Published by SMS group, Volume 18, No. 4, December 2011
Newsletter 4/2011
SMS Meer: World’s largest screw press
VOD plant for Ellwood +++ Heavy-plate mill for Nanjing +++ Aluminum hot and cold rolling mills for Shandong Weiqiao +++ Shougang Jingtang receives two tinning lines +++ Forging line for Dongfeng Nissan +++ Baotou orders section mill +++ Two rolling mills for Xining
NEWSLETTER | Contents
12 Maghreb Steel
03
CORPORATE NEWS
44
Changes in the Managing Boards
04
ENERGY AND ENVIRONMENTAL TECHNOLOGY
46
48
20
49
FORGING PLANTS Dongfeng Nissan orders forging line Wuxi, the world’s most powerful screw press
52
SERVICE – WORLDWIDE Laser measuring made fit for the future Forges de Bologne: Screw press with “new heart”
HOT ROLLING MILLS Tenth heavy-plate mill for China
24
INDUCTION TECHNOLOGY Heating plant with iZone™ put into operation
SECONDARY METALLURGY VOD facility for Ellwood RH-TOP plants at NLMK and Bhushan in operation
22
CC TECHNOLOGY FOR LONG PRODUCTS Dongbei: Bloom caster in full production
STEELWORKS AND CC TECHNOLOGY FOR FLAT PRODUCTS News in brief Two start-ups at Maghreb Steel
BUSINESS AREA SMS MEER News in brief
News in brief Efficient use of combustible gases
10
58 Section mill for Baotou
54
TUBE PLANTS Welded-tube plants: New FEM-analysis concept Baotou: PQF® tube plant has started production
ELECTRICS AND AUTOMATION Upgrade at Xiangtan
57 25
ALUMINUM ROLLING MILLS
Heavy-section mill started at Jiexiu Xintai Baotou orders another section rolling mill Two rolling mills for Xining
Hot and cold rolling mills for Weiqiao Group
27
COLD ROLLING MILLS 20-roll cold mill for titanium strip on stream ahead of schedule
28
COLD MILLS AND STRIP PROCESSING LINES The coupled pickling line/tandem cold rolling mill at MMK Interview: Integration test ensures high product quality
34
STRIP PROCESSING LINES News in brief Two electrolytic tinning lines for Shougang Jingtang
40
TECHNICAL SERVICE – WORLDWIDE Reduction of life cycle costs SMS Siemag service workshops
2
LONG-PRODUCT MILLS
Newsletter of the SMS group 4/2011
60
TRADE FAIRS AND EVENTS SMS Meer at wire and Tube 2012 ICTP: International Conference on Technology of Plasticity
CORPORATE NEWS | Personnel
Changes in the Managing Boards of SMS Siemag AG and SMS Holding GmbH
Dr. Kay Mayland.
Burkhard Dahmen.
Dr. Guido Kleinschmidt.
Upon expiry of his contract on December 31, 2011, Dr. Kay Mayland, President and CEO of SMS Siemag AG and Member of the Managing Board of SMS Holding GmbH, will retire on schedule for reasons of age and join the Supervisory Board of SMS Siemag AG.
Burkhard Dahmen, Member of the Managing Board responsible for Steelmaking Plants & Continuous Casting Technology at SMS Siemag AG, will become the new President and CEO of SMS Siemag AG as of January 1, 2012, and simultaneously a Member of the Managing Board of SMS Holding GmbH.
His successor in the Managing Board responsible for Steelmaking Plants & Continuous Casting Technology at SMS Siemag AG will be Dr. Guido Kleinschmidt, so far a member of the management of the Steelmaking Plants & Continuous Casting Technology Division of SMS Siemag AG.
