BIG RIvER STEEl - SMS group

THE MAGAZINE OF THE SMS GROUP ISSUE 01 / 2016

BIG RIvER STEEl A further milestone on the way to production: The arrival of the millstands

PlUG & WORk

The operating personnel receive a clearer explanation of the produc-tion sequences. 88

COPPER

Finding the correct manufacturing process and benefiting from the advantages. 82

SMS GROUP

The merger between SMS Siemag and SMS Meer is highly advanta-geous for our customers. 04

SMS group

Ohlerkirchweg 6641069 Mönchengladbach, Germany

Phone: +49 2161 350-0Fax: +49 2161 350-1667

[email protected]

SAVE THE DATE

APRIL 4 – 8, 2016

WE TRANSFORM ... THE WORLD OF TUBE AND WIRE.

Tube and wire 2016 is just around the corner. Once again Düsseldorf will be the focal point of our industry. We will be presenting our ideas to transform the world of tube and wire in line with the trade fair‘s motto: “Join the best“. Using exhibits and presentations, we are looking forward to

showcasing our innovative concepts and new developments for effi cient and technologically outstanding plant and machinery. We cordially invite you to visit us at our booth for a personal exchange of ideas and information with our experts. Be our guest and join us in shaping the future!

Hall 7aBooth B15/16Düsseldorf, Germany

SMS group | Elotherm | PWS | SMS Concast

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contents� sms group�newsletter 01�/�2016

2

contents

20 IRONmAKING PLANTs: sinter cooler from Paul Wurth

� ��the�sintering�of�iron�ore�con-centrate�presents�a�challenge�for�the�plants.

25 meTALLuRGy ANd eNvI-RONmeNTAL TechNOLOGy: sIs Injector 4.0

��electric�arc�furnaces�from�sMs�–�productive�and�energy-efficient.

40 FLAT ROLLING mILLs Logistics system: high-bay stores for Aleris

� �sMs�group�is�also�supplying�a�cold�rolling�mill.

46 hot rolling mills: Back to the future

� ��successful�cooperation�with�nucor.

52 cold rolling mills ccm® – a strongly desired of-fer from sms group

��A�new�order�from�Vietnam�and�successful�commisioning�in�Bangladesh�and�Pakistan.

60 Aluminum: Aluminum strip for china

��the�first�production�facilities�of�the�mega-complex�in�op-eration�at�tianjin�Zhongwang.

70 sTRIP PROcessING LINes ANd FuRNAce TechNOLOGy Annealed steel strips in sichuan

��the�anealing�lines�supplied�by�sMs�for�the�Panzhihua�Iron�and�steel�Group�have�com-menced�operation.

16 start�of�production�at�Big�River.

PRocess�cHAIn 20 IRONmAKING PLANTs

24 meTALLuRGy ANd eNvIRON-meNTAL TechNOLOGy

39 FLAT ROLLING mILLs

66 sTRIP PROcessING LINes ANd FuRNAce TechNOLOGy

72 TuBe & PIPe PLANTs

76 LONG PROducT PLANTs

88 eLecTRIcAL ANd AuTOmATION sysTems

92 PROducTION

98 seRvIce

60 the�first�production�facilities�are�in�operation�at�tianjin�Zhongwang.

3

contents

106 Laser�strip-welding�symposium.32 Revamp�at�ssAB�Luleå.

74 TuBe & PIPe PLANTs: NWZ orders three cold-tube pilger mills

� ��High�cost-efficiency�and�pre-cision�for�tubes�made�from�special�materials.

78 LONG PROducT PLANTs metallurgical technology: hybrex® ordered

� ��Royal�United�Metal�and�Glass�from�Dubai�orders�an�extru-sion�press.

79 heat treatment technology: eloFresh: Innovative moni-toring and control system

� ��sMs�elotherm�has�suc-cessfully�commissioned�an�innovation�for�cooling�and�quenching�plants�for�harden-ing�machines.

88 eLecTRIcAL ANd AuTOmATION sysTems: Plug & Work also possible in 3d

� ��sMs�group�trains�the�cus-tomer’s�operating�personnel�already�before�commissioning.�

92 PROducTION: components for wedge press

��over�a�period�of�three�years,�sMs�group�has�replaced�15�machine�tools�during�ongoing�operation�at�the�Mönchenglad�bach�production�location.

94 seRvIce: equipped for the first time with a loading robot

��extrusion�press�revamped�at�st�extruded�Products�Group�for�enhancing�the�production�efficiency.

86 Fast�production.

the�sms group app�is�now�available�in�the�App�store�and�at�Google�Play.

cover:�Arrival�of�the�mill�housings�at�Big�River�steel�in�Mississippi,�UsA.

stAnDARDs 04 IN FOcus

08 PhOTO hIGhLIGhT

10 OuTLOOK – ReTROsPecT

16 NeWs

106 eveNTs

109 PuBLIcATIONs

109 ImPRINT

4

IN FOCUS SmS group newsletter 01 / 2016

WITH CONCENTRATED FORCES FOR METAllURGICAl

PlANT ENGINEERINGThe two companies SMS Siemag and SMS Meer have been merged since

mid-2015. The new name of SMS group now officially unifies the wide range of activities comprising, on the one hand, metallurgical plant and rolling mill

technology and, on the other, tube, long-product, and forging technology. The customer will benefit from this merging of organizations.

From the blast furnace to the bright-drawn steel plant, SMS group is the world market leader in metallurgical plant engineering. This includes not only tailor-made electrical and automation sys-

tems but also comprehensive service provision and envi-ronmental technology.

cLOSE TO ThE cUSTOmER

With their know-how and commitment, the experienced and highly qualified employees of SMS group personify strongly motivated performance in the field of plant engi-neering. Around 12,000 employees are active in SMS group. They ensure perfect interfaces and the greatest possible ef-ficiency along the entire metallurgical process chain. The group is represented by contact persons worldwide. The SMS employees are organized in a way that allows them to have precise knowledge of the technical and commercial expectations and to work closely with the customer at the regional level. SMS group is thus able to serve the indus-trial centers of the steel and NF metals sector on all conti-nents. “This concentration of competences and contacts makes it even easier for our customers to gain access to the full wealth of our range of products and services,” promises Burkhard Dahmen, Chairman of the Managing Board of SMS group. Each of the ten Business Units is

structured such that it can competent-ly fulfill the customers’ expectations also at the level of small, highly fo-cused units of performance. Units that share their functions find it easier to implement their activities, from the initial design concept to the finished turnkey works.

ALONG ThE PROcESS chAIN

In order to satisfy the widely differing requirements of our customers in a perfectly coordinated manner, we have organized our efficient provision of services along the metallurgical pro-cess chain. Here, we focus on continu-ity and, in some areas such as Services and Electrical and Automation Sys-tems, on growth, while keeping our sights on our more than 140 years of experience in metallurgical plant con-struction and mechanical engineering. Our business units are closely harmo-nized with one another, and our pro-cesses intermesh in a customer-

5

IN FOCUS

left: Dr. Heinrich Weiss, Chairman of the Supervisory Board of SMS group.

Bottom: SMS group. More than 140 years of ex-perience in metallur-gical plant construc-tion and mechanical engineering.

6

IN FOCUS SmS group newsletter 01 / 2016

oriented manner. Our own workshops in those regions of the world where demand is high ensure uniform stan-dards of quality that are tailored to the respective expectations of our cus-tomers.

OUR BUSINESS UNITS AT A GLANcE:

Ironmaking Plants Metallurgical Plants and Environ-mental Technology Flat-product Rolling Mills Tube & Pipe Plants long Products Plants Processing lines and Furnace Technology Forging Plants Electrical and Automation Systems Production Technical Service

mEmBERS WITh RESPONSIBILITy FOR

cENTRAL FUNcTIONS

The owners of SMS group as a family-run business have clear ideas as to the firm’s present and future course. Cus-tomer satisfaction has uppermost pri-ority. The Chairman of the Supervisory

Board is Dr.-Ing. E. h. Heinrich Weiss. The management of the company is undertaken by a seven-member Managing Board under the chairmanship of Burkhard Dahmen (CEO). The member responsible for Finances is Eckhard Schulte (CFO). The technical and operative leadership of the Busi-ness Units is under the control of Dr. Guido kleinschmidt (Metallurgical Plants and Environmental Technology, Technical Service), Dieter Rosenthal (Flat Rolling Plants), Marcel Fasswald (Tube & Pipe Plants, long Products Plants, Forging Plants), and Harald Rackel (Processing lines and Furnace Technology, Electrical and Automation Systems, Production). They are the first contact partners for our customers at the Managing Board level of SMS group. Torsten Heising is the Managing Board member with responsibility for the Restructuring and Efficiency Enhancement Program “SMS 2016.”

Focusing on the customer’s requirements: The managing Board of SmS group with the chairman Burkhard dahmen (center).

www.sms-group.com

iSmS group

The amalgamation

of SmS meer Gmbh

with SmS group

Gmbh became

legally effective

on September 1,

2015. The former

business areas are

now operating in

a coordinated and

harmonized manner

on the world market

under the unified

umbrella name of

SMS group.

7

IN FOCUS

More than 140 years of experience

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Concast AG

Demag AG

DahlbrucherEisengießerei

Gebrüder Klein

Carl Eberhard WeissSchmiedebetrieb

MechanischeWerkstätten Harkort

DeutscheMaschinenfabrik AG

Siemag SiegenerMaschinenbau AG

Schloemann AG

Schloemann GmbH

Siegener Maschinenbau AG

Eduard Schloemann OHG

Schloemann-SiemagAktiengesellschaft

Mannesmann DemagHüttentechnik Meer

SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.

Paul WURTH S.A.SMS group

S.A. Anciens Etablissements Paul Wurth

Paul Wurth KGaA

Eugène Müller Kesselfabrek

SMS Siemag AG

elexis AG

elexis AGSMS group

elexis Elektro-holding GmbH

MaschinenfabrikMEER Aktien-gesellschaft

Gebr. MeerMaschinenfabriku. Eisengießerei

SMS Schloemann-Siemag AG

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SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

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elexis AGSMS group





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Schloemann AG

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SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

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elexis AGSMS group





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Schloemann AG

Schloemann GmbH





SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Gebrüder Klein





Schloemann AG

Schloemann GmbH





SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Concast AG

Demag AG


Gebrüder Klein





Schloemann AG

Schloemann GmbH





SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Concast AG

Demag AG


Gebrüder Klein





Schloemann AG

Schloemann GmbH





SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Concast AG

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Schloemann AG

Schloemann GmbH





SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Concast AG

Demag AG


Gebrüder Klein





Schloemann AG

Schloemann GmbH





SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Concast AG

Demag AG


Gebrüder Klein





Schloemann AG

Schloemann GmbH





SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Concast AG

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Gebrüder Klein





Schloemann AG

Schloemann GmbH





SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Concast AG

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Schloemann AG

Schloemann GmbH





SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Concast AG

Demag AG


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Schloemann AG

Schloemann GmbH





SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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SMS Demag AG

Mannesmann Demag AG

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Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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SMS Siemag AG

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elexis AGSMS group





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SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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SMS Demag AG

Mannesmann Demag AG

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Paul Wurth KGaA


SMS Siemag AG

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elexis AGSMS group





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SMS Demag AG

Mannesmann Demag AG

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SMS Siemag AG

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elexis AGSMS group





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SMS Demag AG

Mannesmann Demag AG

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SMS Siemag AG

elexis AG

elexis AGSMS group





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SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

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Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Schloemann AG

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SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Schloemann AG

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SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


SMS Siemag AG

elexis AG

elexis AGSMS group





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Schloemann AG

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SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.



Paul Wurth KGaA


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Paul WURTh S.A. SmS group

mannesmann demag AG

mechanische Werkstätten harkort

Schloemann-Siemag Aktiengesellschaft

SmS demag AG

elexis AG SmS group

elexis Elektro-holding Gmbh

elexis AG

Paul WURTh S.A.

SmS Schloemann-Siemag AG

concast AG

Siemag Siegener maschinenbau AG

demag AG maschinenfabrik mEER Aktienge-sellschaft

mannesmann demag hüttentechnik meer

Siegener maschinenbau AG

deutsche maschinenfabrik AG

Schloemann AG

Schloemann Gmbh

Eduard Schloemann OhG

carl Eberhard Weiss Schmie-debetrieb

dahlbrucher Eisengießerei

Gebrüder Klein

Eugène müller Kesselfabrek

Paul Wurth KGaA


SmS meer Gmbh

SmS Siemag AG

SmS demag AG

SmS group Gmbh

Rolling like the professionals At the international trade fair Metec 2015, SMS group presented the control pulpit of the future, with the electrical and automation system providing all information associated with the production process. On that occa-sion, SMS group demonstrated its vision of machine operation in the future when all ar-eas, without exception, will have been adapt-ed to the activities of the operating staff. The new operating philosophy could be experi-enced live with the rolling mill simulator that offered the visitors to the SMS group booth the opportunity to virtually roll in 3D heavy plate material. Further innovations under the aspect of Industry 4.0 will be advanced by SMS group to reach market readiness in the near future. The photo shows Asa Hutchinson, Governor of the U.S. State of Arkansas. Standing right behind him, Dieter Rosenthal, member of the SMS group Managing Board, is watching the rolling results.

8

Ausblick – Rückblick sms group newsletter 01 / 2016

10

The BCT® process. Finishing stand of a hot strip mill.

At the new control pulpit, op-erators have a clear view of the production process.

OUTlOOk — RETROSPECT SmS group newsletter 01 / 2016

OUTlOOk — RETROSPECT

11

FOCUSING ON THE CUSTOMER WITH SOlUTIONS

FROM A SINGlE SOURCE

The recent international metallurgy trade show and conference combo METEC 2015 in Düsseldorf was a big success – especially for SMS group. It attracted about 80,000 visitors from more than

120 countries, so that the event was just as popular as the previous METEC – a remarkable result considering to-day’s climate in the industry. Particularly appropriate for SMS group is this year’s motto “The Bright World of Metals,” because it draws attention not only to the versatile material steel, but also to other metals such as copper, aluminum, and ferroalloys.

We took the opportunity of a large number of intensive talks with our customers, exhibitors, and other visitors to gain a clearer understanding of new trends and challenges in the metal production industry. That’s because listening close-ly and understanding custom-ers are imperative to modern plant construction.

The rate of change in market requirements for plant con-struction in the steelmaking in-dustry is accelerating all the

dr. Guido Kleinschmidt member of the managing Board, SmS group Gmbh.

time. Overcapacities and the resulting rock-bottom prices of metal products are piling cost pressure on our custom-ers. Added to this are other factors, such as growing de-mand for special grades, stricter environmental protection regulations, and resource scarcity, that pose huge chal-lenges for the metal industry. Furthermore, in the age of

globalization and digitalization, companies can tap into a wealth of complex information and data that open up new po-tentials of plant optimization and production transparency.

As a leading systems sup-plier of plants, machinery, and services along the entire met-allurgical value creation chain, SMS group and its more than 12,000 employees are well placed to offer efficient, unique solutions with compelling eco-nomic benefits.

The product portfolio of SMS group ranges from high-per-formance individual compo-nents right through to turnkey complete plants from one source. Characteristic of the 140-year history of the compa-ny are the continuous new de-velopments that are a key to

Dr. Guido kleinschmidt on trends and challenges affecting plant engineering in the metal-producing industry.

Ausblick – Rückblick sms group newsletter 01 / 2016

12

its success as a global leader in metallurgical plants and rolling mill technology.

BELT cASTING TEchNOLOGy FOR INNOvATIvE STEEL GRAdES

There are good reasons why the automotive industry de-mands lightweight steels for manufacturing load-bearing chassis parts. These materials excel with good formability and high strength. That’s why SMS group, cooperating with TU Clausthal University and Salzgitter Flachstahl GmbH (SZFG), has developed an exciting solution: near-net-shape belt casting technology (BCT®). The industrial-scale plant operates at the Peine location where it is steadily being tested and refined. In contrast to conventional continuous casting, the liquid steel is poured freely from a casting sys-tem onto a water-cooled, circular conveyor belt, where it solidifies. That produces transfer bars free of bending stresses, without casting powder, and at casting speeds of 10 to 30 m/min.

Typical dimensions of the cast plates are 8 to 20 millime-ters thick and 1,000 millimeters wide. After re-heating, they are rolled and wound into coils. The plant has already pro-duced high-manganese HSD® steels that defy conventional casting processes. For SMS group, the compact, cost-sav-ing technology also offers new application options for pro-ducing carbon steels in mini steelworks.

Normally, ferroalloys are produced in submerged-arc furnaces. Due to the process involved, the energy con-sumption is several times that of electric-arc furnaces used for steel production. To tackle this issue, SMS group has developed systems that minimize thermal losses. For instance, the new DC-FeCr furnaces use air-cooled sus-

pended-brick-type instead of conventional water-cooled roofs. As a result, the specific energy consumption is up to 15 percent lower than for a conventional water-cooled sys-tem.

A patented thyristor furnace current controller increases the energy input up to 20 percent, especially in large FeNi furnaces. That makes mega-capacity furnaces possible. last year, POSCO SNNC in Gwangyang/korea commis-sioned a FeNi furnace with a rated power of › 100 MW. Dur-ing commissioning in August 2015, the 100 MW barrier was broken for the first time, something that can only be achieved with thyristor technology. It’s a world record not only for FeNi furnaces but for all other submerged-arc fur-nace applications.

NONFERROUS mETALLURGy – SmS GROUP AcTIvITIES ANd

OPPORTUNITIES

Consistently, for more than a hundred years, SMS group has also applied its know-how to ferroalloys and nonfer-rous metals production. This is where submerged-arc fur-naces are frequently the solution of choice, above all for ferroalloys and silicon grades. Today, there are a total of some 60 different metals and special slags produced with electric-arc furnace technology, and SMS group is the glob-al leader with a market share of over 50 percent.

Equally noteworthy is that SMS group has, in recent years, expanded its process and plant expertise in steel to encompass converters for nonferrous metals. This is re-flected in the fields of refining ferroalloys and silicon where we already have a large catalog of innovative references. Ferroalloy producers are especially interested in the new

Illustration of a vacuum AOD process. Illustration of the 135 MvA furnace at POSCO SNNC, korea.

OUTlOOk — RETROSPECT

13

vacuum AOD converter technology with CO2 as the blowing medium. That’s because it allows low-cost production of MC-FeCr and MC-FeMn grades.

Primary copper production involves several different process stages and assemblies bearing some technical similarities to steel producing systems. Here again, it was logical for SMS group to transfer its exceptional techno-logical expertise from steel production to the copper pro-duction process. This will make it possible in the future to cover the entire primary metallurgical copper route with SMS group technology.

REcONcILING EcOLOGy ANd EcONOmy

SMS group also works intensively on designing metal pro-cessing technologies that are more energy-efficient and generate fewer emissions. There are important economic and ecological reasons for this. First, saving energy and re-sources cuts costs. And second, protecting resources is be-coming more and more important, with extensive environ-mental strategies being essential for every production facility.

Ideal in this context is the SMS group “Ecoplants” brand, providing sustainable solutions that give our customers significant economical as well as ecological advantages. SMS group has defined these factors that identify the added value of Ecoplants solutions:• less raw material input• Reduced input of energy and operating materials• Minimized emissions• Increased recycling quota at constant product qualityEnergy recovery systems achieve a palpable increase in en-

»The product portfolio of SMS group ranges from powerful and efficient single components to turnkey

integrated plants.«

Dr. Guido kleinschmidt, member of the Managing Board, SMS group GmbH

ergy efficiency. Included here, for example, is the genera-tion of steam using the heat from waste gas emitted by electric-arc furnaces, converters, or submerged-arc fur-naces. Afterwards it is possible to use this steam for heat-ing, cooling, or generating mechanical or electric power. To give an example: a Chinese customer will utilize the steam generated by the heat from the electric-arc furnace in its steelworks to drive the vacuum steam-jet pump in a vacu-um degassing plant.

hARmONy BETWEEN mAN ANd mAchINE

Will the metal producing plants of the future operate with-out personnel? Some experts think so. However, at SMS group we believe metallurgical plants will continue to re-quire human control, although machines will increasingly dominate.

Essential here is that man and machine form a homog-enous unit. Even complex tasks can be easy to accomplish in top technical and professional quality, supported by as-sistive automation. This requires that all the production data comes together in the control pulpit. SMS group reacts to the increasing complexity of automated production plants by developing innovative visualization methods and designs that center on the operator much more strongly. Equally significant are optimized ergonomics and user-friendly workplace design. To achieve these improvements, SMS group has developed new control pulpits and HMI masks that give operators a clear view of the production process while also displaying recommended actions.

Crucial in the run-up to modernizations or new installa-tions is preparing personnel for the changed production

OUTlOOk — RETROSPECT SmS group newsletter 01 / 2016

14

process. Here, SMS group relies on its proven Plug & Work method. That ensures shorter commissioning times as well as faster, dependable plant run-up. To achieve this – even before delivery of the automation system – the hard-ware and software components are installed in an SMS group test center and put through their paces. The test cen-ter is also ideal for training operating crews.

INdUSTRy 4.0 – AchIEvING ThE vISION

The term Industry 4.0 describes a possible scenario for the shape of industrial production in ten years’ time. Networked production processes will automatically organize and opti-mize themselves in local and global value creation chains. This is a development process already anchored in the steel industry, and it builds on available technologies. Work on uniform new standards is already ongoing.

This entire field is moving at a highly dynamic pace. All market participants must keep up, and SMS group is lead-ing the way. Companies need to constantly review existing business models and working methods. They need to iden-tify and develop new procedures that help achieve their goals.

Applied in production, Industry 4.0 promises an end to the inefficiency of repairing faults. Instead, the focus will be on avoiding faults in the first place. Yet few manufacturers will build a “Factory 4.0” on a greenfield site. That’s why a key aspect is upgrading existing factories at low cost.

There is a huge potential here for SMS group – as a glob-al player with its own production and service workshops – to increase the quantitative and qualitative capability of its machines and plants as well as its services. Using the digi-

tal, participative engineering and order processing meth-ods it has been applying for years, as well as its own auto-mation platform (X-Pact®), the group is perfectly prepared for this initiative and can respond dynamically to current developments in Industry 4.0.

