OVERVIEW DUFERCO SA

Duferco was established in 1979 with founder Bruno Bolfo seeing an opportunity in emerging markets steel production for a reliable and informed steel trading company to play a role in the growth of exports to previously unexplored markets. In 26 subsequent years Duferco has grown into a multinational steel and steel-related products

trading company with over 8 million tons of steel products and in excess of 7 million tons of raw materials being shipped world wide. In addition, steel production now exceeds 6 million tons per annum with production facilities in the USA, Western and Eastern Europe as well as Africa. Duferco has it’s headquarters office in Lugano Switzerland from where the group’s focus remains firmly

on the key segments of the steel business chain.

They are:

• Raw materials • Shipping

• Logistics

• Production

• Transformation • Trading

• Distribution

DUFERCO STEEL PROCESSING, SOUTH AFRICA Duferco established Duferco Steel Processing (DSP) as a joint venture between Duferco SA of Switzerland and the Industrial Development Corporation of South Africa Limited – the primary objective being to export their production.

Alpine the Austrian industrial group. DSP was proud to see the first shipment of its manufactured products sail from Saldanha Bay in August 1999 destined for the UK closely followed by a shipment to the USA and since then has built a solid reputation as a reliable and high quality manufacturer with an The unique location, 130 km from established client base and a high Cape Town on the West Coast, percentage of repeat customers. is 5 km from Saldanha harbour, which is the deepest natural port At DSP our mission statement in South Africa. is simple “Prime, on time, every The erection of the DSP time”, our drive for continuous production facility, which started improvement has led to a successful commissioning at the end of 1988, certification for ISO 9001:2000, was a turnkey project by Voest a testament to the work ethic of

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all our employees and their focus to ensure customer satisfaction is paramount.

DSP produces a range of steel products consisting of hot rolled pickled and oiled, galvanised and cold rolled products, in excess of 600 000 tons per annum. All equipment is the latest stateof-the-art technology and DSP is confident that their products will meet and surpass the requirements of their clientele.

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Pickle line LINE PARAMETERS Material

Hot rolled strip

Strip Data

Strip Thickness

1.2 mm min 3 mm max

Strip Width

775 mm min 1560 mm max

Coil Weight

28 ton max 5 ton min

Coil OD

1960 mm entry max 1880 mm exit max

Coil Bore

760 mm (-20+30 mm) entry 508/610 mm exit

Coil Data

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Pickle line: OPERATION AND PROCESS DESCRIPTION LINE DESCRIPTION:

pickling system consists of a full

The strip dryer removes any

pickle material in four pickling

is supported in a catenary and

impact blowing. A steering unit

Hydrochloric acid is used to baths of which the free acid and

dissolved iron are controlled to ensure a clean surface.

The entry section of the Pickle

turbulence system where the strip does not drag along the bottom

of the tank.

The acid recirculation system is

using a counter flow turbulent

line consists of 2 pay off reels, system

and

regulates

and

a stitcher and a horizontal

controls the temperature and

a normal running speed through

by circulating it from the storage

accumulator, sufficient to ensure the pickling section.

The pickle section consists of

four pickle baths connected to

concentration of acid in the baths

tanks to the pickling baths.

The cascade rinse system also consists of a counter flow system

moisture from the surface by

keeps the strip in the center

position by scanning the strip edges. The side trimmer is of

turret type and trims material to required width by automatic

blade adjustment. Side scrap is

dealt with by the use of a scrap chopper and removed from the line by a conveyor system.

If

required, material can be oiled by the in-line electrostatic oiler.

four acid recirculation tanks. to rinse material after pickling to Acid fumes generated by the

pickling process are extracted

with a fume exhaust system. The

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ensure as little possible chlorides on the strip.

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Cold Rolled Products MILL PARAMETERS

Product Data

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Material:

Mild Steel Grades SAE 1006, 1008, 1010

Strip Width:

1550 mm max 775 mm min

Entry Strip Thickness:

3 mm max 1.6 mm min

Finished Strip Thickness:

2.0 mm max 0.18 mm min

Maximum coil weight:

28.0 Ton

Specific Coil Weight:

18 kg/mm

Maximum Coil OD:

1880 mm

Coil ID:

508 mm

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Cold Rolled Products: OPERATION AND PROCESS DESCRIPTION 1. C  OLD REVERSING MILL (CRM) The CRM is a single-stand 4 high mill for cold rolling hotrolled and pickled material from the pickling line. The overhead crane deposits a coil on to one of the coil storage stations of the entry coil car. After coil diameter and width measurement, the coils are transferred by the coil car centrally on the pay off-reel mandrel. The strip head is fed through the pinch roll and leveller unit and reaches the mill stand via strip guide tables and the strip press. The strip head is then fed to the exit-side tension reel at threading speed.

reel with the aid of a threading table and belt wrapper. With the correct strip tension now obtained, the mill accelerates to rolling speed. For further reversing passes the strip remains wound on the two tension reel mandrels.

cold roll. The mill will temper roll the cold finished product downstream of the batch anneal. Its extra rolling capacity will be utilized to roll product for the Galvanising Line as well as Cold Rolled Product.

