- SMS group

Transcription

- SMS group

WE TRANSFORM ...
THE WORLD OF TUBE AND WIRE.
THE MAGAZ I NE OF THE SMS GROUP
ISSU E 0 1 / 2 016
T H E MAGA Z I NE O F T H E S MS G R O U P
I SS U E 01 / 2016
SAVE THE DATE
APRIL 4 – 8, 2016
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
Big River
Steel
A further milestone on the way to production:
The arrival of the millstands
showcasing our innovative concepts and new developments
for efficient 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 7a
Booth B15/16
Düsseldorf, Germany
SMS Group
COpper
Plug & Work
The merger between SMS Siemag
and SMS Meer is highly advantageous for our customers.
Finding the correct manufacturing
process and benefiting from the
advantages.
The operating personnel receive a
clearer explanation of the production sequences.
04
SMS group
Ohlerkirchweg 66
41069 Mönchengladbach, Germany
Phone: +49 2161 350-0
Fax:
+49 2161 350-1667
tw2016@sms-group.com
www.sms-group.com
SMS group | Elotherm | PWS | SMS Concast
82
88
sms group newsletter 01 / 2016
contents
Contents
16 Start of production at Big River.
60 The first production facilities are in operation at Tianjin Zhongwang.
PROCESS CHAIN
20IRONMAKING PLANTS
24Metallurgy and Environmental technology
39 Flat rolling mills
66Strip Processing Lines
and Furnace technology
72 Tube & pipe plants
76 LONG PRODUCT PLANTS
88ElectricAL And
AUtomation Systems
92 Production
98Service
20IRONMAKING PLANTS:
Sinter cooler from Paul Wurth
The sintering of iron ore concentrate presents a challenge
for the plants.
25Metallurgy and Environmental technology:
SIS Injector 4.0
Electric arc furnaces from
SMS – productive and energyefficient.
40Flat rolling mills
Logistics system:
High-bay stores for Aleris
SMS group is also supplying a
cold rolling mill.
46Hot rolling mills:
Back to the future
Successful cooperation with
Nucor.
2
52Cold rolling mills
CCM® – a strongly desired offer from SMS group
A new order from Vietnam
and successful commisioning
in Bangladesh and Pakistan.
60Aluminum:
Aluminum strip for China
The first production facilities
of the mega-complex in operation 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 commenced operation.
contents
32 Revamp at SSAB Luleå.
86 Fast production.
106 Laser strip-welding symposium.
Standards
74Tube & Pipe plants:
NWZ orders three cold-tube
pilger mills
High cost-efficiency and precision for tubes made from
special materials.
78Long product plants
Metallurgical technology:
HybrEx® ordered
Royal United Metal and Glass
from Dubai orders an extrusion press.
79Heat treatment technology:
EloFresh: Innovative monitoring and control system
SMS Elotherm has successfully commissioned an
innovation for cooling and
quenching plants for hardening machines.
88ElectricAL and
AUtomation Systems:
Plug & Work also possible
in 3D
SMS group trains the customer’s operating personnel
already before commissioning.
04 In Focus
08Photo highlight
10 OUTLOOK – RETROSPECT
16 News
106EVents
109 PUBLICATIONS
92Production:
Components for wedge press
Over a period of three years,
SMS group has replaced
15 machine tools during
ongoing operation at the
Mönchengladbach production
location.
94Service:
Equipped for the first time
with a loading robot
Extrusion
press revamped at
ST Extruded Products Group
for enhancing the production
efficiency.
109 Imprint
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.
3
In FOcUS
With concentrated
forces for metallurgical
plant engineering
The 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.
F
rom 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 systems but also comprehensive service provision and environmental 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 engineering. Around 12,000 employees are active in SMS group.
They ensure perfect interfaces and the greatest possible efficiency 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 industrial centers of the steel and NF metals sector on all continents. “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
4
structured such that it can competently fulfill the customers’ expectations
also at the level of small, highly focused 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 process chain. Here, we focus on continuity and, in some areas such as Services
and Electrical and Automation Systems, on growth, while keeping our
sights on our more than 140 years of
experience in metallurgical plant construction and mechanical engineering.
Our business units are closely harmonized with one another, and our processes intermesh in a customer-
In FOcUS
Left:
Dr. Heinrich Weiss,
Chairman of the
Supervisory Board of
SMS group.
Bottom:
SMS group. More
than 140 years of experience in metallurgical plant construction and mechanical
engineering.
5
In FOcUS
Focusing on the customer’s requirements: The Managing Board of SMS group with the Chairman Burkhard Dahmen (center).
i
SMS group
oriented manner. Our own workshops
in those regions of the world where
demand is high ensure uniform standards of quality that are tailored to the
respective expectations of our customers.
The amalgamation
of SMS Meer GmbH
Our Business Units at a glance:
with SMS group
Ironmaking Plants
GmbH became
Metallurgical Plants and Environ-
legally effective
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
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.
Members with responsibility for
central functions
The owners of SMS group as a familyrun business have clear ideas as to the
firm’s present and future course. Customer satisfaction has uppermost priority. The Chairman of the Supervisory
6
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 Business 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.”
www.sms-group.com
2012
Paul WURTH S.A.
SMS group
2009
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Mechanische Werkstätten Harkort
7
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 occasion, SMS group demonstrated its vision of
machine operation in the future when all areas, without exception, will have been adapted to the activities of the operating staff. The
new operating philosophy could be experienced 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
9
Ausblick—
OUTLOOK
– Rückblick
RETROSPECT
At the new control pulpit, operators have a clear view of the
production process.
The BCT® process.
10
Finishing stand of a hot strip mill.
OUTLOOK — RETROSPECT
FOCUSING ON THE
CUSTOMER WITH SOLUTIONS
FROM A SINGLE SOURCE
Dr. Guido Kleinschmidt on trends and challenges
affecting plant engineering in the metal-producing industry.
T
he recent international metallurgy trade show time. Overcapacities and the resulting rock-bottom prices
and conference combo METEC 2015 in Düsseldorf of metal products are piling cost pressure on our customwas a big success – especially for SMS group. It ers. Added to this are other factors, such as growing deattracted about 80,000 visitors from more than mand for special grades, stricter environmental protection
120 countries, so that the event was just as popular as the regulations, and resource scarcity, that pose huge chalprevious METEC – a remarkable result considering to- lenges for the metal industry. Furthermore, in the age of
day’s climate in the industry.
globalization and digitalization,
Particularly appropriate for
companies can tap into a
SMS group is this year’s motto
wealth of complex information
“The Bright World of Metals,”
and data that open up new pobecause it draws attention not
tentials of plant optimization
only to the versatile material
and production transparency.
steel, but also to other metals
As a leading systems supsuch as copper, aluminum,
plier of plants, machinery, and
and ferroalloys.
services along the entire metWe took the opportunity of a
allurgical value creation chain,
large number of intensive talks
SMS group and its more than
with our customers, exhibitors,
12,000 employees are well
and other visitors to gain a
placed to offer efficient, unique
clearer understanding of new
solutions with compelling ecotrends and challenges in the
nomic benefits.
metal production industry.
The product portfolio of SMS
That’s because listening closegroup ranges from high-perly and understanding customformance individual compoers are imperative to modern
nents right through to turnkey
plant construction.
complete plants from one
The rate of change in market
source. Characteristic of the
requirements for plant con140-year history of the compastruction in the steelmaking inny are the continuous new deDr. Guido Kleinschmidt
dustry is accelerating all the
velopments that are a key to
Member of the Managing Board, SMS group GmbH.
11
Ausblick – Rückblick
Illustration of a vacuum AOD process.
Illustration of the 135 MVA furnace at POSCO SNNC, Korea.
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 demands 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 system 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 millimeters thick and 1,000 millimeters wide. After re-heating, they
are rolled and wound into coils. The plant has already produced high-manganese HSD® steels that defy conventional
casting processes. For SMS group, the compact, cost-saving technology also offers new application options for producing carbon steels in mini steelworks.
Normally, ferroalloys are produced in submerged-arc
furnaces. Due to the process involved, the energy consumption 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 sus12
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 system.
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 commissioned a FeNi furnace with a rated power of › 100 MW. During 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 furnace 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 nonferrous metals production. This is where submerged-arc furnaces 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 global 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 reflected 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
»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
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 technological expertise from steel production to the copper production 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 processing technologies that are more energy-efficient and
generate fewer emissions. There are important economic
and ecological reasons for this. First, saving energy and resources cuts costs. And second, protecting resources is becoming more and more important, with extensive environmental 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 quality
Energy recovery systems achieve a palpable increase in en-
ergy efficiency. Included here, for example, is the generation of steam using the heat from waste gas emitted by
electric-arc furnaces, converters, or submerged-arc furnaces. Afterwards it is possible to use this steam for heating, 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 vacuum degassing plant.
Harmony between man and machine
Will the metal producing plants of the future operate without personnel? Some experts think so. However, at SMS
group we believe metallurgical plants will continue to require human control, although machines will increasingly
dominate.
Essential here is that man and machine form a homogenous unit. Even complex tasks can be easy to accomplish
in top technical and professional quality, supported by assistive 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 installations is preparing personnel for the changed production
13
»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
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 hardware and software components are installed in an SMS
group test center and put through their paces. The test center 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 optimize 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 leading the way. Companies need to constantly review existing
business models and working methods. They need to identify 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 global 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 digi14
tal, participative engineering and order processing methods it has been applying for years, as well as its own automation 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 conditionbased maintenance and repairs. Included here is overall
functional connectivity of all machines, materials, and personnel 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 economically 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-
Steam generation at Fuxin Special Steel, China.
vice offers solutions that guarantee customers reliable,
cost-effective operation of their plants throughout the service life. Whether replacement parts, maintenance/repairs,
or large or small revamps of existing plants. Even after
commissioning, SMS group supports customers as a reliable partner.
The backbone of any company is its workforce. Essential
for this are the right expertise and comprehensive understanding of the task in hand. That’s where the SMS TECademy provides effective support. Maintaining a focus on
practical and technical know-how, the training academy
offers standardized as well as customized courses. On request, 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, maintenance, 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. Whether an online shop for replacement parts, software for monitoring slab quality, the Genius Condition Monitoring System 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 metallurgical facilities’ competitiveness at a more modest cost.
Generally speaking, revamps are slightly more complex because they involve optimizing an old plant with the existing
infrastructure and equipment. The advantages for the customer 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-effectiveness assessments.
Fit for the future
With its constant innovative approach, SMS group demonstrates how it can satisfy both today’s and tomorrow’s markets. Experiences combined with vision have created a
product portfolio that matches the new market requirements.
www.sms-group.com
15
NEws
Arrival of the millstands for the cold
rolling mill.
