Meer’s Long range of products Products Plants Business Unit. In – from standard via 2013, SMS Meer delivered a new uni- sheet piling sec- versal mill to EVRAZ ZMSK where the tions and rails up company is producing among others to special profiles. 100-meter-long rails for high-speed Integrated in the tracks. the plant is designed for an rolling lines is also annual capacity of 1.3 million tons, and the respective heat 400,000 tons alone are for rail produc- treatment. tion. But beams, channels as well as rounds and squares are also manufactured on the plant.

www.sms-meer.com/ In new splendor: The roughing stand of the plant in front of the Evraz long-products-plants production facilities.

92 Projects — forging plants

SETTING THE COURSE FOR GROWTH

Cansan Alüminyum has placed an order for the supply of an extrusion press with 32/35-MN press force to produce high-precision profiles for the automotive industry.

Cansan Alüminyum from Bursa, Turkey, has placed an order with SMS Meer, Germany, for the supply of a short-stroke front-loading extrusion press with 32/35-MN press force. i The press is to be installed at the Hasanag˘a Works and can handle aluminum billets up to 1,500 millimeters in length. Extrusion presses The plant has an annual capacity of 30,000 tons. The extrusion press will be used to produce high-preci- As the only manu- sion profiles for the automotive industry. In order to ensure With the new plant Cansan is able to facturer, SMS Meer high productivity, the machine operates with the “CADEX” produce high-quality profiles for the offers extrusion automotive industry. technology system which calculates the optimum extrusion processes for all speed curve and the minimum billet temperature required materials and alloys on the basis of the current process parameters. CADEX in- partner for the automotive industry. In including ancillary creases the productivity by up to six percent. addition to the low energy consump- facilities and automa- Thanks to the new “ecoDraulic” concept from SMS Meer, tion of the SMS Meer extrusion press, tion systems. The the hydraulic main drives operate with an intelligent start- we were also impressed by the service front-loading design stop function, ensuring energy-efficient production. Side ta- offered. Good and quick service is an further developed ble and billet loader are driven by modern servo-motors in- important aspect for us in safeguard- by SMS Meer has stead of conventional hydraulic drives. The extrusion press ing our position in the strongly com- established itself therefore satisfies the preconditions for the Ecoplants label. petitive environment.” the plant is worldwide as the Senol Akbas, Managing Director of Cansan Alüminyum: scheduled to go into operation in the cutting-edge press “The new extrusion press is equipped with modern tech- second quarter of 2014. technology. nologies. We are setting the course for growth. Thereby, we will further expand our strong market position as a reliable www.sms-meer.com/forging-plants

Hydraulic cylinder of an aluminum extrusion press.

93 Projects sms group newsletter 02 / 2014

Wang Min, owner of Jilin Liyuan (2nd from 80-MN ring blank press: SMS Meer supplies a The SMS Meer team in front of the Carpenter left) and the SMS Meer representatives in machine of this type to Russia. forging machine SMX 1100/22MN. front of the extrusion press.

Profiles for Aerospace in Quite railways focus large

Extrusion press at Jilin Innovative ring Forging machine at Liyuan in operation. rolling line. Carpenter.

Jilin Liyuan Aluminium Company in Li- VSMPO-AVISMA from Yekaterinburg, A forging machine delivered by SMS aoyuan, jilin Province, china, has Russia, has placed an order with Meer has been put on stream by Car- commissioned a 100-MN front-load- SMS Meer for the supply of a ring penter technology in Athens, Ala- ing extrusion press supplied by rolling line for the production of large bama, U.S.A. the machine of the SMS Meer. With this press, the OD jet engine rings from titanium al- SMX 1100/22MN type is the largest Chinese company is expanding its loys. With the new line the russian ever built by sMS Meer.“With the product portfolio in the market for very company is expanding its product forging machine from SMS Meer, we large aluminum profiles. With a maxi- range for the aerospace industry and can produce forging products very mum billet charge weight of 1,500 kilo- is thus enhancing its competitive- profitably. A high capacity and the grams, jilin Liyuan can produce, for ness. Among other things, VSMPO enormous pressing force of the ma- example, profiles for railway construc- produces parts for the Airbus A 380 chine give us the flexibility to react tion and shipbuilding with the 100-MN and Boeing 777. quickly to changing demand condi- press – and that with profile widths of A combined forging / ring rolling tions,“ says jim seitz, Program Di- up to 700 millimeters. Jilin Liyuan has process will be employed on the new rector at Carpenter. also ordered a 160-MN front-loading line for the first time worldwide. This 50,000 tons of forged material can press, a 60-MN direct and a 36-MN di- SMS Meer technology will enable be produced on the machine per rect / indirect tube press from sMS VSMPO to produce rings with ex- year. The forging machine features a Meer. the latter is producing billets tremely complex inside and outside pressing force of 22 MN for each of with lengths between 500 and 1,350 profiles. Furthermore, the material the four cylinders. The maximum in- millimeters, allowing highly accurate consumption is far lower than with put diameter for the material is 1,000 pipe tolerances, and on this press Jilin the conventional forging process that millimeters and the maximum billet Liyuan is producing eight to ten tons of the company has employed to date. weight is 10,000 kilograms. high-strength alloys each year for the Commissioning is scheduled for the oil industry. first quarter of 2015.

www.sms-meer.com/ www.sms-meer.com/forging-plants www.sms-meer.com/forging-plants extrusion-presses

94 ProJECTS — NF METALS

60 tons per hour

Kunshan Deli Copper orders high-performance casting and rolling plant for copper wire rod. The plant convinces with its sustainable solutions

Kunshan Deli Copper from Kunshan, Jiangsu Province, China, has placed an order with SMS Meer, Germany, for the supply of a CONTIROD® plant of type CR 3700. With a production capacity of 60 tons of cast and rolled copper wire rod per hour, the plant will achieve the world’s highest plant output in this sector. On the CONTIROD® CR 3700 Deli Copper will primarily produce ETP copper wire rod (electrolytic tough pitch) used as semi-finished product for the manufacture of electric conductors. By using new energy-efficient technologies, the CONTIROD® CR 3700 satisfies the preconditions for an ecoplants solution. ecoplants is the sMS Meer label for sustainable solutions offering companies economic advantages at the same time.