To give a concrete example: already in test operation is a data-driven, self-learning, real-time forecasting model for more efficient process control installed by SMS group in a German steelmaking plant. This shows that SMS group has, in fact, successfully branched out into Industry 4.0.

In the near future, SMS group will come up with further market-ready innovations in line with Industry 4.0. One of the goals is to offer customers solutions for condition-based maintenance and repairs. Included here is overall functional connectivity of all machines, materials, and per-sonnel along the very deep value creation chain in the steel industry. That will result in optimized production processes in terms of quantities and costs, product quality, flexible process logistics, warehouse management, and energy consumption.

FOcUS ON ThE cUSTOmER – SERvIcES

At SMS group, the focus is always on the customer. Only by listening closely and considering customer requirements and experience can engineers design and maintain a plant that combines the technically possible with the economi-cally useful. That’s why, for many years, service has been a steadily growing field within SMS group.

Fast, professional, dependable, and local, yet backed by a global network. This is what sets SMS group services apart. And that means more than just spare parts. Our ser-

»Fast, competent, trustworthy, and local with a worldwide network. Excellent features of Technical

Service at SMS group.«

Dr. Guido kleinschmidt, member of the Managing Board, SMS group GmbH

15

vice offers solutions that guarantee customers reliable, cost-effective operation of their plants throughout the ser-vice life. Whether replacement parts, maintenance/repairs, or large or small revamps of existing plants. Even after commissioning, SMS group supports customers as a reli-able partner.

The backbone of any company is its workforce. Essential for this are the right expertise and comprehensive under-standing of the task in hand. That’s where the SMS TECad-emy provides effective support. Maintaining a focus on practical and technical know-how, the training academy offers standardized as well as customized courses. On re-quest, TECademy trainers can also travel to the customer’s location and instruct staff directly on their own plant. The subjects covered include technology, plant operation, main-tenance, and repairs.

Today, customers usually expect rapid support, because a plant out of production costs a lot of money. That’s why SMS group insists on fast communication channels and a broad product portfolio of support and optimization. Wheth-er an online shop for replacement parts, software for mon-itoring slab quality, the Genius Condition Monitoring Sys-tem that prevents plant stoppages, or online training courses – these are just a few examples of how SMS group helps customers enhance plant performance.

Modernization is an excellent way of increasing metal-lurgical facilities’ competitiveness at a more modest cost. Generally speaking, revamps are slightly more complex be-cause they involve optimizing an old plant with the existing infrastructure and equipment. The advantages for the cus-tomer are obvious. Normally, improving the performance

and efficiency of a plant that has already been written off is more profitable than erecting a new plant. SMS group helps customers decide by providing studies and cost-effective-ness assessments.

FIT FOR ThE FUTURE

With its constant innovative approach, SMS group demon-strates how it can satisfy both today’s and tomorrow’s mar-kets. Experiences combined with vision have created a product portfolio that matches the new market require-ments.

Steam generation at Fuxin Special Steel, China.

www.sms-group.com

NEWS SmS group newsletter 01 / 2016

Arrival of the mill-stands for the cold rolling mill.

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NEWS

BIG RIvER STEEl – lOOkING FORWARD TO THE

START OF PRODUCTIONSMS group delivering North America’s most advanced steelmaking

plant to Big River Steel. Already in 2016, the production of tube grades for pipelines, silicon steels for electronic sheet, and AHSS grades for the

automotive industry in the South of the U.S.A. will start.

The project of this size takes about two years to build. It is a complex process that has a large number of milestones to it. Milestones show the plant owner that the start of pro-duction is moving closer.

visitors to the METEC 2015 trade fair had the opportu-nity to get a first impression of the scope of supply at the SMS group booth. There, a drive spindle was exhibited, which in the future will be driving one of the seven mill-stands at Big River Steel. The drive spindle was manufac-tured at the SMS workshop in Hilchenbach and will be in-stalled in the CSP® plant at Osceola in the U.S. State of Arkansas. The drive shaft is characterized by a new, opti-mized toothing geometry allowing for larger angles and the transmission of higher torques.

ARKANSAS IS A LEAdING STATE IN STEEL PROdUcTION

With the words “Good for Arkansas,” Asa Hutchinson, Gov-ernor of the U.S. State of Arkansas, signed the spindle dur-ing his visit to the SMS booth at the METEC trade fair. “SMS group is very engaged in the construction of Big River Steel, which when it comes on line will make Arkansas the Num-ber 1 steel producing region in the nation – in the United States of America. So Arkansas is at the forefront of steel production and we’re delighted with the partnership and engagement of SMS group,” the Governor said.

Another important milestone of the project is the arrival of the millstands for the cold rolling mill. Mark Bula, Chief Commercial Officer at Big River Steel: “We right now

SUPPlY PACkAGESmS group scope of supply for Big River Steel

The SMS group scope of supply covers the entire equip-ment, including the mechanical equipment and the electri-cal and automation systems. For the steelworks, SMS group is erecting two electric arc furnaces, two twin-ladle furnac-es and an RH-TOP facility. Besides the provision of the electrical and automation systems, SMS group is also fo-cusing firmly on environmental engineering. The Big River Steel plant will be equipped with a gas cleaning system to be able to comply with the strict environmental standards.

The finished CSP® plant will consist of two CSP® casters, two tunnel furnaces, the CSP® rolling mill, laminar strip cooling equipment, and two downcoilers. Big River Steel operates the widest of all CSP® plants, with a maximum strip width of 1,930 millimeters. The hot strip from the CSP® plant will be processed to high-grade cold strip on the adjoining combined pickling line/tandem cold mill.

The tandem cold mill supplies a wide range of products. In combination with the two downstream strip processing lines, hot-dip galvanized cold strip is produced on the con-tinuous process route, via the annealing and galvanizing line together with an inline skin-pass mill. The convincing fea-ture of the offline skin-pass mill stand installed downstream of the batch annealing furnace is its very high roll force. Big River Steel is able to manufacture strips in widths from 914 to 1,880 millimeters and gauges from 1.4 to 0.28 millimeters.

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NEWS

receive about 40 to 50 crates a day from overseas, from all over where SMS is producing this equipment. The next major milestone for us is beginning to assemble this equip-ment. The tandem cold mill is the next large step in our process.”

ARRIvAL OF ThE mILLSTANdS

Six other millstands, each weighing about 105 tons, were manufactured by SMS experts in Germany and shipped across the Atlantic Ocean to the U.S.A. David Stickler, CEO at Big River Steel, on the millstands for the cold rolling mill: “One of the things that I am most looking forward to is the arrival of the millstands. Those millstands were fabricated over in Hilchenbach. Some of my colleagues had the op-portunity to travel to Hilchenbach and see those millstands actually being fabricated. That will be a very, very large milestone for this project. I think it’s a compliment to SMS that the millstands are arriving ahead of schedule. The in-spection of those millstands before they were loaded on the ship was very, very, outstanding.”

SMS group will supply the entire equipment for Big Riv-er Steel, including the mechanical equipment and the electrical and automation systems. In the first wave of con-

From 2016 on, Big River Steel will operate North America’s most advanced steelworks on a total area of 567 hectares.

struction, the works will produce 1.5 million tons of hot strip per year. It is planned to increase production step-by-step via several expansion stages. David Stickler: “Ultimately, this mill will produce close to four million tons of steel. We are also working with our partners at SMS, and are looking else-where in North America for future mill sites.”

Axel Sprenger [email protected]

19

Transportation work at the mississippi River.

1.5million tons of hot strip per year will be produced by the works in Osceola in the first stage of construction.

David Stickler, CEO at Big River Steel. In the back-ground, the construction works for the completion of the steelworks are in progress.

you can call up a

film on the arrival of

the millstands at Big

River Steel under:

www.sms-group.

com/qr/BRS-WS

20

IRONMAkING PlANTS SmS group newsletter 01 / 2016

Sustainability has become an increasingly urgent issue during the last few years. Therefore, there is a constant search for possibilities to make production and operational processes more efficient and more environmentally friend-ly. In this respect, hot sinter cooling offers ample potential for improvement. Numerous companies operating sinter cooling equipment rely on technology that is often more than 30 years old. At the same time, the requirements of the market and the legislator become increasingly exact-ing. While production volumes have been growing, increas-ingly stringent environmental regulations must be com-plied with. Sintering is a pre-stage to steelmaking. Sinter plants produce agglomerates of fine ore and concentrates in a high-temperature process. The agglomerates are sub-jected to cooling before they are ready for being fed into the blast furnace. Cooling frequently takes place in round coolers, which consist of a rotating ring equipped with var-ious cooling air blowers, which by blowing the air through the cooler, reduce the sinter temperature. After about one rotation of the cooler, the sinter has usually cooled down so much that it can be removed from the cooler. However, due to their small height of just about one and a half me-ters they require a lot of space and very powerful drives for

SINTER COOlER FROM PAUl WURTH

the cooler and the blowers. An alter-native cooling technology is what is referred to as a shaft cooler. This technology has existed for many years and has proven very successful in practice. It provides for the sinter to be placed in a cooler, which is also round but several meters high. The sinter will remain in the cooler for several rotations. This cooling system re-quires much less space for an equiva-lent cooling capacity.

EFFIcIENcy ANd EcOLOGy

Paul Wurth Umwelttechnik GmbH has been consistently working on sophisti-cating the shaft cooling technology in order to meet and even exceed the growing requirements of the market. It was decided to apply the counter-flow principle instead of the cross-flow principle for the cooling air. While the sinter in the cooler “migrates” from

Sintering of iron ore concentrate is a high-temperature process immediately followed by the cooling of the sintered material –

a genuine challenge not only for the process equipment but also in terms of environmental protection and energetic efficiency.

iPaul Wurth

is the SmS group

expert for primary

processes of inte-

grated steelmaking.

The company’s port-

folio includes blast

furnace technology,

coke oven technol-

ogy, sinter plants,

and environmental

protection equip-

ment.

21

IRONMAkING PlANTS

the top to the bottom, the cooling air flows from the bottom to the top. The top of the cooler is fitted with a dust-tight hood that sucks the cooling air through the cooler. This principle achieves the counter flow of the air, fully exploit-ing the cooling potential of the air. The counter-flow prin-ciple brings along various direct and indirect benefits for the environment. Thanks to the high cooling efficiency, con-siderably less cooling air is needed. This in turn provides the benefits of needing smaller drives and reducing energy consumption. Capital investments and operating costs will be lower as a result, so will be emissions of CO2. An addi-tional effect of the counter-flowing air is that almost 100 percent of the dust particles sitting on the sinter are carried off and guided via the suction hood to a dust collection plant. Dust emissions near the cooler become so minimal that environmental thresholds are easily met or that the values remain even below them.

ENERGy REcOvERy

By optimally exploiting the potential of the cooling air, the air temperature in the suction hood can be up to 450° C. This high air temperature is ideal for effective heat recov-ery. This makes it possible to connect a heat recovery sys-tem to the suction hood. Depending on the customer’s re-quest, a steam generator may be used to supply steam to the fresh steam network of the works or to generate elec-tricity via a downstream steam turbine. Per ton of sinter, approximately 20 to 40 kW of electricity can be generated, equalling the electricity requirement of 20 to 30 private households. Depending on the size of the sinter plant, more than 20 MW of electricity can be generated. The generated power may be used for internal purposes or sold by feeding it into the external power grid. These options allow what

may be considered as undesired and useless waste heat from the sinter to be optimally exploited and result in cost savings for the overall works.

www.paulwurth.com

Sinter cooler at ArcelorMittal Tubarao, Brazil.

20megawatts of electricity can be generated by recovering heat from a sintering plant.

22

IRONMAkING PlANTS SmS group newsletter 01 / 2016

Salzgitter commissions PCI system

Midrex and Paul Wurth to build direct reduction plant in Algeria

In the first quarter of 2015, Salzgit-ter Flachstahl (SZFG), Germany, started pulverized coal injection (PCI) at its blast furnaces. In Au-gust 2013, Paul Wurth had received the order for the turnkey supply of PCI equipment for Salzgitter Flach-stahl’s blast furnaces “A” and “B.” The newly installed equipment comprises two coal grinding and drying plants, for a production rate of 50 tons of pulverized coal per hour each, and two injection sys-tems designed for a capacity of 200 kg of pulverized coal per ton of hot metal. Thanks to the PCI technolo-gy implemented by Paul Wurth, flat

Midrex Technologies Inc. and Paul Wurth S.A. have been contracted by Turkish steel producer Tosyali Hold-ing to engineer and build a new multi-product direct reduction plant in Bethioua, near Oran, in Algeria.

The Midrex NG™ plant will be designed for an annual production of 2.5 million tons of direct reduced iron (DRI). The plant will be able to make hot DRI (HDRI) and/or cold DRI (CDRI) without having to stop produc-tion when switching between the two. This combination plant, which will be the largest DRI unit of its kind in the world, will offer the operator maximum flexibility in the production of high-grade DR products.

steel producer Salzgitter has been able to improve the pro-ductivity and efficiency of its blast furnaces.

Main building of the PCI plant at SZFG in Salzgitter.

Midrex plant for the production of 1.54 million tons per year of DRI.www.paulwurth.com

www.paulwurth.com

23

IRONMAkING PlANTS

www.paulwurth.com

The best technology available

In March 2015, following a decision of the Government of Italy, IlvA had to shut down No. 5 Blast Furnace, the largest one at Taranto works. The plant shall be upgraded by EU-defined Best Available Technologies in order to match latest environmen-tal standards.

As a result of the bidding process, the Paul Wurth group, a part of SMS group, has been awarded several packages for engineering, supply,

and installation of technologies that will make up a state-of-the-art iron-making facility. On the side of hot blast generation, the four existing krupp-koppers units will be com-pletely replaced by a group of three one-dome hot blast stoves with ex-ternal combustion chamber. This sub-plant will also feature Paul Wurth’s patented waste gas heat re-covery system and a complete EIC system. Performance and maintain-

ability of the BF top gas cleaning plant will be improved by replace-ment of the existing dust catcher, and by modification of the scrubber system. At the slag granulation plant, a new, seawater based steam condensation system will eliminate the release of sulfur-laden steam to the atmosphere.

Finally, the furnace’s stockhouse gets a brand new de-dusting system with equipment rated for a 2,000,000 m3/h suction capacity and ensuring a maximum of 5 mg/Nm3 dust content in the air leaving the stack. A chal-lenging schedule foresees project completion by Paul Wurth within 12 months.

After completion of this large-scale reline project, Taranto’s steel plant will be able to operate its new BF5 in compliance with the latest environmental and safety stan-dards.

Blast Furnace AF5 in Taranto, Italy

Paul Wurth offers new service for coke-oven batteries

In July 2015, Paul Wurth commenced the hot repairs of coke-oven batter-ies 4A, AB, and 5 at CSN in volta Re-donda, Brazil. The activities are scheduled to take 21 months. This order, covering a total of 105 ovens, is the first ever hot repair order re-ceived by Paul Wurth. With this or-

der, Paul Wurth has entered a new terrain in the coke-oven service business.

Based on a very specific know-how, coke ovens can be refurbished during running operation, resulting in minimal production loss. As only worn or damaged components are

replaced and the overall repairs take less time, Paul Wurth now offers an optimal solution to coking plant op-erators aiming to prolong the life of their coke-oven batteries.

www.paulwurth.com

22

METAllURGY AND ENvIRONMENTAl TECHNOlOGY SmS group newsletter 01 / 2016

22

Georg Fischer orders Ecomelt melting furnace from Hertwich Engineering

SMS Metix: Reinier Meyjes retires

Georg Fischer from Altenmarkt, Aus-tria, has placed an order with Hert-wich Engineering, a company of SMS group, for a multi-chamber melting furnace type HE-Ecomelt-PS70 for melting and holding aluminum with a

production capacity of up to 90 tons per day. The new multi-chamber melting furnace operates with scrap preheating and uses the immersion melting process, thereby reducing the metal loss to less than 0.5 per-

Reinier Meyjes, for many years a member of the board of our South Af-rican subsidiary SMS Metix, has re-tired. Reinier Meyjes founded Metix in 2003. SMS Metix is active in plant en-gineering and as equipment supplier for the ferroalloys industry. The com-pany’s product and service portfolio

comprises complete engineering for, and the supply of, plant and equip-ment especially for the production of ferrochrome and ferromanganese as well as sintering plants for chromium ore and manganese ore.

cent. It is particularly suitable for melting ingots and thin-walled re-vert scrap – even with adhering coolants and lubricants from ma-chining. The multi-chamber melt-ing furnace is characterized by high metal yield, low energy consump-tion, and reduced emissions.

With less than 550 kWh/t, the heating energy consumption at nominal load is far below that of other plants in the market, the elec-tric energy consumption is less than 30 kWh/t. The furnace achieves a melting rate of up to 4.5 tons per hour, its melt content is up to 25 tons. Due to the extremely limited space in the existing casthouse, the design of the new melting furnace had to be specially adapted by Hert-wich to the local conditions. The plant is scheduled to start produc-tion in the 4th quarter of 2015.

Multi-chamber melting furnace type HE-Ecomelt-PS70.

25

METAllURGY AND ENvIRONMENTAl TECHNOlOGY

NEW GENERATION: SIS INJECTOR

In the electric arc furnace (EAF), all processes – from scrap melting, decarburizing, and temperature control of the bath through to tapping – must be perfectly harmonized. In order to increase productivity and save on electrical energy, com-bined burner-injector units are used to melt the scrap and superheat the bath. While the energy input and the melt-down capacity are highest in the furnace center, cold spots occur at the wall panels. Burners or injectors supply addi-tional thermal energy to these spots, making for a homoge-neous temperature distribution inside the furnace. SMS group has taken the SIS (SMS Injection System) one step ahead and has achieved first highly convincing operating results.

EASy TO hANdLE

The new SIS injector is easy to handle. The lateral gas burner for the generation of the hot shroud-gas jet has been dispensed with. Air and combustion gas are now di-rectly and most efficiently fed into the coaxial casing pipe and ignited there, generating a shrouding gas jet made up of hot off-gas. If operating in injector mode, the coaxial shroud-gas jet protects the oxygen jet in the center, shield-ing it from the hot furnace environment. This leads to a markedly higher efficiency of the oxygen jet. In stand-by mode, the shroud-gas jet serves as a protection against splashing slag or metal for the entire injector. The SIS pro-totype was used at one single position on the 125-ton No. 2 EAF of Peiner Träger GmbH for the duration of one furnace campaign. The SIS had been designed for approx. 17 per-cent less oxygen. First tests have shown that the metallur-gical results remain virtually constant.

Electric arc furnaces from SMS – highly productive and highly energy-efficient.

For more informa-

tion, please refer to

the SmS group paper

presented at ESTAd

2015.Jan [email protected]

New generation: SIS Injector 4.0.

26

left: First blooms arriving at discharge area.

Right: Bloom in cool-ing chamber.

Jumbo bloom caster successfully commissioned at TISCO

The first blooms were used for wheels of high-speed trains.

In 2015, the first heat was successfully cast on the three-strand caster for round blooms at TISCO (Shanxi Taigang Stainless Steel Co. ltd.), Taiyuan, China. The plant is de-signed to cast blooms in size ranges of 390, 550, 690, and 800 millimeters.

The new melt-shop equipment including twin CONARC® with ERS, twin lF, and three-strand bloom caster was sup-plied by SMS group.

ANNUAL OUTPUT OF 530,000 TONS

The continuous casting plant with a radius of 16.5 meters provides equipment for the production of highly sophisti-cated goods. The product range includes forging material, tool steels, and stainless steels.

The scope of supply covers Convex molds with optimized primary cooling, mold, and final stirrer as well as air-mist spray cooling. For reducing center segregation and for min-imizing core porosities the plant provides “Dynamic Me-chanical Soft Reduction” (DMSR) with up to ten single mod-ules per strand. These modules allow optimum adjustment of the modules depending on casting conditions and steel

iSmS group

The Shanxi Taigang

Stainless Steel co.,

Ltd. is the larg-

est stainless steel

producer in China.

The company sup-

plies steel products

worldwide in the

automotive, rail,

shipbuilding, petro-

leum, oil, and chemi-

cal industries.

grades. After commissioning the plant has produced top-quality grades from the outset. Already the first blooms cast satisfied the strict feedstock re-quirements for producing high-speed train wheels and were awarded with the qualification certificate of the end user CHINA RAIlWAY.

The X-Melt® CONARC® furnace supplied by SMS group is designed for charging both scrap and hot metal and the ERS (Energy Recovery System) im-proves the energy balance. To achieve this, steam is recovered from the waste heat of the CONARC® furnace that is used by the customer for fur-ther processes. The plant has an an-nual output of 530,000 tons.

www.sms-concast.ch

27


In addition to the five-stranded Block & caster, SMS group has successfully installed the 1000th electromagnetic CONSTIR Stirrer at vizag Steel Plant (vSP) vishakhapat-nam (Andhra Pradesh/India).

CONSTIR Stirrers are used in continuous casting to im-prove the steel quality and to stabilize productivity. SMS group low-frequency stirrers deliver maximum magnetic force to the liquid steel for the strongest metallurgical ef-fect. Slag, gas bubbles, and other impurities move away from the billet shell, resulting in enhanced surface quality. Stirring also breaks off the dendrite tips in the solidifying billet, resulting in the formation of new solidification nuclei, which further enhances billet quality. Convective heat transfer between the liquid steel core and the shell is also

1000TH ElECTROMAGNETIC STIRRER CONSTIR

increased with a significant positive impact on product quality.

TAILOR-mAdE

Whether for a mould, strand, or final position, every electromagnetic stirrer is custom-built in order to meet each client’s specific quality requirements. SMS group has proven the robustness and cost-effective application of their stirrers over decades. SMS group is at the forefront with simulation tools to further improve the application of ev-ery stirrer.

Customized stirrers for a better quality and higher productivity.

Extra-narrow stirrer housing for large round sections with small strand spacing.

Typical applications of the stirrer

mould Stirrer (CONSTIR-MEMS)

Strand Stirrer (CONSTIR-SEMS)

Final Stirrer (CONSTIR-FEMS)

m-EmS:- Releases entrapped slag- Breaks up pinholes and blowholes- Reduces sub-surface inclusions,

segregation and porosity

S-EmS:- Expands equiaxed zone- Reduces center porosity,

segregation

F-EmS:- Reduces center porosity and

segregation

www.sms-concast.com

28


Commissioning at Stahlwerk Thüringen

SMS group successfully completes CRS® straightener modernization.