16
News
Big River Steel –
looking forward to the
start of production
SMS 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 production is moving closer.
Visitors to the METEC 2015 trade fair had the opportunity 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 millstands at Big River Steel. The drive spindle was manufactured at the SMS workshop in Hilchenbach and will be installed in the CSP® plant at Osceola in the U.S. State of
Arkansas. The drive shaft is characterized by a new, optimized 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, Governor of the U.S. State of Arkansas, signed the spindle during 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 Number 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
i
Supply Package
SMS group scope of supply for Big River Steel
he SMS group scope of supply covers the entire equipT
ment, including the mechanical equipment and the electrical and automation systems. For the steelworks, SMS group
is erecting two electric arc furnaces, two twin-ladle furnaces and an RH-TOP facility. Besides the provision of the
electrical and automation systems, SMS group is also focusing 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.
he tandem cold mill supplies a wide range of products. In
T
combination with the two downstream strip processing
lines, hot-dip galvanized cold strip is produced on the continuous process route, via the annealing and galvanizing line
together with an inline skin-pass mill. The convincing feature 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.
17
NeWS
From 2016 on, Big
River Steel will operate
North America’s most
advanced steelworks
on a total area of 567
hectares.
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 equipment. 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 opportunity 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 inspection of those millstands before they were loaded on the
ship was very, very, outstanding.”
SMS group will supply the entire equipment for Big River Steel, including the mechanical equipment and the
electrical and automation systems. In the first wave of con18
struction, the works will produce 1.5
million tons of hot strip per year. It is
planned to increase production stepby-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 elsewhere in North America for future mill
sites.”
Axel Sprenger
axel.sprenger@sms-group.com
David Stickler, CEO at Big
River Steel. In the background, the construction
works for the completion
of the steelworks are in
progress.
Transportation work at
the Mississippi River.
1.5
You can call up a
film on the arrival of
the millstands at Big
River Steel under:
www.sms-group.
com/qr/BRS-WS
million tons of hot strip per year will be
produced by the works in Osceola in the first
stage of construction.
19
Ironmaking Plants
Sinter cooler from
Paul Wurth
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.
i
Paul Wurth
is the SMS group
expert for primary
processes of integrated steelmaking.
The company’s portfolio includes blast
furnace technology,
coke oven technology, sinter plants,
and environmental
protection equipment.
20
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 friendly. 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 exacting. While production volumes have been growing, increasingly stringent environmental regulations must be complied 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 subjected 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 various 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 meters they require a lot of space and very powerful drives for
the cooler and the blowers. An alternative 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 requires much less space for an equivalent cooling capacity.
Efficiency and ecology
Paul Wurth Umwelttechnik GmbH has
been consistently working on sophisticating 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
Ironmaking Plants
Sinter cooler at ArcelorMittal Tubarao, Brazil.
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 exploiting the cooling potential of the air. The counter-flow principle brings along various direct and indirect benefits for
the environment. Thanks to the high cooling efficiency, considerably 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 additional 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 recovery. This makes it possible to connect a heat recovery system to the suction hood. Depending on the customer’s request, a steam generator may be used to supply steam to
the fresh steam network of the works or to generate electricity 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
20
megawatts of electricity can be generated by
recovering heat from a sintering plant.
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
21
IronMaking Plants
Salzgitter commissions
PCI system
In the first quarter of 2015, Salzgitter Flachstahl (SZFG), Germany,
started pulverized coal injection
(PCI) at its blast furnaces. In August 2013, Paul Wurth had received
the order for the turnkey supply of
PCI equipment for Salzgitter Flachstahl’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 systems designed for a capacity of 200
kg of pulverized coal per ton of hot
metal. Thanks to the PCI technology implemented by Paul Wurth, flat
steel producer Salzgitter has
been able to improve the productivity and efficiency of its
blast furnaces.
www.paulwurth.com
Main building of the
PCI plant at SZFG in
Salzgitter.
Midrex and Paul Wurth to build direct
reduction plant in Algeria
Midrex Technologies Inc. and Paul Wurth S.A. have
been contracted by Turkish steel producer Tosyali Holding 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 production 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.
www.paulwurth.com
22
Midrex plant for the production of 1.54 million tons per year of DRI.
IronMaking Plants
The best technology available
Blast Furnace AF5 in Taranto, Italy
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 EUdefined Best Available Technologies
in order to match latest environmental 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 ironmaking facility. On the side of hot
blast generation, the four existing
Krupp-Koppers units will be completely replaced by a group of three
one-dome hot blast stoves with external combustion chamber. This
sub-plant will also feature Paul
Wurth’s patented waste gas heat recovery system and a complete EIC
system. Performance and maintain-
ability of the BF top gas cleaning
plant will be improved by replacement 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 challenging schedule foresees project
completion by Paul Wurth within 12
months.
After completion of this largescale reline project, Taranto’s steel
plant will be able to operate its new
BF5 in compliance with the latest
environmental and safety standards.
www.paulwurth.com
Paul Wurth offers new service for
coke-oven batteries
In July 2015, Paul Wurth commenced
the hot repairs of coke-oven batteries 4A, AB, and 5 at CSN in Volta Redonda, Brazil. The activities are
scheduled to take 21 months. This
order, covering a total of 105 ovens,
is the first ever hot repair order received 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 knowhow, 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 operators aiming to prolong the life of
their coke-oven batteries.
www.paulwurth.com
23
Metallurgy and Environmental Technology
Georg Fischer orders Ecomelt melting
furnace from Hertwich Engineering
Georg Fischer from Altenmarkt, Austria, has placed an order with Hertwich 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-
Multi-chamber
melting furnace
type HE-EcomeltPS70.
SMS Metix:
Reinier Meyjes retires
Reinier Meyjes, for many years a
member of the board of our South African subsidiary SMS Metix, has retired. Reinier Meyjes founded Metix in
2003. SMS Metix is active in plant engineering and as equipment supplier
for the ferroalloys industry. The company’s product and service portfolio
22
comprises complete engineering for,
and the supply of, plant and equipment 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 revert scrap – even with adhering
coolants and lubricants from machining. The multi-chamber melting furnace is characterized by high
metal yield, low energy consumption, 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 electric 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 Hertwich to the local conditions. The
plant is scheduled to start production in the 4th quarter of 2015.
New generation:
SIS Injector
Electric arc furnaces from SMS –
highly productive and highly energy-efficient.
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, combined burner-injector units are used to melt the scrap and
superheat the bath. While the energy input and the meltdown capacity are highest in the furnace center, cold spots
occur at the wall panels. Burners or injectors supply additional thermal energy to these spots, making for a homogeneous 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 directly 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, shielding 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 prototype 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 percent less oxygen. First tests have shown that the metallurgical results remain virtually constant.
New generation: SIS Injector 4.0.
For more information, please refer to
the SMS group paper
presented at ESTAD
Jan Bader
jan.bader@sms-group.com
2015.
25
Left: First blooms
arriving at discharge
area.
Jumbo bloom caster
successfully commissioned at TISCO
Right: Bloom in cooling chamber.
The first blooms were used
for wheels of high-speed trains.
In 2015, the first heat was successfully cast on the threestrand caster for round blooms at TISCO (Shanxi Taigang
Stainless Steel Co. Ltd.), Taiyuan, China. The plant is designed 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 supplied 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 sophisticated 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 minimizing core porosities the plant provides “Dynamic Mechanical Soft Reduction” (DMSR) with up to ten single modules per strand. These modules allow optimum adjustment
of the modules depending on casting conditions and steel
26
grades. After commissioning the plant
has produced top-quality grades from
the outset. Already the first blooms
cast satisfied the strict feedstock requirements 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) improves the energy balance. To achieve
this, steam is recovered from the
waste heat of the CONARC® furnace
that is used by the customer for further processes. The plant has an annual output of 530,000 tons.
www.sms-concast.ch
i
SMS group
The Shanxi Taigang
Stainless Steel Co.,
Ltd. is the largest stainless steel
producer in China.
The company supplies steel products
worldwide in the
automotive, rail,
shipbuilding, petroleum, oil, and chemical industries.
Metallurgy and Environmental technology
1000th
ELECTROMAGNETIC
STIRRER CONSTIR
Customized stirrers for a better quality
and higher productivity.
In addition to the five-stranded Block & caster, SMS group
has successfully installed the 1000th electromagnetic
CONSTIR Stirrer at Vizag Steel Plant (VSP) Vishakhapatnam (Andhra Pradesh/India).
CONSTIR Stirrers are used in continuous casting to improve the steel quality and to stabilize productivity. SMS
group low-frequency stirrers deliver maximum magnetic
force to the liquid steel for the strongest metallurgical effect. 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
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
Extra-narrow stirrer housing for large round
sections with small strand spacing.
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 every stirrer.
www.sms-concast.com
27
Changing the straightening rolls on the CRS® straightener.
Commissioning at
Stahlwerk Thüringen
SMS group successfully completes
CRS® straightener modernization.
Stahlwerk Thüringen GmbH, Germany, has successfully
commissioned its CRS® straightener following modernization 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 con28
cept now implemented involving the
continued use of existing machine
components of the original straightener, it was possible to reduce the investment 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 Stahlwerk Thüringen can now not only meet
the growing demands for long product
mills in terms of productivity, flexibility, and cost-efficiency, but also increase its competitiveness on the domestic and international markets.
sectionandbilletmills@sms-group.com
Copper-matte settling
furnace in operation
Furnace supplied by SMS Metix separates copper matte and
slag in Zambia, Africa’s most important copper mining area.
The furnace for the separation of copper matte and slag, supplied by SMS
Metix, South Africa, to Kansanshi Mining PLC, has been started up successfully. With the new furnace, Kansanshi
Mining PLC (majority shareholder:
First Quantum Minerals) has expanded its copper smelting plant in the
province of Copperbelt, Zambia’s largest copper mining area. SMS Metix’s
scope of supply comprised the engineering and supply of a copper-matte
settling furnace, the feeding system,
the refractory lining, the tapping sys-
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 emulsion (a finely dispersed mixture of two
liquids that are usually unmixable).
The copper matte thus obtained is further processed into copper anodes.
Technical data
Size of furnace hearth
26 m long x 9 m wide
x 6.5 m high
Nominal installed power
Electrode stroke
24 MVA
1,600 mm
Slag capacity
353 m3 or 1,132 t
Copper matte production
91 tons per hour
Slag output 142 tons per hour
www.metix.co.za
Democratic Republic
of the Congo
i
SMS group
Copperbelt is an
industrial area in
Zambia, which also
Photo bottom right: MellonDor/Wikimedia
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.
29
Unique in the world:
Energy Collector E-CO
SMS group development saves resources and energy.