REDUCED GAS CONSUMPTION, EHNHANCED QUALITY The scope of supply includes a shaft melting furnace, a twin-belt caster, a 14-stand rolling mill with separate individual drives, a deoxidization and cooling section, a wire coiling station and an automatic tying unit.The melting fur- wire is first reduced by a chemical reac- Roc Chang (third nace is equipped with a lambda control system and im- tion with a water/alcohol solution. Af- from right), Xianfeng Wu (sixth from right), proved cathode distribution. this technology minimizes terwards, it is cooled to the desired tar- both Kunshan Deli natural gas consumption and increases product quality. get temperature in a second step, using Copper, and Thomas The preconditions for the great plant performance are water without the addition of alcohol. Schatz (fifth from created by the large cross-section of the cast ingot with the Since the two process steps take place right), SMS Meer, after signing the dimensions 75 x 132 millimeters, while the process technol- in succession, a significant reduction in contract. ogy of the twin-belt caster ensures a symmetrical casting the alcohol consumption is achieved. microstructure. The downline rolling mill with its 14 individu- Commissioning is scheduled for the ally driven stands creates a very fine-grain microstructure in fourth quarter of 2014. the copper wire. In this way, the product fulfills the conditions for the subsequent drawing process – in particular for www.sms-meer.com/nf-metals-plants the production of enameled wire and multi-fine wire. In the cooling section, the oxide layer on the surface of the

95 Projekte sms group newsletter 02 / 2014

Ecomelt melting furnace from Hertwich Engineering in operation.

Scrap recycling

Audi has commissioned the Ecomelt melting furnaces from Hertwich Engineering. The heating system fulfils the high demands in terms of melting of small-sized scrap.

Automobile manufacturer Audi has suc- heating system thoroughly preheats cessfully commissioned two ecomelt the charge before melting, resulting in melting furnaces from Hertwich engi- low metal losses with good metal neering. the two ecomelt PR-50 fur- quality. the two melting furnaces at naces supply the newly constructed Audi produce 100 tons of liquid metal die-casting line in Münchsmünster, per day. the Hertwich engineering Germany, with liquid metal. Audi de- scope of supply also includes a multi- cided in favor of the Ecomelt technology container charging system, crucibles, 100 from Hertwich Engineering in order to melting tanks and a crucible charging meet the high demands on the melting and treatment station. tons of liquid metal are produced by the two melting furnaces of the Ecomelt PR-50 type of small-sized scrap. at automobile manufacturer Audi every day. www.hertwich.com Reduced metal loss The ecomelt melting furnaces from Hertwich stand for a particularly cost- effective melting process. The energy consumption is low – thanks also to the automation technology. The high-performance Ecomelt PR-50

96 ProJECTS — NF METALS

With the new ultrasonic testing device DUBAL Purso Oy receives a comparable plant for billets Hertwich Ecomelt furnaces utilize metal and ensures the casting of high-quality billets. from Hertwich Engineering. energy more efficiently than comparable plants.

Capacity Extruded New melting boosted rapidly furnace

DUBAL receives ultra- Purso Oy orders plant Order by Reynolds Con- sonic testing devices. for billets. sumer Products, U.S.A.

Dubai Aluminium (DUBAL) based in Profile manufacturer Purso Oy, Fin- Reynolds Consumer Products has the United Arab Emirates has award- land, has placed an order with Hert- placed an order with Hertwich Engi- ed Hertwich engineering the supply wich Engineering for the supply and neering for the supply of an Ecomelt of two helical ultrasonic testing de- commissioning of a billet homoge- PS-140 melting furnace for their Hot vices for its casthouses. the new nizing plant. the continuous ho- Springs rolling mill in Arkansas, equipment will raise the capacity of mogenizing line replaces separately U.S.A. this furnace type provides DUBAL’s testing facilities to ensure operated batch homogenizing and great flexibility during charging of good product quality and to manage sawing plants. The automated plant scrap material, in particular with oily higher production volumes. requires less operating personnel. and coated scrap. The new Hertwich Both ultrasonic testing devices are Moreover, energy savings of about Ecomelt PS-140 replaces two small- equipped with 10 volume probes and 20 percent are achievable. The im- er furnaces and shall supply liquid 20 angle-beam scanning probes and proved billet homogenizing quality metal to two existing casting lines in are thus able to examine the entire ensures more efficient and faster the future. billet volume and the surface zone for extrusion. Annual capacity is 20,000 Thanks to the well-proven tech- defects and inclusions. the two fa- tons of billets with diameters rang- nology, Hertwich Ecomelt furnaces cilities are designed to examine bil- ing from 203 to 228 millimeters, stand out for particularly low energy lets with diameters from 152 to which are processed at the in-house consumption and low metal loss. 406 millimeters. Commissioning of extrusion plant. The scope of supply includes an au- the ultrasonic testing devices in The scope of supply includes a tomatic container charging system Casthouse 2 already took place in continuous homogenizing furnace, with a capacity of 5 containers, a February 2014, while commissioning cooling station, ultrasonic testing flue-gas treatment plant and the in Casthouse 1 is scheduled for unit as well as sawing and packing melting furnace with vertical pre- July 2014. equipment. Commissioning took heating shaft and regenerative place in April 2014. burner system. Commissioning was in the second quarter of 2014.

www.hertwich.com www.hertwich.com www.hertwich.com

97 Projects sms group newsletter 02 / 2014

Ho mogeneous temperature distribution

ThyssenKrupp Veedersburg orders induction heating system of the EloForge™ L type from SMS Elotherm, enabling greater efficiency in production.

ThyssenKrupp Crankshaft from Veedersburg, Indiana, U.S.A., has placed an order with SMS Elotherm for an induction heating, type EloForgeTM L. The integrated technology iZone® ensures homogeneous temperature distribution and achieves energy savings of up to 15 percent compared to older heating systems. “With the new induction heating system from SMS Elotherm we will be able to produce more profitably and save money and energy at the same time,“ explains Valmir Tadeu Marchiori, Head of Business Opera- tions at ThyssenKrupp Crankshaft U.S.A. With a rated output of 2 x 2300 kW the system is heating up to 12 tons of steel per hour. The EloForgeTM is fully automated, operating with a robot loading and unloading system.

Modular system A series of perfectly matched components are available for EloForgeTM by which high-performance, fully automated production lines can be realized. Individual extension op- tions include robot systems, material magazines, material separation systems and transfer units for downline forming units. spiral conveyors and step feeders, empty running equipment, three-way valve or extraction tongs are also included in the system program. With its developments and system solutions, SMS Elotherm has been a market leader in induction technology for decades. SMS Elotherm combines all key components on issues around induction technology.

www.sms-elotherm.com

Jochen Gies (left) and Herbert Metternich from SMS Elotherm in front of the EloForgeTM L. ProjekteProjekte — WärmetechnikWärmetechnik

The billet heating plant from IAS at Constellium Extrusions Deˇcˇín makes 9,000 tons per year. C lose temperature tolerances

Constellium Extrusions Deˇcˇín, Czech Republic, takes into operation an induction billet heating plant from IAS making it possible to save 20 to 25 percent of energy.