Stahlwerk Thüringen GmbH, Germany, has successfully commissioned its CRS® straightener following modern-ization by SMS group. The goal of modernizing this straightener, which was supplied by SMS in 2002, was to upgrade the machine and at the same time to extend the straightening range to include larger beams. From now on, Stahlwerk Thüringen will be able to supply the market with straightened beam qualities up to IPE 600, HE 280–340, and HEM 260.

LONG-STANdING cOOPERATION

Stahlwerk Thüringen and SMS group have benefited from a close partnership since the company took delivery of the combined section mill in 1983. With the modernization con-

cept now implemented involving the continued use of existing machine components of the original straight-ener, it was possible to reduce the in-vestment costs and completion time considerably.

The modernization included a wider spacing of the straightening shafts and more powerful drive units. At the same time, the safety technology was brought up to date and an offline straightening model installed.

After a shutdown of just two weeks, the machine was recommissioned and production started on schedule. The modernized plant means that Stahl-werk Thüringen can now not only meet the growing demands for long product mills in terms of productivity, flexibili-ty, and cost-efficiency, but also in-crease its competitiveness on the do-mestic and international markets.

Changing the straightening rolls on the CRS® straightener.

[email protected]

Metallurgy and environMental technology

29

www.metix.co.za

The furnace for the separation of cop-per matte and slag, supplied by SMS Metix, South Africa, to kansanshi Min-ing PlC, has been started up success-fully. With the new furnace, kansanshi Mining PlC (majority shareholder: First Quantum Minerals) has expand-ed its copper smelting plant in the province of Copperbelt, Zambia’s larg-est copper mining area. SMS Metix’s scope of supply comprised the engi-neering and supply of a copper-matte settling furnace, the feeding system, the refractory lining, the tapping sys-

COPPER-MATTE SETTlING FURNACE IN OPERATION

tem, the electrodes, the high-current system, and the transformers. The rectangular six-in-line furnace (six electrodes) features a hearth bottom area of approx. 26 x 9 meters and a transformer capacity of 24 MvA. The settling furnace separates matte and slag present in the form of an emul-sion (a finely dispersed mixture of two liquids that are usually unmixable). The copper matte thus obtained is fur-ther processed into copper anodes.

Furnace supplied by SMS Metix separates copper matte and slag in Zambia, Africa’s most important copper mining area.

Size of furnace 26 m long x 9 m wide hearth x 6.5 m high

Nominal installed power 24 mvA

Electrode stroke 1,600 mm

Slag capacity 353 m3 or 1,132 t

Copper matte production 91 tons per hour

Slag output 142 tons per hour

Technical data

SmS group

copperbelt is an

industrial area in

Zambia, which also

extends into the

democratic Republic

of the congo. It is the

most important copper

mining area in Africa.

Copperbelt accounts

for more than one

tenth of the world’s

copper deposits.

iDemocratic Republic of the Congo

Pho

to b

otto

m r

ight

: Mel

lonD

or/W

ikim

edia

Metallurgy and environMental technology sms group newsletter 01 / 2016

30

The Energy Collector E-CO, an SMS group development, is the first system of its kind in the world. The application of the Energy Collector E-CO , which is designed to capture radiant heat, requires that the system is directly exposed to a hot material of more than 600 degrees Celsius. Example: continuous slab caster. On the roller table, the hot slabs are transferred to a position covered by a heat exchanger. There they rest until the next hot slab arrives. The onward move-ment of a slab in order to give way to the next red-hot slab is triggered by automated roller table controls. Thus, the next arriving slab will automatically stop under the heat ex-changer. The slabs radiate between 30 and 45 kW of energy per square meter, depending on their surface tempera-tures. The heat exchangers absorb the radiant heat and convert it into steam.

UNIQUE IN THE WORlD:ENERGY COllECTOR E-CO

SMS group development saves resources and energy.

www.sms-group.com

Functional principle of the Energy Collector E-CO.

FACTS AND FIGURESModular expandable design

No impact on production process

Maintenance-free, fully automatic

Specific radiant heat of 30–45 kW/m² of slab surface

Pilot plant at SZFG, May 2015 – 1 ton of saturated steam/hour – Fast run-up in only five days

i

31


Salzgitter Flachstahl Gmbh (SZFG) has been using the E-cO pilot plant built by SmS group to its full extent.

Interview with Dr. Peter Müller, Head of Continuous Casting Plants & Finishing lines at Salzgitter Flachstahl GmbH.

dr. müller, at Salzgitter Flachstahl, you place great emphasis on environmental protection, and you have been very active in this field. Obviously, environmental awareness is more than just an image promotion for your company.With our environmental targets and measures, we strive to make an ongoing contribution to a better environment. Our main focus is on reducing emissions and conserving re-sources. Almost half of our environmental targets relate to the conservation of resources. We look at both, direct ways of resource saving and ways to reuse by-products.

A continuous caster releases a lot of thermal energy. At your continuous casting plant, you are now recovering part of that energy and using it for other purposes. What is the story behind that technology?The colleagues of SMS group had suggested that we should install a pilot plant that would recover unused radiation heat from hot slabs by means of heat exchangers and feed that energy in the form of steam into our saturated steam network – steam that would no longer have to be generated by our power plant. We were immediately thrilled by the

A perfect solution

Interview

idea. After clarifying and specifying a few aspects, we agreed to have the E-CO plant implemented.

What are the results? does the E-cO plant provide what you had expected?The pilot plant provides an average steam capacity of al-most one ton per hour. The peak values are much higher than forecast, reaching up to two tons per hour. That is much more than our specified target and allows us to make another highly valuable contribution to the protection of the environment. A further important aspect for us is the fact that the pilot plant in no way affects the slab transport.

can you recommend the E-cO technology?For works with a steam network, E-CO is a perfect solution. And, it should not go unmentioned that this project was sponsored by the German Federal Environmental Founda-tion. I think this speaks for itself. There will most likely be additional possibilities of using the recovered heat, for ex-ample by producing hot water that could be fed into district heating systems. So why should we let the energy simply escape?

Thank you very much for this interview.

32


SSAB lUlEA WEll EQUIPPED FOR THE FUTURE

THANkS TO REvAMPSRevamp with lamella converter suspension systems from

SMS group increases yield.

One of the two new converters at SSAB Luleå.

33


At SSAB luleå, Sweden, SMS group has successfully com-missioned the modernized converter shop and the pertain-ing environmental technology. SSAB fully achieved its own target of increasing the yield of both converters and satisfy-ing the high environmental standards demanded. kurt lindqvist, Project Manager of the Converter Shop at SSAB luleå, is highly satisfied with the performance of SMS. “The proven technology of SMS provides very good results. Fur-thermore, the cooperation and communication during the erection and commissioning went very smoothly in an at-mosphere of strong team spirit.”

SMS group supplied two converter vessels with lamella suspension and the tilt drive systems. The two-motor tilt drive systems are easily accessible and very maintenance-friendly. The scope of supply also included the converter trunnion bearings, the height increase of the existing trun-nion pedestals, and the installation of the vessels and trun-nion rings.

PROvEN SmS TEchNOLOGy

Thanks to the design concept developed by SMS group, the new converter vessels have become significantly larger: With an unchanged quantity of charge material of up to 130 tons, the internal volume of the converter has been in-creased by 10 percent. The additional capacity enables more environment-friendly process control and efficient energy recovery. This increase in capacity was achieved by improved utilization of the existing installation space. This was possible thanks to the lamella converter suspension system developed and patented by SMS group. It is a main-tenance-free converter suspension system designed for ar-ranging the converter vessel in the trunnion ring without restraint.

The converters are well prepared for the thermal loads thanks to the use of the lamella suspension system, along with the design of a larger clearance and the use of high-

grade heat-resistant fine-grained structural steels. This is achieved without any additional cooling fluids; sufficient cooling is ensured merely by the natural thermal conditions.

SMS group’s Ecoplants solution comprised the revamp of the primary gas cooling system of the BOF steel-making plant. For this, the cooling stacks of both converters were modi-fied in a first phase and provided with easy-to-maintain SMS group Baumco adjustable skirts. These are lowered hydraulically onto the converter mouth during the blowing phase and they en-able the primary gases to be extracted efficiently under suppressed combus-tion. In addition, diffuse dust emis-sions are substantially reduced. Gas recovery is used in the best possible way by generating CO gas under sup-pressed combustion.

The SMS group scope of supplies and services included the revamp of the primary gas cooling system as well as the engineering and supply of the major cooling stack components. These incorporate the adjustable skirts with labyrinth seal and the moderniza-tion of the inlet section leading into the scrubbing tower for further flue gas cooling. The steam produced in the cooling stacks is used as process steam in the entire integrated iron and steel plant. The complete energy re-covery from the two cooling stacks is thus performed with extremely high energy efficiency. “We are highly satis-fied with the Ecoplants technology and we have a clean environmental con-science as regards production,” is the opinion of kurt lindqvist, Project Man-ager of the Converter Shop at SSAB luleå, Scandinavia’s largest producer of flat steels.

iEcoplants

Ecoplants is the

hallmark of SmS

for sustainable

solutions. Sustain-

ability has become a

key growth factor for

our customers: for

economic reasons

because because

saving energy and

raw materials

reduces costs; and

ecologically because

protecting resources

is becoming increas-

ingly important.

Ecoplants solutions

do justice to both

aspects.

130tons is the charged material quantity. And yet following the revamp the internal volume of the converter was increased by 10 percent.

Jan Bader [email protected]

34


34

SMS Group has extended the existing production line meant for tools and special steels consisting of EAF-, lF-, vD-Ingot Casting at Metal Ravne, a Slovenian steel producer in the first half of 2015. SMS’s supply package broadly included- lF, vD-vOD and a separate de-slagging station as well as a filter plant. Metal Ravne’s inten-tion behind the installation of the new ladle metallurgical center was to in-crease its overall production and achieve additional production capacity in secondary metallurgy to include stainless steel in its product range, which will ultimately open up new markets for Metal Ravne and increase its market share of re-melted steels.

The plant comprises a movable tank car and a stationary cover for the vOD as well as a stationary cover for the ladle furnace. These were designed to treat heats with nominal weights from 45 to 60 tons. Also included in the scope of supply was the vacuum sys-tem, the temperature and sampling device, the electrical lifting system and the gantry, a wire feeding machine, the electrical, instrumentation, pro-cess automation systems and erec-tion, and cold and hot commissioning.

LAyOUT OF ThE LAdLE mETALLURGIcAL

cENTER

As the average number of heats to be treated was only ten, both the lF and the vD units were designed as a single unit. Both units are connected by a rail track to transport the ladle quickly from one unit to the other without any crane handling and the transport is

INCREASED CAPACITIES AND MARkET SHARE

In 2015 SMS group successfully commissioned the newly erected Secondary Metallurgical Center at

the Slovenian steelmaker, Metal Ravne.

ladle furnace at Metal Ravne.

35


managed by one tank car. Therefore, in each treatment position only the re-spective treatment cover has to be lifted or lowered to start the treatment. Both stations are equipped with man-ual argon couplings with high-temper-ature-resistant hoses intended for supplying the inserted ladle with bot-tom-stirring gas. The vacuum tank is connected to a vacuum pump system with a suction pipe and the graphite electrodes are connected to the trans-former via high-current cabling.

The vD/vOD cover is equipped with an oxygen lance for forced decarburi-zation and a semiautomatic lance for hydrogen measurement (HYDRIS). Both the units – lF and vD-vOD – have equipment for semiautomatic sam-pling and temperature measurement at atmospheric pressure. The treat-ment covers are lifted and lowered hy-draulically. likewise, mounted on the vacuum cover is a vacuum lock for the

feeding of bulk additives like ferroa-lloys and slag formers, also during vacuum treatment. At the lF, there is a collecting hopper for material addi-tion during treatment and additionally one four-strand wire-feeding system for the feeding of metallurgical wires after treatment.

The de-slagging stand is equipped with a movable de-dusting hood, a la-dle tilting stand, and a hydraulically operated de-slagging machine. Be-sides the de-slagging equipment at this position, there is also an immer-sion lance, which serves for addition of gaseous nitrogen for steel grades with defined nitrogen contents.

INcREASEd cAPAcITIES …

INcREASEd mARKET ShARE

Metal Ravne has extended the existing process line to have the metallurgical capability of treating special construc-tion steels that require degassing for

»The investment into a new lF, vD-vOD plant, which was installed

at Ravne in cooperation with SMS Mevac and SMS INNSE, is part of the modernization activities in our

steel plant. The aim of this investment is to increase our productivity and

to expand our possibilities also to the area of the production of

low-carbon steels.«

Andrej Gradišnik

managing director,

metal Ravne, SIJ

Group.

removal of undesired elements like H, N, or S as well as stainless steel grades. Together with the existing lF and vD unit, Metal Ravne has now con-siderably reinforced and improved the ladle metallurgical capability. Not to mention, with stainless steel picking up demand in various segments, Metal Ravne will definitely reap the benefits of this successful extension.

Axel Kopp [email protected]

36


New silicon-metal works for Iceland

Turnkey plant on the basis of hydropower and geothermal energy

Dr. Peter Wenzel, member of the Managing Board of PCC BakkiSilicon hf (left) and Burkhard Dahmen, CEO SMS group GmbH, signing the contract.

PCC BakkiSilicon hf has placed an order with SMS group for the turnkey supply of a silicon-metal works, including the design and construction of the plant. The new works will be laid out for an annual production of 32,000 tons. Built at Húsavík in the north of Iceland, the plant is sched-uled to start producing in 2017.

The main assets of the works will be two submerged-arc furnaces (SAF), including the cooling water plant and the transformers. Each of the furnaces will have an installed power of 24 MW. They will both be powered by renewables, namely geothermics and hydropower. SMS will equip the works with X-Pact® electrical and automation systems.The primary and secondary dedusting plants that will clean the air and the process gases will use proven SMS group environmental technology. The separated dust will be com-

pacted, collected in silos, and sold, for example, as an ingredient of concrete.The filter house for primary dedusting will be designed as backwashable fil-ters allowing fine filtration of solids and, as a result, significantly more ef-ficient cleaning. The dedusting plant design will allow for an energy-recov-ery system to be retrofitted at a later stage in order to further improve the efficiency of the plant.

SmS GROUP AS A STRONG PARTNER

SMS group will supply the material and product handling systems all the way down to the dispatch area, the pouring bay equipment, the workshop, laboratory equipment, as well as the cranes and vehicles. PCC is an inter-nationally active group of companies led by PCC SE located in Duisburg, Germany. The production of silicon metal requires the use of quartzite. The quartzite for the new works in Ice-land will be shipped from Poland where PCC owns a quartzite mine.

martin Köneke [email protected]

Metallurgy and environMental technology

37

Ronald J. O’Malley, Second Officer at large of AIST and head of delega-tion, presenting a commemorative certificate on the plant tour to lothar Fischer, Head of Technical Sales Continuous Casting Plants at SMS group.

On the occasion of a study tour focusing on continuous casters, 32 members of AIST (Association for Iron & Steel Technology) visited SMS group. Representatives of ten American customers were fascinated by the three-dimen-sional design in virtual reality. Demonstrations and lec-tures also informed the delegation on new SMS group developments.

DElEGATION OF AIST vISITED SMS GROUP

IN DüSSElDORFParticipants gained insight in three-dimensional design.

38

The SmS mevac experts know the technological requirements placed on vacuum pumps.

SmS mevac

SmS mevac now

offers its expertise

in secondary and

tertiary metallurgy

also in the form of

consulting ser-

vices, which allow

customers to plan

their revamping or

building projects

in a most target-

oriented way.

Within SMS group, SMS Mevac is the center of competence for all aspects of secondary metallurgy of steels and the associated plant and process technology, with special em-phasis on RH/RH-OB and RH-TOP plants. SMS Mevac has a track record of more than 180 such plants sold and com-missioned worldwide. The SMS Mevac experts also know what requirements such applications place on vacuum pumps and their proficiency allows them to offer operators of ladle-metallurgy plants solutions that are perfectly tai-lored to their needs. Among the various ladle-metallurgy processes, the vacuum treatment of liquid steel plays an outstanding role due to its versatility, especially in the pro-duction of higher-grade steels.

cLEAR cOST AdvANTAGES

In modern, efficient ladle-metallurgy plants, the fine vacu-um required for the vacuum treatment of steels is set by steam ejector or mechanical pumps. In order to be able to decide which of these systems would be the most appropri-ate choice in a particular case, not only the metallurgical task and the specific operating costs have to be taken into account, but also the possibility of optimizing the overall system including the ancillary facilities. SMS Mevac has al-ready equipped vD/vOD plants with mechanical vacuum

Specialists in mechanical pump systems

pump systems in the past, most of them in electric steelmaking plants that do not have any internal steam generation capacities and therefore rely on the use of mechanical pumps. Meanwhile, operators also request that RH plants – which have a much larger evacuation volume – be equipped with mechanical pumps. Calculations have shown that, although they involve high-er investment costs than steam ejector vacuum pumps, mechanical pumps pay off much faster.

SMS Mevac boasts vast experience in the field of vacuum pumps.

Jochen Schlü[email protected]

i


FlAT ROllING MIllS — lOGISTICS SYSTEMS

The storage system is directly con-nected to a new litho finishing line and comprises an inspection area, an au-tomatic coil manipulator, and 28 dou-ble cantilever arms to receive the litho coils weighing about 11 tons. The new packaging line is arranged to follow immediately and permits the coils to be automatically placed on shipping pallets with the axis either in horizon-tal or vertical position. These pack-ages are then wrapped for shipment, strapped, weighed, and finally provid-ed with a shipping label. An essential characteristic of the line is that, during the entire transport as well as deposi-tion on the pallet, handling of the ex-tremely shock-sensitive litho coils is

lITHO COIlS PACkED GENTlY

The new packag-ing line for litho coils at Bridgnorth Aluminium.

accomplished exclusively through the coil eye and not at the circumference to avoid damage. Once the coils have safely been deposited on the pallet, the subsequent packaging process is per-formed automatically without need for moving them again.

cONvINcING cONcEPT

“The concept offered by SMS logistik-systeme convinced us,” says Paul Smith, Project Manager in charge of the litho expansion project at Bridgnorth Aluminium. “The automat-ic coil handling exclusively through the eye ensures the sensitive litho foil is gently interim-stored and fed to the packaging line on demand. This con-

To Bridgnorth Aluminium limited, SMS logistiksysteme will supply an automatic coil cantilever store with downstream coil packaging line, which will

more than double the production capacity for lithographic material.

cept does not only provide the neces-sary buffer between production and packaging, but also helps us react to impulse customer requests at short notice and deliver promptly.”

Another benefit for the customer: thanks to the compact design of the system, the space required for the in-terim store and the packaging line is clearly smaller than expected. With this investment, Bridgnorth Alumini-um ltd. will increase its capacity and further consolidate its position among the top suppliers of lithographic qual-ity aluminum strip in Europe.

Stefan [email protected]

40

FlAT ROllING MIllS SmS group newsletter 01/ 2016

high-bay store for aluminum coils.

41


“It was the technically mature overall concept that tipped the scale in favor of SMS logistiksysteme and also the large number of successfully established reference sys-tems,” explains Grégory Misonne, Project Manager. “An-other factor that impressed us was the features of the warehouse management system precisely developed to meet our needs.”

hIGh-BAy STORE WITh TWO STAcKER cRANES

The coils leaving the hot strip mill are loaded on large-size pallets able to receive four to six coils and then carried over a distance of about 100 meters, to the new facility by a shut-tle car. Energy supply to the car is accomplished by a mo-torized cable reel. The car is furthermore provided with all required safety equipment to make fencing of the driving route superfluous and hence to permit cross-traffic of fork-lift trucks or individuals. In the unloading area, the load is automatically registered and measured by means of a laser scanner. Thereafter, a manipulator takes the coils and car-ries them to the high-bay store. Before the coils are stored, however, their ID is scanned and all data are compared to the production plan data provided by the superordinated control system. If the values are identical, a coil car will transport the coil to the high-bay store. There, the coil is placed to stock by one of the two stacker cranes.

To the engineers of SMS logistiksysteme, the space conditions, in particular, meant a major challenge in find-ing the right concept with respect to the concrete structure and to installation as the storage system is to be estab-

HIGH-BAY STORE FOR AlERIS, U.S.A.

lished upstream cold rolling mill be-tween the existing rows of support pil-lars of two halls. The spatial size of the store is determined by the large dis-tances between the transfer positions of the two annealing lines and the cold rolling mill, as they all have to be with-in reach of the stacker cranes.

OPTION FOR FUTURE EXTENSION

To be prepared for future demands, the store is designed for easy extension by further bin locations without having to modify the steel structures. Subse-quent installation of a coil cooling sys-tem will also be possible.

At its lewisport location in the U.S. federal state of kentucky, Aleris Rolled Products, Inc., is going to enhance the production ca-

pacity of its automotive body system. For the new facility, SMS group is to supply a cold rolling mill, while for interim coil storage between the individual processing steps, a high-bay store including connected

transport equipment was ordered with SMS logistiksysteme.

www.sms-logistiksysteme.com

horst [email protected]

42

FlAT ROllING MIllS SmS group newsletter 01 / 2016

From top to bottom:The stocks on hand can easily be sorted, filtered and processed in the form of a table. The user can adapt the display to his or her personal requirements and store it. More-over, details can be viewed and actions, such as transport, can be initiated.

The interactive 3D visualization provides a dimensionally true and real-time reflection of the situation in the works.

In coordination with the customer, different features can be shown up in color. These include, for example, coil temperatures, next production step and position status.

iWmS

The WmS provides

a good overview of

all relevant data and

offers various possi-

bilities for process-

ing these and for

monitoring the ma-

terial flow. It seam-

lessly integrates

both existing system

configurations and

those which are still

being developed.

43


With its comprehensive range of functionalities, the system provides an attractive and reliable solution for automated material flow control and warehouse administration.