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 movement 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 exchanger. The slabs radiate between 30 and 45 kW of energy
per square meter, depending on their surface temperatures. The heat exchangers absorb the radiant heat and
convert it into steam.
i
Facts and figures
Modular expandable design
No impact on production process
Maintenance-free, fully automatic
pecific radiant heat of 30–45 kW/m² of
S
slab surface
ilot plant at SZFG, May 2015
P
– 1 ton of saturated steam/hour
– Fast run-up in only five days
www.sms-group.com
Functional principle of the
Energy Collector E-CO.
30
Salzgitter Flachstahl GmbH (SZFG) has been using the E-CO pilot plant built by SMS group to its full extent.
Interview
A perfect
solution
Interview with Dr. Peter Müller, Head of Continuous Casting
Plants & Finishing Lines at Salzgitter Flachstahl GmbH.
idea. After clarifying and specifying a few aspects, we
agreed to have the E-CO plant implemented.
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 resources. 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.
What are the results? Does the E-CO plant provide what
you had expected?
The pilot plant provides an average steam capacity of almost 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.
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
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 Foundation. I think this speaks for itself. There will most likely be
additional possibilities of using the recovered heat, for example 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.
31
One of the two new converters at SSAB Luleå.
SSAB LULEA WELL
EQUIPPED FOR THE FUTURE
THANKS TO REVAMPS
Revamp with lamella converter suspension systems from
SMS group increases yield.
32
At SSAB Luleå, Sweden, SMS group has successfully commissioned the modernized converter shop and the pertaining environmental technology. SSAB fully achieved its own
target of increasing the yield of both converters and satisfying 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. Furthermore, the cooperation and communication during the
erection and commissioning went very smoothly in an atmosphere 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 maintenancefriendly. The scope of supply also included the converter
trunnion bearings, the height increase of the existing trunnion pedestals, and the installation of the vessels and trunnion 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 increased 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 maintenance-free converter suspension system designed for arranging 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-
130
tons is the charged material quantity. And yet
following the revamp the internal volume of
the converter was increased by 10 percent.
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 steelmaking plant. For this, the cooling
stacks of both converters were modified 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 enable the primary gases to be extracted
efficiently under suppressed combustion. In addition, diffuse dust emissions are substantially reduced. Gas
recovery is used in the best possible
way by generating CO gas under suppressed 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 modernization 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 recovery from the two cooling stacks is
thus performed with extremely high
energy efficiency. “We are highly satisfied with the Ecoplants technology and
we have a clean environmental conscience as regards production,” is the
opinion of Kurt Lindqvist, Project Manager of the Converter Shop at SSAB
Luleå, Scandinavia’s largest producer
of flat steels.
i
Ecoplants
Ecoplants is the
hallmark of SMS
for sustainable
solutions. Sustainability 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 increasingly important.
Ecoplants solutions
do justice to both
aspects.
Jan Bader
jan.bader@sms-group.com
33
Ladle furnace at
Metal Ravne.
INCREASED
CAPACITIES and
MARKET SHARE
In 2015 SMS group successfully commissioned
the newly erected Secondary Metallurgical Center at
the Slovenian steelmaker, Metal Ravne.
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 intention behind the installation of the new
ladle metallurgical center was to increase 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 system, the temperature and sampling
device, the electrical lifting system and
the gantry, a wire feeding machine,
the electrical, instrumentation, process automation systems and erection, 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
Andrej Gradišnik
Managing Director,
Metal Ravne, SIJ
Group.
»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.«
managed by one tank car. Therefore, in
each treatment position only the respective treatment cover has to be
lifted or lowered to start the treatment.
Both stations are equipped with manual argon couplings with high-temperature-resistant hoses intended for
supplying the inserted ladle with bottom-stirring gas. The vacuum tank is
connected to a vacuum pump system
with a suction pipe and the graphite
electrodes are connected to the transformer via high-current cabling.
The VD/VOD cover is equipped with
an oxygen lance for forced decarburization and a semiautomatic lance for
hydrogen measurement (HYDRIS).
Both the units – LF and VD-VOD – have
equipment for semiautomatic sampling and temperature measurement
at atmospheric pressure. The treatment covers are lifted and lowered hydraulically. 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 addition 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 ladle tilting stand, and a hydraulically
operated de-slagging machine. Besides the de-slagging equipment at
this position, there is also an immersion lance, which serves for addition of
gaseous nitrogen for steel grades with
defined nitrogen contents.
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 considerably 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
axel.kopp@sms-mevac.com
INCREASED CAPACITIES …
INCREASED MARKET SHARE
Metal Ravne has extended the existing
process line to have the metallurgical
capability of treating special construction steels that require degassing for
35
New silicon-metal
works for Iceland
Turnkey plant on the basis of
hydropower and geothermal energy
pacted, collected in silos, and sold, for
example, as an ingredient of concrete.
The filter house for primary dedusting
will be designed as backwashable filters allowing fine filtration of solids
and, as a result, significantly more efficient cleaning. The dedusting plant
design will allow for an energy-recovery system to be retrofitted at a later
stage in order to further improve the
efficiency of the plant.
SMS group as a strong partner
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 scheduled 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-
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 internationally 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 Iceland will be shipped from Poland
where PCC owns a quartzite mine.
Martin Köneke
martin.koeneke@sms-group.com
Dr. Peter Wenzel, member of the Managing Board of PCC BakkiSilicon hf (left) and Burkhard Dahmen, CEO SMS group
GmbH, signing the contract.
36
DELEGATION OF AIST
VISITED SMS GROUP
in Düsseldorf
Participants gained insight in three-dimensional design.
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-dimensional design in virtual reality. Demonstrations and lectures also informed the delegation on new SMS group
developments.
Ronald J. O’Malley,
Second Officer at
Large of AIST and
head of delegation, presenting a
commemorative
certificate on the
plant tour to Lothar
Fischer, Head of
Technical Sales
Continuous Casting
Plants at SMS group.
37
Metallurgy and Environmental Technology The SMS Mevac experts know
the technological requirements
placed on vacuum pumps.
Specialists in mechanical
pump systems
SMS Mevac boasts vast experience in the field of vacuum pumps.
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 emphasis on RH/RH-OB and RH-TOP plants. SMS Mevac has
a track record of more than 180 such plants sold and commissioned 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 tailored 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 production of higher-grade steels.
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 higher investment costs than steam ejector
vacuum pumps, mechanical pumps
pay off much faster.
i
SMS Mevac
SMS Mevac now
offers its expertise
in secondary and
tertiary metallurgy
also in the form of
consulting services, which allow
customers to plan
Clear cost advantages
In modern, efficient ladle-metallurgy plants, the fine vacuum 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 appropriate 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 already equipped VD/VOD plants with mechanical vacuum
38
Jochen Schlüter
jochen.schlueter@sms-mevac.com
their revamping or
building projects
in a most targetoriented way.
FLAt rolling Mills — LOGISTICS SYSTEMS
LITHO COILS
PACKED GENTLY
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.
The storage system is directly connected to a new litho finishing line and
comprises an inspection area, an automatic coil manipulator, and 28 double 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 horizontal or vertical position. These pack
ages are then wrapped for shipment,
strapped, weighed, and finally provided with a shipping label. An essential
characteristic of the line is that, during
the entire transport as well as deposition on the pallet, handling of the extremely shock-sensitive litho coils is
The new packaging 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 performed automatically without need for
moving them again.
CONVINCING CONCEPT
“The concept offered by SMS Logistiksysteme convinced us,” says Paul
Smith, Project Manager in charge of
the litho expansion project at
Bridgnorth Aluminium. “The automatic 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-
cept does not only provide the necessary 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 interim store and the packaging line is
clearly smaller than expected. With
this investment, Bridgnorth Aluminium Ltd. will increase its capacity and
further consolidate its position among
the top suppliers of lithographic quality aluminum strip in Europe.
Stefan Mathmann
stefan.mathmann@sms-logistics.com
FLAt rolling Mills
High-bay store for
aluminum coils.
40
sms group newsletter 01/ 2016
HIGH-BAY STORE FOR
ALERIS, U.S.A.
At its Lewisport location in the U.S. federal state of Kentucky,
Aleris Rolled Products, Inc., is going to enhance the production capacity 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.
“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 systems,” explains Grégory Misonne, Project Manager. “Another factor that impressed us was the features of the
warehouse management system precisely developed to
meet our needs.”
lished upstream cold rolling mill between the existing rows of support pillars of two halls. The spatial size of the
store is determined by the large distances between the transfer positions
of the two annealing lines and the cold
rolling mill, as they all have to be within reach of the stacker cranes.
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 shuttle car. Energy supply to the car is accomplished by a motorized 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 forklift 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 carries 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 finding the right concept with respect to the concrete structure
and to installation as the storage system is to be estab-
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. Subsequent installation of a coil cooling system will also be possible.
www.sms-logistiksysteme.com
Horst Thorn
horst.thorn@sms-logistics.com
41
FLAt rolling Mills
i
WMS
The WMS provides
a good overview of
all relevant data and
offers various possibilities for processing these and for
monitoring the material flow. It seamlessly integrates
both existing system
configurations and
those which are still
being developed.
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. Moreover, 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.
42
LONG-LASTING
SUCCESS STORY
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.
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 designing a completely new user surface, the software engineers
paid particular attention to intuitive operation, high performance, 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 current 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 extended and precisely adapted to customer-specific requirements. 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 provides 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 sequences. If processing steps have been determined in advance, the system will use this information to optimize
transport and storage strategies. In line with the customer’s request, it is also possible to initiate material transports at a specified date on the basis of predefined shipping
schedules.
MANY ADDITIONAL FUNCTIONS
Further functions such as user and rights management,
language change, consistent input validation and web administration interface for expert settings, reporting functionality, 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 backups.
The WMS comes with interfaces with subordinated controls as well as with the superordinated system. In particular 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 proven 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 management tasks.
www.sms-logistiksysteme.com
Justus Deussen
justus.deussen@sms-logistics.com
43
Flat Rolling Mills
44
FLAt rolling Mills — Hot Rolling mills
Coilbox without mandrel
The coilbox alteration at Tata Steel Jamshedpur
will lower temperature losses and reduce maintenance.
Tata Steel Ltd. has placed an order
with SMS group for modifying the coilbox of the Jamshedpur, India, hot strip
mill to a mandrel-less coilbox. The alteration of the coilbox, which had been
installed in 1993, to a design without
mandrel will reduce wear and the effort for maintenance. Furthermore,
temperature losses at the inner windings of the coiled strip will be avoided
in the future and make the rolling
stock enter the finishing mill at a homogenous temperature over the entire
length. Foundation work for the alteration can be kept to a minimum as the
design of the coilbox will be adapted
accordingly.
After the alteration,
the coilbox will work
without mandrel.