Constellium extrusions from Deˇcˇín, Czech Republic, has 9,000 tons and monthly throughput is about 220 tons higher commissioned a complete induction billet heating plant than for conventional plants. What’s more, 20 to 25 percent from IAS, a subsidiary of SMS Elotherm. Together with a of energy is saved. new 28-MN indirect extrusion press from sMS Meer the The induction billet heating plant is equipped with an heating plant will be used for the production of precise alu- IGBT converter of the latest generation. The converter minum tubes. It enables the required temperature accura- provides six outlets supplying two furnaces operating in cy and various billet lengths can be manufactured. parallel. The two 500-kW furnaces provide three zones each. Billet sizes ranging from 248 x 880 millimeters are High demands on heating plant heated. “We make high demands on our heating plant. It must be suited for our existing indirect extrusion press and ensure www.ias-induction.com close temperature tolerances,“ says Josef Kreuter, Project Manager at Constellium extrusions Deˇcˇín. the installed billet heating plant achieves an annual tube capacity of

99 service – Innovations – ecoplants sms group newsletter 02 / 2014

GR EenLIGHT FOR NEW ways

Cost-efficient, service-oriented and resource-saving. Every day, engineers of the SMS group work on solutions which provide plant operators with added value, be it through swift assistance in the event of a plant malfunction or through innovations helping production plants to comply with increasingly stringent environmental regulations.

100 Rubrik — Unterrubrik

oviver ew

Accurate: 60 years of Morgoil® bearings 102 Reliable: Equipment Check increases efficiency 106 Speedy: Service call from Eisenhüttenstadt 107 Clean: Clean Lance System boosts production 108 Smart: Blast furnace recovers energy 110 Efficient: Ecoplants solutions from SMS Meer 120 Service sms group newsletter 02 / 2014

35.000

In the last 60 years, SMS Siemag supplied more than 35,000 of these highly accurate enclosed plain bearings worldwide to more than 150 customers.

In a rolling mill Morgoil® bearings absorb the load-bearing backup rolls. A hydrodynamic oil film transmits high dynamic forces, thus preventing metallic contact of the sliding surfaces.

102 Service

PRI EC SIOnIN PERFECTION

This year, the Morgoil® bearing will be celebrating its 60th birthday at SMS Siemag. Since 1954, the plant manufacturer has been relying on the use of these bearings in rolling mills.

In the 30s, the Morgan Construction us with technological know-how, longer service lives, exceptionally safe Company from Massachusetts, U.S.A., training and support on site,“ explains handling and less work in the bearing developed the first Morgoil® bearings. Christian Hamann, Head of Bearing and roll workshop as well as reliable Rolling mill manufacturer Bernhard and Roll Workshop WBW2 at Thyssen- sealing. A short, thick neck contour Weiss (SIEMAG) recognized the prog- Krupp steel AG. “We have benefited absorbs higher axial forces and reduc- ress of this invention. He signed a li- from modernizations several times es the weight of the roll. censing contract for the european and were able to always roll demand- “The result of our pilot project has market. From then on, rapid rolling ing products in a precise and opera- convinced us,“ expressed Sigurd Van- speeds and high rolling forces were no tionally reliable manner. In 2008, we rysselberghe, Roll and Roll Workshop longer a taboo. Even then, plant own- have boosted the bearing capacity in Expert, CTO Department, ArcelorMittal ers preferred components easy to two stands with new KLX® bearings to Ghent, Belgium. “On the basis of our maintain. Compared to anti-friction be able to roll high-strength steels empirical values we identify a potential bearings, the Morgoil® bearings prom- even better.“ saving of approx. 60 percent of the op- ised a longer service life. Easy assem- erating costs of the Morgoil® system. bly, repairability and replacability im- EASY AND SAFE HANdLING With an annual procurement of spare proved the economic efficiency of the Since 2001, sMs siemag has always rolls we are now upgrading the backup plants. equipped new rolling mills with tailor- roll bearings of our three rolling mills The demands on friendly mainte- made sealing systems and symmetri- in Ghent step by step. We have started nance, reliable service life and efficient cal backup rolls: for designing opera- to transfer the new concept parallel to use have grown further. Service, safety tionally reliable roll necks the other plants of our Group.“ at work and resource preservation engineers created thicker and shorter Depending on the requirement of were added through the decades. SMS roll neck ends. Here, operational sta- the customers, efficiency, safety at Siemag has always sought to further bility, safety at work, lowering of costs work, quality, reliability and mainte- develop the overall system of the and preserving of resources were in nance are decisive for the final design. backup roll bearings in the interest of the focus. Four years ago, SMS Siemag The assembly and disassembly of a its customers. developed a concept to make use of conventional, mechanical mounting of Since the beginning of planning the these advantages also in existing the bearings is time-consuming and Hot Rolling Mill 2 in the early 60s, at plants. together with ArcelorMittal unsafe. even today many customers the time under the name of August Ghent and Gontermann Peipers it test- use indoor cranes and cables, accept- Thyssen Hütte, thyssenKrupp, Duis- ed those in an existing cold tandem ing undefined forces. This mechanism burg, has been closely cooperating mill and on a hot strip mill. After care- is now being replaced by proven with the Morgoil® experts from sMS. ful testing the experts totally revolu- hydraulic systems. the new sys- “The Morgoil® service always assists tionized the earlier design. It promises tems provide a portable hydraulic

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Reduction of operational expenditures of a 7-stand hot rolling mill with annual modernization of one stand

ROI Investment costs for Morgoil® bearings upgrade (1 Long-term stand per year) savings Operational expenditures of a Morgoil® system with symmetrical backup rolls

Operational Year 1 2 3 4 5 6 7 8 9 expenditures of a conventional Morgoil® system

cylinder which is temporarily docked up roll itself maintains the two bear- sioned with a clearly defined force and onto the roll. In this way, installation ings exactly in center position. the are maintained in this position in a and dismantling are easy to handle. spacer rods are omitted ensuring easy backlash-free manner by means of a Many customers are still using and safe handling. this ensures that frictional connection. For dimension- backup rolls with a thick neck end on many roll campaigns are easily real- ing the new symmetrical roll necks the the non-locating bearing side, with an ized. design engineers of SMS Siemag con- eccentric center of gravity affecting sider above all the arising tension. the precise production of flat strips. A RELIABLE AND PRECISE By using thrust bearings with a guide bearing was installed by sMS High strip quality requires exact roll large bore and adapted neck geometry Siemag in the Morgoil® bearing of the concentricity. nowadays, a perfect the tension was able to be reduced non-thrust bearing side. Consequent- bearing seating on the rolls is based significantly. The new neck form pre- ly, the symmetric construction is now on a backlash-free connection. the vents premature failure and thus re- fully utilizing its advantages. The back- bearings are hydraulically preten- duces the consumption of backup

Milestones

Service adoption Morgoil® Service right Improved handling for Mesta and from the start. through quick change. MDS bearings. 1954

Temper mill The Morgoil® Kl® with 44“-90“ neck sleeve for Morgoil® bear- perfect concen- ings at Hoesch, tricity. Dortmund.