Quite recently, SMS logistiksysteme put the entire WMS concept to the test and revised it thoroughly. When design-ing a completely new user surface, the software engineers paid particular attention to intuitive operation, high perfor-mance, and optimized search and filter functions. Within seconds, the operator can view all information on the stock level and see the current system status. A special highlight here is offered by the revised 3D display. Stock level and material transports are visualized in real-time – the cur-rent transport situation and also the warehouse itself are hence convenient and visually appealing to view.

FLEXIBLE APPLIcATION

The WMS core was optimized and can now be flexibly ex-tended and precisely adapted to customer-specific require-ments. The system is independent of both the operating system and the database. The client-server architecture is designed to permit an unlimited number of clients to be connected to the server. The benefit for the customer: if so required, it can install WMS clients on any PC within a few seconds without paying additional license fees, which pro-vides it with a high degree of flexibility. In addition to the typical functionalities of a warehouse management system, the WMS offers support in the planning of production se-quences. If processing steps have been determined in ad-vance, the system will use this information to optimize transport and storage strategies. In line with the custom-er’s request, it is also possible to initiate material trans-ports at a specified date on the basis of predefined shipping schedules.

lONG-lASTING SUCCESS STORY

mANy AddITIONAL FUNcTIONS

Further functions such as user and rights management, language change, consistent input validation and web ad-ministration interface for expert settings, reporting func-tionality, temperature curve simulations, and many more offer the user additional benefit. Apart from providing the respective software, SMS logistiksysteme takes care of the design, procurement, and installation of suitable server hardware and network infrastructure using redundant high-availability systems and configuring automatic back-ups.

The WMS comes with interfaces with subordinated con-trols as well as with the superordinated system. In particu-lar situations, when the conveying system operates in the manual mode, the functionalities of the WMS make sure the material flow can still be supervised fully automatically. The improved current version of the WMS has already prov-en its worth in numerous major projects and impressed the customers with its future-oriented functions. It will be part of the orders from Aleris and AMAG for high-bay stores and will coordinate all material tracking and warehouse man-agement tasks.

The Warehouse Management System (WMS) of SMS logistiksysteme is an in-house development incorporating decades of experience from programming

and commissioning of warehouse management systems.

www.sms-logistiksysteme.com

Justus [email protected]

44


45

FlAT ROllING MIllS — HOT ROllING MIllS

Link fehlt

Tata Steel ltd. has placed an order with SMS group for modifying the coil-box of the Jamshedpur, India, hot strip mill to a mandrel-less coilbox. The al-teration of the coilbox, which had been installed in 1993, to a design without mandrel will reduce wear and the ef-fort for maintenance. Furthermore, temperature losses at the inner wind-ings of the coiled strip will be avoided in the future and make the rolling stock enter the finishing mill at a ho-mogenous temperature over the entire length. Foundation work for the altera-tion can be kept to a minimum as the design of the coilbox will be adapted accordingly.

cOILBOX WITh X-PAcT® AUTOmATION

The new X-Pact® automation system for the coilbox will be installed and tested in advance during ongoing op-eration and thus permit the change-over to the new system to be accom-plished during the downtime period, which is scheduled to take about two weeks. On this occasion, too, SMS will integrate the crop shear automation

COIlBOX WITHOUT MANDRElThe coilbox alteration at Tata Steel Jamshedpur

will lower temperature losses and reduce maintenance.

into the new system. All drives in the coilbox area will be changed by SMS group from DC to AC.

After the alteration, the coilbox will work without mandrel.

Uwe Warnke [email protected]

46

FlAT ROllING MIllS

Also outstanding technologies, like the thin slab technolo-gy launched by SMS group in 1989 under the name “Com-pact Strip Production” (CSP®), must be constantly ad-vanced. Nucor Steel, U.S.A., had immediately recognized the benefits of this technology and commissioned the world’s first CSP® plant in Crawfordsville, Indiana, U.S.A. as early as in 1989. The plants in Hickman (Arkansas) and Berkeley (South Carolina) followed in 1992. SMS group up-graded the Berkeley plant in 2013/2014, during a project period of just a few weeks. “Now, as we can make widths of

BACk TO THE FUTURE

Twenty-five years after the supply of the first CSP® plant, the pioneers in thin

slab technology, Nucor Steel and SMS group, recently modernized the CSP®

plant in Berkeley (South Carolina), which has been in operation for 18

years. Wider strips, smaller final gaug-es, and lower energy use are the

results of a successful collaboration.

1,880 millimeters, we can with even better cater to our customers’ requirements,” says John Witherow, Hot Mill Manager at Nucor Steel. “SMS group has developed a cost-optimized modernization concept specially for us. It is perfectly tailored to our needs and provides us even more flexibility.”

Through the revamp, the final strip width has been in-creased from 1,680 to 1,880 millimeters. At Nucor Steel, SMS group for the first time implemented a new modern-ization concept designed to expand the product range and

47

Successful cooperation: John Witherow, Nucor Steel, thanks Alexander volland, SmS group, for the successful revamp of the cSP® plant.

reduce energy consumption at the same time. For the very first time, an induction heating system was installed up-stream of the CSP® rolling mill. “To make this possible, the existing tunnel furnace was shortened by approximately 6.5 meters,” explains Alexander volland, Project Manager at SMS group.

This solution provides two advantages: by means of the induction heating units supplied by SMS Elotherm, it is pos-sible to increase the temperature of the thin slabs, as re-quired, right before they run into the rolling mill. This enables

Nucor Steel to achieve greater reductions per pass and ex-pand its mix of products in the thin gauge range. A wider portfolio of grades can now be produced.

SIGNIFIcANT ENERGy SAvINGS

An additional benefit of the inductive heating systems is the fact that the energy consumption of the CSP® plant can be even further reduced. The possibility of flexibly adjusting the thin slab temperature prior to rolling provides the pre-condition for lowering the furnace temperature to a


48


level suitable for rolling the major part of the steel grades and strip gauges, without compromising pro-cess stability or the product quality. For all strips requiring a higher entry temperature, the inductive heating systems will be there to provide the ex-tra heating. By means of this concept, it is possible to achieve both the exten-sive product range typical of the CSP®

technology and marked savings on en-ergy.

dETAILEd PLANNING

Additionally, the modernization mea-sures comprised modifications to one of the two CSP® casters, the extension of the CSP® rolling mill, and the re-newal of the X-Pact® electrical and au-tomation systems.

The CSP® caster was fitted with new molds, a new four-cylinder oscillation system, markedly wider segments, and a new bending and straightening unit. Thanks to the implementation of the liquid Core Reduction (lCR 3) module in the containment zone, the thickness of the thin slabs can be infinitely ad-justed between 48 and 63 millimeters. “Although increasing the casting width by 200 millimeters was definitely a challenge at the beginning of the proj-ect, the implementation eventually did not pose any major problems thanks to the good planning and successful col-laboration,” says volland.

From top to bottom: A world first: Never before had the experts of SMS group installed an inductive heating system in a CSP® plant.

The continuous casting plant received a new bending and straightening unit. The width was increased by 200 millimeters.

iNucor

With an annual

production of more

than 21 million tons

(2014), Nucor is one

of the largest steel-

makers in the U.S.A.

As its first user, the

company was instru-

mental in helping

the CSP® technology,

developed by SMS, to

achieve its world-

wide breakthrough.

49


SMS group added a seventh finishing stand to the CSP® rolling mill. The new stand features CvC® plus technology, like the stands F1 through F6. The CSP® rolling mill also received a new X-Pact® level-2 automation system in-cluding shape, contour, and flatness control systems as well as a cooling model.

“With the experts of SMS group, we had partners at our side who we could rely on at all times. Despite the chal-lenging project implementation, the cooperation was always very construc-tive and trusting,” says Witherow. “The modernized plant has markedly im-proved our competitiveness in the market for premium flat steel prod-ucts.”

What was so special about this cSP® modernization at Nucor Steel?It was the world’s first CSP® plant receiving an induction heating system to be installed between the equalizing fur-nace and the rolling mill entry. Also the increase in width by 200 millimeters is certainly worth a special mention.

What are the benefits of installing the induction heating system? The induction technology efficiently combines two aspects. The starting point was the fact that only very few products made on a CSP® plant need the maximum tunnel furnace temperature. The combination of a gas-heated tunnel fur-nace and an inductive heating plant makes it possible to reduce the tunnel furnace temperature to a lower level.

Those products requiring a higher entry temperature are now heated up, as required, by the inductive system direct-ly ahead of the first stand of the CSP® rolling mill. With the furnace temperature now being lower, it is easier to use non-cooled, dry transport rollers inside the tunnel furnace. These dry rollers reduce the heat losses in the furnace compared to the water-cooled variants. The use of dry roll-ers thus helps to cut the energy consumption by 40 percent.

Is it possible to transfer this concept to other cSP® plants?Yes, definitely. With this concept, it is possible to expand the product mix and reduce the energy consumption of any CSP® plants. As to the width increase, the specific plant features and conditions must be taken into account. As far as the latter aspect was concerned, especially in the CSP® rolling mill, the Nucor plant had major reserves.

Reducing the energy consumption of the furnace roller by 40 percent

Interview

Alexander vollandProject manager,

SmS group.

www.sms-group.com

50


PARTNERSHIP WITH HOUGHTON INTERNATIONAl

Plants and fluid technologies from a single source for efficient and ecological cold strip production

In December 2015 SMS group GmbH and Houghton International Inc., with head office in Pennsylvania, USA, agreed their partnership for the development and marketing of oil-based cooling lubricants and emulsions for cold rolling mills. Two leading suppliers have joined forces in this partnership with a view to providing their joint customers with the added value obtained from a harmonized symbiosis of plant and fluid technology.

STRATEGIc PARTNERShIP

Houghton International Inc., is a top-of-the-range supplier in the field of fluids and special chemicals for metal processing. The partnership covers the common development and marketing of oil-based cooling lubricants and emulsions for

steelmaking. Under this partnership, SMS and Houghton will be pooling their research and development re-sources with a view to offering the in-novative cooling lubricant technolo-gies to steelmakers.

„We are happy to have entered this partnership as it will enable the SMS group and Houghton International to become even better at satisfying the ever more exacting demands of the market relating to product quality and productivity, both at present and in the future“, says Rüdiger Holz, vice Presi-dent at SMS group‘s Flat Rolling Plants Cold Rolling Mills Business Unit. „This partnership offers innova-

tive solutions to our joint customers worldwide in the metal-producing industries.“

„We are most happy to be able to announce this exclusive partnership because both SMS and Houghton are leaders in the fields of rolling technology and fluids“, says Marcello Boldrini, President for Global Metals & Mining and Asia at Houghton. „We can now provide the worldwide manufacturers of steel and other metals with the only systems that integrate plant engineering and lubricant technology, thus allowing us to of-fer the most advanced integrated solutions to our customers.“

Patrick [email protected]

Partnership for integrated plant engineering and lubricant technology.

ihoughton International

Since 1865,

houghton Inter-

national Inc. has

been serving the

aluminum and steel

industries as well as

various other sectors

with the develop-

ment and manu-

facture of special

chemicals, oils and

lubricants. With its

head office in valley

Forge, Pennsylva-

nia, USA, Houghton

operates develop-

ment and production

facilities all over the

world.

Flat rolling mills — Cold rolling mills

Pure Rolling Oil For Bright Strips

As part of the modernization of the 20-roll cold mill SG3 at its location in krefeld, Germany, Outokumpu Nirosta GmbH awarded a follow-up order to

SMS group covering the adaptation of the existing rolling oil system.

Outokumpu group is one of the leading producers world-wide of sophisticated stainless steel materials. At the krefeld location, the mono-block 20-roll cold mill SG3 which had been supplied by SMS more than 45 years ago is used to produce high-quality stainless steel strips. To be able to roll also ferritic materials of thin strip dimensions and high-gloss quality (2R bright-annealed), Outokumpu Nirosta commissioned SMS group in September 2014 to modernize all equipment required for that purpose. In 2015, Outokumu Nirosta awarded a follow-up order to SMS group comprising the modernization of the existing rolling oil sys-tem to make the rolling mill fit for producing such high-gloss grades. Part of the equipment remains and will be re-used. The most important equipment to be newly in-stalled include a dirt oil tank with automatic pre-separator and the extremely fine filter system SUPAFINE® from SMS. In the future, vertical filter pumps will discharge the rolling oil contaminated by the rolling process from the dirt oil tank to the SUPAFINE® filter system for cleaning. The cleaned oil will then be fed to the existing clean oil tank and be used

again for the rolling process. The mixture of rolling oil and abrasive particles obtained in the course of SUPAFINE® fil-ter backwashing is conditioned in a further filtration stage and the recovered rolling oil returned to the system. As the SUPAFINE® filter elements are suited for backwashing, an extremely high filter fineness is achieved without using any filter aids that would create high additional costs for con-sumption and disposal.

cONvINcING SUPAFINE® FILTERS

Customers are impressed with the performance and effi-ciency of the SUPAFINE® filter systems supplied by SMS group. This is testified by the number of 210 SUPAFINE® filters that have already been installed all over the world until now. To comply with Outokumpu Nirosta’s request, SMS group will modify the mechanical mill stand equip-ment and the rolling oil system within a very tight time schedule to ensure Outokumpu Nirosta can start produc-ing the desired material grades on this mill as early as possible.

Example of a rolling oil facility with SUPAFINE® filter system.

52


CCM® - A SUCCESS STORY FOR UP-AND-COMING

COUNTRIESA new order from vietnam and successful commissioning

in Bangladesh and Pakistan.

53

FlAT ROllING MIllS — COlD ROllING MIllS

kYCR’s new CCM® prior to hot commis-sioning.

CCM® sets new benchmarks for thin strips

On August 16, 2015, the new Compact Cold Mill (CCM®) at kYCR Coil Industries limited started operation in Bangladesh. The cold rolling mill is based

upon an existing reversing cold mill, which was revamped by SMS group within the scope of a flexible and economical extension concept.

Bangladesh is a newly industrializing country with a continuously growing economy and a steadily developing in-dustry. Beside the publically noticed branches of the textile industry and ship breaking, now expansion efforts of the steel industry are coming into the focus. An example for this is the young company kYCR Coil Industries limited.

kYCR is a subsidiary of kDS Steel and therefore belongs to the conglom-erate kDS group. In 2000, the modern cold strip production complex of kYCR was erected in kumira, located at 25 kilometer’s distance to Chittagong. The main production plant of this facil-ity was the reversing cold mill (RCM) by SMS group in 6-high design with CvC® plus, operating since 2002. In addition, there is a pickling as well as a slitting and recoiling line installed. With the cold strip produced there, kYCR further processes roofing sheets via a continuous galvanizing line and a color coating line.

After more than twelve years of mill operation, kYCR decided to extend ca-pability and capacity of the RCM and to use the flexible extension concept of-fered by SMS group. The company placed an order with SMS group for the extension of the RCM to a twin stand Compact Cold Mill (CCM®) with X-Pact® electrical and automation sys-

tems and capacity adjustment of auxil-iary plants as parts of the supply scope.

FLEXIBLE EXTENSION cONcEPT

In order to keep the retrofit as short as possible, SMS group had designed the RCM foundations in a way that the sec-ond mill stand could be installed with low efforts. Only the exit side equip-ment like tension reel, coil car, and belt wrapper had to be relocated. In August 2015, kYCR for the first time rolled a strip on the CCM®. The mill produces very thin strips for the local market with widths between 600 and 1,050 millimeters and final gauges down to 0.09 millimeters. The annual produc-tion capacity now is 170,000 tons.

Helmut klatt, Project Manager Tech-nology in the order handling and exe-cution department of SMS group, says: “beside CvC® plus, the CCM® is pro-vided with highly dynamic control sys-tems covering set-up approaches and technological control loops. This en-sures the economy of the production process and high product reliability and quality, and helps kYCR to strengthen its own market position.”

helmut [email protected]

54


COMPACT COlD MIll AT ABUl kHAIR HAS STARTED

OPERATIONOn April 23, 2015, the new Compact Cold Mill (CCM®) at Abul khair

Strip Processing ltd. started operation. SMS group has designed this CCM® especially for rolling of very thin strip qualities.

The new CCM® by SMS group occupies a central position in the cold strip production facilities of Abul khair Strip Pro-cessing ltd. in Chittagong. On the CCM® the Bangladeshi cold strip producer rolls strips with widths up to 1,250 mil-limeters and incoming thicknesses up to 4.00 millimeters to final gauges down to 0.09 millimeters. The CCM® has an annual capacity of 185,000 tons. The quality-determining mill components originate from SMS in-house manufac-turing. Rolling technologies such as CvC® plus combined with work roll and intermediate roll bending, entry and exit side multi-zone cooling system, plus dry strip system offer Abul khair the guarantee, that the products will meet all customer requirements on strip thickness, flatness, and

surface quality. SMS group also supplied the emulsion plant with chain-type magnetic separator and vacuum filter for the efficient cleaning of emulsion. By using speed-con-trolled pumps, the emulsion volume is supplied tailored to requirements, which ensures energy-saving operation of the emulsion plant. For this reason, the CCM® does not only operate flexibly but also saves resources.

A BENchmARK FOR QUALITy

Markus Gümpel, Project Manager Technology at SMS group comments on the commissioning: “Already a few days after the first strip we were able to roll prime coils to final gaug-es down to 0.4 millimeters with excellent flatness and sur-face results. The further progress of the commissioning satisfied Abul khair as well. With this new plant, the com-pany definitely establishes a new standard for cold strip quality on its local markets.“

The first finished strip is being coiled on the tension reel.

markus Gü[email protected]

185,000The CCM® at Abul khair has an annual capacity of 185,000 tons. The mill specializes in thin strip.

55

The recently commissioned Rcm of Nam Kim Steel will soon be complement-ed by a twin-stand ccm®. Entry section with pay-off and tension reel 1.

Nam kim Steel Joint Stock Company is a leading supplier of surface-coated cold strip in vietnam. Esmech Equip-ment Pvt. ltd., joint venture partner of SMS group located in India, supplied –in cooperation with SMS India Pvt. ltd. for electrical and automation systems – a high-performance reversing cold mill (RCM) with proven rolling technol-ogy by SMS group to Nam kim Steel, which successfully started operation in April 2015. The RCM in 6-high de-sign with CvC® plus by SMS group rolls strips with widths up to 1,250 mil-limeters to minimal exit gauges down to 0.11 millimeters. Already with this mill Nam kim Steel has set new benchmarks for cold strip quality on the local market.

In the course of further company expansion, in April 2015 Nam kim Steel placed an order with SMS group for the reversing full-line supply of a twin stand Compact Cold Mill (CCM®).

Nam kim Steel once more entrusts Esmech Equipment Pvt. ltd. as sup-plier of the mechanical equipment, combined with rolling technology and core equipment by SMS group Germa-ny, and of all auxiliary plants. As for the RCM, electrical and automation systems will be provided by SMS India Pvt. ltd.

ROcK-SOLId PLANT TEchNOLOGy

The CCM® in 6-high design will help Nam kim Steel to increase the annual capacity for high-grade cold strip up to 435,000 tons and to strengthen its own position on the regional market. This will be supported by the modern and rock-solid plant technology by SMS group. The CCM® is equipped with CvC® plus in combination with positive and negative work- and intermediate roll bending and provides a very large setting range for roll gap adjustment. Together with the X-Shape flatness

Torsten [email protected]

Nam kim Steel expands production of high-grade cold strip in vietnam

After the successful ramp-up of the new reversing cold mill at Nam kim Steel in April 2015, the steel producer in vietnam entrusted

SMS group with full line supply of a Compact Cold Mill (CCM®).

Commissioning End 2016

Annual capacity 435,000 t

Strip width 650–1,250 mm

Strip thickness 1.60–4.50 mm (entry) 0.20–2.00 mm (exit)

Material carbon steel

Technical data

measuring and control system, a pre-cise rolling result with best flatness is ensured. By both belt wrappers on the tension reels, smooth winding of the finished strip on sleeves is supported. Devices for fast work and intermediate roll change reduce nonproductive times and increase the mill’s produc-tivity.

It is estimated that at the end of 2016, Nam kim Steel will be able to produce on the new CCM®.

56


Pakistan’s first CCM® in operation

On July 26, 2015, the first coil was successfully rolled on the new Compact Cold Mill (CCM®) of International Steels limited (ISl).

With the successful commissioning of the CCM® to Inter-national Steels limited (ISl) in karachi, Pakistan, and is-suing of the acceptance certificate on December 12, 2015, the extension project of the cold strip producer is brought to a close. In the center of the production development there was the reversing cold mill (RCM), supplied and commissioned by SMS group in 2011. Already when de-signing the RCM, SMS has considered the opportunity for later extension.

SUccESS STORy

Only a few years after commissioning, the cold rolled prod-ucts have become so successful in the markets that ISl urgently required a capacity increase. In 2014, ISl placed an order with SMS group for the extension to a CCM®, through wich the annual production capacity increases up

to 450,000 tons. In addition to the ex-isting mill stand, SMS group supplied for the CCM® an identically construct-ed second 4-high mill stand with hy-draulic gap control, CvC® plus and work roll bending as well as X-Shape flatness measuring and control sys-tem.

During the installation of the new equipment, the concept of SMS has proven itself. To create space for the new mill stand, only the exit side equipment had to be relocated. Thus, the first strip was successfully rolled after a short shut down.

Thereby, ISl is provided with a state-of-the-art twin stand reversing cold mill for precise, reproducible high-quality rolling results.

ISl’s CCM®.


Commissioning July 26, 2015

Annual production 450,000 t

Strip widths 700–1,250 mm

Strip thickness 1.6–1,250 mm (entry) 0.25–2.0 mm (exit)

Material carbon steel, deep drawing material

Technical data

Flat rolling mills — Cold rolling mills

57

6-high stand of a similar RCM with CvC® plus.


GRP, located in Bekasi, West Java, was founded in 2001 and belongs to Gu-nung Steel Group. Since 1996, GRP has operated a steckel mill from SMS group and produces a large range of hot rolled flat products at an annual capacity of 1.2 million tons.

Gunung Steel Group is convinced about SMS group’s expertise in metal-lurgical plants. Currently, further or-ders in the fields of steel production and long products are in different stages of realization.