Link fehlt
Coilbox With x-pact® Automation
The new X-Pact® automation system
for the coilbox will be installed and
tested in advance during ongoing operation and thus permit the changeover to the new system to be accomplished during the downtime period,
which is scheduled to take about two
weeks. On this occasion, too, SMS will
integrate the crop shear automation
into the new system. All drives in the
coilbox area will be changed by SMS
group from DC to AC.
Uwe Warnke
uwe.warnke@sms-group.com
45
Flat rolling mills
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 gauges, and lower energy use are the
results of a successful collaboration.
Also outstanding technologies, like the thin slab technology launched by SMS group in 1989 under the name “Compact Strip Production” (CSP®), must be constantly advanced. 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 upgraded the Berkeley plant in 2013/2014, during a project
period of just a few weeks. “Now, as we can make widths of
46
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 increased from 1,680 to 1,880 millimeters. At Nucor Steel,
SMS group for the first time implemented a new modernization concept designed to expand the product range and
Flat rolling mills — HOT rolling mills
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 upstream 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 possible to increase the temperature of the thin slabs, as required, right before they run into the rolling mill. This enables
Nucor Steel to achieve greater reductions per pass and expand 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 precondition for lowering the furnace temperature to a
47
Flat rolling mills
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.
i
Nucor
With an annual
production of more
than 21 million tons
(2014), Nucor is one
of the largest steelmakers in the U.S.A.
level suitable for rolling the major
part of the steel grades and strip
gauges, without compromising process stability or the product quality.
For all strips requiring a higher entry
temperature, the inductive heating
systems will be there to provide the extra heating. By means of this concept,
it is possible to achieve both the extensive product range typical of the CSP®
technology and marked savings on energy.
As its first user, the
company was instru-
DETAILED PLANNING
mental in helping
Additionally, the modernization measures comprised modifications to one
of the two CSP® casters, the extension
of the CSP® rolling mill, and the renewal of the X-Pact® electrical and automation 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 adjusted between 48 and 63 millimeters.
“Although increasing the casting width
by 200 millimeters was definitely a
challenge at the beginning of the project, the implementation eventually did
not pose any major problems thanks to
the good planning and successful collaboration,” says Volland.
the CSP® technology,
developed by SMS, to
achieve its worldwide breakthrough.
48
Flat rolling mills — HOT rolling mills
Interview
Reducing the energy
consumption of the furnace
roller by 40 percent
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 including 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 challenging project implementation, the
cooperation was always very constructive and trusting,” says Witherow. “The
modernized plant has markedly improved our competitiveness in the
market for premium flat steel products.”
www.sms-group.com
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 furnace 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?
Alexander Volland
The induction technology efficiently combines two aspects.
Project Manager,
The starting point was the fact that only very few products
SMS group.
made on a CSP® plant need the maximum tunnel furnace
temperature. The combination of a gas-heated tunnel furnace 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 directly 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 rollers 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.
49
Flat rolling Mills
Partnership with
Houghton International
Plants and fluid technologies from a single source for efficient and
ecological cold strip production
steelmaking. Under this partnership,
SMS and Houghton will be pooling
their research and development resources with a view to offering the innovative cooling lubricant technologies 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 President at SMS group‘s Flat Rolling
Plants Cold Rolling Mills Business
Partnership for integrated plant engineering and lubricant technology.
Unit. „This partnership offers innovaIn December 2015 SMS group GmbH and tive solutions to our joint customers worldwide in
Houghton International Inc., with head office in the metal-producing industries.“
„We are most happy to be able to announce
Pennsylvania, USA, agreed their partnership for
the development and marketing of oil-based this exclusive partnership because both SMS and
cooling lubricants and emulsions for cold rolling Houghton are leaders in the fields of rolling
mills. Two leading suppliers have joined forces in technology and fluids“, says Marcello Boldrini,
this partnership with a view to providing their President for Global Metals & Mining and Asia at
joint customers with the added value obtained Houghton. „We can now provide the worldwide
from a harmonized symbiosis of plant and fluid manufacturers of steel and other metals with the
only systems that integrate plant engineering
technology.
and lubricant technology, thus allowing us to offer the most advanced integrated solutions to
Strategic Partnership
Houghton International Inc., is a top-of-the- our customers.“
range supplier in the field of fluids and special
chemicals for metal processing. The partnership
covers the common development and marketing
Patrick Wischnewski
patrick.wischnewski@sms-group.com
of oil-based cooling lubricants and emulsions for
50
i
Houghton
International
Since 1865,
Houghton International Inc. has
been serving the
aluminum and steel
industries as well as
various other sectors
with the development and manufacture of special
chemicals, oils and
lubricants. With its
head office in Valley
Forge, Pennsylvania, USA, Houghton
operates development 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 worldwide 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 system to make the rolling mill fit for producing such highgloss grades. Part of the equipment remains and will be
re-used. The most important equipment to be newly installed 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® filter 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 consumption and disposal.
CONVINCING SUPAFINE® FILTERS
Customers are impressed with the performance and efficiency 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 equipment and the rolling oil system within a very tight time
schedule to ensure Outokumpu Nirosta can start producing the desired material grades on this mill as early as
possible.
Example of a rolling oil facility
with SUPAFINE® filter system.
FLAt rolling Mills
CCM® - A SUCCESS STORY
FOR UP-AND-COMING
COUNTRIES
A new order from Vietnam and successful commissioning
in Bangladesh and Pakistan.
52
FLAt rolling Mills — cold rolling mills
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 industry. 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 conglomerate 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 facility 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 capability and capacity of the RCM and to
use the flexible extension concept offered 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 auxiliary 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 second mill stand could be installed with
low efforts. Only the exit side equipment 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 production capacity now is 170,000 tons.
Helmut Klatt, Project Manager Technology in the order handling and execution department of SMS group, says:
“beside CVC® plus, the CCM® is provided with highly dynamic control systems covering set-up approaches and
technological control loops. This ensures the economy of the production
process and high product reliability and
quality, and helps KYCR to strengthen
its own market position.”
Helmut Klatt
helmut.klatt@sms-group.com
KYCR’s new CCM®
prior to hot commissioning.
53
Flat Rolling Mills
Compact Cold Mill
at Abul Khair has started
operation
On 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 Processing Ltd. in Chittagong. On the CCM® the Bangladeshi
cold strip producer rolls strips with widths up to 1,250 millimeters 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 manufacturing. 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-controlled 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 gauges down to 0.4 millimeters with excellent flatness and surface results. The further progress of the commissioning
satisfied Abul Khair as well. With this new plant, the company definitely establishes a new standard for cold strip
quality on its local markets.“
Markus Gümpel
markus.guempel@sms-group.com
185,000
The first finished strip is being coiled on the tension reel.
54
The CCM® at Abul Khair has an annual
capacity of 185,000 tons. The mill specializes
in thin strip.
Entry section with pay-off and tension reel 1.
The recently commissioned RCM of Nam Kim Steel will soon be complemented by a twin-stand CCM®.
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®).
Nam Kim Steel Joint Stock Company
is a leading supplier of surface-coated
cold strip in Vietnam. Esmech Equipment 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 technology by SMS group to Nam Kim Steel,
which successfully started operation
in April 2015. The RCM in 6-high design with CVC® plus by SMS group
rolls strips with widths up to 1,250 millimeters 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 supplier of the mechanical equipment,
combined with rolling technology and
core equipment by SMS group Germany, 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
measuring and control system, a precise 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 productivity.
It is estimated that at the end of
2016, Nam Kim Steel will be able to
produce on the new CCM®.
Torsten Seeger
torsten.seeger@sms-group.com
Technical data
Commissioning
End 2016
Annual capacity
435,000 t
Strip width
650–1,250 mm
Strip thickness1.60–4.50 mm (entry)
0.20–2.00 mm (exit)
Material
Carbon steel
55
FLAt rolling Mills
ISL’s CCM®.
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 International Steels Limited (ISL) in Karachi, Pakistan, and issuing 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 designing the RCM, SMS has considered the opportunity for
later extension.
SUCCESS STORY
Only a few years after commissioning, the cold rolled products 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
56
to 450,000 tons. In addition to the existing mill stand, SMS group supplied
for the CCM® an identically constructed second 4-high mill stand with hydraulic gap control, CVC® plus and
work roll bending as well as X-Shape
flatness measuring and control system.
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.
Torsten Seeger
Technical data
Commissioning
July 26, 2015
Annual production 450,000 t
Strip widths
700–1,250 mm
Strip thickness1.6–1,250 mm (entry)
0.25–2.0 mm (exit)
MaterialCarbon steel, deep
drawing material
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.
GRP, located in Bekasi, West Java, was
founded in 2001 and belongs to Gunung 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 metallurgical plants. Currently, further orders 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 primarily applied in the construction industry 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 production 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
6-high stand of a similar RCM with CVC® plus.
Technical data
Material
Carbon steel
Strip width
600–1,270 mm
Strip thickness1.20–5.00 mm (entry)
0.15–2.50 mm (exit)
Coil weight
Max. 27 t
Rolling speed
1,200 m/min.
Rolling force
Max. 5 MN
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 modern actuators like hydraulic gap control, 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 sensor systems is the proven X-Shape
flatness measurement roll by SMS.
The X-Shape roll is going to be installed both on the entry and on the
exit side. In spring 2017, the combined
reversing and skin-pass mill will start
operation.
Torsten Seeger
Work roll diameter 300/350 mm
57
Flat rolling mills sms group newsletter 01 / 2016
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 control 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 completed at the beginning of 2016. The X-Shape flatness measuring 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.
Equipped with the X-Shape flatness measuring roll from SMS, Starcore’s RCM will be
capable of rolling even higher-quality cold
strip for Thailand in the future.
Detlef Böttner
detlef.boettner@sms-group.com
The highly precise and, at the
same time, robust X-Shape
flatness measuring roll can be
smoothly integrated in existing
cold rolling mills, too.
58
Flat rolling mills — Aluminum
Interview
50th Multi-Plate®
filter
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 depends 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.
A successful product developed by a whole team: Jan-Peer Remy,
second from left, and his colleagues in the Hilchenbach workshop.
The dispatch of the 50th Multi-Plate® filter caused the editorial 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 MultiPlate® filter being such a successful product?
The Multi-Plate® filter supplements our sophisticated aluminum cold rolling mills with a harmonized, in-house made
filter technology that supports efficient and environmentally 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 material ensures good tightness between the individual filter
chambers. After assembly, the filters are thoroughly
checked and tested to ensure smooth and rapid commissioning on the customer’s site.
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 volume 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 minute.
What further developments are planned for the system?
In the meantime, we have gained extensive practical experience in filter manufacture and operation. Based on numerous feedbacks we receive from starting-up or from the
workshop, the plate filter is consistently improved and advanced. 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-manufactured 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 individual cycle is run, tested, and optimized.