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»THE NEW SEALING SYSTEMS REDUCED THE OIL LOSS IN THE MORGOIL® OIL LUBRICATION SYSTEM BY MORE THAN 90 PERCENT«

Franz Dumfart, Mechanical Maintenance Hot Rolling Mill, voestalpine Stahl GmbH.

rolls. The backlash-free design effec- lubrication system by more than 90 Roll costs are neutral, as there is no tively stops wearing. Modern guide el- percent.“ The improved design leads to extra expenditure in addition to the ements are installed inside the bear- a much more reliable overall system. regular roll replacement costs. The in- ings and are therefore protected. The All in all, the latest developments have vestment in the new Morgoil® design symmetry of the system is the ideal a positive effect on the efficiency of the will be returned in just three years”, condition for precise guidance of the Morgoil® bearings. Long service lives, states Vanrysselberghe. sealing systems, which are now seal- reliable usage, cost-conscious con- ing reliably and permanently. thus, struction methods and increased safe- Frank Benfer [email protected] leakages belong to the past. Franz ty at work make it a very efficient in- Dumfart, Mechanical Maintenance Hot vestment. “The new bearing design on Rolling Mill, voestalpine Stahl GmbH, the basis of a symmetrical backup roll comments: “The new sealing systems provides us not only increased safety reduced the oil loss in the Morgoil® oil but also significant cost advantages.

Start of Morgoil® Customized sealing manufacture in Zhang- system. jiagang, China. 2014

Introducing the KLX® KLX® bearing with Innovative metallic technology. a stand force of coating of the up to 140 MN for bearings. heavy plate mills.

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Ring rolling plants stay in shape thanks to MEERcare®.

Improved efficiency and planning certainty

A MEERcare® equipment check at Ovako Tube & Ring AB on a ring rolling plant enhances efficiency.

Experts from sMS Meer pay regular maining competitive”, said Leif West- visits to plant owners worldwide to lund, Senior Project Manager for Ovako check the condition of their machin- Hot Rolled Rings. “We can only achieve ery – this time the customer was Ovako this if the condition of our machinery is in Hofors/Sweden. The manufacturer of checked at regular intervals. In this re- profiled rings for the antifriction bear- spect sMS Meer has proved to be a ings industry sets great store by these strong Service partner at our side.” inspections because they help improve To ensure things are kept running at both the plant’s availability as well as Ovako, SMS Meer compiles detailed re- their long-term planning capability. ports using machine-based checklists. As with the last inspection in Swe- During their last visit to sweden the den, the experts from SMS Meer were experts from sMS Meer came to the Permanently smooth operation has now been tasked with the analysis and evaluation conclusion that the inspected plant achieved at Ovako Tube and Ring AB. of the machine’s condition. three would continue to operate efficiently as members of the company’s service a result of improved maintenance and team were on site to identify potential servicing alone. As Mr. Westlund ex- for improvement. The results of the ex- plained: “The comprehensive report tensive analysis of the machine’s con- provided by the SMS Meer team makes dition were available just two days later. our job easier in the long term.” “A high level of availability and long service life are essential factors in re-

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Speedy help

In early 2014, SMS Mevac received an emergency call from Eisenhüttenstadt, Germany. ArcelorMittal Eisenhüttenstadt had observed that the evacuation performance of its RH plant was deteriorating. SMS Mevac rendered immediate help.

Successful performance by SMS Mevac during the service call at “The plant is healthy again” was how ArcelorMittal eisen- ArcelorMittal Eisenhüttenstadt. The photo shows Andreas Opitz, En- gineer Secondary Metallurgy Operations at AM Eisenhüttenstadt, and hüttenstadt expressed its satisfaction in an e-mail to Lud- Ludwig Heinrichs, Technical Service Specialist of SMS Mevac. wig Heinrichs, Technical Service Specialist of SMS Mevac, about the service he had rendered to fix the problem occurring at the company’s RH plant. What had happened? For several weeks, ArcelorMittal Service expert Heinrichs asked Arce- Eisenhüttenstadt had been observing that the evacuation lorMittal to describe the problems. Al- capacity of the RH plant was deteriorating. “We were no though the steelmaker forwarded all i longer able to set the steel analysis with the necessary ac- available information to him, it was dif- curacy. Drawing on our experience, we did some trouble- ficult to make a remote diagnosis. Eisenhüttenstadt shooting and were actually able to fix some deficiencies. Therefore, Heinrichs decided to visit However, all our efforts to solve the evacuation problem the site and see for himself what the Eisenhüttenstadt failed,” explains the customer. problem was. Heinrichs and the ex- was established as a perts from ArcelorMittal jointly per- socialist planned city Basis for the production of high-quality steels formed another treatment during in the 1950s together The steels made by ArcelorMittal Eisenhüttenstadt include which the phenomenon occurred with the metallurgi- high-alloy grades, low-carbon grades and steels with high again. By measurements with the cal combine. The alloys contents for electrical engineering applications. plant in the cold run, the source of iron and steelworks, More than 30 percent of the heats produced depend on the trouble was localized. It was in one of the former metal- RH plant. Here, the basis is set for the production of high- the pipelines. The next day, that pipe- lurgical combine quality steels which are used, for example, in automotive line was opened and the problem fixed. VEB Eisenhütten engineering. the plant is indispensible for making deep- The very next heat was perfect again. kombinat Ost, today decarburized and high-alloyed grades. ArcelorMittal had to “Thanks to the know-how of SMS Mev- belongs to Arcelor- perform several manipulations on the pump control system ac, the RH plant was running excel- Mittal. It is the most of the RH plant in order to be able to treat any steel at all. lently again in no more than 24 hours,” important provider of However, in the long run, that situation would have been commented the customer. jobs in the region. intolerable. Therefore, the steelmaker called on SMS Mev- ac. Their experts had already completely renewed the vac- Ludwig Heinrichs uum system back in 1999/2000. [email protected]

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CLEAN LANCES

The new stable protective lance system (clean lance system) from SMS Siemag ensures that caking on oxygen lances during the operation Skulled lances are consistently annoying. SMS Siemag finds a remedy. of BOF converters is prevented.

Skulled oxygen lances are consistently annoying and con- age. Slag splashes drip off, which is controlled by the op- siderably affect the production output, cost efficiency and erator manually or automatically. Salzgitter Flachstahl and safety of the BOF converters. Foamy slag means that metal HKM examined the promised effect with success. and slag spray onto the oxygen lances. In the course of time, major caking develops, restricting the functionality of Oliver Wiens the lance nozzles which requires an increased supply of [email protected] oxygen. Caking may also come off jeopardizing safe operation. In addition to that, the excess weight of constantly growing skulls exceeds the limits of the lifting device.