On the new RCM, GRP is going to produce cold strip products, to be pri-marily applied in the construction in-dustry for facade and roof cladding. The full-line supply comprises the complete mechanical and electrical equipment, automation system, as well as the auxiliaries. GRP places value on single-source supply and technologically well-synchronized pro-duction plants.

TWO OPERATING mOdES

The new reversing cold mill will roll strips with width up to 1,270 mm and maximum entry thickness up to 5.0 mm to final gauges down to 0.15 mm. Depending on the product requirements, the operation mode can be changed between rolling and skin

COlD ROllING All-ROUNDER FOR INDONESIA

Indonesian steel producer PT Gunung Raja Paksi (GRP) has placed an order with SMS group for the full-line supply of a reversing cold mill (RCM) in

CvC® plus 6-high design with skin-pass operation mode.

Material carbon steel

Strip width 600–1,270 mm

Strip thickness 1.20–5.00 mm (entry) 0.15–2.50 mm (exit)

Coil weight max. 27 t

Rolling speed 1,200 m/min.

Rolling force max. 5 mN

Work roll diameter 300/350 mm

Technical data

passing. With the maximum rolling speed of 1,200 meters per minute the mill is designed for an annual capacity of approximately 200,000 tons.

The high quality requirements of the rolled strips are ensured by mod-ern actuators like hydraulic gap con-trol, wedge adjustment, CvC® plus in combination with positive and negative work and intermediate roll bending, entry and exit side multi-zone cooling, and most modern dry strip systems.

The X-Pact® automation includes the online level 2 system and provides fully automatic, precise, and efficient plant operation. Part of the highlights of the online measurement and sen-sor systems is the proven X-Shape flatness measurement roll by SMS. The X-Shape roll is going to be in-stalled both on the entry and on the exit side. In spring 2017, the combined reversing and skin-pass mill will start operation.

Flat rolling mills sms group newsletter 01 / 2016

58

The highly precise and, at the same time, robust X-Shape flatness measuring roll can be smoothly integrated in existing cold rolling mills, too.

Equipped with the X-Shape flatness measur-ing roll from SMS, Starcore’s RCM will be capable of rolling even higher-quality cold strip for Thailand in the future.

STARCORE ORDERS X-SHAPE FlATNESS CONTROl SYSTEM

Flatness control of the latest generation for Starcore.

Starcore Co. ltd. has placed an order with SMS group to supply an X-Shape flatness measuring system with entry and exit side measuring rolls and an X-Pact® flatness con-trol system for a 4-high CvC® cold rolling mill at its works in Rayong, Thailand. The cold rolling mill was supplied and commissioned in 2012 by the Indian company Esmech Equipment Pvt. ltd., which is part of SMS group. The cold rolling mill produces cold strip in reduction and skin-pass operation.

The extension of the CvC® cold rolling mill will be com-pleted at the beginning of 2016. The X-Shape flatness mea-suring system is being manufactured in the SMS group workshop in Hilchenbach, Germany. With the stand-alone flatness measurement and control system from SMS group, almost every cold rolling mill can be retrofitted in a smooth, quick, and cost-efficient manner. Thanks to the extension of the CvC® cold rolling mill, Starcore Co. ltd. will be able to provide products of even higher quality.

detlef Bö[email protected]

59

FlAT ROllING MIllS — AlUMINUM

A successful product developed by a whole team: Jan-Peer Remy, second from left, and his colleagues in the Hilchenbach workshop.

Tobias hä[email protected]

The dispatch of the 50th Multi-Plate® filter caused the edi-torial team to interview Jan-Peer Remy, Product Area Emulsion, Rolling Oil, and Filter Systems at SMS, on the recipe for this success.

mr. Remy, what do you think is the reason for the multi-Plate® filter being such a successful product? The Multi-Plate® filter supplements our sophisticated alu-minum cold rolling mills with a harmonized, in-house made filter technology that supports efficient and environmen-tally friendly plant operation.

Which are the special features that characterize this filter system? Our filters stand out due to the filter plate material. We use high-performance plastic material offering us, and hence our customers, two crucial benefits: on the one hand, the filter weight is much lower, a fact that simplifies transport and reduces the cost of foundations. On the other, the ma-terial ensures good tightness between the individual filter chambers. After assembly, the filters are thoroughly checked and tested to ensure smooth and rapid commis-sioning on the customer’s site.

50th Multi-Plate® filter

Interview

Since when has SmS been offering the multi-Plate® filter? how has the concept been created? We can count on twelve years of experience. The concept was originally developed in 2003 and then quickly advanced to market maturity.

Which was the biggest multi-Plate® filter SmS has ever made? We can choose from a modular system. The filter size de-pends on the requirements of the end user. The largest one to date is a so-called MPF 3-21, which is able to filter up to 12,500 liters of rolling oil per minute. MPF 3-21 means three filter stacks with 21 filter chambers each. Until now, we have built a total of 19 plate filters of that large size.

And which one was the smallest?The smallest filter supplied so far has been an MPF 1-16, that is one stack with 16 filter chambers. It had a filter vol-ume of 2,750 liters per minute. The smallest available size, in theory, is an MPF 1-10, which is stored in the modular system, but has never been manufactured to date. This filter covers the smallest filtrate volumes of 1,400 liters per min-ute.

What further developments are planned for the system?In the meantime, we have gained extensive practical expe-rience in filter manufacture and operation. Based on nu-merous feedbacks we receive from starting-up or from the workshop, the plate filter is consistently improved and ad-vanced. Thanks to these tried-and-tested adjustments, we are able to make a superb product even better.

The compact Multi-Plate® filters made by SMS group are used for highly-efficient cleaning of cooling lubricants needed for the cold rolling of aluminum and of nonferrous metals. In the Hilchenbach workshops, the pre-manufac-tured individual components are supplemented by in-house made elements and finally assembled to the Multi-Plate® filter unit. Thereafter, the Multi-Plate® filter is subjected to a function test of several days, which simulates the entire future filtration process in the customer’s plant. Each indi-vidual cycle is run, tested, and optimized.

Flat rolling mills sms group newsletter 01 / 2016

60

AlUMINUM STRIP FOR CHINA

First production plant of the mega-complex at Tianjin Zhongwang was put into operation.

61


On June 30, 2015 the first aluminum coil was rolled successfully on the alu-minum cold rolling mill (CRM3) at Tianjin Zhongwang Aluminium Co. ltd. The first strip came with a 1,650-mil-limeter width and a 4.00-millimeter entry thickness. It was reduced to a 2.96-millimeter final gauge. During the continuing ramp-up phase, the mill will now be set up in an optimal way for its rolling jobs.

The material to be produced on this mill is mainly dedicated to the produc-tion of plates and composite strips.

Beside the cold rolling mill CRM3, the rolling mills include two further hot rolling lines and five other cold rolling mills (among these, two tan-dem cold mills). SMS group also sup-plies a color coating line, two plate stretchers, and four ingot scalpers from one source. The 1+1+3 hot rolling

Klaus [email protected]

mill (HSM1) commenced operations on August 15, 2015 with the production of the first aluminum plate and on September 18, 2015 with the first rolled aluminum hot strip.

A further cold rolling mill, the CRM2, went into operation on Novem-ber 24, 2015.

2.96millimeters is the final gauge with a strip width of 1,650 millimeters.

Rightly happy about the first strip rolled are Gustav Foditsch, supervisor electri-cal systems assembly (in the foreground) and Klaus Siegert, technical project manager (in the background). Both from SmS group Gmbh.

left: The first strip is wound up precisely. Bottom: SMS automation commissioning team (SDT) and project team Tianjin Zhong-wang (dressed in orange).

62


November 21, 2014, and February 25, 2015, are important milestones in the company history of the Chinese alumi-num producer Guangxi Alnan Alumini-um Fabrication Co. ltd., since on these two days the company assumed re-sponsibility for the new hot and cold rolling mills that had been completely supplied and commissioned by SMS group and started operation at their location in Nanning, capital of the Chi-

PRODUCTION OF HIGH- QUAlITY AlUMINUM PlATES

AND STRIPS

nese province of Guangxi. With the new rolling mills, Guangxi Alnan pro-duces a wide range of high-quality aluminum plates and strips including special aluminum alloys for the air-craft and transport industries.

hOT ROLLING mILL

The hot rolling mill is one of the most efficient facilities worldwide to pro-duce special rolled products of alu-

Guangxi Alnan Aluminium Fabrication Co., ltd. granted SMS group the final acceptance of the 1+1 hot rolling line, comprising plate stand, and

single-stand finishing mill, and of the cold rolling mill.

minum. It is designed as a 1+1 hot rolling mill, which means it consists of a plate/roughing stand and a finishing stand. The plate/roughing stand is equipped with one of the most powerful drives worldwide for aluminum stands and is able to produce aluminum plates with a width of up to 3,800 millimeters in a thickness range between 8 and 260 millimeters and a maximum

63

length of 38 meters. The rolling line also includes a finishing stand with CvC® plus technology. This finishing stand is able to produce up to 2,900-millimeter-wide coils with a final strip thickness between 2.2 and 12 millimeters. The maximum coil weight is 31 tons. An edger, two divid-ing shears, and an automatic plate piler able to move plates from 4 to 38 meters in length and a weight of up to 31 tons supplement the rolling line.

cOLd ROLLING mILL

On the cold mill Guangxi Alnan is roll-ing extra-thick and -hard aluminum grades. The material range includes the 2xxx to 7xxx series with a maxi-mum ongoing thickness of 10 millime-

ters and a final thickness of minimum 0.2 millimeters. Strip widths are be-tween 1,200 and 2,650 millimeters.

The cold rolling mill comprises a mill stand with CvC® plus, which, in concerted action with the work and in-termediate roll bending system, offers a wide adjustment range for flatness control. The tight strip edges that are typical in aluminum cold rolling are prevented by a Hot Edge Spray system (HES). Finally, a multi-zone cooling system compensates asymmetrical flatness defects. last, but not least, the X-Shape flatness measuring roll contributes its share to the excellent strip quality.

SMS group equipped both the hot and the cold rolling mill with X-Pact® electrical and automation systems in-

Guido [email protected]

Thomas dö[email protected]

The length of 400 meters is not the only impressive feature of Guangxi Alnan’s hot rolling line.

cluding AluControl. Furthermore in-cluded in the supply package were drives, instruments, and measuring devices as well as the level-1 process controls and the technological models of level 2. All media and filter systems required for operation of the hot and cold rolling mills were also supplied by SMS group.


64


Mr. Chen, Presi-dent of Shandong Iron and Steel (4th from left) and Dieter Rosenthal, member of the Managing Board of SMS group, with the respon-sible Project Managers from both companies.

SmS group will supply a complete flat steel

complex to Shandong Iron and Steel Rizhao.

65

Shandong Iron and Steel Rizhao, Chi-na, has contracted SMS group to sup-ply a complete flat steel complex in-cluding a newly developed quality assurance system and special opera-tion know-how to Shandong province on China’s east coast. A special fea-ture of the project will be its cross-process know-how covering simulta-neous monitoring, documenting, and securing of product characteristics. The flat steel complex will comprise a hot wide-strip mill, a pickling tandem mill, as well as a hot-dip galvanizing line and two annealing lines. Thanks to this investment in high-quality equipment technology combined with extensive know-how and an innovative quality surveillance system (PQA = Product Quality Analyzer), Shandong will have one of the most up-to-date

GREENFIElD PROJECT FOR THE PRODUCTION OF

AUTOMOTIvE GRADES

plants worldwide. In addition to pro-ducing tube grades and cold strip for the construction and household appli-ances industries, the focus will be on sophisticated steel grades for the au-tomotive industry. The steel complex is scheduled to commence operation in 2017. Shandong will then be able to produce almost five million tons of hot strip and two million tons of surface-finished cold strip per year.

SMS group to supply complete flat steel complex including high-performance quality assurance system

and operation know-how to China.

iSmS Group

In the next issue

of our customer

magazine you will

learn more about

this major order.

Olaf [email protected]

FlAT ROllING MIllS — COlD ROllING MIllS

66

SmS group newsletter 01 / 2016

From top to bottom: The optimized turbu-lence pickling process continues to be the most efficient solution for pickling steel strip.

Based on the experi-ence gained in 55 new plants and numerous modernization proj-ects, SMS group will further develop the turbulence process in a continuous manner.

iSmS group

The new develop-

ments have already

proven them-

selves in practical

operation and have

been successfully

implemented in sev-

eral references after

being tailored to the

respective require-

ments.

67

STRIP PROCESSING lINES/FURNACE TECHNOlOGY

New developments such as the “ECO Pickling and Production” model, the recuperator tank, and the “Spray Boost Cells” will amplify the performance and efficiency of pickling lines. Espe-cially the low maintenance and operat-ing costs, the reduced consumption of resources and the high pickling capac-ity speak for themselves. Based on the experience gained from 55 success-fully installed new plants and numer-ous modernization projects, SMS group has further developed the al-ready established turbulence pickling process in a continuous manner, thus providing the most efficient solution for pickling steel strip. This particu-larly applies to new plants, but also to modernization projects.

LOW cONSUmPTION,

hIGh PROdUcTIvITy

The newly developed “ECO Pickling and Production” model records and monitors all process and material data relevant for the pickling process and automatically controls production. In the turbulence tank pickling system, the relevant process parameters are rapidly adapted to the respective re-quirements, so that a high-quality pickling result can be achieved with minimum resource consumption. Fur-thermore, the model optimizes the

NEW DEvElOPMENTS FOR EFFICIENT PICklING

strip sequence and the transition pro-cess between the different strips. With this Industry 4.0 approach, the process yields an optimum production result at low operating costs, thus maximizing the operating result.

Spray headers continuously spray heated acid into the flat channel of a turbulence tank pickling system, thus generating extreme turbulences. This maximizes the contact between the pickling acid and the entire strip sur-face. A patented immersion cover seals the surface of the acid, thus minimizing evaporation and the re-sulting energy losses.

The newly developed recuperator tank arranged upstream of the first

SMS group has extended its range of products for efficient pickling around the proven turbulence pickling system with several innovations.

pickling tank provides for a further in-crease in efficiency. Here, pickling acid that has already been used in the pro-cess is applied to the incoming strip. In doing so, loose scale particles are re-moved from the strip while the strip is preheated at the same time. Further-more, the surface is chemically acti-vated and the downstream pickling process therefore accelerated. In addi-tion to the optimized pickling result and the saving of thermal energy, also the consumption of acid is reduced be-cause no loose scale particles are transported into the acid cascade.

With the innovative “Spray Boost Cells,” a very high pickling capacity can be achieved on a short distance. This system is an efficient solution specially for modernizations in the framework of which the pickling capacity is to be in-creased with only limited space avail-able. Here, the acid is sprayed onto the strip at high pressure, thus achieving a high pickling capacity. The spray head-ers patented by SMS ensure a homo-geneous distribution of the acid across the entire strip width. Furthermore, the desired pickling capacity can be flexibly adapted here via the process parameters.

[email protected]

55successfully installed new plants and numer-ous revamps form the basis for the continu-ous further development of the already es-tablished turbulence-tank pickling system.

FLAHWALZWERKE sms groupnewsletter 01/2016

68

One of the pickling tanks was completely replaced within a short downtime period last summer.

It is a particular connection that SMS group has with line 76 of Outokumpu Stainless in Avesta, Sweden. The stain-less steel annealing and pickling line, which had already been established in 1976 for an annual production of 300,000 tons of hot and cold strip, has been repeatedly modernized in the course of the years. This made the per-formance of the line continue to grow whereas operating costs were lowered. In addition to further components, the line was equipped with jointly developed and patented plastic pickling tanks for stainless steel strip and with a tension leveler of 120 tons’ tension. Further moderniza-tions were carried out within the two-week summer down-times in 2013 and 2015.

REPLAcEmENT OF PIcKLING TANK

last summer, SMS replaced one of the three pickling tanks. The new tank features a higher pickling performance and improved sludge removal. Modified pipelines and an addi-tional pump increase the turbulence inside the tank and

The new pickling tank during a turbulence test with water.

CONSISTENTlY IMPROvEDFurther modernization of

Outokumpu’s stainless steel annealing and pickling line.

hence also the pickling rate. The optimized tank design permits easier automatic discharge of the sludge generat-ed by the pickling of stainless steel grades. Furthermore, it is now possible to simply remove the grinding stones for tank cleaning. The tank is made from a special polypropyl-ene material as Outokumpo mainly produces Duplex steels that can only be pickled by means of highly concentrated and very aggressive hydrofluoric acid.

In 2013 already, the four squeezing chambers and six compensators had been replaced. Thanks to an improved installation of the spray beams in the squeezing chambers, it was possible to lower the exhaust air volume. An opti-mized arrangement of the sliding doors excludes leakages. The new compensator design simplifies compensator changes and reduces the time needed for this work from previously one day to a maximum three hours now.


Nordine Beskri [email protected]

69

STRIP PROCESSING lINES / FURNACE TECHNOlOGY

The investment helps MMk boost its produc-tion capacity of high-quality, galvanized cold strip for the construc-tion industry.

The Russian steelmaker MMk (Magnitogorsk Metallurgical Combine) awarded SMS group an order to supply a hot-dip galvanizing line for the production of high-quality steel plates for the construction industry. The line will have an annual capacity of 450,000 tons and will be installed in the company’s main plant in Magnitogorsk in the southern Ural Mountains. MMk is one of the leading steelmakers in Rus-sia. With this investment, it will expand its production of galvanized cold strip for the construction industry. The strip will also be used to make facade panels.

The finished material will have a width between 800 and 1,400 millimeters and a thickness ranging from 0.25 to 1.0 millimeters. The maximum speed in the process section will be 180 meters per minute, whereas the strip will pass the entry and exit sections at a maximum of 250 meters per minute. The first step in the line will be to remove residual

MMk ordered hot-dip galvanizing line

Russian steelmaker will produce high-quality steel plates for the construction industry as of the beginning of 2017

dirt particles from the strip surface in a cleaning section by means of spraying, brushing, and rinsing actions. A fully horizontal Drever furnace will first heat the strip in a pre-heating zone, followed by a direct-fired zone and a radiant tube zone. A gas cooling system will reduce the strip tem-perature for the galvanizing process. The eco-friendly fur-nace is equipped with several facilities to recover energy. The preheating zone, among others, takes advantage of the hot emissions from the burners. Furthermore, the com-bustion air is heated by energy from the exhaust air of the burners and radiant tubes. The downstream air-knife sys-tem made by SMS precisely sets the thickness of the zinc layer. A four-high skin-pass mill stand, a tension leveler and spray passivation will be available for material post-treatment. Strip edge straightening and strip width adjust-ment will be accomplished by an ASC side trimmer with integrated scrap chopper. As the shear will be of twin-head design, the trimming knives can be changed in mainte-nance position while production is going on.

TRAINING ThE OPERATING STAFF

SMS group will supply the complete plant from one source including mechanical equipment, process technology, fur-nace technology, as well as automation and electrical equipment. In addition to design and manufacture, the scope of supplies will include the supervision of erection and commissioning assistance. The complete plant control system will be simulated, tested, and optimized in a Plug & Work Test in advance. On that occasion, the future operat-ing staff of the line will be trained to manage the upcoming tasks.

NUmEROUS FAcILITIES mAdE By SmS

Commissioning of the hot-dip galvanizing line is scheduled to take place at the beginning of 2017. MMk and SMS group are proud of their long-standing cooperation. In Magni-togorsk, MMk operates numerous facilities supplied by SMS, such as another hot-dip galvanizing line as well as a combined annealing and hot-dip galvanizing line that was supplied as part of the cold rolling complex “Cold Mill 2000” and was commissioned in 2012.

Reinhard [email protected]

FLAHWALZWERKE sms groupnewsletter 01/2016

70

Annealed steel strip in Sichuan

Two continuous annealing lines put on stream at Panzhihua.

The two continuous annealing lines are designed to produce more than 1.7 million tons of high-quality steel strip per year.

The two annealing lines SMS supplied to Panzhihua Iron and Steel Group have started operation. In July 2014 al-ready, line No. 1 produced its first coil in the new plant in the province of Sichuan in southwest China and, shortly af-ter commissioning, achieved a monthly production of near-ly 80,000 tons. In the summer of 2015, this was followed by the second line, which mainly produces CQ, DQ, and DDQ grades and later on also high-strength material grades. In total, Panzhihua’s two lines will be capable of producing more than 1.7 million tons of high-quality steel strips to be used in the electrical appliance and automotive industries, among others. The annealing process and the particularly high cooling rates serve to reduce material strain-harden-ing resulting from the rolling process and to precisely set the desired mechanical properties.

hOmOGENEOUS mEchANIcAL PROPERTIES

The two lines are equipped with identical components. They mainly differ in the maximum steel strip widths and strengths. In addition to designing the mechanical equip-ment and to manufacturing several special components, the SMS group’s scope of supplies included the supervision of erection and commissioning. For both lines, Drever In-

ternational supplied high-efficiency annealing furnaces with integrated ultrafast cooling system to produce high-strength material grades. Another important process com-ponent is one six-high skin-pass stand per line to give the strips their homogeneous mechanical properties as well as the required strip shape and surface quality.

LINE NO. 1 LINE NO. 2

Capacity 920,000 t/a 810,000 t/a

Strip width 870–1,870 mm 870-1,620 mm

Strip thickness 0.35 to 2.0 mm 0.3 to 2.5 mm

Entry speed 700 m/min 700 m/min

Process speed 420 m/min 430 m/min

Exit speed 840 m/min 840 m/min

Steel grades cQ, dQ, ddQ, SEddQ, cQ-hSS, dQ-hSS, ddQ-hSS, Bh-hSS, dP, TRIP

Technical data

[email protected]

71

80 PERCENT lOWER CONSUMPTION

OF NATURAl GAS SMS Meer S.p.A., Italy, carried out a modernization at

ArcelorMittal Asturias, Spain, covering the walking-beam furnace of the wire rod mill, which has a throughput of 150 tons per hour.

The result of the modernization is a reduction in operating costs to boost competitiveness. The project mainly covered the conversion of the combustion facilities. Up to date, the furnace has been operated on the basis of natural gas, but can now also use blast furnace gas as fuel, if so desired. The new combustion equipment offers the option of using a natural and blast furnace gas mixture in different pro-portions. The blast furnace gas is preheated in a newly in-stalled recuperator unit. Thanks to these measures, about 80 percent of the natural gas consumed so far can now be saved.