Tobias Hänel
tobias.haenel@sms-group.com
59
Flat rolling mills
Aluminum strip
for China
First production plant of the mega-complex at
Tianjin Zhongwang was put into operation.
60
Flat rolling mills — Aluminum
2.96
millimeters is the final gauge with a strip
width of 1,650 millimeters.
Left: The first strip is wound up precisely.
Bottom: SMS automation commissioning
team (SDT) and project team Tianjin Zhongwang (dressed in orange).
Rightly happy about the
first strip rolled are Gustav
Foditsch, supervisor electrical systems assembly (in
the foreground) and Klaus
Siegert, technical project
manager (in the background).
Both from SMS group GmbH.
On June 30, 2015 the first aluminum
coil was rolled successfully on the aluminum cold rolling mill (CRM3) at
Tianjin Zhongwang Aluminium Co. Ltd.
The first strip came with a 1,650-millimeter 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 production 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 tandem cold mills). SMS group also supplies a color coating line, two plate
stretchers, and four ingot scalpers
from one source. The 1+1+3 hot rolling
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 November 24, 2015.
Klaus Siegert
klaus.siegert@sms-group.com
61
Flat Rolling Mills
PRODUCTION OF HIGHQUALITY ALUMINUM PLATES
AND STRIPS
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.
November 21, 2014, and February 25,
2015, are important milestones in the
company history of the Chinese aluminum producer Guangxi Alnan Aluminium Fabrication Co. Ltd., since on these
two days the company assumed responsibility 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-
62
nese province of Guangxi. With the
new rolling mills, Guangxi Alnan produces a wide range of high-quality
aluminum plates and strips including
special aluminum alloys for the aircraft and transport industries.
HOT ROLLING MILL
The hot rolling mill is one of the most
efficient facilities worldwide to produce special rolled products of alu-
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
Flat Rolling Mills — AlumiNum
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 dividing 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 rolling extra-thick and -hard aluminum
grades. The material range includes
the 2xxx to 7xxx series with a maximum ongoing thickness of 10 millime-
ters and a final thickness of minimum
0.2 millimeters. Strip widths are between 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 intermediate 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-
cluding AluControl. Furthermore included 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.
Thomas Döring
thomas.doering@sms-group.com
Guido Fick
guido.fick@sms-group.com
The length of 400
meters is not the only
impressive feature of
Guangxi Alnan’s hot
rolling line.
63
Flat Rolling Mills
Mr. Chen, President of Shandong
Iron and Steel
(4th from left) and
Dieter Rosenthal,
member of the
Managing Board
of SMS group,
with the responsible Project
Managers from
both companies.
SMS group will supply
a complete flat steel
complex to Shandong
Iron and Steel Rizhao.
64
GREENFIELD PROJECT
FOR THE PRODUCTION OF
AUTOMOTIVE GRADES
SMS group to supply complete flat steel complex
including high-performance quality assurance system
and operation know-how to China.
Shandong Iron and Steel Rizhao, China, has contracted SMS group to supply a complete flat steel complex including a newly developed quality
assurance system and special operation know-how to Shandong province
on China’s east coast. A special feature of the project will be its crossprocess know-how covering simultaneous 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
plants worldwide. In addition to producing tube grades and cold strip for
the construction and household appliances industries, the focus will be on
sophisticated steel grades for the automotive 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 surfacefinished cold strip per year.
i
SMS Group
In the next issue
of our customer
magazine you will
learn more about
this major order.
Olaf Stalfort
olaf.stalfort@sms-group.com
65
From top to bottom:
The optimized turbulence pickling process
continues to be the
most efficient solution
for pickling steel strip.
Based on the experience gained in 55 new
plants and numerous
modernization projects, SMS group will
further develop the
turbulence process in
a continuous manner.
i
SMS group
The new developments have already
proven themselves in practical
operation and have
been successfully
implemented in several references after
being tailored to the
respective requirements.
66
Strip processing Lines/Furnace Technology
New developments for
efficient pickling
SMS group has extended its range of products for efficient pickling around the
proven turbulence pickling system with several innovations.
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. Especially the low maintenance and operating costs, the reduced consumption of
resources and the high pickling capacity speak for themselves. Based on the
experience gained from 55 successfully installed new plants and numerous modernization projects, SMS
group has further developed the already established turbulence pickling
process in a continuous manner, thus
providing the most efficient solution
for pickling steel strip. This particularly 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 requirements, so that a high-quality
pickling result can be achieved with
minimum resource consumption. Furthermore, the model optimizes the
55
successfully installed new plants and numerous revamps form the basis for the continuous further development of the already established turbulence-tank pickling system.
strip sequence and the transition process 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 surface. A patented immersion cover
seals the surface of the acid, thus
minimizing evaporation and the resulting energy losses.
The newly developed recuperator
tank arranged upstream of the first
pickling tank provides for a further increase in efficiency. Here, pickling acid
that has already been used in the process is applied to the incoming strip. In
doing so, loose scale particles are removed from the strip while the strip is
preheated at the same time. Furthermore, the surface is chemically activated and the downstream pickling
process therefore accelerated. In addition to the optimized pickling result and
the saving of thermal energy, also the
consumption of acid is reduced because 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 increased with only limited space available. Here, the acid is sprayed onto the
strip at high pressure, thus achieving a
high pickling capacity. The spray headers patented by SMS ensure a homogeneous distribution of the acid across
the entire strip width. Furthermore,
the desired pickling capacity can be
flexibly adapted here via the process
parameters.
strip.processing@sms-group.com
67
FLAHWALZWERKE
Flat
Rolling mills
The new pickling tank during a turbulence test with water. One of the pickling tanks was completely replaced within a short downtime period
last summer.
CONSISTENTLY IMPROVED
Further modernization of
Outokumpu’s stainless steel annealing and pickling line.
It is a particular connection that SMS group has with Line
76 of Outokumpu Stainless in Avesta, Sweden. The stainless 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 performance 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 modernizations were carried out within the two-week summer downtimes 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 additional pump increase the turbulence inside the tank and
68
hence also the pickling rate. The optimized tank design
permits easier automatic discharge of the sludge generated 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 polypropylene 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 optimized 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
nordine.beskri@sms-group.com
Strip processing lines / Furnace Technology
MMK ordered hot-dip
galvanizing line
Russian steelmaker will produce highquality steel plates for the construction
industry as of the beginning of 2017
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 Russia. 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
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 preheating zone, followed by a direct-fired zone and a radiant
tube zone. A gas cooling system will reduce the strip temperature for the galvanizing process. The eco-friendly furnace is equipped with several facilities to recover energy.
The preheating zone, among others, takes advantage of the
hot emissions from the burners. Furthermore, the combustion air is heated by energy from the exhaust air of the
burners and radiant tubes. The downstream air-knife system 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 posttreatment. Strip edge straightening and strip width adjustment 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 maintenance 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, furnace 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 operating 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 Magnitogorsk, 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 Reddel
reinhard.reddel@sms-group.com
The investment helps
MMK boost its production capacity of highquality, galvanized cold
strip for the construction industry.
69
FLAHWALZWERKE
The two continuous annealing lines are designed to produce more than 1.7 million tons of high-quality steel strip per year.
Annealed steel strip in Sichuan
Two continuous annealing
lines put on stream at Panzhihua.
The two annealing lines SMS supplied to Panzhihua Iron
and Steel Group have started operation. In July 2014 already, line No. 1 produced its first coil in the new plant in
the province of Sichuan in southwest China and, shortly after commissioning, achieved a monthly production of nearly 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-hardening 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 equipment and to manufacturing several special components,
the SMS group’s scope of supplies included the supervision
of erection and commissioning. For both lines, Drever In70
ternational supplied high-efficiency annealing furnaces
with integrated ultrafast cooling system to produce highstrength material grades. Another important process component 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.
strip.processing@sms-group.com
Technical data
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 gradesCQ, DQ, DDQ, SEDDQ, CQ-HSS, DQ-HSS,
DDQ-HSS, BH-HSS, DP, TRIP
Strip processing Lines / Furnace Technology
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 proportions. The blast furnace gas is preheated in a newly installed 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 provided 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 system 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 facilities as described above are permanently monitored by
the newly developed Prometheus system, to optimize the
combustion process. This system contributes to the target-
Furnace modernized by SMS.
ed improvement of the metallurgical properties through, for
example, advanced temperature homogeneity and the minimization of negative influences like decarburization or increased scale formation. In addition, Prometheus helps
save fuel by applying heating strategies, minimizing temperature set points and, at the same time, ensuring the
specified temperature values in the final stock.
Simone Zussino
simone.zussino@sms-group.com
71
Tube & Pipe plants
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 standards among existing comparable facilities.
Several months of close collaboration between TimkenSteel 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 austenitizing and tempering processes.
QUENCHING SHELL® WATER SPRAYER
Unique in this field, SMS’s deliverables under its contract
with TimkenSteel will include plant erection and commissioning. The line will be capable of processing up to 10 tons
per hour of tubes and bars, ranging from 4'' to 13'' in diameter, made up of a variety of different steel grades that
characterizes TimkenSteel’s portfolio. The cornerstone of
i
TimkenSteel
Corporation
TimkenSteel creates
Tubes and bars are heated up and soaked
with a combination of induction and combustion furnaces.
ucts and services
for demanding applications, helping
the AQTF line will be the brand new
Quenching Shell®, an advanced OD/ID
water sprayer, characterized by highquench severity and, at the same time,
great flexibility to adapt to changing
process conditions.
The Quenching Shell®, although a
concept created to fulfill the requirements of this specific project, prom
ises to become the standard for similar 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 commercial operation.
Pietro Della Putta
pitro.dellaputta@sms-group.com
72
tailored steel prod-
customers push the
boundaries of what’s
possible within their
industries.
Rohranlagen
The commissioning team.
Corinth has commenced production at its large-diameter pipe mill in Thisvi.
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 commissioned 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
to customers from the oil and gas industry 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.“
i
SMS group
The CPW largediameter pipeline
LSAW@sms-group.com
offers a size range
that has been extended considerably.
Pipe sizes with high
wall thicknesses and
small pipe diameters
can also be produced in cost-effective
quantities.
73
TUbe & Pipe Plants
NWZ orders three
cold pilger mills
High cost-efficiency and precision for tubes of special materials.
NWZ has specialized in high-quality
products for the power generation industry, including in particular tubes of
zirconium alloys. With the new machines from SMS group, the company
will be able to expand its tube production.
i
SMS group
During the cold
pilgering process,
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. Commissioning 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 optimizations 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 control that permits stepless setting of feed rate and turn angle
of the shells during continuous rolling, two aspects of crucial importance for the tube quality.