SPRAY UNIT DIRECTLY INSTALLED ON LANCE DOME Up to now, the operators had to replace the lances com- i pletely or remove the skulls by flame-cutting. This is dan- ADVANTAGES gerous, reduces the service life of the lances and again and again leads to interruptions of the melting process. All con- Advantages of a clean lance are: cepts for preventing skulling have been inefficient or un- successful so far. The new clean lance solution from SMS Rise in production Siemag makes sure that caking developing in the process Reduced maintenance of time is effectively prevented. A spray unit is directly in- Low costs stalled by SMS Siemag on the lance dome, wetting the Greater safety of operation Saving of resources lance with a viscous liquid via a separate feeder. Due to the resulting lotus effect it protects the surface against dam-

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Failures can be rapidly remedied with the aid At MEERconsult® the experts from SMS Meer The new oil film bearing technology convinced of the SMS Siemag service portal. develop concepts and advise plant operators. NLMK.

S upported at Improving Proven any time performance bearings

The service portal of Kverneland relies on NLMK ordered 24 SMS Siemag. MEERconsult®. backup roll chocks.

The X-Cellize® service portal of SMS Improving preventive maintenance In May 2014, the Service Division of Siemag is a tool for the integration of and thereby avoiding unplanned SMs siemag supplied a total of 24 industrial services for commission- downtimes – this is the goal of the backup roll chocks with MORGOIL® ing tasks, preventive maintenance Norwegian company Kverneland. oil film bearings for the five-stand and rapid failure management. For Therefore, the manufacturer of agri- tandem cold rolling mill of NLMK in the X-Pact® electrical and automa- cultural machines has opted for the Russia. the company relies on this tion systems of plants, the service consultancy service MEERconsult® technology as the bearings convince, portal provides a special opportunity from sMS Meer. together with the among others, by an improved seal- for short-term failure elimination operating staff, SMS Meer works out ing system. essential to these im- throughout the whole life cycle of the strategies and concepts to maintain proved properties were the close col- plant. As early as in the commission- the plants at any time. the equip- laboration between NLMK and SMS ing phase, sMs siemag sets up a ment checks on the closed-die forg- Siemag and the technical research. “remote access” for plant support ing plants of Kverneland have al- The advanced sealing system en- that enables stable, protected and ready been performed by SMS Meer sures a better sealing efficiency and fast communication between two for some years. “With the mainte- thus increases the life-time of the networks. this way, the experts of nance concept, tailored individually rubber neck seals. This, in turn, re- SMS Siemag are able to access the to our plants by the experts from duces maintenance costs and makes automation system of the plant and SMS Meer we will improve our plant the production process run smooth- to support the customer’s staff by availability and increase our efficien- ly. SMS Siemag will render full-scale providing immediate remote diagno- cy,“ said Egil Brastad Hansen, Tech- service for this type of bearings and ses and tele-maintenance from the nical Director of Kverneland. “In this its components. very beginning. This ensures support way, we are able to significantly en- at any time. hance our competitiveness in the hard-fought market.“

www.sms-siemag.com/en/service www.sms-meer.com/en/service www.sms-siemag.com/en/service

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I GNteLLI EntRECOVERY OF ENERGY AT THE BLAST FURNACE

Paul Wurth is setting new standards in environmental technology with an innovative method for processing blast furnace slag. 2013 In 2013 Paul Wurth received the Environment Award from the Business Federation Luxem- bourg, FEDIL, in the “Process” category, for the newly developed process for energy recovery from blast furnaces.

110 Innovationen

The pilot plant has been in operation since 2013. The Paul Wurth project team received the Luxembourg Environment Award.

In view of the growing importance of native slag-processing method that The process also allows considerable ecological and energy questions, envi- would allow energy recovery by means saving of water compared to the tradi- ronmental considerations are always of dry granulation. The first few trials tional granulation, along with a reduc- the focal point of research and devel- already provided evidence of the tech- tion of the CO2 and sulfur emissions opment activities in the Paul Wurth nical, energetic and economic feasibil- and lower transport and further pro- Group. Over the past few years, the ef- ity of the process. The mixing of steel cessing costs for the product. forts being made in this area have balls into the liquid slag in a consistent With the assistance of the Luxem- been largely directed at improving the manner causes the slag to cool down bourg Ministry of Economic Affairs, an energy efficiency of metallurgical pro- quickly from 1,450 degrees Celsius to industrial pilot plant was built as from cesses, particularly in the field of 650 degrees Celsius and to solidify in October 2012 on the premises of Dill- granulation of blast furnace slag. glass-like form. inger Hütte and put into operation in In the blast furnace process, slag November 2013. the plant, at Blast is formed as a secondary product in The energy obtained from this Furnace No. 4, is designed for a pro- the manufacture of crude iron. Owing would supply electricity for 20,000 duction of 80 tons of slag per day. Af- to its physical and chemical proper- households ter a three-month test phase, this ties, this residual material is often re- This is also a prerequisite for using the forecast quantity of 80 tons of slag can utilized in the cement industry. As a slag as a valuable replacement for be reliably collected from the furnace, rule, for this purpose, the liquid slag clinker in the cement industry. In addi- at mass flow rates of up to 6 t/min, is turned into granulated blast-fur- tion, the energy contained in this mix- and allowed to solidify. over the fol- nace slag by abrupt water-cooling ture is recovered by using a counter- lowing months, the granulation pro- when it leaves the blast furnace. In flow heat exchanger. this energy, cess will be optimized with regard to another process, the slag is tapped representing 1,800 MJ per ton of slag, the product quality. In a second phase, into so-called “beds”, where it cools is recovered in the form of hot air (ap- scheduled for 2014, all efforts will down, before subsequently being prox. 600 degrees Celsius) and serves then be focused on the energy recov- used in road construction for exam- to reduce the energy consumption of ery aspect. The process has been suc- ple. In both cases, the major propor- burners used in furnaces, dryers or cessfully tested with steelworks, elec- tion of the energy contained in the hot blast stoves, or in the form of tric-arc furnace and ferro-nickel slag liquid slag is lost. steam, and can subsequently be trans- types and can also be implemented in Paul Wurth wished to overcome the formed into electricity. Assuming that these plants. challenge of utilizing the energetic po- a blast furnace produces 9,000 tons tential of these processes. From 2009, of crude iron per day, this could cover www.paulwurth.com various series of trials were carried the annual electricity consumption of out with a view to developing an alter- 20,000 families.

111 Innovationen sms group newsletter 02 / 2014

The laminar cooling system is the cooling method that has the widest distribution worldwide.