ShORT REvAmP PERIOd, FAST cOmmISSIONING

The technical approach had been developed over a long time in close cooperation between SMS and ArcelorMittal with respect to several goals such as fuel saving, reduction of pollutant emission, and the shortest-possible conversion time. The narrow time frame for this turnkey project pro-vided for the furnace to resume operation in September 2015 already, after a downtime period of only one month. Within the scope of the project, the whole combustion sys-tem was adapted to the latest European safety standards (in compliance with European Safety Standard EN 746/2:2010). The new equipment permits the complete material portfolio to be heated, without any exemptions. The billets processed have cross-sections of 150 x 150 millimeters and lengths between 12,000 to 15,200 millimeters. The combustion fa-cilities as described above are permanently monitored by the newly developed Prometheus system, to optimize the combustion process. This system contributes to the target-

ed improvement of the metallurgical properties through, for example, advanced temperature homogeneity and the min-imization of negative influences like decarburization or in-creased scale formation. In addition, Prometheus helps save fuel by applying heating strategies, minimizing tem-perature set points and, at the same time, ensuring the specified temperature values in the final stock.

Furnace modernized by SMS.

Simone Zussino [email protected]

STRIP PROCESSING lINES / FURNACE TECHNOlOGY

72

TUBE & PIPE PlANTS SmS group newsletter 01 / 2016

NEW HEAT TREATMENT lINE FOR TIMkENSTEEl

SMS group is to design, manufacture, and install a complete new heat treatment plant for tubes and bars at TimkenSteel at

the company’s Gambrinus complex in Canton, Ohio, U.S.A.

The new heat treatment line, named the Advanced Quench & Temper Facility (AQTF), will set new performance stan-dards among existing comparable facilities.

Several months of close collaboration between Timken-Steel and SMS resulted in the development of the AQTF – a compact line, characterized by a combination of induction preheaters and combustion furnaces for both the austen-itizing and tempering processes.

QUENchING ShELL® WATER SPRAyER

Unique in this field, SMS’s deliverables under its contract with TimkenSteel will include plant erection and commis-sioning. The line will be capable of processing up to 10 tons per hour of tubes and bars, ranging from 4'' to 13'' in diam-eter, made up of a variety of different steel grades that characterizes TimkenSteel’s portfolio. The cornerstone of

Tubes and bars are heated up and soaked with a combination of induction and combus-tion furnaces.

the AQTF line will be the brand new Quenching Shell®, an advanced OD/ID water sprayer, characterized by high-quench severity and, at the same time, great flexibility to adapt to changing process conditions.

The Quenching Shell®, although a concept created to fulfill the require-ments of this specific project, prom-ises to become the standard for simi-lar applications. The challenging time schedule provides for SMS to bring the line into operative conditions in the second quarter of 2016, this is just a half-year from greenfield to commer-cial operation.

iTimkenSteel corporation

TimkenSteel creates

tailored steel prod-

ucts and services

for demanding ap-

plications, helping

customers push the

boundaries of what’s

possible within their

industries.

Pietro della Putta [email protected]

RohRanlagen

73

large-diameter pipe mill at Corinth Pipeworks commissioned

The Greek pipe producer, Corinth Pipeworks, is commencing production at the JCOE® large-diameter pipe mill in Thisvi.

The Greek pipe producer, Corinth Pipeworks, has commis-sioned the JCOE® large-diameter pipe mill at its works in Thisvi. Corinth rolled the first longitudinally welded pipe there on June 11, 2015. During August, the first order for 30’’/36’’ x 38.1 mm has been produced. In future 400,000 t of pipes are to be produced here with outside diameters between 16“ and 56“ in wall thicknesses up to 40 mm and lengths up to 18.3 m. The starting material consists of high-strength steel plates with grades up to X100. CPW will supply the new pipes

iSmS group

The cPW large-

diameter pipeline

offers a size range

that has been exten-

ded considerably.

Pipe sizes with high

wall thicknesses and

small pipe diameters

can also be produ-

ced in cost-effective

quantities.

The commissioning team. Corinth has commenced production at its large-diameter pipe mill in Thisvi.

to customers from the oil and gas indus-try worldwide. “Our good cooperation with SMS has paid off once again,” says Athanasios Tazedakis, Deputy Director Engineering and Technology at CPW. “It enabled us to put the large-diameter pipe mill into production on schedule.“

[email protected]

74

NWZ ORDERS THREE COlD PIlGER MIllS

High cost-efficiency and precision for tubes of special materials.

Signing the contract (from right to left): Zhao Yuhua, Wang Wie, Yuan Gaihuan (all NWZ), Gerd Müller and Oliver Strehlau (both SMS group).

The Chinese company Northwest Zircocladding Co., ltd. (NWZ) in Baoji, Shaanxi Province, has placed an order with SMS group for the supply of three cold pilger mills, two cold pilger mills of type kPW 18 lC+ and one kPW 50 lC. Com-missioning of the plants is scheduled for the third quarter of 2016.

The two kPW 18 lC+ represent the latest generation of cold pilger mills with their innovative drive concept based on direct drives. The improved drive concept minimizes the oil consumption, with the extensive SMS design optimiza-tions leading to an energy saving of around 20 percent.

The larger kPW 50 lC offers a finished tube diameter in a bigger range and is equipped with a conventional crank drive and up-line speed-shift gearbox. All three cold pilger mills will be equipped by SMS with fully automatic PlC con-trol that permits stepless setting of feed rate and turn angle of the shells during continuous rolling, two aspects of cru-cial importance for the tube quality.

NWZ has specialized in high-quality products for the power generation in-dustry, including in particular tubes of zirconium alloys. With the new ma-chines from SMS group, the company will be able to expand its tube produc-tion.

hIGh-QUALITy SEAmLESS TUBES

The cold pilgering process is particu-larly suitable for high-precision re-duction of tubes made from materials that are difficult to form. The distinc-tiveness and cost-efficiency of cold pilgering derives from the fact that thanks to the large cross-sectional reduction, intermediate processes such as annealing, pickling, cleaning, straightening and cutting are neces-sary far less often than with other pro-cesses, such as drawing. Further-more, cold pilgering allows selective positive influencing of the microstruc-ture of the rolled product due to the three-axis compressive stresses ap-plied to the material.

These three new machines repre-sent a continuation of the successful partnership between NWZ and SMS group. SMS group had already deliv-ered new machines to NWZ in previ-ous years.

iSmS group

during the cold

pilgering process,

a large number

of forming steps

improves roundness,

stresses homogene-

ity and the surface

roughness of tubes.

SMS group’s cold

pilger mills are also

suitable for forming

difficult materials

that are beyond the

capabilities of other

processes, e.g.,

drawing.

[email protected]

TUBE & PIPE PlANTS SmS group newsletter 01 / 2016

PROFILWALZWERKE — HÜTTENTECHNIK

75

Al Gharbia Pipe Company has awarded the consortium of larsen & Toubro limited and SMS group as the EPC (Engineering, Procurement, Construc-tion) contractor with the supply of a turnkey lSAW (longitudinal Sub-merged Arc Welded) pipe production facility. SMS group will be responsible for the engineering and supply of pro-cess equipment for the large-diameter pipe production facility to be built in Abu Dhabi. larsen & Toubro limited – SMS’s partner in the consortium – will be responsible for the civil works and erection of the equipment.

The new lSAW large-pipe produc-tion facility, which will be located within the khalifa Industrial Zone Abu Dhabi (kIZAD), will start producing in 2018. Material grades up to X80 will be pro-cessed at a production capacity of 240,000 tons per year. The pipes will be suitable for use as offshore line pipes and onshore applications. The new line will be designed to make pipes up to 12.2 meters long with an outside diam-eter ranging from 18 to 56 inches. The maximum wall thickness will be 44.5 millimeters.

Besides the engineering and project planning, scheduling, and coordina-tion, SMS group will supply all key ma-chinery as well as the process equip-ment. This also includes workshops, laboratories, and MES (Manufacturing Execution System) equipment. The production line will consist of an edge miller, a crimping press, a JCOE® pipe forming press, tack welder, inside and outside welder, mechanical expander, and a hydrostatic pipe tester.

FLEXIBLE IN dIAmETER,

STRONG IN WALL ThIcKNESS

The JCOE® pipe forming process devel-oped by SMS offers a whole range of advantages as the plant operator can change over to other pipe dimensions quickly, allowing them to produce even smaller batch sizes economically with the utmost precision. All presses are equipped with variable speed pumps (vSP) providing for an efficient hydrau-lic system with pressures up to 450 bar, which reduces energy consump-tion by 30 percent compared with con-ventional hydraulic systems. The shape automation system developed by SMS

Greenfield project in Abu Dhabi for the production of high-grade large-diameter longitudinal welded steel pipes.

performs the fully automatic control of the forming process. It improves the performance as well as compensates the influences of plate inhomogeneity in the forming process. Thus, a consis-tently high pipe quality can be guaran-teed.

Al Gharbia Pipe Company will man-ufacture high-grade large-diameter longitudinal welded steel pipes mainly for the energy sector and is targeting at markets in Bahrain, kuwait, Oman, Qatar, Saudi Arabia, and the UAE (Unit-ed Arab Emirates). With the develop-ment and production of oil and gas forecast to be robust in these coun-tries, the demand for high-quality steel pipelines to transport these resources is expected to grow. Al Gharbia Pipe Company is a joint venture of invest-ment company Senaat, JFE Steel, and Marubeni-Itochu Steel (MISI). The new company is leveraging JFE Steel’s technology for high-quality large-di-ameter longitudinal welded steel pipes, MISI’s sales capabilities, and Senaat’s industrial footprint in Abu Dhabi.

SMS group to supply turnkey production fa-cility for large-diameter pipes to Al Gharbia

From left to right: Pinaki chakraborty, Amit Swarnkar, derek michael Shah (all Larsen & Toubro Limited), Tadayuki Baba (marubeni-Itochu Steel), Tariq Al Wahedi, Jamal Salem Al dhaheri (both Senaat), marcel Fasswald, Frank Lüth (both SmS group).

[email protected]

76

lONG PRODUCT PlANTS SmS group newsletter 01 / 2016

The award was presented during the AISTEch meeting in Cleveland (Ohio) in May 2015. It rewards an individual, group, or organization that has implemented and achieved energy conservation or a significant improvement in ener-gy-related productivity through the application of new tech-nology, practices, and/or engineered methods in the iron and steel producing sector.

REdUcEd ENERGy cONSUmPTION

Fully engineered, manufactured, and erected in Smedje-backen by the Italian SMS Group company located in Tarcento, the awarded application commissioned at Ovako succeeded in strongly reducing greenhouse gas emissions and energy consumption, the most significant environmen-tal aspects of Ovako’s business. While maintaining all the tasks provided for by the BAT, the plant works using the same electrical energy consumption but with an increased suction capacity of approximately 40 percent more than be-fore and with emissions, in terms of contaminants, always less than half those required by EU norms and stringent local regulations, and with a boundary noise level below 40 dB(A).

This successful application has led the way to the recent sale of two similar stand-alone fume treatment plants, one located in Qatar and the other in Sweden.

Awarding of the Energy Achievement Award for the “tapered fume exhaust hood and fume treatment plant at Ovako“. (From left: k. Nygren, Ovako Bar AB and M.P. Caruso, SMS Concast Italia Spa).

For its application of the tapered fume exhaust hood and new fume treatment plant, Ovako Bar AB, with head office in Smedjebacken, Sweden, has been

honored with the Energy Achievement Award 2015 by the AIST Committee for Energy and Supply Engineering.

2015 ENERGY ACHIEvEMENT AWARD

marco Peter cudicio [email protected]

77

lONG PRODUCT PlANTS — METAllURGICAl TECHNOlOGY

High-speed eight strand billet caster at JSPl Plant in Angul, Odisha.

Francesco Fabris [email protected]

Optimum monitoring

High-speed commissioning

Ferriere Nord has placed an order with SMS group for level 2 automa-tion to be installed in their scrap

yard facility in Osoppo (Udine), Italy. Using a series of innovative solu-tions, the new system will track and

document the quality of all the scrap passing through the yard on its way to the Ferriere Nord melt shop, which produces low-carbon steel billets. The ultimate goal is to evalu-ate the compliance of the incoming scrap loads and produce evidence to support claims against suppliers when necessary. Following the suc-cess of the EAF-lF-CCM level 2 system already deployed, SMS group looks forward to continuing the technological partnership with Fer-riere Nord for this challenging new project.

Jindal Steel and Power limited (JSPl) has successfully commissioned its high-speed eight-strand billet caster at its Angul Odisha Plant. The caster is the largest high-speed billet caster in India. The JSPl and SMS group team has commissioned the plant within 13 months from ground-breaking. Most of the equipment has been man-ufactured at Raipur manufacturing works of JSPl, based on the design and engineering drawings of SMS.

The supplied billet caster is able to attain the speed of 3.6 m/min for sections of 165 x 165 mm and can pro-duce 2.3 million tons per year. It has a casting radius of 9 m with 8 strands, and is designed to cast low- and high-carbon steels, ball bearing steel, and free-cutting steel. With this new high-speed billet caster with CON-vEX® technology, JSPl will benefit from lower opera-tion costs.

www. sms-concast.com

Scrap bucket charging at Ferriere Nord.

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lONG PRODUCTS PlANTS SmS group newsletter 01 / 2016

The IAS TEM-PRO® billet heater NIB 650.5/229x1,300 Al/ITN-2P consists of two induction furnaces, each with a rating of 650 kW. It ensures precision heating in five zones of aluminum ex-trusion billets with a diameter of 229 mm and a length of up to 1,300 mm exactly as required for the process. The “CADEX” (Computer Aid-ed Direct Extrusion) software calcu-lates the optimum extrusion speed curve and the minimum billet temper-atures required on the basis of the current process parameters and con-trols the billet heater according to the results. CADEX boosts productivity by up to ten percent compared with ex-trusion without feedback. The extru-sion press also operates with a billet length optimization tool. It calculates the optimum billet length on the basis of the extruded billets and the set ex-trusion parameters in order to in-crease the material yield. The result is fed back to the hot saw that cuts the billets to the required length for the extrusion process. This allows the scrap rate to be reduced.

ENERGy SAvINGS OF UP TO 55 PERcENT

Compared with conventional presses, the HybrEx saves up to 55 percent of

energy as it uses the hydraulics only for extrusion. The ancillary move-ments of the extrusion press are per-formed by dynamic, electric servo drives. Compared with those in con-ventional presses, the drives achieve twice the speed with 1,000 mm/s and thus reduce the dead cycle times. A shortening of one second here trans-lates into an increase in production of up to 100 t/year.

HybrEx is SMS group’s latest generation of extrusion presses. The machine enclosure ensures a high standard of safety even without ad-ditional measures.

ROYAl UNITED ORDERS HYBREX

Royal United Metal and Glass from Dubai (United Arab Emirates) has placed an order with SMS group for a HybrEx 32 extrusion press and the up-line inductive billet heater.

“Royal United Metal and Glass decided in favor of SMS group because we could offer them the ‘care-free package,’” says Jens Magenheimer, Sales Manager Extrusion Presses at SMS. “The significant energy savings that the new press concept offers com-pared with other processes was an im-portant argument here.”

The HybrEx extrusion press is equipped with internal gear pumps, which operate efficiently over the whole speed range. Thanks to its spe-cial design, the HybrEx requires less space compared with earlier plant types. The enclosure makes barriers unnecessary, and no additional noise emission control measures have to be taken.

Royal United will use the press for the production of aluminum profiles for facades and windows. It extrudes 9” billets and has a capacity of approx. 14,000 t profiles per year. The plant is scheduled to go into operation in the fourth quarter of 2016.

Axel [email protected]

Long product pLants — Heat treatment tecHnoLogy

79

EloFresh ensures high process reliability for the hardening process itself, and consequently for the induction tooling.

The induction tool life depends significantly on the me-chanical wear and the electrical stresses, but also on the optimal cooling of the induction coil, which in turn is influ-enced by the quality of the cooling water of the electrical circuit (Elk). Using EloFresh achieves the optimal cooling, and thus lifetime, of the inductors as also prohibits corro-sion. The standard system “Elk Modul 1” provides moni-toring of the water quality by a corrosion-measuring sec-

EloFresh: Innovative Media Analysis Solution

tion as well as a display of pH- and conductance value of the system’s cooling water.

Apart from this base module, cus-tomers also benefit from three option-al modules: “Elk Modul 2” offers a time-based water usage control and indicates inductor leakages, “Elk Modul 3” provides the post-dosing of biocide and copper inhibitor.

INcREASING ThE PROcESS RELIABILITy

The focus in the module for quenchant circuit (“AMk Modul”) is on hardening process safety. Fully automatically and continuously, the concentration of the quenchant is monitored and corrected as needed. Obligatory manual mea-surements of the concentration and lab analyses are not required.

Especially, the innovative integrated monitoring and control of the cooling and quenchant circuits of Elotherm’s innovative EloFresh system stand for a meaningful increase of the process re-liability of hardening processes com-pared to today.

SMS Elotherm has successfully commissioned the first EloFresh Monitoring and Control system for cooling and

quenching of hardening machines.

Elotherm EloFresh operator interface on a modern Elotherm harden-ing machine.

Loïc de vathaire [email protected]

www.sms-elotherm.com

80

SMS group is building a new generation of the Sutton extru-sion press in the U.S.A. During a ceremony to celebrate the 100th anniversary of the Sutton brand, SMS presented the new Sutton Mk-v in Cranberry Township, Pennsylvania. The extrusion press has been developed over the last two years. All mechanical, hydraulic, and electrical components and spare parts come from the U.S.A. This guarantees that they can be procured relatively easily and quickly – a competitive benefit for the extrusion press companies in the NAFTA re-gion (U.S.A., Canada, and Mexico) at which the new press is targeted. “The fifth generation of the Sutton extrusion press combines the best of the two worlds of SMS and Sutton,”

SMS GROUP BUIlDS NEW GENERATION OF SUTTON

EXTRUSION PRESS Manufactured in the U.S.A. for the American market,

with SMS group know-how.

says Holmer kleist, Project Manager Forging at SMS group. In concrete terms this means the plate-type press frame now employed – an SMS development – makes the construc-tion of the press significantly more rigid and more resistant. The linear guides for the container holders and moving crosshead operate precisely and are practically mainte-nance-free – a major advantage compared with the flat guides previously used.

REdUcEd cOSTS ThANKS TO A hOLISTIc SOLUTION

In this new press generation, the pumps are again located inside the tank. This reduces the space requirement by

The Sutton mK-v 27. SmS presented the latest generation of press at a ceremony to celebrate the 100th an-niversary of the Sutton brand.


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lONG PRODUCTS PlANTS — FORGING PlANTS

Axel [email protected]

Induction furnace system for Brazeway

Brazeway Inc. has ordered a TEM-PRO® induction furnace system from IAS for its plant in Shelbyville, In-diana, U.S.A.. The order is supported by a local energy supplier within the scope of a sustainability project. The system is equipped with two parallel multi-zone furnaces and a block han-dling unit that ensures low material wear-out. It is also equipped with an energy-saving IGBT converter of the fourth generation and assures very close temperature tolerances. During the process, extremely fine and nar-row aluminum tubes are produced for HvAC applications, such as for heat exchangers. Compared to other sys-tems, the wastage produced by the TEM-PRO® is up to 20 percent lower

thanks to continuous power control and more even heating of the materi-al. The new system enables Brazeway to increase its production quantity in

spite of it having replaced two older systems. Brazeway has another two IAS induction furnace systems in op-eration in kentucky.

Induction furnace with loading unit.

around 30 percent compared to the installation on the shop floor. The holistic solution developed by SMS for American extrusion press operators also includes the foundation, the design of which is better suited for the Sutton press. This reduces the costs of the extrusion press for the owner.

The motors of the press are started using soft-starters. This allows the pumps not required during the extrusion process to be shut down and facilitates a soft run-up when they are switched back in. This method saves up to 25 per-cent of the energy used compared to presses with conven-tional drives, where pumps that are not required continue to idle.

The Sutton Mk-v is offered on the NAFTA region market in four different sizes – with press forces ranging from 2,000 to 4,000 U.S. short tons, corresponding to 18 to 35 MN. Rob-ert Saroli signed the contract for this press right at the site in Cranberry Township. “I am very impressed by the work-manship of the press,” said the owner of the Canadian alu-minum processing company, Can Art Aluminum Extrusion Inc. “And the press has just the right size for us.” Saroli is convinced that the new press will help Can Art improve its

position on the hotly contested market. The press will go into operation at Can Art in January 2016. The U.S.A. is an important extrusion press market for SMS. The new Sutton press is specially tailored to the needs of customers in the automotive industry and in the construction and transport industries. The extrusion presses are equipped with Allen Bradley controllers. A further benefit for the customers is that manufacture in the U.S.A. means an elimination of im-port duties. The Sutton extrusion presses are marketed and sold in the U.S.A. through the SMS national company, SMS Technical Services llC. Customers therefore have the right contacts directly on hand, making order handling and ser-vice support faster and more flexible.

The Sutton Engineering Company was founded in 1914. After being a member of the SMS family since 1979, in 1998 Sutton was eventually merged with the SMS company Eu-muco. Up until 2001, extrusion presses were manufactured in Bellefonte under the name SMS Sutton.

8282

COPPER: WHICH MANUFACTURING PROCESS

IS MORE EFFICIENT?Smartphones, PCs, tablets, lED-Tvs, automotive

electronics, sun collectors, wind power plants, fuel cells, power cables ... copper truly deserves the name “the red gold.”


8383

Our modern lifestyle is unimaginable without copper and copper alloys. And this doesn’t only apply to electri-cal engineering. The hygienic proper-ties of the metal are ideal for water pipes and the thermal conductivity of copper tubes is used for air-condi-tioners.

It can easily be defined which prop-erties should be achieved by a copper product in everyday use. But the route to the desired top-quality end product is complex. For manufacturing copper tubes, two different process routes are available, including numerous other variations. Manufacturers thus face the question: which of the competing production processes are most effi-cient to reach my goals?

WhIch PROdUcTION vOLUmE?