74
high-quality seamless tubes
a large number
The cold pilgering process is particularly suitable for high-precision reduction of tubes made from materials
that are difficult to form. The distinctiveness 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 necessary far less often than with other processes, such as drawing. Furthermore, cold pilgering allows selective
positive influencing of the microstructure of the rolled product due to the
three-axis compressive stresses applied to the material.
These three new machines represent a continuation of the successful
partnership between NWZ and SMS
group. SMS group had already delivered new machines to NWZ in previous years.
of forming steps
seamlesstubeplants@sms-group.com
improves roundness,
stresses homogeneity 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.
From left to right: Pinaki Chakraborty, Amit
PROFILWALZWERKE
—Shah
HÜTTENTECHNIK
Swarnkar, Derek Michael
(all Larsen &
Toubro Limited), Tadayuki Baba (MarubeniItochu Steel), Tariq Al Wahedi, Jamal Salem
Al Dhaheri (both Senaat), Marcel Fasswald,
Frank Lüth (both SMS group).
SMS group to supply turnkey production facility for large-diameter pipes to Al Gharbia
Greenfield project in Abu Dhabi for the production of high-grade
large-diameter longitudinal welded steel pipes.
Al Gharbia Pipe Company has awarded
the consortium of Larsen & Toubro
Limited and SMS group as the EPC
(Engineering, Procurement, Construction) contractor with the supply of a
turnkey LSAW (Longitudinal Submerged Arc Welded) pipe production
facility. SMS group will be responsible
for the engineering and supply of process 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 production 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 processed 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 diameter ranging from 18 to 56 inches. The
maximum wall thickness will be 44.5
millimeters.
Besides the engineering and project
planning, scheduling, and coordination, SMS group will supply all key machinery as well as the process equipment. 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 developed 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 hydraulic system with pressures up to 450
bar, which reduces energy consumption by 30 percent compared with conventional hydraulic systems. The shape
automation system developed by SMS
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 consistently high pipe quality can be guaranteed.
Al Gharbia Pipe Company will manufacture 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 (United Arab Emirates). With the development and production of oil and gas
forecast to be robust in these countries, the demand for high-quality steel
pipelines to transport these resources
is expected to grow. Al Gharbia Pipe
Company is a joint venture of investment company Senaat, JFE Steel, and
Marubeni-Itochu Steel (MISI). The new
company is leveraging JFE Steel’s
technology for high-quality large-diameter longitudinal welded steel pipes,
MISI’s sales capabilities, and Senaat’s
industrial footprint in Abu Dhabi.
LSAW@sms-group.com
75
Long product Plants
2015 Energy Achievement
Award
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.
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 energy-related productivity through the application of new technology, practices, and/or engineered methods in the iron
and steel producing sector.
REDUCED ENERGY CONSUMPTION
Fully engineered, manufactured, and erected in Smedjebacken 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 environmental 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 before 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.
Marco Peter Cudicio
marco.cudicio@sms-group.com
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).
76
Long product Plants — Metallurgical Technology
Optimum monitoring
Ferriere Nord has placed an order
with SMS group for Level 2 automation to be installed in their scrap
yard facility in Osoppo (Udine), Italy.
Using a series of innovative solutions, the new system will track and
Scrap bucket charging at Ferriere Nord.
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 evaluate the compliance of the incoming
scrap loads and produce evidence to
support claims against suppliers
when necessary. Following the success of the EAF-LF-CCM Level 2
system already deployed, SMS group
looks forward to continuing the
technological partnership with Ferriere Nord for this challenging new
project.
Francesco Fabris
francesco.fabris@sms-group.com
High-speed commissioning
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 highspeed 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 manufactured 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 produce 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 CONVEX® technology, JSPL will benefit from lower operation costs.
www. sms-concast.com
High-speed eight strand billet caster at JSPL Plant in Angul, Odisha.
77
Long products plants
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.
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 extrusion 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 Aided Direct Extrusion) software calculates the optimum extrusion speed
curve and the minimum billet temperatures required on the basis of the
current process parameters and controls the billet heater according to the
results. CADEX boosts productivity by
up to ten percent compared with extrusion without feedback. The extrusion 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 extrusion parameters in order to increase 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
78
energy as it uses the hydraulics only
for extrusion. The ancillary movements of the extrusion press are performed by dynamic, electric servo
drives. Compared with those in conventional 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 translates 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 additional measures.
“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 compared with other processes was an important argument here.”
The HybrEx extrusion press is
equipped with internal gear pumps,
which operate efficiently over the
whole speed range. Thanks to its special 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 Bauer
axel.bauer@sms-group.com
Long product plants — Heat Treatment technology
EloFresh: Innovative Media
Analysis Solution
SMS Elotherm has successfully commissioned the
first EloFresh Monitoring and Control system for cooling and
quenching of hardening machines.
tion as well as a display of pH- and
conductance value of the system’s
cooling water.
Apart from this base module, customers also benefit from three optional 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
Elotherm EloFresh operator interface on a modern Elotherm hardening machine.
EloFresh ensures high process reliability for the hardening
process itself, and consequently for the induction tooling.
The induction tool life depends significantly on the mechanical wear and the electrical stresses, but also on the
optimal cooling of the induction coil, which in turn is influenced 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 corrosion. The standard system “ELK Modul 1” provides monitoring of the water quality by a corrosion-measuring sec-
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 measurements 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 reliability of hardening processes compared to today.
Loïc de Vathaire
l.vathaire@sms-elotherm.com
www.sms-elotherm.com
79
Long products plants
The Sutton MK-V 27. SMS presented
the latest generation of press at a
ceremony to celebrate the 100th anniversary of the Sutton brand.
SMS group builds new
generation of Sutton
extrusion press
Manufactured in the U.S.A. for the American market,
with SMS group know-how.
SMS group is building a new generation of the Sutton extrusion 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 region (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,”
80
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 construction of the press significantly more rigid and more resistant.
The linear guides for the container holders and moving
crosshead operate precisely and are practically maintenance-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
Long products Plants — Forging Plants
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 percent of the energy used compared to presses with conventional 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. Robert Saroli signed the contract for this press right at the site
in Cranberry Township. “I am very impressed by the workmanship of the press,” said the owner of the Canadian aluminum 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 import 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 service 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 Eumuco. Up until 2001, extrusion presses were manufactured
in Bellefonte under the name SMS Sutton.
Axel Bauer
axel.bauer@sms-group.com
Induction furnace system for Brazeway
Brazeway Inc. has ordered a
TEM-PRO® induction furnace system
from IAS for its plant in Shelbyville, Indiana, 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 handling 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 narrow aluminum tubes are produced for
HVAC applications, such as for heat
exchangers. Compared to other systems, the wastage produced by the
TEM-PRO® is up to 20 percent lower
thanks to continuous power control
and more even heating of the material. 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 operation in Kentucky.
Induction furnace with loading unit.
81
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.”
82
Long Products Plants — Forging Plants
Our modern lifestyle is unimaginable
without copper and copper alloys.
And this doesn’t only apply to electrical engineering. The hygienic properties of the metal are ideal for water
pipes and the thermal conductivity of
copper tubes is used for air-conditioners.
It can easily be defined which properties 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 efficient to reach my goals?
WHICH PRODUCTION VOLUME?
SMS group therefore offers a neutral
process-independent
consultation.
Since SMS, as worldwide leading manufacturer, is able to produce almost all
variations of copper lines with more
than 50 years of experience in this sector, nearly all configurations can be
realized for the customers. End product and production volume are the criteria for selecting the process route.
An illustrative example for copper
tubes: when a customer plans its copper tube production with high annual
output the process line, including vertical continuous caster, hot forming
with extrusion, and subsequent drawing is the most economically efficient
solution. For smaller production volumes 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 rolling mill and then formed to its final
tube geometry by drawing. This process 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, annealing facilities are used. Even special requirements such as for air-conditioning pipes can be fulfilled. On
inner grooving lines the copper tubes
are provided with a larger surface improving heat exchange.
i
Service
Copper – scope of supply of
SMS group
Electric arc slag refining furnaces
Anode casting wheels
Melting furnaces
orizontal and vertical continuous
H
casters
Stationary sawing lines
Cold rolling mills
Hot rolling mills
Billet heating
Extrusion presses
DECISION-MAKING BASIS
CONTIROD® plants
Conclusion: SMS not only offers complete plants from a single source but
also provides support for the analysis
of future profitability, thereby establishing a well-founded decision-making 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 rewarded by the customers. Moreover, we
need not fear competition. Our machines are excellent, we offer patented
technology in part, all at a fair price/
performance ratio. Our process-neutral advice pays off – for us and for
customer satisfaction.“
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
Patrick Schneider
patrick.schneider@sms-group.com
83
Long Products plants
Interview
The customer benefits
twice from us
Mr. Schneider, you supply plants or processes completely
from a single source. For whom would this offer be beneficial?
There are basically two customer groups: newcomers and
customers with metallurgical knowledge who already operate plants. Our offer is of interest to both of them. The newcomers are often companies with the intention to strengthen their value-added chain, for example a manufacturer of
air-conditioning units who wants to manufacture air conditioner pipes in-house.
Within the scope of a greenfield project, these companies 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 already 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 processes. 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 possibilities in structural design. In many cases, we also provide
84
support in determining the conversion
costs and compare the individual processes in terms of energy and media
consumption and personnel expenses.
On this basis, we are able to provide a
clear and well-founded decision-making tool for the customer.
One contact person for customers –
Patrick Schneider
what does that look like in practice?
The interaction of the plant manufac- Head of Sales
turer’s individual departments must Copper SMS group.
be arranged in-house. We have created an organizational structure that will
make this possible, enabling us to assent internally, making use of short
communication channels. The customer benefits twice: on the one hand,
the way of the customer into our company organization is easy, and on the
other hand, advisory services are improved and sped up in the project planning phase as well as within processing in the event of order.
Patrick Schneider
patrick.schneider@sms-group.com
Long product plants — Forging plants
TR-device as of now
available in the product
portfolio of SMS group
Insertion tool for long crankshafts in
hydraulic processes.
With a TR-device large crankshafts are produced. The device realizes forming required for large multiple-cranked
shafts with cranks offset against each other. While avoiding
an interrupted fibrous structure to the greatest possible extent, 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 portfolio either as retrofitting for an existing installation or directly in combination with a hydraulic forging press. The
TR-device can be easily integrated into a forging press, offering strategic advantages to the plant operator as a useful extension of his product range.
i
FACTS AND FIGURES
Technical 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 mm
Installation width 2,896 mm
Product range
Max. envelope circle diameter (blank) 1,000 mm
Crank length
250–650 mm
Max. crank radius (1/2 Hub) 350 mm
Weights and dimensions
forgingplants@sms-group.com
Total delivery weight Length (of supporting beam) Width Height (closed state, without ribs) 105,000 kg
5,160 mm
2,800 mm
2,550 mm
TR-device for
producing large
crankshafts.