C EnteR FOR COOLING TECHNOLOGY

SMS Siemag will in future be able to use a new test cooling section for cooling technologies in order to perform trials and further development under real conditions in the field of heavy plate manufacture. The equipment was installed in cooperation with the Salzgitter Mannesmann Forschung research institute in the Duisburg laboratory mill of the Salzgitter Group.

In hot rolling, the cooling of strips and plates is a matter which has proven its value for several decades, spray cooling of great importance. In modern steel grades, powerful involves the spraying of water under pressure via nozzles, and efficient cooling has a decisive influence on achieving thus enabling very high cooling rates to be achieved. Spray the attainable mechanical properties, on the alloying con- cooling was first applied in 2005 in the heavy-plate mill at cept to be utilized and thus also on the product costs. The Baosteel in China, where it was combined with laminar cool- homogeneous and finely dispersed spraying of water is ing. Meanwhile, six heavy-plate manufacturers now make decisive for the inherent-stress condition and for the flat- use of combined spray and laminar cooling. In some of the ness of the products. newest mills, such as the 4.3-m mill at Hyundai Steel, South Spray cooling has enabled SMS Siemag to successfully Korea, which started up in 2013, SMS Siemag has also in- establish a new cooling technology on the heavy-plate mar- stalled “pure” spray-cooling systems. these systems pos- ket over the last few years. Unlike the laminar technology, sess a high-pressure and a low-pressure section. For further

112 Innovations

development of the cooling technology, Interview SMS Siemag has now installed, together with the salzgitter Mannesmann “Improved design Forschung research institute (SZMF) in Duisburg, a cooling section of modular of cooling system“ structure and around five meters in length. In each of the four cooling segments, use can be made optionally of a cooling header from a U-bend-type laminar cooling system, from a laminar-curtain cooling system or from a Why does SMS Siemag focus on spray cooling system, thus enabling cooling? different combinations to be tested. Cooling is playing an ever greater role in heavy-plate manufacture because it VARIABLES FOR FLEXIBLE TRIALS is the crucial tool for further develop- The distance between the cooling ment of the mechanical properties. For headers and the plate, the spraying this reason, we introduced onto the angle of the nozzles, and the water market the combined spray and lami- pressure in the spray cooling system nar cooling system in 2005 and the Dipl.-Ing. Dirk are variable. series of trials can thus “pure” spray cooling system in 2011. Schmidt be carried out and the correct configu- Senior Project ration of the cooling section can be de- Which objectives is SMS SIEMAG Manager in the Sales termined for the respective application. pursuing with the test cooling section Heavy-Plate Mills Furthermore, the development engi- at SZMF? specialist depart- neers can compare different types of The test cooling section enables us to ment nozzles or examine the influence of further develop and improve our cooling various nozzle arrangements on the systems. Here we test various combina- plate flatness. tions of cooling systems and can vary The test cooling section is integrat- the distance between the cooling head- ed into the existing laboratory mill of ers and the plate and also vary the wa- SZMF. The equipment makes it possi- ter pressure. During the commissioning ble to implement various rolling and of a mill, for example, there is often in- cooling strategies. sufficient time and lack of access to the mill for the performance of such intensive tests because the customer natu- rally wishes to produce as quickly as possible without interruption.

What advantages do customers have from this equipment? From the tests we will gain a better understanding of how we can purposefully influence the cooling process with a view to achieving more precise results. We will thus be able to design our cooling sections to take even better account of the requirements of our customers.

Different cooling technologies can be combined in the test cooling Dirk Schmidt section. It thus offers ideal testing possibilities. [email protected]

113 ecoplants sms group newsletter 02 / 2014 ecoplants

STI A NLEsssteeL EFFICIENTLY PRODUCED

At Fuxin Special Steel, SMS Siemag for the first time implemented an environmental concept for a special steelmaking plant. Off-gases from the EAF and the AOD converter are used to produce steam for the works’ steam network.

Fuxin special steel Co. Ltd., taiwan, dards. The primary emissions are ex- has successfully commissioned a tracted via cooled stacks and fed to steelworks supplied by SMS Siemag at two bag filters. The EAF and the AOD i the Zhangzhou location in the Chinese converter are enclosed to ensure ef- province of Fujian. the works makes fective capturing of the dust-laden Ecoplants slabs from special steels. It is the first secondary emissions. other dusts special steel plant in the world to ex- arising are likewise collected and ex- Ecoplants is the ploit the waste heat from the AOD con- tracted. The filters of the gas cleaning hallmark of the SMS verter and the electric arc furnace plants are designed for a filter capac- group for sustain- (EAF). Fuxin special steel benefits ity of more than 2.3 million m3 of air able solutions. from this solution in the form of a per hour. Sustainability is to-

60,000 tons per year reduction of CO2 day a critical growth emissions. the project involved the ECOLOGY AND ECONOMY IN UNISON factor for steel new construction of a special steel The steelworks is equipped with an companies – for both plant, a continuous slab caster and Ecoplants energy recovery system, economic and eco- environmental technology for gas which exploits the thermal energy logical reasons. Eco- cleaning and energy recovery. The new contained in the more than 2,000 de- plants solutions give works has been designed for an an- grees Celsius hot waste gases from due consideration to nual steel production of 720,000 tons. the EAF and the AOD converter to pro- both aspects. duce steam. The steam is fed into the VESSEL CHANGED IN HALF THE TIME network and can be used, for example, The X-Melt® steelworks consists of a to cool the electrical equipment. The 160-ton electric arc furnace with tap- energy recovery systems provide ping spout, a 180-ton AOD-L convert- about 36 tons per hour of saturated er and a 180-ton ladle furnace. Relin- steam, which is fed into the works’ ing of the AOD converter is performed steam network. A duplex RH plant, to by means of a special changing car. be supplied by sMS Mevac, will use This solution makes it possible to this steam to produce vacuum. the change the converter vessel twice as dusts arising during the VOD process quickly, thus minimizing downtimes. will be separated as early as in the The steelworks complies with strin- vacuum stage by special cloth filters. gent environmental protection stan- “We decided in favor of the sMS

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Above: Successful cooperation between Fuxin and SMS Siemag. From left to right: Wen-yen Ou, Steelworks Director at Fuxin, Jan Büchner, Project Manager of SMS Siemag, Hung- Jen Chen, Vice-Presi- dent Fuxin.

Left: The Fuxin steelworks is the first stainless steel plant in the world to exploit the waste heat from the AOD converter and the electric arc 60,000 furnace.

60,000 tons less of CO2 are emitted by the Fuxin Special Steel plant in China – thanks to the SMS Siemag environmental concept and the innovative waste-heat recovery system.

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Above: Steam drum for Watch a video on the transfer and use of the plant via the the generated steam. following link Below: The continuous or scan the below casting machine has been QR code. fitted with Intelligent Slab Casting modules. www.sms-group. com/qr/fuxin

More information and photos are available in our app.