Newsletter of the SMS group 4/2011
3
ENERGY AND ENVIRONMENTAL TECHNOLOGY | News in brief
➤ New orders
➤ New order
Dillinger Hüttenwerke, Germany
Bhushan Energy, Angul/India
Optimization of top-gas power station
Gas cleaning system for SAF
For Steag New Energie GmbH, SMS Siemag will be per-
SMS Siemag received an order from Bhushan Energy for
forming optimization measures at the BF top-gas boiler at
the supply of a gas cleaning plant operating on the new
Dillinger Hütte. SMS Siemag received the order in Sep-
submerged arc furnace (SAF) built for the production of
tember 2011 and will provide technical support and make
ferro-manganese and silicon-manganese. The gas cleaning
adjustments
plant (bag filters) is rated for a 39,000-kVA SAF.
n to optimize the burners for operation with 100 % top gas n to reduce emissions
➤ Orders in progress
n to minimize the use of back-up fuels
Shandong Weiqiao, China
Emulsion treatment plant The Environmental Technology Division of SMS Siemag is planning an emulsion treatment plant with a throughput rate of 5,000 l/h to be installed in the hot rolling mill.
PT. Krakatau Posco, Cilegon/Indonesia
New primary-gas cleaning system For a new converter steelworks of PT. Krakatau Posco, SMS Siemag is supplying the core components of a primarygas cleaning plant using dry-type electrostatic precipita-
Müllheizkraftwerk Kassel GmbH, Germany
tors from SMS Elex. The system will be designed to operate
Thermal calculations and burner inspection
on a 300-t BOF converter. PT. Krakatau Posco is a joint venture between state-owned
The order scope comprises the following services: recal-
Indonesian PT. Krakatau Steel and South Korean steel
culation of the thermal design of the boiler plant for mod-
producer Posco.
ifications to the refractory brickwork in the combustion chamber, inspection of the burner including a visual check, cleaning of the internal components, reassembly and commissioning.
4
Newsletter of the SMS group 4/2011
➤ Orders in progress Fujian Fuxin Special Steel, China
Efficient use of steam in the steelworks
Connecting duct of roof cover.
At this Chinese steelworks, two energy recovery plants from SMS Siemag will be installed. The plants will use the waste heat arising during the production of high-chromium steels in the AOD converter and from the EAF. From the waste heat, the two steam generators will produce a total of 45 t/h of saturated steam at 25 bar and 224 °C. Saturated steam is frequently used in the steel industry as an efficient energy carrier. Fujian Fuxin Special Steel will use the steam for different purposes, namely for the steam-ejector pump which produces the vacuum in the VD process, for air-conditioning buildings and for feeding the steam network of the works. Commissioning is scheduled for the end of 2012.
Eti Krom A.Ş., Turkey
CO2 savings through use of heat from SAF operation SMS Siemag will supply two waste heat recovery plants to the Turkish customer Eti Krom. The plants will produce
Sound-protection enclosure of the fans.
steam from the waste heat of two submerged arc furnaces used for the production of FeCr. The plants will generate 5 MW of electrical power from 30 t/h of superheated steam. This environmentally friendly process, which exploits the waste heat from SAF operation, will lead to savings on CO2 emissions amounting to some 30,000 tpy. The supply and service scope comprises planning, installation and commissioning of the steam generator and the dedusting plants. Start-up is expected to take place in 2013. Gas cleaning plant of an electric steelworks.
Newsletter of the SMS group 4/2011
5
ENERGY AND ENVIRONMENTAL TECHNOLOGY
For 15,500 m3 of cleaned water per hour
SSAB, Borlänge: WTP and laminar cooling line in operation ➤ Commissioning | SMS Siemag modernized the water treat-
employ control valves for infinite setting of the
ment plant and the laminar cooling line of the hot strip mill of
water flow enabling implementation of different
SSAB in Borlänge. Both facilities were recently successfully
cooling strategies. The adjusting ranges of the
brought on stream. The objective of the revamp was to achieve
new cooling line provide SSAB great flexibility in
even higher cooling rates for further expansion of the product
developing innovative materials.
range. The SMS Siemag supplies for the new water treatment facilities also included X-Pact® electrical and automation systems.