85
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.
86
Long Products Plants — Forging plants
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
610
millimeters is the maximum processing
diameter during peeling, depending on
the process and product.
year, the mechanical engineering division of the traditional brand from
Aachen – including the product program KIESERLING – have been operating under the umbrella of SMS group at
the Mönchengladbach location.
The move into the new office buildings
and the integration into the Long Products 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 offering all the processes regarding
drawing, peeling, straightening, grinding, 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 structure 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 equipment manufacturer) knowledge ensures high availability for the entire life
cycle of the machines.
Top: Bright steel; Bottom: Bright steel center.
Sebastian Schulz
sebastian.schulz@sms-group.com
Vertrieb
brightsteelplants@sms-group.com
87
Electrical and Automation Systems
1.55
million tons of steel will be the plant’s total
capacity once the final construction stage
has been completed.
Above: The customer’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.
88
ElectricAL and Automation Systems
Plug & Work
also possible
in 3D
SMS group trains a customer’s operating personnel before the actual commissioning on-site.
SMS group has been commissioned by the Brazilian construction company Construtora Andrade Gutierrez S.A. to
build an integrated steel plant for the state-owned Venezuelan steel company Siderúrgica Nacional (SN). The complex 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 future operators to be familiar with the supplied equipment
and the associated operating elements before the commissioning of the plant, a great number of Siderúrgica Nacional 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.
Interview
Mr. Ortiz, how would you rate our test
fields?
To say it in one word: excellent. The atmosphere was highly professional. The
SMS group experts were always available and ready to answer our staff’s
questions and explain how solutions
Manuel Ortiz
can be found. In other words, the colProject Manager at
laboration was very good.
Siderúrgica Nacional
Had you heard of our Plug & Work (SN).
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 customer’s site had been an entirely new experience 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 extraordinary service.
Plug & Work tests in 3D
The Plug & Work tests for the electric steelworks, the continuous 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 effect of the Plug & Work tests.
Peter Waldhoff
peter.waldhoff@sms-group.com
Has it been helpful for your employees
to see the processes visualized in 3D
during the integration test?
Visualization in 3D helps us to understand the mechanical components of
the plants and the way they operate
even better. This is particularly beneficial 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 visualization.
89
EZDK, Egypt: Revamping
order for CSP® plant
The planned revamp will focus on upgrading the electrical
and automation systems.
Al EZZ Dekheila Steel Company (EZDK)
has contracted SMS group for a comprehensive 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 replacing obsolete automation and drive
systems. A second target is to expand
the product range in terms of steel
grades and product formats, while improving the product quality.
SMS group is to supply complete
modernization package and SMS group
will renew the complete automation
equipment, namely Level 1 (basic automation) and Level 2 (process automation), of the CSP® plant. Throughout the
plant, innovative X-Pact® solutions will
be used, implementing the technological know-how via extremely highly performing hardware systems. EZDK will
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 optimizes the cooling strategies throughout
the casting process. MMSplus will pro-
The modernized CSP® plant of EZDK
Upgrade of Liquid
Core Reduction
(LCR)
New mill main drive
converters
Super reinforced laminar
cooling
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 automation systems Level 1 and
Level 2 incl. PSC, PCFC, CSC
and MPM (Material Property
Model)
New static VAR
compensation (SVC)
90
New mill and coiler
auxiliary drive systems
Upgrade of thickness
profile gauge
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.
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 automation equipment, SMS group will also
equip the containment zone of the
CSP® caster with Liquid Core Reduction (LCR). This will allow EZDK to flexibly 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 technological controls will allow the industrial production of strips down to
“New generation edge masking”
for all cooling groups
New surface
inspection system
1.0 mm thickness. Additionally, the
MPM Material Property Model, a model developed by SMS group for microstructural 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 existing steel grades. Being a one-stop
shopping supplier, SMS group will also 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 higherstrength steel grades while leaving the
chemical composition unchanged. The
newly developed asymmetrical edge
masking system improves strip flatness, especially in the strip edge area.
SMS group’s scope of supply also includes a surface inspection system
featuring the latest optical techniques
to assess and document the surface
quality directly after rolling.
New operating elements
Within the framework of this modernization project at EZDK, also the systems 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 ergonomic findings, providing for intuitive operation 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 procedure. Prior to the installation at the
customer’s site, the automation system will be tested and optimized in the
test field in Hilchenbach in a near-reality simulation, mapping the entire
mechanical equipment, the drive systems, and the processes. Pre-commissioning and optimizing the automation 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 modernization concept most favorably, minimizing 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.
Georg Padberg
georg.padberg@sms-group.com
91
Production
Components for
wedge press: Time saved
with SMS manufacture
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.
Pitman of wedge press
1.5 m wide x 4.9 m long
and 2.8 m high, weight
33 tons.
92
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.
1,800
machining hours at least were used up in
three-shift operation in two months.
The components for a wedge press
and a trimming press can be considered 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 machining hours were used up in a threeshift operation. The result is a reduction of the throughput time by 1.5
months. With the wedge press of SMS
group forgings in a longitudinal direction can be manufactured.
Interim assembly work
could be performed
directly on the metal-
cutting machine. No
additional workpiece
transport was required.
Ram of trimming
press
Weight: 28 tons.
Manufacturing
procedure: pre-machining on boring
machine – inserting
the bushes during
assembly – finishmachining 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.
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
transporting of the
workpiece was
necessary. The
quality check was
carried out directly
on the metal-cutting
machine.
93
Service
8,000
employees 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 station (position was
maintained).
Precise robot grip on
billet after measurement for exact insertion into the press.
i
Services
SMS Technical
Service develops individual solutions in
cooperation with the
customer. A robot is
being used for the
first time for loading
an extrusion press.
94
Service
Extrusion press equipped
with loading robot for
the first time
Upgrade of extrusion press at ST Extruded Products Group.
SMS group has successfully modernized 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 addition to that, SMS group was responsible for supervision of the erection and
commissioning.
AN INDIVIDUAL SOLUTION
The Bitterfeld plant of STEP/G formerly belonged to the Aluminum Extrusion
Division of Aleris. With the sale of the
Division at the beginning of April 2015,
the Japanese company Sankyo Tateyama 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 production of forging stock and aluminum
profiles. Special feature: due to a restricted space situation within the
plant conventional loading facilities for
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 robot 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 including the periphery, achieving excellent results in practical use. The seven-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 programming of the robot it can be quickly readjusted to new process sequences or
modified billet geometries.
Apart from the use of the robot, other 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
than before. The conversion to frontloading technology and the increasing
of the extrusion force was realized by
using new hydraulic and cylinder components in combination with adaptations and overhauling the existing machinery parts.
After exact positioning by the robot,
the billet is first clamped against the
die by means of the extrusion ram. After the container has crossed the billet, concentric billet upsetting takes
place from the center and then the recipient is vented. The reamer is loaded
into the press from behind between
the container and ram. Filling and extrusion 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
ben.zander@sms-group.com
95
Service
Precision –
the driving force
at STP
Successful for decades through the use of
SMS plants and thanks to expert services of
SMS group.
Whether long highway journeys, stopand-go traffic in major cities, or dynamic 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, minimizing CO2 emissions. This can only
be achieved with quality parts made
of high-strength materials maintaining precision even when subject
to extreme stress. Schmiedetechnik
Plettenberg (STP), Germany, is a re-
Dismantling and cleaning of MP 1000 in the
workshop of SMS group.
96
nowned and experienced manufacturer of precision components for the
automobile industry.
With about 400 employees, the owner-run company mainly produces highly 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 requirements 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 forging machines and inductive heating
systems of SMS group. Business relations 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 preforming presses, a screw press, two
reducer rolling mills, two ring rolling
machines, several forge hammers,
and induction lines from SMS.
Successful expansion
The ring rolling machines are typical
examples of the cooperative partnership 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 increased so that SMS group received another 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-
Technischer Service
20
million 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.
Dismantling
and cleaning of
MP 1000 in the
workshop of
SMS group.
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 billets to forging temperature. Via a
transport device they reach the transfer position where the billets are inserted 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 unloaded 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 capacity of the plant but it also has a redundancy in the production process.
This is an important requirement of
the automotive industry from its longterm 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 overhaul.
Zijia Guo, Project Manager from
SMS group: “The customer has commissioned us to carry out a general
overhaul of the Maxi press to perma-
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 recommissioning.“
Within the scope of a general overhaul 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 overhauled. In addition, the press was
provided with a new lubrication system. The result: the 26-year-old press
not only looks like new but also
achieves highly precise products in
continuous operation.
service@sms-group.com
97
To have the required spares at its site as fast as possible, the SMS experts establish the warehouse close to the customer’s plant.
WAREHOUSING
AT CLOSE QUARTERS TO
THE CUSTOMER
SMS group undertaking the complete logistics process.
98
Service
SMS group offers to undertake all its
customers’ activities involved in the
stock-keeping of spares and wear
parts. Under the heading of “Warehousing” 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 comprises complete logistics from the receipt of goods to packaging and further to subsequent goods issue. This
full support of an entire logistics process 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 system involved always aiming to ensure
high plant availability or even increase
it. For such individual warehousing the
customer will have to pay a predetermined 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 optimization. One of the services provided by
the experts is machine-specific equipment checks. Regular inspections and
maintenance measures help ensure
plant efficiency and detect potential
weak points at an early stage. A combination of both concepts reduces the
amount of tied-up capital.
Warehousing by SMS group makes
sure all required spare parts are permanently available. If so requested,
the SMS group’s experts will run the
warehouses 24 hours per day and seven 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 reliably. SMS will take care of the inventory and only supply new components
in compliance with the current state of
the art.
i
Services
SMS group
Individual warehousing concepts
24/7 availability of spares
ull range of services for the
F
logistics process
Selected references
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.
In operation since 900 m2
2010
Arcelor Mittal Ruhrort in Duisburg, Germany
Surface area approx.
610 m2
SULB Company B.S.C. in Hidd, Bahrain
Surface area approx. 560 m2
99
Drawing carriage after repair – well-proven technique in
modern design.
Chamfered bright steel processing lines of high quality – straightness and precision for finishing processes thanks to upgraded equipment.
Modernization of
drawing lines
Higher availability and maximized output.
SMS group revamps drawing lines and
brings machines up to date – mechanically, electrically, and electronically.
This also applies to SCHUMAG equipment: SMS group has taken over the
Mechanical Engineering Division of
the traditional brand offering all components and services in OEM (Original
Equipment Manufacturer) quality. Existing machinery and equipment are
upgraded to increase productivity and
product quality.