117 ecoplants sms group newsletter 02 / 2014

»From the moment of commissioning, our plants have been running highly efficiently thanks to the technology supplied by SMS Siemag and the technical support provided by the SMS engineers. The energy recovery system installed by SMS Siemag helps us comply with high environmental protection standards.«

Hung-Jen Chen, Vice-President, Fuxin Special Steel

Siemag energy recovery system adjusted during casting within a range Siemag ensure both good internal and for our electric arc furnace and the from 800 to 1,600 millimeters. surface quality of the special-steel AOD converter because sMs siemag slabs produced. offered the best package in terms of INCREASED PROCESS FLEXIBILITY Fuxin Special Steel Co. Ltd. is part combining aspects of ecology and The continuous caster is fitted with In- of the Formosa Plastics Group, a pri- economy,” says tzuo-Ying Mei from telligent Slab Casting (ISC®) modules. vate group of companies headquar- Fuxin Special Steel. ”By means of the These include the hydraulically actu- tered in Taipeh, Taiwan. energy recovery system provided by ated resonance oscillation system and SMS Siemag, waste heat generated in position-controlled CYBERLINK seg- www.sms-ecoplants.com the production process can be exploit- ments. the electromagnetic stirrer ed to produce steam which we will use (EMS), a development by SMS Siemag in the future for the VOD process.” The and sMs elotherm, is used when a grades produced by the steelworks very high slab quality is required. The encompass ferritic, austenitic and effect of the eMS is to produce fine- martensitic special steels, which are grained, globulitic and homogeneous cast on the X-Cast® continuous cast- microstructures, while increasing the ing plant into 200- or 220-mm-thick process flexibility and the throughput. slabs. The slab width can be infinitely The technologies developed by sMS

The Fuxin Special Steel plant with the world’s first implementation of the new environmental concept.

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The diagram shows the measuring points in Display and input of production defects. The The system supports fast and safe threading the piping network. software is suitable for every tablet. and unthreading.

E fficiently Mobile Fast rolling dedusted checking start

Gas Cleaning Assistant for “Product Inspector” Reduced Off-gage dust collecting facilities. safeguards quality. lengths with TRC®.

SMs siemag has developed a new With the “Product Inspector” sMS SMS Siemag launched the rolling as- system for the energy-efficient con- Siemag is offering a software appli- sistance system Total Roll Gap Con- trol of dust collecting plants. A net- cation for tablets. In addition to the trol (TRC®). The rolling assistant sys- work model of the dust collecting previous possibility of performing tem reduces rolling risks and plant is stored in the plant control quality logging at fixed stations for improves the output. An example of a system. An algorithm calculates the the slabs produced, the operating critical rolling task is the threading opening positions of the exhaust air personnel can now carry out mobile and unthreading of strips. TRC® -sup flaps and the required negative pres- checks at any suitable location in the ports this threading and unthreading sure. The model’s description of the works. The “Product Inspector” has process so that the strip can be piping system allows the flaps to be online access to data of the Integrat- rolled to the defined thickness and positioned with a high degree of ac- ed Product Quality System (IPQS) of desired quality as early and as long curacy in the plant. A variable nega- SMS Siemag. IPQS performs contin- as possible. this way, the off-gage tive pressure ensures very good en- uous documentation of the process lengths at the strip head and strip ergy efficiency. The algorithm reacts and product quality right through the tail can be reduced. The quality of the in a flexible and robust manner to the individual process steps. Acting as strip filet is not affected. TRC® was various process requirements and an interface, it collects all quality- first installed in a tandem mill at Bil- does not require any additional mea- relevant data, evaluates these and stein GmbH & Co. KG within the suring technology. Initial calculations makes the operating personnel frame of the modernization of the demonstrate that an energy saving of aware in good time of any possible complete electric and automation by over 25 percent is possible. At the production defects such as cracks SMS Siemag. Off-gage lengths could customer Kardemir, Turkey, the Gas arising on the slab surface. the be reduced by around 50 percent. Cleaning Assistant indicates an en- Product Inspector is based on open ergy reduction of up to 39 percent, Web standards and can be utilized with the average covering all process on any suitable tablet (office or in- steps being more than 21 percent. dustrial devices).

Jörg Thomasberger www.sms-siemag.com www.sms-siemag.com/cold-rolling-mills [email protected]

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GR EenAND PROFITABLE PRODUCTION

At the leading trade fairs, wire & Tube in Düsseldorf, Germany, many discussions dealt with the latest Ecoplants solutions from SMS Meer. Two new brochures summarize the most important aspects for plant owners from the tube and wire sectors.

120 ecoplants

Industrial companies worldwide have set themselves the tional methods. Despite high speeds, task to better harmonize profitability and sustainability. production waste and plant wear re- Within the metal industry there is great potential to save main low. With a soft starter, light- i energy and thus reduce costs and emissions. With eco- metal extrusion presses for tube pro- plants solutions, plant owners achieve economical and duction from SMS Meer will be able to New brochures ecological advantages over competitors. To obtain the Eco- operate even more efficiently in future. plants label a technology has to meet strict ecological and The reason for this is the automatic SMS Meer has economical criteria. To achieve this, engineers from SMS starting and stopping of the gearbox- published two new perform sustainability checks. Reference plants at the cus- es, reducing energy consumption by Ecoplants brochures tomer serve as a basis. the criteria are: significant de- 50,000 kilowatt hours per drive and with information on crease of raw material input, reduction of energy and con- year. The costs decline by four euros Ecoplants technolo- sumable input, lowering of emissions and improvement of per ton. Otto Fuchs from Germany is gies for tube plants recycling rate. already operating a 55-MN extrusion and wire rod mills. press from SMS Meer with Soft Start- Read more under ECOPLANTS SOLUTIONs FOR TUBE PRODUCTION er. Dietmar Ebel from Otto Fuchs: “The www.sms-meer. For tube production SMS Meer offers five Ecoplants tech- technology is worth the money since com/news-media/ nologies: PQF®, PERFECT Arc®, soft starter, directube® the drives can be stopped separately publications (under and optimized heating technology. With PQF® (Premium when full output is not required at that the headings of Tube Quality Finishing) manufacturers of seamless tubes attain particular moment.“ Plants or Wire Rod excellent quality in producing thin-walled precision tubes. and Bar Mills). The heart of this technology is a rolling mill with three rolls SOLUTIONS FOR WIRE ROD PRODUCTION equipped with single roll drive and fully hydraulic roll ad- The CMT™ method (Continuous Mill justment. In this way, the roll gap is precisely adjusted and Technology) developed by sMS Con- readjusted within fractions of a second. An investment in cast, sMs elotherm and sMS Meer PQF® technology pays off for plant owners: energy con- re-synchronizes the rolling and sumption decreases by ten percent, efficiency rises by five continuous casting processes. the percent. Production costs are lower by 26 euros per ton. For INVEX®system enables to operate with an efficient spiral pipe production mill owners rely on the higher casting speeds, charging the “perfect electric arc“: PERFECT Arc®. The spiral pipe spe- billets directly to the rolling mill. In- cialist PWS, which is part of the SMS Meer Business Area, stead of oil- and gas-fired furnaces an offers a well controllable solution for arc- and submerged- inductive heating plant is used, ho- arc welding. A digitized power source generates the electric mogenizing the temperature profile of arc, consuming 30 to 40 percent less energy than conven- the billets before rolling. Carbon diox- ide emissions are about 72,000 tons per year lower than for conventional plants. the costs decrease by eleven euros per ton.

www.sms-ecoplants.com

For tube production SMS Meer offers numerous Ecoplants solutions.