Cooling model determines the right cooling strategy. SMS Siemag’s cooling model calcu-
Enhanced flexibility for new materials. The new laminar cooling
lates the cooling strategies. The model is based
line achieves not only higher cooling rates but also finer adjustment
on physical-mathematical calculations, which
of the individual cooling groups. Each cooling group features six
describe the microstructure as a function of the
valves arranged above and six below (in the trimming zone 12 valves
chemical analysis and of different temperatures
in each case) to set partial water flows. The first four cooling groups
and cooling rates. Closed-loop cooling system. The water treatment and supply system at SSAB is designed such that the water coming from the cooling line flows via a scale flume into a holding tank. From there, the water is pumped into the sedimentation tank for dirt particles to settle. Coarse particles are already retained upon flowing into the holding tank by a rake-type device. Part of the pre-cleaned water undergoes further cleaning in a sand filter system. The cooling water is cooled down in heat exchangers rather than in conventional cooling towers. Efficient and resource-saving.This closed water circuit enables efficient and resource-saving utilization of the service water. After cleaning and cooling, the water is pumped into an elevated tank and can be used again for strip cooling.
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Newsletter of the SMS group 4/2011
Tailor-made, cost-effective solutions
Use of combustible gases from metallurgical processes In the iron and steel industry, energy costs account for a substantial portion of the production costs. And this portion is likely to grow further in the future. Against this background, energy saving or energy recovery have been playing and will play an increasingly important role, central issues of discussion here being the efficiency of energy use and the resulting savings in CO2 emissions.
»
Calorific values of natural gas and process gases
FeMn SAF gas LCV = approx. 11.4 MJ/m3
Coke oven gas LCV = 16 - 18 MJ/m3
BF top gas LCV = 2.5 - 3.3 MJ/m3
Converter gas LCV = 7.0 - 8.4 MJ/m3
Natural gas L LCV = 31.4 MJ/m3
Submerged arc furnace
Coke oven
Blast furnace
Converter
Natural gas L
Newsletter of the SMS group 4/2011
7
ENERGY AND ENVIRONMENTAL TECHNOLOGY
Cont’d.: Use of combustible gases from metallurgical processes
The challenge: Use of gaseous byproducts from steelmaking
The solution: Standardized steam generators and power plants
Along the steelmaking route, different gaseous byproducts arise
For the targeted use of these gases, for exam-
at various process stages. These byproducts, especially blast fur-
ple the generation of process steam or the
nace top gas, coke oven gas and converter gas, contain much en-
generation of electricity within a complete
ergy in the form of combustible components. Using these gases
power-generation process, SMS Siemag of-
as primary fuels in a firing plant provides a massive improvement
fers a well scaled, versatile range of steam
in a steelworks’ energy efficiency, cutting overall steelmaking costs
generators that incorporate numerous stan-
and reducing CO2 emissions.
dardized components. With this equipment you save, or recover, energy economically and effectively.
Flow chart of power generation by process gas: Efficient steam cooling and saving of CO2
Stack Steam generator
Electricity
BF top gas Coke oven gas
Turbine
Natural gas
Generator Pre-heater HP pre-heater
Process steam
Fan Cooling tower Feed-water tank
LP pre-heater Feed-water pump
8
Newsletter of the SMS group 4/2011
Condenser
Selection of generator design: Multiple requirements
The SMS portfolio: Suspended or self-supporting steam generators
It is very important for SMS Siemag to con-
SMS Siemag’s portfolio includes suspended and self-supporting
sider the many demands that influence
natural-circulation generators with top outputs. These machines
the choice of the generator type. Examples
attain fresh-steam pressures of up to 160 bar and fresh-steam tem-
of these demands are:
peratures of up to 540 °C.
n Low emissions of hazardous substances
SMS Siemag offers single and multi-pass designs, providing a very
n The possibility of using a wide range of
high degree of versatility to fulfill most different tasks. The SMS product range also includes:
different fuels n Compact design of the plants n Fast-start capability n Flexible operation modes, suitability for variable- and fixed-pressure modes as
n Waste-heat recovery boilers (cooling towers) for converters, electric arc furnaces and submerged arc furnaces n Spare parts service (for reviews, revamps and repairs)
well as daily starting and stopping n High availability n High cost-effectiveness
Single-pass steam generator Technical features: suspended design with naturalcirculation boiler. Flue gas outlet directly into the stack arranged on top, or flue gas can be guided to downstream heat exchangers. Front, corner or bottom firing possible. Suitable for liquid, gaseous and solid fuels.