The requirements for drawing
speed, drawing force, and material dimensions are becoming constantly
more demanding. Nevertheless, plant
operators are still producing competitively even years after commissioning
of their drawing line, tapping into new
markets with improved products – because SMS group offers a number of
modernization measures that can specifically enhance individual characteristic values and plant parameters. The
pre-straightener of a drawing line, for
100
example, may be retrofitted to a sturdier model. In addition, we upgrade the
drawing unit by replacing the assemblies or converting the drawing jaw
control. For the straightener, SMS Service experts are able to provide professional advice with regard to questions
on suitable rolling corrections and reduce setup times through automation
of the straightening roll adjustment.
Moreover, various modernizations can
be performed in the finishing processes. In this way, for example, individual
storage concepts or optimizations of
the sawing and chamfering units may
be carried out subsequently and individual assemblies may be replaced or
re-engineered.
Well serviced
The product portfolio of SMS group
Services covers the complete production process: it ranges from handling
of the feedstock in the form of bars or
coils up to the testing and bundling
devices for drawn and straightened
bar material. The drawing lines ensure highly accurate dimensions and
a flawless surface quality. The dimensions range from two to 60 millimeters. With drawing forces up to 450 kN
and drawing speeds up to 250 meters
per minute, the machines set standards – SMS group Service experts
make sure that this remains over the
entire lifetime of the machine.
Sebastian Schulz
sebastian.schulz@sms-group.com
i
SERVICES
Reduced downtimes
Improved process reliability
easonably priced and available
R
spare parts
Service
Straightener of type Sutton KTC.
Mold plate with the new “bionic-textured mold” surface.
Conversion
in a fortnight
SMS molds
last longer
Straightener back in
reliable operation.
The new surface texture, known as “bionic-textured
mold,” lengthens the service lives of copper plates.
In only two weeks SMS group converted a Sutton 2 KTC Straightener for the
straightening of tubes and long product components for the leading steel
producer in Ohio this June. The reconstruction work was performed around
the clock including weekends. SMS
sub-supervised the subsequent new
start-up at the plant. It was the second 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 straighteners 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 automotive, industrial, and building industry equipment.
For its customers, SMS group has developed a new idea as to how the
molds necessary for continuous casting achieve a longer service life: the
specially designed texture “bionictextured 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 copper 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 crucial 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 accumulates in the cavities and is evenly distributed between mold and strand
shell – i.e., less powder is needed. Also 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 eliminated thanks to the innovatory rough surface, 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 network with specially trained expert
staff offers coating, servicing, and refurbishing of mold plates.
Oliver Wiens
oliver.wiens@sms-group.com
101
Service
Innovative coatings
for copper molds
For exacting process requirements – SMS offers its customers
the UniGuard® mold coating.
In order to achieve a trouble-free process flow in continuous casting and a
cast strand of prime quality, it is necessary to make sure that the mold
plates are in an optimal condition, particularly 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
strong strand shell. Defects on the
strand surface, such as longitudinal
cracks, are a major quality impairment and may even result in a failure
of the caster. The solidification processes taking place in the continuous
casting mold are highly complex and
dynamic, as a varying number of solidification phases take place depending on the steel grade. The difference
between ingot casting and continuous
Wasserkasten
mit UniGuard®Beschichtung.
102
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-
Water jacket
with UniGuard®
coating.
Service
pact, plant operators have been using electroplated or metal-ceramic coated mold plates. Especially the metal-ceramic coating has been proved to provide a significant
improvement in the service life and quality of the equipment. For most exacting process requirements, SMS group
offers the UniGuard® coating. UniGuard® is a tungsten carbide 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 aircooled combustion chamber. The combustion chamber is
mainly charged with spray materials in powder form. By
means of the carrier gas, the coating particles are accelerated to supersonic velocity resulting in dense spray coatings with excellent adhesion characteristics.
broad faces. Without sufficient wear
protection, the hard material would
grind down the profile of the plates.
This in turn would reduce the dimensional stability of the strand shell during the primary solidification. The result would be intensifying and
excessive movements and permanent
stresses in the microstructure within
the thin and sensitive strand shell.
Therefore, the SMS group service experts recommend operators of slab
casters that process a mix of critically
solidifying hard steel grades to make
use of the metal-ceramic UniGuard®
coating.
METAL-CERAMIC MATERIAL - TUNGSTEN CARBIDE
Tungsten carbide was originally developed for use in cutting 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 cermet (metal-ceramic) material in combination with cobalt.
The resulting coating excellently withstands the compressive 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 longitudinal 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 Wiens
oliver.wiens@sms-group.com
UniGuard® coating
applied by means
of the HVOF (High
Velocity Oxygen Fuel)
method.
103
Service
i
Services
DUMA-BANDZINK offers
comprehensive services to
their customers:
Spare parts
Technical support
Inspections and maintenance
Repairs and coatings
From top to bottom:
Dr. Guido Kleinschmidt,
member of the Managing Board SMS group
GmbH, in his opening
address in Mönchen
gladbach.
Prof. Pino Tesè, Executive Vice President, SMS
Technical Service, (third
from left) in front of the
novel HVOF (HighVelocity Oxygen Fuel)
coating line.
104
Service
NEW WORKSHOP,
NEW MACHINERY –
NEW SERVICE BUSINESS
DUMA-BANDZINK opened new workshop in
SMS Business Park, Mönchengladbach, Germany.
DUMA-BANDZINK, which has successfully positioned itself on the market with its galvanizing plants, oiling
machines, and modernization concepts for strip processing lines, has
already been part of SMS group since
2008 and has now massively invested
in the expansion of the service business. At the beginning of 2015, it combined 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 audience at the opening of the new workshop facility.
In their opening addresses, Dr. Guido Kleinschmidt, member of the Managing Board SMS group GmbH, and
Prof. Pino Tesè, Executive Vice President, SMS Technical Service, emphasized the great importance of the service business. In his address, Dr.
Holger Behrens, Executive Vice President, Strip Processing Lines and Furnace Technology of SMS group, presented current trends in the field of
strip processing technology to a great
number of German and international
customers. The Mayor of the City of
Mönchengladbach, Hans Wilhelm
Reiners, was visibly impressed by the
new machinery and equipment, which
were shown to an international audience in a live demonstration, and emphasized how much he appreciated
the strengthening of Mönchengladbach as a business location. Investments were made in mechanical processing 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 Fuel) coating line could be presented.
Consequently, a Japanese delegation
of the longtime technology partner
and licensor, Tocalo, was also among
the guests.
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 process rollers from strip processing
lines, the new investments at the
Mönchengladbach location play an
important complementary role in the
services offered to the European market.
www.duma-bandzink.com
1,600
mm is the maximum diameter for machining
rolls on the new machining centers.
On a Growth path
“SMS group likes to invest in promising 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 exter105
Events sms group newsletter 01 / 2016
The brochure “X-Pro®
Laser Welder”
published on the
occasion of the event
is available from the
ordering service.
A large number of details were discussed during the inspection of the
machine in the SMS workshop in Hilchenbach.
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.
106
Events
Enthusiastic about
laser welding – Using
co2 and fiber lasers
Laser Strip Welding Symposium at SMS group in Hilchenbach.
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 result 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, because each time the first try shows a brilliant weld,” said
Nisula after further successful welds. “We, too, are enthusiastic 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 designed for.”
i
Fiber laser
ADVANTAGES OF THE LASER WELDER
PG Laser, Germany,
The major advantages of the machine
are its patented inductive pre-treatment 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 impressive feature of the machine is its cycle
time of less than 60 seconds.
The event began with an introduction by Michael Cottin, Executive Vice
President, Strip Processing Lines and
Furnace Technology at SMS group.
This was followed by information on
made a welding
source available
for the successfully
conducted fiber laser
tests. The exchangeability of the welding
sources, allowing a
rapid response to
new developments,
guarantees the
secure future of the
X-Pro® laser welder.
107
Events Michael Cottin
Executive Vice
President, Strip
Processing Lines and
Furnace Technology
at SMS group.
»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 referred 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 subject of welding metal strips. Dr. Dirk
Petring, Head of Macro-Joining and
Cutting at the Fraunhofer Institute for
Laser Technology ILT, explained general trends towards the use of laser technology in strip processing lines.
Markus Jaenecke
markus.jaenecke@sms-group.com
108
The X-Pro® laser
welder in action.
The participants
convinced themselves 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 suggestions from
the discussions.
Publications
New releases: Publications and
films from SMS group
Brochures and various film formats provide a detailed
insight into the range of products.
Imprint
SMS group newsletter
Issue 01 /2016
Publisher
SMS group Corporate
Communications, Eduard-
Schloemann-Straße 4
40237 Düsseldorf, Germany
Responsible under Press
Law: Thomas Isajiw
Phone +49-211-8810
E-mail: communications@
sms-group.com
www.sms-group.com
Printing and prepress
processes
Druckhaus Kay GmbH
Hagener Straße 121
57223 Kreuztal,
Germany
The SMS group product range is growing continuously. New technologies
and machines are being developed.
Orders are being completed successfully. To provide our customers with
more detailed information on our innovations, we publish all essential news
in our brochures, magazines, and videos. In the following, please find a selection 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 deliver efficient plants for the manufacturing of high-quality products all from
one source. Our portfolio includes mechanical equipment, process engineering, heat treatment, electrical and
automation systems, and the required
production know-how. The new brochure “Strip Processing Lines – Product 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 production of stainless steel slabs at their location in Zhangzhou in the Chinese
Fujian Province. It is the first stainless
steel plant in the world to utilize the
STRIP PROCESSING LINES
EFFICIENT VACUUM CONVERTER
FOR INDIVIDUAL NEEDS
Product Portfolio, Technology & References
Refined steels and ferroalloys
SMS group
METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY
Strip Processing Lines
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 developed by SMS.
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 characteristics of the products concerned. 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 intended to have, and will not
have, legal effect. An obligation to deliver products
having particular characteristics shall only exist if expressly agreed in the terms
of the contract.
Learn more about
upcoming events at:
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 interesting insights into the modernization process.
www.sms-group.
com/en/press/
trade-showsconferences.html
communications@sms-group.com
109
WE TRANSFORM ...
THE WORLD OF TUBE AND WIRE.
SAVE THE DATE
APRIL 4 – 8, 2016
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 efficient 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 7a
Booth B15/16
Düsseldorf, Germany
SMS group
Ohlerkirchweg 66
41069 Mönchengladbach, Germany
Phone: +49 2161 350-0
Fax:
+49 2161 350-1667
tw2016@sms-group.com
www.sms-group.com
SMS group | Elotherm | PWS | SMS Concast

- SMS group

Transcription

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