SMS group therefore offers a neutral process-independent consultation. Since SMS, as worldwide leading man-ufacturer, is able to produce almost all variations of copper lines with more than 50 years of experience in this sec-tor, nearly all configurations can be realized for the customers. End prod-uct and production volume are the cri-teria for selecting the process route.

An illustrative example for copper tubes: when a customer plans its cop-per tube production with high annual output the process line, including ver-tical continuous caster, hot forming with extrusion, and subsequent draw-ing is the most economically efficient solution. For smaller production vol-umes and thin-walled tubes with small diameters, a route via a horizontal continuous caster in the directube® process is more meaningful. In this way, a near-net-shape tube is directly

cast, which is subsequently rolled out into a mother tube in a planetary roll-ing mill and then formed to its final tube geometry by drawing. This pro-cess is compact and cost-efficient since hot forming is omitted.

For both process routes other units are also employed. To be able to attain the desired metallurgical properties such as soft, semi-hard, or hard, an-nealing facilities are used. Even spe-cial requirements such as for air-con-ditioning pipes can be fulfilled. On inner grooving lines the copper tubes are provided with a larger surface im-proving heat exchange.

dEcISION-mAKING BASIS

Conclusion: SMS not only offers com-plete plants from a single source but also provides support for the analysis of future profitability, thereby estab-lishing a well-founded decision-mak-ing basis for plant owners. Patrick Schneider, Head of Sales Copper Plants, Forging Plants Business Unit of SMS group, is aware that much know-how is disclosed at a pre-order stage: “Experience shows us that in the vast majority of cases our trust and know-how investment is reward-ed by the customers. Moreover, we need not fear competition. Our ma-chines are excellent, we offer patented technology in part, all at a fair price/performance ratio. Our process-neu-tral advice pays off – for us and for customer satisfaction.“

SERvICEcopper – scope of supply of SmS group

Electric arc slag refining furnaces

Anode casting wheels

Melting furnaces

Horizontal and vertical continuous casters

Stationary sawing lines

Cold rolling mills

Hot rolling mills

Billet heating

Extrusion presses

CONTIROD® plants

directube® plants

Combined drawing lines

Drawing cascades

leveling and polishing machines

Drum-type drawing lines

Inner grooving lines

level winders

Tube manufacturing lines

Material transport systems

i



84


mr. Schneider, you supply plants or processes completely from a single source. For whom would this offer be bene-ficial?There are basically two customer groups: newcomers and customers with metallurgical knowledge who already oper-ate plants. Our offer is of interest to both of them. The new-comers are often companies with the intention to strength-en their value-added chain, for example a manufacturer of air-conditioning units who wants to manufacture air condi-tioner pipes in-house.

Within the scope of a greenfield project, these compa-nies receive from us all machines and perfectly harmonized process steps from a single source. And what really counts ist that these customers have the assurance that it works.

Companies ordering individual machines who are al-ready operating plants also benefit from our know-how as a full-service system supplier since we have detailed knowledge of the interfaces to up- and down-line process-es. We know for example which workpiece tolerances our machine has to produce to be seamlessly integrated into an existing process chain.

What does process-independent consultation mean?To manufacture a copper product different manufacturing processes are possible. Since almost all machines are in our portfolio we do not prefer a certain method but are free to choose. We know the differences and can compare them in the interest of the customer. These are often technical aspects such as the possible size range of the end products in connection with desired annual capacities, material flow diagrams of individual process routes and reviewing possi-bilities in structural design. In many cases, we also provide

The customer benefits twice from us

Interview

Patrick Schneider

head of Sales

copper SmS group.

support in determining the conversion costs and compare the individual pro-cesses in terms of energy and media consumption and personnel expenses. On this basis, we are able to provide a clear and well-founded decision-mak-ing tool for the customer.

One contact person for customers – what does that look like in practice?The interaction of the plant manufac-turer’s individual departments must be arranged in-house. We have creat-ed an organizational structure that will make this possible, enabling us to as-sent internally, making use of short communication channels. The cus-tomer benefits twice: on the one hand, the way of the customer into our com-pany organization is easy, and on the other hand, advisory services are im-proved and sped up in the project plan-ning phase as well as within process-ing in the event of order.


85

lONG PRODUCT PlANTS — FORGING PlANTS

TR-device for producing large crankshafts.

With a TR-device large crankshafts are produced. The de-vice realizes forming required for large multiple-cranked shafts with cranks offset against each other. While avoiding an interrupted fibrous structure to the greatest possible ex-tent, the geometry is close to the final contour.

In principle, the TR-device is able to produce unlimited long crankshafts since forming only takes place partially, meaning that only subsections are heated and formed.

SMS group now offers the TR-device in its product port-folio either as retrofitting for an existing installation or di-rectly in combination with a hydraulic forging press. The TR-device can be easily integrated into a forging press, of-fering strategic advantages to the plant operator as a use-ful extension of his product range.

TR-DEvICE AS OF NOW AvAIlABlE IN THE PRODUCT PORTFOlIO OF SMS GROUP

Insertion tool for long crankshafts in hydraulic processes.

FACTS AND FIGURESTEchNIcAL SPEcIFIcATION OF REQUIREd FORGING PRESS (35 mN)Recommended pressing force to make use of the max. pressing force of the device 35 mN Installation height 3,660 mmInstallation width 2,896 mm

PROdUcT RANGEMax. envelope circle diameter (blank) 1,000 mmCrank length 250–650 mmMax. crank radius (1/2 hub) 350 mm

WEIGhTS ANd dImENSIONSTotal delivery weight 105,000 kglength (of supporting beam) 5,160 mmWidth 2,800 mmHeight (closed state, without ribs) 2,550 mm

i

[email protected]

86

SCHUMAG TECHNOlOGY WITHIN SMS GROUP

With the restructuring of SMS group, the Bright Steel Processing lines Product Unit moved from Aachen to Mönchengladbach and the product portfolio

is now based in the long Products Plants Business Unit.


PM0 peeling machine.

87

Pulling together out of tradition – since the sale of the first combined drawing machine to a German steel mill in 1929, no other name symbolizes the drawing process as much as the brand name of SCHUMAG. Since the beginning of this

year, the mechanical engineering divi-sion of the traditional brand from Aachen – including the product pro-gram kIESERlING – have been operat-ing under the umbrella of SMS group at the Mönchengladbach location.

Top: Bright steel; Bottom: Bright steel center.

The move into the new office buildings and the integration into the long Prod-ucts Plants Business Unit lead to the closer linkage of products, reducing the number of interfaces. Thanks to the new structure, synergy effects can be combined. The type catalog was therefore revised to further increase competitiveness. Besides production, sales, and engineering, the service competence of the Business Unit has also been combined.

Since 2008, SMS group has been of-fering all the processes regarding drawing, peeling, straightening, grind-ing, and finishing. Depending on the process and product the manufacturing diameters are up to 600 millimeters.

High speeds, large size ranges, and minimized tool changing times ensure the highest productivity at consistently high manufacturing tolerances.

SERvIcE

The integration into the service struc-ture with its worldwide service centers ensures not only the supply of spare parts of the existing SCHUMAG, kIESERlING, and SMS bright steel processing lines, but other services such as maintenance, training, and modernization are also available. In addition to that, OEM (original equip-ment manufacturer) knowledge en-sures high availability for the entire life cycle of the machines.

610millimeters is the maximum processing diameter during peeling, depending on the process and product.


Sebastian [email protected] vertrieb [email protected]

88

1.55million tons of steel will be the plant’s total capacity once the final construction stage has been completed.

Above: The custom-er’s personnel take an active part in the Plug & Work Tests.

Left: The participants are prepared for their future tasks at the original control pulpits.

ELEcTricAL And AuTomATion SySTEmS sms group newsletter 01 / 2016

89

SmS group has been commissioned by the Brazilian con-struction company construtora Andrade Gutierrez S.A. to build an integrated steel plant for the state-owned Venezu-elan steel company Siderúrgica nacional (Sn). The com-plex to be erected in ciudad Piar in the Venezuelan state of Bolivar will comprise an electric steelworks, a continuous casting plant and a heavy-plate mill. A second construction phase will see the addition of a ladle degassing station and a Steckel mill. The product range will consist of heavy plate and hot strip for the domestic industry. in order for the fu-ture operators to be familiar with the supplied equipment and the associated operating elements before the commis-sioning of the plant, a great number of Siderúrgica nacio-nal employees took advantage of the opportunity to actively participate in the Plug & Work tests parallel to a training course organized as part of the SmS TEcademy.

Plug & Work tests in 3D

The Plug & Work tests for the electric steelworks, the con-tinuous caster, and the heavy-plate mill were conducted in the presence of the future plant operators. That involved the visualization in 3d of the caster and the rolling mill. compared to 2d, Plug & Work in 3d provides an enhanced and easier-to-comprehend view of the complex functions and processes represented. manuel ortiz, Project manager at Siderúrgica nacional (Sn), is highly satisfied with the ef-fect of the Plug & Work tests.

PLuG & Work ALSo PoSSiBLE in 3dSmS group trains a customer’s operat-ing personnel before the actual com-missioning on-site.

mr. ortiz, how would you rate our test fields? To say it in one word: excellent. The at-mosphere was highly professional. The SmS group experts were always avail-able and ready to answer our staff’s questions and explain how solutions can be found. in other words, the col-laboration was very good.

Had you heard of our Plug & Work concept before? yes, indeed. A few years ago, i had the opportunity to attend an integration test in Hilchenbach. At that time, seeing the complete automation system tested prior to its installation at the custom-er’s site had been an entirely new expe-rience for me. i had never thought that such a thing would be possible. Last but not least, training the customer’s operating personnel at the original control pulpits had also been a very ex-traordinary service.

Has it been helpful for your employees to see the processes visualized in 3D during the integration test? Visualization in 3d helps us to under-stand the mechanical components of the plants and the way they operate even better. This is particularly benefi-cial in situations where operators are presented with the new equipment for the very first time. Also the individual process steps within a plant are much more comprehensible in a 3d visualiza-tion.

interview

manuel ortiz

Project manager at

siderúrgica nacional

(sn).

Peter [email protected]

ELEcTricAL And AuTomATion SySTEmS

ElEctricAl And AutomAtion SyStEmS sms group newsletter 01 / 2016

90

Al EZZ dekheila Steel company (EZdK) has contracted SmS group for a com-prehensive revamp of its cSP® plant in Alexandria. EZdK is a subsidiary of Ezz Steel, Egypt’s biggest steel producer. the cSP® plant was first commissioned in 1999. its current annual capacity amounts to one million tons of flat steel products.

EZdK’s primary objective is to regain a high level of plant availability by re-placing obsolete automation and drive systems. A second target is to expand

EZdK, EgyPt: rEvAmPing ordEr for cSP® PlAnt

the product range in terms of steel grades and product formats, while im-proving the product quality.

SmS group is to supply complete modernization package and SmS group will renew the complete automation equipment, namely level 1 (basic auto-mation) and level 2 (process automa-tion), of the cSP® plant. throughout the plant, innovative X-Pact® solutions will be used, implementing the technologi-cal know-how via extremely highly per-forming hardware systems. EZdK will

the planned revamp will focus on upgrading the electrical and automation systems.

upgrade of liquid core reduction (lcr)

new caster auxiliary drive systems

new caster automation system leven 1 and level 2 incl. dynamic Solidification calculation (dSc) and mold monitoring System (mmSplus)

new mill and coiler auto-mation systems level 1 and level 2 incl. PSc, Pcfc, cSc and mPm (material Property model)

new mill main drive converters

new static vAr compensation (Svc)

new mill and coiler auxiliary drive systems

Super reinforced laminar cooling

The modernized CSP® plant of EZDK

upgrade of thickness profile gauge

benefit above all from the fact that these latest technological solutions will all be provided by a single supplier.

improved product quality

in the area of the cSP® caster, SmS group will implement the technological process model dynamic Solidification control (dSc) and the mold monitoring System mmSplus. dSc will provide sustainably improved product quality as it optimiz-es the cooling strategies throughout the casting process. mmSplus will pro-

ElEctricAl And AutomAtion SyStEmS

91

vide reliable data about the in-mold processes. the integrated breakout prediction system will reduce incidents of expensive production loss and repair costs to a minimum. in addition to the comprehensive revamp of the automa-tion equipment, SmS group will also equip the containment zone of the cSP® caster with liquid core reduc-tion (lcr). this will allow EZdK to flex-ibly adjust the casting thickness.

in the rolling mill area of the cSP® plant, the proven level 2 models (PSc, Pcfc, and cSc) developed by SmS group and the high-performance tech-nological controls will allow the indus-trial production of strips down to

1.0 mm thickness. Additionally, the mPm material Property model, a mod-el developed by SmS group for micro-structural calculations, will assure the quality of the mechanical properties and reduce the need of sampling. the model also facilitates the development of new and the sophistication of exist-ing steel grades. Being a one-stop shopping supplier, SmS group will al-so replace all auxiliary drives and the direct converters of the stand drives in the cSP® rolling mill. Additionally, SmS will equip the laminar cooling system with more powerful cooling groups and a new-generation edge masking system. the possibility of more intensive cooling will reduce the consumption of alloying elements and make it possible to produce higher-strength steel grades while leaving the chemical composition unchanged. the newly developed asymmetrical edge masking system improves strip flat-ness, especially in the strip edge area. SmS group’s scope of supply also in-cludes a surface inspection system featuring the latest optical techniques to assess and document the surface quality directly after rolling.

New operatiNg elemeNtsWithin the framework of this modern-ization project at EZdK, also the sys-tems serving the operation of the cSP® plant will be completely renewed. SmS group will replace all control pulpits, local operating units, and the Hmi. the

innovative operating concept will be designed according to latest ergonom-ic findings, providing for intuitive op-eration and facilitating a most clear view of the production process to achieve optimal results.

well-coNceived coNcepts

Before commissioning on-site, SmS group will test the X-Pact® automation systems, which are part of the overall supply package for this cSP® revamp, using its proven Plug & Work proce-dure. Prior to the installation at the customer’s site, the automation sys-tem will be tested and optimized in the test field in Hilchenbach in a near-re-ality simulation, mapping the entire mechanical equipment, the drive sys-tems, and the processes. Pre-com-missioning and optimizing the auto-mation equipment in such tests will pay off later through less time needed for cold commissioning and faster ramp-up. Additionally, the operators of EZdK will be trained on the virtual plant to be optimally prepared for their future tasks. these measures complement the tailor-made modern-ization concept most favorably, mini-mizing the necessary downtime and the ramp-up of the plant.

the modernization of the cSP® plant is scheduled to be completed in the second half of 2016.

Harald rackel, member of the managing Board of SmS group (5th from left), together with the responsible Project managers at the time of signing the contract.

georg [email protected]

new surface inspection system

“new generation edge masking” for all cooling groups

92

PRODUCTION SmS group newsletter 01 / 2016

Over a period of three years SMS group has replaced 15 machine tools at the Mönchengladbach manufacturing location during ongoing operation

and restructured the mechanical manufacture not only technologically, but also organizationally and in terms of process. A major advantage for customers

is that the throughput can now be realized even faster.

COMPONENTS FOR WEDGE PRESS: TIME SAvED WITH SMS MANUFACTURE

Pitman of wedge press 1.5 m wide x 4.9 m long and 2.8 m high, weight 33 tons.

93

PRODUCTION

Ram of wedge press

Ram with protection plate mounted underneath approx. 2.5 m wide x 2.8 m long and 3.2 m high. The Upper sliding surface on which the wedge moves is approx. 3.9 m long. The weight is approx. 92 tons.

Interim assembly work could be performed directly on the metal- cutting machine. No additional workpiece transport was re-quired.

Wedge of wedge press 2.3 m wide x 3.1 m long and 3.2 m high, weight approx. 64 tons. Owing to a mobile applicable hardening process, no additional trans porting of the workpiece was necessary. The quality check was carried out directly on the metal-cutting machine.

Ram of trimming press Weight: 28 tons.

Manufacturing procedure: pre-ma-chining on boring machine – inserting the bushes during assembly – finish-machining on boring machine.

The ram could be manufactured in an assembly hall so that only crane transport was required. Time-consuming operations with a plateau trolley from hall to hall could therefore be prevented.

The components for a wedge press and a trimming press can be consid-ered as an example for a successful manufacturing process. They have been recently manufactured by SMS group for Asian customers at the Mönchengladbach site. The three workpieces of the wedge press could be manufactured in parallel by a varied selection of metal-cutting machines for large components (up to 180 tons). In two months, more than 1,800 ma-chining hours were used up in a three-shift operation. The result is a reduc-tion of the throughput time by 1.5 months. With the wedge press of SMS group forgings in a longitudinal direc-tion can be manufactured.

1,800machining hours at least were used up in three-shift operation in two months.

94

iServices

SmS Technical

Service develops in-

dividual solutions in

cooperation with the

customer. A robot is

being used for the

first time for loading

an extrusion press.

SERvICE SmS group newsletter 01 / 2016

8,000employees work at the Japanese technology group STEP/G, it reaches an annual turnover of 2.9 billion US dollars and operates 23 extrusion presses in 6 plants worldwide.

From top to bottom: Central control sta-tion (position was maintained).

Precise robot grip on billet after measure-ment for exact inser-tion into the press.

95

SERvICE

SMS group has successfully modern-ized a 42.5-MN extrusion press from 1972 at ST Extruded Products Group (STEP/G) in Bitterfeld, Germany. The upgrade included converting the press to front-loading technology, increasing the extrusion force, a billet extension, use of a new billet loading robot, new automation software and hardware, and new safety engineering according to the EU Machinery Directive. In addi-tion to that, SMS group was responsi-ble for supervision of the erection and commissioning.

AN INdIvIdUAL SOLUTION

The Bitterfeld plant of STEP/G former-ly belonged to the Aluminum Extrusion Division of Aleris. With the sale of the Division at the beginning of April 2015, the Japanese company Sankyo Tateya-ma became the new owner and plant operator. The Japanese technology group has 8,000 employees, reaches an annual turnover of 2.9 billion US dollars and operates 23 extrusion presses in 16 plants worldwide.

The upgraded extrusion press in Bitterfeld is employed for the produc-tion of forging stock and aluminum profiles. Special feature: due to a re-stricted space situation within the plant conventional loading facilities for

EXTRUSION PRESS EQUIPPED WITH lOADING ROBOT FOR

THE FIRST TIME

the press were not an option. The technicians of STEP/G and the service experts of SMS group have therefore developed a customized solution: a ro-bot is used for the first time for loading an extrusion press.

ENhANcEd EFFIcIENcy

This particular space-saving solution at STEP/G replaces the billet loader in-cluding the periphery, achieving excel-lent results in practical use. The sev-en-axis robot provides a floor-guided linear traversing axis, caring for billet loading and ensuring that the billets are safely and quickly positioned in the press center. Due to shorter distances and quicker loading, temperature losses in the billet are minimized and energy efficiency of the whole process is enhanced. Furthermore, the robot offers cost advantages in terms of maintenance. Thanks to free program-ming of the robot it can be quickly re-adjusted to new process sequences or modified billet geometries.

Apart from the use of the robot, oth-er basic modernization measures were performed by SMS group. Owing to the billet extension from 1,000 to 1,350 millimeters and the extrusion force increase from 42.5 MN to 50 MN, the plant output is significantly higher

Upgrade of extrusion press at ST Extruded Products Group.

than before. The conversion to front-loading technology and the increasing of the extrusion force was realized by using new hydraulic and cylinder com-ponents in combination with adapta-tions and overhauling the existing ma-chinery parts.

After exact positioning by the robot, the billet is first clamped against the die by means of the extrusion ram. Af-ter the container has crossed the bil-let, concentric billet upsetting takes place from the center and then the re-cipient is vented. The reamer is loaded into the press from behind between the container and ram. Filling and ex-trusion billets for a size range from 400 to 1,350 millimeters are loaded into the press from the front between die and container.

The upgrade by SMS group shows that even an aging extrusion press can be efficiently brought up to date by a specific conversion and extension project.

Ben Zander [email protected]

96

Whether long highway journeys, stop-and-go traffic in major cities, or dy-namic driving pleasure on winding country roads, ... modern cars must always perform reliably under all conditions. At the same time, the aim is to consume less and less fuel, mini-mizing CO2 emissions. This can only be achieved with quality parts made of high-strength materials maintain-ing precision even when subject to extreme stress. Schmiedetechnik Plettenberg (STP), Germany, is a re-

PRECISION – THE DRIvING FORCE AT STP

nowned and experienced manufactur-er of precision components for the automobile industry.

With about 400 employees, the own-er-run company mainly produces high-ly precise gear, motor, and drivetrain components used in passenger cars and utility vehicles. Every year, approx. 20 million forgings are produced from around 65,000 tons of starting material at STP. Despite this large quantity, each single part must fulfill the quality re-quirements of STP. This can only be achieved with plant technology that permanently ensures high productivity and precision at the same time.

For decades STP has relied on forg-ing machines and inductive heating systems of SMS group. Business rela-tions date back to 1958. At that time, SMS supplied a reducer rolling mill to STP then still operating under the name “Hammerwerk Schulte.“ The good cooperation continued in the years to follow: STP operates two closed-die forging plants, two pre-forming presses, a screw press, two reducer rolling mills, two ring rolling machines, several forge hammers, and induction lines from SMS.

Successful for decades through the use of SMS plants and thanks to expert services of SMS group.


SUccESSFUL EXPANSION

The ring rolling machines are typical examples of the cooperative partner-ship between STP and SMS group. In 2007, the forging company successfully expanded its product range by ring rolled gear components, ring gears, and crown wheels using the first ring rolling machine supplied by SMS. SMS integrated the machine into an existing line. The demand for new products in-creased so that SMS group received an-other order for a ring rolling machine from STP. The special aspect: due to good experiences in the past SMS has been awarded the order for a complete fully automated production line and in 2015 it supplied all quality-crucial core components.

Robert Düser, Sales Ring Rolling + Wheel Rolling Machines of SMS group: “We have improved the machine and process details together with the cus-

Dismantling and cleaning of MP 1000 in the workshop of SMS group.