One-and-a-half-pass steam generator Technical features: suspended design with naturalcirculation boiler. Front, corner or bottom firing possible. Suitable for liquid, gaseous and solid fuels.
Two-pass steam generator Technical features: self-supporting, standing design with natural-circulation boiler. Front or bottom firing possible. Suitable for liquid, gaseous and solid fuels.
Three-pass steam generator Technical features: self-supporting, standing design with natural-circulation boiler. Front or bottom firing possible. Suitable for liquid, gaseous and solid fuels.
Two-pass steam generator.
Newsletter of the SMS group 4/2011
9
STEELWORKS AND CC TECHNOLOGY FOR FLAT PRODUCTS | News in brief
➤ New orders PT. Gunung, Indonesia
Tata Steel, India
Slab casting plant
Segments for slab caster
PT. Gunung contracted SMS Siemag for
Tata Steel placed an order with SMS
the supply of a single-strand slab casting
Siemag to supply 48 segments for
plant with an annual capacity of 1.2 mil-
the two-strand slab caster at the
lion t. The caster will be installed at the
Kalinganagar works in the state of
Bekasi site in the province of West Java,
Orissa in east India.
with commissioning slated for mid-2013.
Tata Steel, India
SAF for FeSi metals
Segments, molds and copper plates for CSP®
Posco awarded SMS Siemag the order to
On top of that, the Indian steel pro-
Posco, Korea
supply a 30-MVA submerged arc furnace
ducer ordered segments, molds and
for the production of ferro-silicon.
copper plates for the CSP® plant.
➤ Plant start-ups Severstal Columbus, U.S.A.
Kazzinc, Kazakhstan
Second construction stage up and running
Electric furnace for copper-slag cleaning
The U.S. works of SMS Siemag’s Russ-
In July 2011, SMS Siemag success-
ian customer recently saw the com-
fully commissioned an electric fur-
missioning of the second electric
nace for copper-slag cleaning at the
meltshop and the second CSP® caster
newly built copper production facil-
with tunnel furnace. The push-pull
ity of JSC Kazzinc, a Kazakh mining
pickling line and the second hot-dip
and metallurgical combine.
galvanizing line had already been started up earlier, in June this year.
10
Newsletter of the SMS group 4/2011
➤ Cooperation
SMS Siemag and SiCon
Treatment concept for recycled scrap on technologies that reduce the environmental impact. The cooperation between SMS Siemag and SiCon will offer the customers competences that will comply with plant and environmental technology standards of the future. Safeguarding of the raw material basis. Scrap is a commodity traded worldwide and with growing importance for future steel production. Worldwide rising recycling rates have increased the availability of scrap grades with limited suitability for Heiner Guschall (left), Managing Director of SiCon, shaking hands with Dr. Guido Kleinschmidt, Executive Vice President Steelmaking Plants/Continuous Casting Technology Division of SMS Siemag.
quality steel making. For electric steelmakers to remain competitive in the future, it is crucial to safeguard availability of supe-
In October 2011, SMS Siemag entered into a cooperation
rior scrap grades in sufficient quantities
agreement with SiCon on the joint marketing of a treatment
and at moderate prices.
process that prepares recycled scrap for use as charge material in electric arc furnaces. Enabling the recovery of up to 100 % of the metal fraction, these treatment facilities for recycled scrap set new productivity and profitability benchmarks. The process provides breakthrough results in terms of precision of
➤ Cooperation
analysis and degree of purity. It involves various process stages that reduce undesired tramp elements in the scrap to a minimum. Also substances, such as plastics, that are extremely difficult to
Slag control equipment jointly marketed with Monocon
handle by waste gas cleaning plants, are removed in the process. In June 2011, SMS Siemag signed a cooperation agreePartnership for reduced environmental impact. SiCon is spe-
ment with Monocon International Refractories, United
cialized in the treatment and recycling of scrap, plastic and elec-
Kingdom, on the marketing of slag control equipment.
tronic waste as well as waste from steel and paper making
The agreement also covers the marketing of consum-
processes. Being committed to improving the eco-balance of pro-
ables, such as floating darts.
duction processes, SMS Siemag designs steelmaking plants based
Newsletter of the SMS group 4/2011
11
STEELWORKS AND CC TECHNOLOGY FOR FLAT PRODUCTS | Report
Two start-ups at Maghreb Steel
First heat and first slab
Job accomplished. The first slab is cast.