121 EVENTS sms group newsletter 02 / 2014

Right: As diverse as the company: The wire & Tube appearance of the SMS group. Full house on the booth.

Bottom left: Alberto Bregante (SMS INNSE, left) and Aposto- los Papavasiliou, CEO Corinth Pipeworks, have reached an agreement on the supply of a hydrostatic pipe tester.

Bottom right: Heinrich Weiss (center), Chairman of the Super- visory Board of the SMS group, welcomed Gonzalo Urquijo, Member of the Group Manage- ment Board of ArcelorMittal (2nd from left) on the trade fair booth in Düsseldorf. The latter was accompanied by Arnaud Jouron, Vice President and CEO of ArcelorMittal Tubular Products (2nd from right). Jens Barth (left) and Rolf Hagmann also took part in the talks.

122 EVENTS — tube & Wire

THOUSANDS OF VISITORS AND TWO IMPORTANT CONTRACTS

SMS Meer presented its portfolio at the “wire & Tube“. Guests showed great interest and placed orders.

The 14th SMS Meer appearance at the Board of SMS Meer. “This also means “wire & tube “ in April was centered that we have the economical benefit of on significant agreements concluded. our customers in mind and that sus- During the leading international fair of tainable solutions are offered to them.“ the tube, wire and cable industries in SMS has its own distinctive brand mark Düsseldorf the Russian company Tula- for highly efficient plants and equip- chermet-Steel and the SMS group con- ment: the ecoplants label. tracted the supply of a complete steelworks with connected billet caster and AN EXPERIENCE ALSO VIRTUALLY two light-section mills. For about a quarter of the guests the The order value comes to around interest in machines for tube process- EUR 180 million. Andrey Zubitskiy, Se- ing was the deciding factor for visiting nior Vice President of tulachermet’s the trade fair. In this sector, SMS Meer co-shareholder KOKS Group, and Bur- has a high technological competence. khard Dahmen, spokesman of the The portfolio comprises seamless Managing Board of the sMS group, tube plants, welded tube plants and signed the contract on the booth. spiral tube plants – the latter under Corinth Pipeworks and the SMS group the PWS brand. The forging technology agreed upon the delivery of a 26“ hydro- sector supplements this product range static pipe tester for the production of by extrusion presses on which forged 5 6 /8“-26“ HFI welded tubes. the pipe tubes can be manufactured. The port- tester manufactured by SMS Innse will folio is rounded off by heat treatment supplement the new large-diameter plants from SMS Meer and SMS Elo- pipe mill to be supplied by SMS Meer. therm. The “wire“ sector is also cov- The pipes up to 26 meters long are in ered by SMS Meer. Light section mills, great demand especially on the US wire rod and bar mills are offered as 300 market. the trade fair presence had well as bright steel processing lines. the motto lived by sMS Meer ”Quality The Schumag & Copper Product Unit A good 300 guests came to the traditional “half-time party“ in the Schlösser Quartier Unites“. everything revolves around supplements the product range by Bohème in Düsseldorf’s Old Town. good service. “Our customers benefit machines and processing lines for from a full advisory service and a know- copper wire rod and copper tube pro- how transfer with future-oriented production. duction technologies“, says Marcel Fasswald, Member of the Managing www.sms-meer.com

123 S Versanstaltungen sms group newsletterEVENT 02 / 2014 e worldwid 2014

Focus on Middle East steel market

More than 700 visitors attended the Middle East Iron & Steel sion, Long Products Plants at SMS Meer, delivered a speech Conference (MEISC) in Dubai. Also the SMS group was rep- on latest technologies and rolling mill solutions for long- resented. Local steel producers reported about the current product making, highlighting the competence of SMS Meer market situation and the future development in the Middle in the field of minimills. This year’s MEISC will take place on East region. According to the general opinion, especially the December 8 through 10 in Dubai. On December 8, the SMS regional infrastructure will be a growth market for steel group will stage a Preconference seminar, featuring new products in the future. Ulrich Svejkovsky, Sales Head of Divi- and proven technological solutions for the region.

E xtrusion press shown

In the course of the HybrEx symposium in Witten, Germany, sMS Meer introduced its HybrEx25 extrusion press to about 130 guests from the aluminum extrusion press industry. Thanks to the hybrid drive concept of the HybrEx, energy consumption can be reduced by up to 55 percent compared to conventional extrusion presses. T Sechnology ymposium

More than 120 experts from Sabic participated in the Technology Symposium held by the SMS group at Saudi Iron & Steel (Hadeed) in Al Jubail (Saudi Arabia) in March 2014. Experts from SMS Siemag and SMS Meer presented innovations in plant technology for flat and long products. One focus was on the energy-efficient and environmentally friendly Ecoplants® technologies for steel making and steel processing. As Sabic aims high in reducing energy and water consumption, new technologies like the S/EAF® (Steady Electric Arc Furnace) or the CMTTM minimill (Continuous Mill Technology) met with great interest.

124 Contents sms group newsletter 02 / 2014 Events

Anniversary

24 Salzgitter Flachstahl invests in new plant equipment. Metix celebrates tenth anniversary

again through modern- Published on July 31, 2014 /© SMS izations. group / Circulation in German 6,200, in English 11,500 / Printed in Germany

THE MAGAZINE OF THE SMS GROUP at: www.sms-group. ISSUE 02 / 2014 2014

/ ISSUE 02 ISSUE future 07.10.–09.10. Aluminium 2014 | Düsseldorf, Germany com/conferences.php

Bild tauschen 50 years is not old age for steelmaking plants.

2 125 40237 Düsseldorf, Germany Trust... E SMS group always meettheconstantlyrisingchallengesofmarket. From thermalpre-treatmenttoreshapingandrefining,we comprehensive offeringintheareaofaluminumproduction. around theworld,thismeansbeingabletocountona team member,isthefoundationforsuccess.Toourcustomers Being abletotrustintheexpertiseandperformanceofevery duard-Schloemann-Strasse 4 Solid competenceforthealuminumindustry

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