Technischer service

97

nently ensure production and quality and to prevent unplanned downtimes. As a full-support service partner of STP we have provided all services completely from a single source: from dismantling the machine via transport to our service workshop and basic overhaul up to successful recommis-sioning.“

Within the scope of a general over-haul a newly forged eccentric shaft was delivered by SMS and the main assembly groups such as push rod, ram, compensating cylinder, brake, coupling, and ejector were over-hauled. In addition, the press was provided with a new lubrication sys-tem. The result: the 26-year-old press not only looks like new but also achieves highly precise products in continuous operation.

20million forgings are produced by STP per year. To ensure that each single part fulfills high quality requirements there has been close and long-term cooperation between STP and SMS group experts.

tomer so that the availability of the ring rolling line was optimized and the yield compared to the existing line could be increased by 20 percent.“

The new ring rolling line consists of an inductive billet preheater from SMS Elotherm heating the small round bil-lets to forging temperature. via a transport device they reach the trans-fer position where the billets are in-serted into a generally overhauled closed-die forging press by a robot. In three forging processes a ring blank is produced reaching the lifting table of the ring rolling machine via a conveyor belt. At this point, the decisive ring rolling process of the components takes place, then the billets are un-loaded via the lifting table and further transported to the sizing press by another robot where the precise final dimensions of the workpiece are achieved. Robert Düser: “With the

new machine the customer was not only able to more than double the ca-pacity of the plant but it also has a re-dundancy in the production process. This is an important requirement of the automotive industry from its long-term suppliers, that is now fully met by STP.“

EFFIcIENT mOdERNIZATION

But not only new facilities are in the focus at STP. The company puts high value on all machines in top condition and therefore relies on the services provided by SMS group. In 2014, a closed-die forging press in monobloc construction of the MP 1000 type from 1989 was subjected to a general over-haul.

Zijia Guo, Project Manager from SMS group: “The customer has com-missioned us to carry out a general overhaul of the Maxi press to perma-

dismantling and cleaning of mP 1000 in the workshop of SmS group.

[email protected]

98

WAREHOUSING AT ClOSE QUARTERS TO

THE CUSTOMER SMS group undertaking the complete logistics process.

To have the required spares at its site as fast as possible, the SMS experts establish the warehouse close to the customer’s plant.

99

SERvICE

maintenance measures help ensure plant efficiency and detect potential weak points at an early stage. A com-bination of both concepts reduces the amount of tied-up capital.

Warehousing by SMS group makes sure all required spare parts are per-manently available. If so requested, the SMS group’s experts will run the warehouses 24 hours per day and sev-en days a week. Plant users can hence focus on their core business and may rest assured that all required spare parts will be on-site quickly and reli-ably. SMS will take care of the inven-tory and only supply new components in compliance with the current state of the art.

SMS group offers to undertake all its customers’ activities involved in the stock-keeping of spares and wear parts. Under the heading of “Ware-housing” the service experts define, together with the business partner, the required storage concept and the store size. To make sure response times are as short as possible, SMS recommends that the warehouse to be established in the direct vicinity of the production site.

To SMS group, warehousing means everything to do with stock-keeping and the related services and com-prises complete logistics from the re-ceipt of goods to packaging and fur-ther to subsequent goods issue. This full support of an entire logistics pro-cess means there will be one contact partner for all concerns the customer may have.

cUSTOmIZEd SERvIcE

Thanks to this close contact, both sides are able to adapt further service activities to the particular plant or sys-tem involved always aiming to ensure high plant availability or even increase it. For such individual warehousing the customer will have to pay a predeter-mined amount according to its stock volume and the scope of services. Costs for individual parts will have to be paid only after the parts have been requested. Additional services offered by SMS group help the demand of spares to be defined and reflected with the aim of warehousing optimiza-tion. One of the services provided by the experts is machine-specific equip-ment checks. Regular inspections and

Pervouralsk New Pipe Plant JSC in Pervouralsk, Russia; Surface area approx. 4,000 m2 In operation since 2011

TNC kazchrome in Aqtöbe, kazakhstan; Surface area approx. 940 m2 In operation since 2014

Magnitogorsk Iron & Steel Works in Magnitogorsk, Russland Surface area approx. 900 m2

In operation since 2010

Arcelor Mittal Ruhrort in Duisburg, Germany Surface area approx. 610 m2

In operation since 2012

SUlB Company B.S.C. in Hidd, Bahrain Surface area approx. 560 m2 In operation since 2012

Selected references

SERvICESSmS group

Individual warehousing concepts

24/7 availability of spares

Full range of services for the logistics process

i

[email protected]

100

SMS group revamps drawing lines and brings machines up to date – mechan-ically, electrically, and electronically. This also applies to SCHUMAG equip-ment: SMS group has taken over the Mechanical Engineering Division of the traditional brand offering all com-ponents and services in OEM (Original Equipment Manufacturer) quality. Ex-isting machinery and equipment are upgraded to increase productivity and product quality.

The requirements for drawing speed, drawing force, and material di-mensions are becoming constantly more demanding. Nevertheless, plant operators are still producing competi-tively even years after commissioning of their drawing line, tapping into new markets with improved products – be-cause SMS group offers a number of modernization measures that can spe-cifically enhance individual character-istic values and plant parameters. The pre-straightener of a drawing line, for

MODERNIZATION OF DRAWING lINES

example, may be retrofitted to a stur-dier model. In addition, we upgrade the drawing unit by replacing the assem-blies or converting the drawing jaw control. For the straightener, SMS Ser-vice experts are able to provide profes-sional advice with regard to questions on suitable rolling corrections and re-duce setup times through automation of the straightening roll adjustment. Moreover, various modernizations can be performed in the finishing process-es. In this way, for example, individual storage concepts or optimizations of the sawing and chamfering units may be carried out subsequently and indi-vidual assemblies may be replaced or re-engineered.

WELL SERvIcEd

The product portfolio of SMS group Services covers the complete produc-tion process: it ranges from handling of the feedstock in the form of bars or coils up to the testing and bundling

Higher availability and maximized output.

SERvICES

Reduced downtimes

Improved process reliability

Reasonably priced and available spare parts

i

devices for drawn and straightened bar material. The drawing lines en-sure highly accurate dimensions and a flawless surface quality. The dimen-sions range from two to 60 millime-ters. With drawing forces up to 450 kN and drawing speeds up to 250 meters per minute, the machines set stan-dards – SMS group Service experts make sure that this remains over the entire lifetime of the machine.

Drawing carriage after repair – well-proven technique in modern design.

Chamfered bright steel processing lines of high quality – straightness and preci-sion for finishing processes thanks to upgraded equipment.

Sebastian Schulz [email protected]

SmS group newsletter 01 / 2016

101

SERvICE

Straightener of type Sutton kTC.

Conversion in a fortnightStraightener back in reliable operation.

In only two weeks SMS group convert-ed a Sutton 2 kTC Straightener for the straightening of tubes and long prod-uct components for the leading steel producer in Ohio this June. The recon-struction work was performed around the clock including weekends. SMS sub-supervised the subsequent new start-up at the plant. It was the sec-ond conversion of this straightener; the first was carried out in 1989 at the former SMS Sutton manufacturing plant in Bellefonte. The steel producer is now operating five kTC straighten-ers of the Sutton type in Shelby, all in use for the straightening of welded tubes with diameters between 2 3/8 and 12 inches. At this location, the company manufactures welded tubes for varied industries, among them au-tomotive, industrial, and building in-dustry equipment.

Mold plate with the new “bionic-textured mold” surface.

SMS molds last longerThe new surface texture, known as “bionic-textured mold,” lengthens the service lives of copper plates.

For its customers, SMS group has de-veloped a new idea as to how the molds necessary for continuous cast-ing achieve a longer service life: the specially designed texture “bionic-textured mold surface” improves the flow rate of steel and reduces the thermal and mechanical loads on the mold plates. A mold in continuous casting consists of water-cooled cop-per plates or tubes. liquid steel in the mold is cooled to such an extent that it forms a thin shell while it is shrinking. This solidification in the mold is cru-cial for the quality of the end product – it is only with a flawless strand shell that a slab is formed, which can be further processed into high-quality flat steel bars. A bionic-textured mold surface achieves different roughness values. The casting powder accumu-lates in the cavities and is evenly dis-tributed between mold and strand shell – i.e., less powder is needed. Al-so the heat distribution is enhanced, mainly in the mold level area. The slab can thus be pulled out of the mold us-

ing less force and the risk of cracking is diminished. Since time-consuming and costly polishing work is eliminat-ed thanks to the innovatory rough sur-face, maintenance time and costs are less compared to a smooth mold.

Apart from this new texture, SMS offers special coatings for mold plates, increasing service lives by up to 100 percent. A global service net-work with specially trained expert staff offers coating, servicing, and re-furbishing of mold plates.

Oliver [email protected]

[email protected]

102


In order to achieve a trouble-free pro-cess flow in continuous casting and a cast strand of prime quality, it is nec-essary to make sure that the mold plates are in an optimal condition, par-ticularly in terms of heat dissipation and wear condition. The copper plates, which act as heat exchangers, must fulfill two main tasks:First and foremost, their function is to form a fault-free and sufficiently

For exacting process requirements – SMS offers its customers the UniGuard® mold coating.

INNOvATIvE COATINGS FOR COPPER MOlDS

strong strand shell. Defects on the strand surface, such as longitudinal cracks, are a major quality impair-ment and may even result in a failure of the caster. The solidification pro-cesses taking place in the continuous casting mold are highly complex and dynamic, as a varying number of so-lidification phases take place depend-ing on the steel grade. The difference between ingot casting and continuous

casting is that the continuously cast strand solidifies dynamically due to the effect of the oscillating mold and a preset casting speed.

UNIGUARd® cOATING

The second major requirement is to maximize the service life of the mold plates, which are exposed to extreme thermal and mechanical loads. To minimize wear due to mechanical im-

Wasserkasten mit UniGuard®-Beschichtung.

Water jacketwith UniGuard®

coating.

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SERvICE

broad faces. Without sufficient wear protection, the hard material would grind down the profile of the plates. This in turn would reduce the dimen-sional stability of the strand shell dur-ing the primary solidification. The re-sult would be intensifying and excessive movements and permanent stresses in the microstructure within the thin and sensitive strand shell. Therefore, the SMS group service ex-perts recommend operators of slab casters that process a mix of critically solidifying hard steel grades to make use of the metal-ceramic UniGuard® coating.

UniGuard® coating applied by means of the HvOF (High velocity Oxygen Fuel) method.

pact, plant operators have been using electroplated or met-al-ceramic coated mold plates. Especially the metal-ce-ramic coating has been proved to provide a significant improvement in the service life and quality of the equip-ment. For most exacting process requirements, SMS group offers the UniGuard® coating. UniGuard® is a tungsten car-bide metal-ceramic coating that is applied using the HvOF (High velocity Oxygen Fuel) method. During high-velocity flame spraying (HvOF), fuels are continuously combusted under high-pressure conditions inside a water- or air-cooled combustion chamber. The combustion chamber is mainly charged with spray materials in powder form. By means of the carrier gas, the coating particles are acceler-ated to supersonic velocity resulting in dense spray coat-ings with excellent adhesion characteristics.

mETAL-cERAmIc mATERIAL - TUNGSTEN cARBIdE

Tungsten carbide was originally developed for use in cut-ting tools because it contains ceramic crystals of only a few micrometers in size in a shapeable metal alloy compound. Being a hard, brittle ceramic material, it forms a hard cer-met (metal-ceramic) material in combination with cobalt. The resulting coating excellently withstands the compres-sive loads and friction stresses acting on the mold during the casting process and provides appropriate wear and oxidation resistance at high temperatures. Furthermore, the tungsten carbide/cobalt material is characterized by high thermal-shock resistance and therefore is able to withstand sudden temperature changes. Another highly valuable property of a cermet material is that it contributes to an improvement of the product quality. The distribution of forces and stresses in the strand shell is lower due to the more homogeneous heat density. This means that the strand solidifies in a more constant manner and the shell has homogeneous contact around the circumference of the mold, significantly reducing depressions with longitu-dinal cracking.

The UniGuard® coating is highly wear-resistant. This property is beneficial especially when casting special and carbon-manganese grades, as these steels are cast at lower casting speeds. It is not unusual to achieve more than five-times longer service lives of the narrow and

Oliver [email protected]

104


From top to bottom: Dr. Guido kleinschmidt, member of the Manag-ing Board SMS group GmbH, in his opening address in Mönchen-gladbach.

Prof. Pino Tesè, Execu-tive vice President, SMS Technical Service, (third from left) in front of the novel HvOF (High-velocity Oxygen Fuel) coating line.

SERvICESdUmA-BANdZINK offers comprehensive services to their customers:

Spare parts

Technical support

Inspections and maintenance

Repairs and coatings

i

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SERvICE

DUMA-BANDZINk, which has suc-cessfully positioned itself on the mar-ket with its galvanizing plants, oiling machines, and modernization con-cepts for strip processing lines, has already been part of SMS group since 2008 and has now massively invested in the expansion of the service busi-ness. At the beginning of 2015, it com-bined its locations of Duisburg and langenfeld in the SMS Business Park in Mönchengladbach. In late summer of 2015, Mr. Daniel Plätzer, Managing Director of DUMA-BANDZINk, was able to welcome an international audi-ence at the opening of the new work-shop facility.

In their opening addresses, Dr. Gui-do kleinschmidt, member of the Man-aging Board SMS group GmbH, and Prof. Pino Tesè, Executive vice Presi-dent, SMS Technical Service, empha-sized the great importance of the ser-vice business. In his address, Dr. Holger Behrens, Executive vice Presi-dent, Strip Processing lines and Fur-nace Technology of SMS group, pre-sented current trends in the field of strip processing technology to a great number of German and international customers. The Mayor of the City of

NEW WORkSHOP, NEW MACHINERY –

NEW SERvICE BUSINESS

Mönchengladbach, Hans Wilhelm Reiners, was visibly impressed by the new machinery and equipment, which were shown to an international audi-ence in a live demonstration, and em-phasized how much he appreciated the strengthening of Mönchenglad-bach as a business location. Invest-ments were made in mechanical pro-cessing capacities with a new CNC lathe and a CNC grinder for machining roll diameters up to 1,600 millimeters, as well as a complete roller coating line, comprising sandblasting cabin, coating center, and heat-treatment furnace. As a special highlight, the novel HvOF (High-velocity Oxygen Fu-el) coating line could be presented. Consequently, a Japanese delegation of the longtime technology partner and licensor, Tocalo, was also among the guests.

ON A GROWTh PATh

“SMS group likes to invest in promis-ing models, which DUMA-BANDZINk has already proved in its recent past – and will also demonstrate in the future with an increased focus on the service business,“ Dr. Guido kleinschmidt said at the opening ceremony. After exter-

DUMA-BANDZINk opened new workshop in SMS Business Park, Mönchengladbach, Germany.

nal vendors have been increasingly used in the past by DUMA-BANDZINk for grinding and coating work of, among other things, zinc bath and furnace rollers as well as other pro-cess rollers from strip processing lines, the new investments at the Mönchengladbach location play an important complementary role in the services offered to the European mar-ket.

www.duma-bandzink.com

1,600mm is the maximum diameter for machining rolls on the new machining centers.

EvEnts sms groupnewsletter 01/2016

106

Through the use of special strip processing equipment, which includes the welder, existing strip processing lines maintain and enhance their competitiveness, explains markus Jaenecke in his introductory presentation.

A large number of details were discussed during the inspection of the machine in the SmS workshop in hilchenbach.

The brochure “X-Pro®

Laser Welder”

publish ed on the

occasion of the event

is available from the

ordering service.

EvEnts

107

laser Strip Welding Symposium at SMS group in Hilchenbach.

ENTHUSIASTIC ABOUT lASER WElDING – USING CO2 AND FIBER lASERS

In November 2015, a laser Strip Welding Symposium was held at the SMS location in Hilchenbach. The event focused on the demonstration of the X-Pro® laser Welder and on welding tests using a conventional CO2 laser source and a modern fiber laser. Around 50 participants representing steel and aluminum makers from all over Europe did not miss the opportunity to let themselves be convinced of the machine’s capabilities and also to weld their own plates.

The participants watched in fascination as the first weld was produced: a blinding laser beam travelled from one side of the plate to the other, and, simultaneously, the weld was inductively preheated and post-heated. Then, the re-sult was presented and a strength test made. “The weld looks really good and the test shows that it can withstand high stresses,” confirmed Heikki Nisula, General Manager Maintenance and Investments at SSAB Hämeenlinna site in Finland. He had sent the 3.6 millimeter thick plate, which was difficult to weld owing to its high boron alloy content. “I wonder whether they have been practicing secretly, be-cause each time the first try shows a brilliant weld,” said Nisula after further successful welds. “We, too, are enthu-siastic about directly attaining such a good result,” was

the opinion of Christian Dornscheidt, the responsible Project Manager for the laser welder at SMS, “but this is exactly what the machine was de-signed for.”

AdvANTAGES OF ThE LASER WELdER

The major advantages of the machine are its patented inductive pre-treat-ment and post-treatment of the weld and the automatic adaptation of the welding parameters on the basis of a melt analysis of the material as well as the integrated automated weld seam monitoring system. A further impres-sive feature of the machine is its cycle time of less than 60 seconds.

The event began with an introduc-tion by Michael Cottin, Executive vice President, Strip Processing lines and Furnace Technology at SMS group. This was followed by information on

iFiber laser

PG Laser, Germany,

made a welding

source available

for the successfully

conducted fiber laser

tests. The exchange-

ability of the welding

sources, allowing a

rapid response to

new developments,

guarantees the

secure future of the

X-Pro® laser welder.

EvEnts sms groupnewsletter 01/2016

108

»I am highly satisfied with the great popularity of our machine among the customers. It shows that there

is demand for a reliable and innovative welding machine, and that the customers are open to new

technologies such as the fiber laser.«

special strip processing equipment by SMS Sales Manager Markus Jaenecke. The equipment components he re-ferred to can be installed easily and quickly into existing strip processing lines and thus maintain and enhance their competitiveness. Further papers werepresented specifically on the sub-ject of welding metal strips. Dr. Dirk Petring, Head of Macro-Joining and Cutting at the Fraunhofer Institute for laser Technology IlT, explained gener-al trends towards the use of laser tech-nology in strip processing lines.

markus [email protected]

The X-Pro® laser welder in action.

The participants convinced them-

selves of the high quality of the first

weld, with the strength also being

tested by means of the Erichsen

cup test.

The SMS laser Welder Team is

pleased with the altogether positive feedback from the

participants and with the ideas and sug-

gestions from the discussions.

michael cottin

Executive vice President, Strip Processing Lines and Furnace Technology at SmS group.

109

PUBlICATIONS

New releases: Publications and films from SMS group

Learn more about

upcoming events at:

www.sms-group.

com/en/press/

trade-shows-

conferences.html

ImprintSMS group newsletterIssue 01 /2016

PublisherSMS group Corporate Communications, Eduard- Schloemann-Straße 440237 Düsseldorf, Germany Responsible under Press law: Thomas IsajiwPhone +49-211-8810E-mail: [email protected]

Printing and prepress processesDruckhaus kay GmbHHagener Straße 121 57223 kreuztal, Germany

Published on January 29, 2016 © SMS group / circulation in German 6,600, in English 14,000 / printed in Germany

The information provided in this magazine contains a general description of the performance characteris-tics of the products con-cerned. The actual products may not always have the characteristics described and, in particular, these may change as a result of further developments of the products. The provision of this information is not in-tended to have, and will not have, legal effect. An obliga-tion to deliver products having particular character-istics shall only exist if ex-pressly agreed in the terms of the contract.

The SMS group product range is grow-ing continuously. New technologies and machines are being developed. Orders are being completed success-fully. To provide our customers with more detailed information on our inno-vations, we publish all essential news in our brochures, magazines, and vid-eos. In the following, please find a se-lection of our latest releases:

Strip processing lines are especially characterized by highly sophisticated processes for improving material and surface properties, such as pickling, annealing, or coating. As an integrated systems supplier, SMS is able to de-liver efficient plants for the manufac-turing of high-quality products all from one source. Our portfolio includes me-chanical equipment, process engi-neering, heat treatment, electrical and automation systems, and the required production know-how. The new bro-chure “Strip Processing lines – Prod-uct Portfolio, Technology, & Refer-ences” shows our extensive range of services.

Fuxin Special Steel Co. Ltd., Taiwan, has successfully commissioned a steel plant delivered by SMS for the produc-tion of stainless steel slabs at their lo-cation in Zhangzhou in the Chinese Fujian Province. It is the first stainless steel plant in the world to utilize the

waste heat from the AOD converter and the electric arc furnace. The interactive video is available in Chinese, German, English, and Russian.

Efficient vacuum converter for individual needs is the title of a brochure that provides a detailed description of another innovation from SMS. The vacuum converter for the production of stainless, acid, and heat-resistant steel grades and high-alloy special-purpose steel was devel-oped by SMS.

For Steel Dynamics (SDI), SMS successfully expanded the existing bar mill in the USA. With the modernization, SDI has doubled its production capacity and extended its product portfolio, especially to include high-quality bars in special bar quality (SBQ). The video provides interest-ing insights into the modernization process.

Brochures and various film formats provide a detailed insight into the range of products.

[email protected]

EFFICIENT VACUUM CONVERTERFOR INDIVIDUAL NEEDSRefined steels and ferroalloys

Strip Processing Lines

METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY

STRIP PROCESSING LINESProduct Portfolio, Technology & References

SMS group

SMS group

Ohlerkirchweg 6641069 Mönchengladbach, Germany

Phone: +49 2161 350-0Fax: +49 2161 350-1667

[email protected]

SAVE THE DATE

APRIL 4 – 8, 2016

WE TRANSFORM ... THE WORLD OF TUBE AND WIRE.

Tube and wire 2016 is just around the corner. Once again Düsseldorf will be the focal point of our industry. We will be presenting our ideas to transform the world of tube and wire in line with the trade fair‘s motto: “Join the best“. Using exhibits and presentations, we are looking forward to

showcasing our innovative concepts and new developments for effi cient and technologically outstanding plant and machinery. We cordially invite you to visit us at our booth for a personal exchange of ideas and information with our experts. Be our guest and join us in shaping the future!

Hall 7aBooth B15/16Düsseldorf, Germany

SMS group | Elotherm | PWS | SMS Concast

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BIG RIvER STEEl - SMS group

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