3. BATCH ANNEALING The Batch Anneal Facility The strip tension is measured comprises of 12 bases, each at the reels and the thickness capable of annealing a batch of 4 is measured by the two x-ray to 5 coils at a time. The Batch thickness gauges, one entry side Anneal System anneals coils from and one exit side of the mill stand. the CRM for the Cold Finished Strip shape is measured by two Product. shape metres positioned both at the exit as well as the entry sides Annealing is by Ebner Hicon of the mill and controlled by 100% H2 ensuring very consistent the multi-zone spray headers on mechanical properties and a entry and exit sides of the work uniform grain size throughout rolls. This ensures that shape can the coils. Once the coils have The strip head is coiled on to the be closely monitored through undergone the annealing exit side tension reel by means the entire pass schedule in both cycle they are cooled to a core of the belt wrapper. When 2 to directions and results in excellent temperature of 160˚C using a 3 windings have been coiled the shape control. combined air and water cooling wrapper is retracted and the cold system and unloaded from mill is then accelerated to rolling 2. COLD REVERSING the bases for further cooling TEMPER MILL (CRTM) speed for the first pass. For the prior to the temper rolling and 2nd pass in reversing operation, The CRTM is identical to the oiling process. the strip tail is now fed onto the CRM in every respect except mandrel of the entry side tension that it can temper roll as well as

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Galvanising HOT DIP GALVANISING LINE PARAMETERS Material

Pickled and cold reduced, or hot rolled and pickled steel strip

Coating weights

90 g/m2 to 450 g/m2 (both sides)

Strip Data:

Coil Data:

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Strip Thickness:

0.20 mm min

2.0 mm max

Strip Width

775 min mm

1524 mm max

Coil Weight:

28 ton max

Coil OD:

1880 mm max

Coil Bore:

508/610 mm

5 ton min

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Galvanising: OPERATION AND PROCESS DESCRIPTION LINE DESCRIPTION The Galvanizing Line entry section comprises of two pay off reels and an overlap seam welder for strip joining.

The jet cooling section consists of 7 cooling fans to cool the strip down to the required temperature (approximately 460°) for entering the Hot Dip Bath.

The Hot Dip Galvanising Line utilises a horizontal entry accumulator. The entry accumulator is located directly below the furnace section at floor level and utilises a six strand loop car. Three strip steering units are provided within the accumulator to correct any strip misalignment which may occur.

The Hot Dip Bath consists of a bath roll system to control strip shape and coating. The air-knife system ensures accurate coating control based on an x-ray gauge moving across the strip measuring the coating on both sides.

The exit comprises of a multi strand vertical accumulator to facilitate coil removal and continuous processing. Before coiling and splitting coils, the product is visually inspected over the entire length by a dedicated inspector.

The composition of the bath is controlled with additions of Aluminium and Antimony. The The line includes a horizontal mill is fitted with a 4 high Skin furnace section, consisting of a Pass Mill and a wet temper Non Oxidizing Furnace, gas- system that reduces zinc pick fired, to ensure strip cleanliness, – ups and thereby frequent roll an Electrical Heated Furnace, to changes. A chromating unit maintain strip temperature and a applies the passivating agent and Soaking Furnace, also electrically an electrostatic oiler is utilised for heated, to anneal the strip. clients requiring oiled material.

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PACKING OPERATION AND PROCESS DESCRIPTION PACKING DESCRIPTION Material identification and traceability Material is identified throughout the entire process by automatically generated tags after each process. Typical information on the tag can include (SI or /and imperial unit): - Customer name

- Final Customer name - Port Name

- Product description

- Gauge, width, length, ID - Gross and Netto mass

packed coil is labeled on the inner diameter and on each side (wall) of the coil. PACKING FOR EXPORT The coil is covered with VCI paper in such a way to prevent any dampness to reach the surface of the coil. Edge protectors are fitted to prevent damage to VCI paper and stretchfilm. VCI paper is folded to cover the complete side of the coil to at least reach the inner diameter of the coil.

- Purchase contract no. (also bar coded)

VCI stretch film is wrapped over the VCI paper, around the outer wraps, through the inner wraps with overlapping.

The unpacked coil is labeled on the inner diameter as well as outer diameter. The completely

Galvanized sheeting is fitted with strapping to the outer diameter of the coil and a seal protector if necessary.

- DSP Sales order

- DSP coil no. (also bar coded)

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Donuts are placed on the sides and a sheet to protect the eye (inner diameter). Edge protectors are then fitted with strapping and seal protectors if necessary. Six evenly spaced straps are fitted through the eye to keep packing material in place and if necessary, seal protectors are used to prevent strapping seals to cause damage to material.

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