➤ Commissioning | On October 22, 2011, the SMS Siemag-supplied electric steel plant and slab caster were successfully commissioned at the new steel mill complex of Maghreb Steel near Casablanca in Morocco. The new steelworks has an annual production capacity of some 1.0 million t.
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Newsletter of the SMS group 4/2011
Othman Benmlih, General Manager of Maghreb Steel, was deeply impressed by the results achieved: “ese are the first slabs ever produced in Morocco. And we have succeeded in casting perfect slabs right om the start. is could not have been better. We thank SMS Siemag for the excellent job done.”
From steel processor to full-line producer of flat products The new steel mill complex means a marked increase in production capacity of Maghreb Steel, one of the Those responsible at Maghreb Steel follow the commissioning activities with great attention: Youssef Sekkat, Member of the Management; Othman Benmlih, General Manager; Sofia Aarab, Project Manager (from right).
biggest producers of cold rolled products in North Africa, and is a major enhancement of the company’s value chain.
With these two start-ups, another two key production units of the new steel mill complex went on stream, following the start-up of the Steckel mill (March 2010) and of the 2.8-m heavy-plate mill (October 10, 2011). The Steckel mill and the plate mill were also supplied by SMS Siemag. The members of the international commissioning team of SMS Siemag came from China, India, Spain, the Czech Republic and Germany.
The new steelworks and the slab caster supply the two rolling mills with in-house produced input material. In the past, the existing rolling mills of Maghreb Steel processed slabs and sheets purchased from external sources. The expansion of Maghreb Steel’s production chain is a milestone in the history of the company, which was founded in 1975. Therefore it was decisive for Maghreb Steel to choose the right partner – a partner capable not only of supplying the equipment but also of communicating the required operating and process know-how to the personnel. Sofia Aarab, Project Manager at Maghreb Steel states: “In the past, we have been operating various rolling mills and strip processing lines. With the newly set up production complex, we are now entering steelmaking. We wanted to have the best supplier for this project. Therefore we chose the world market leader SMS Siemag. It was important to us to have a partner capable of offering the full line of plants covering the entire process chain of steelmaking and steel processing. This is not our first project with SMS Siemag. During previous projects, our experience with SMS Siemag has been very good.” The plants operated by Maghreb Steel in the past included two cold rolling mills, each with an annual capacity of 200,000 t, and various pickling, annealing, hot-dip galvanizing, coating and shearing lines.
»
Treatment in the ladle furnace.
Newsletter of the SMS group 4/2011
13
STEELWORKS AND CC TECHNOLOGY FOR FLAT PRODUCTS | Report
Sofia Aarab, the responsible project manager.
Customer praises team work with SMS Siemag The start-ups of the new steel plant and the new slab caster at Maghreb Steel could not have been better. Thanks to the vast experience of SMS Siemag and the efficient preparatory activities, start of production was perfectly smooth. Sofia Aarab:
“With SMS Siemag, we have a trusting partner at our side and are very satisfied with our cooperation. e project went smoothly and was characterized by open dealings with each other. During the different project phases, we benefited om the know-how and the experience of the SMS experts. We solved problems jointly and were always able to depend on each other.”
The new, energy-efficient electric steelworks The new electric steel plant uses a 120-t Arccess® electric arc furnace (EAF) equipped with high-efficiency burners and SIS injectors for minimized energy consumption. This effectively cuts production costs. The design of the EAF provides the possibility of using hot metal as input material in the future. SMS Siemag’s contract scope for the steelworks also included a 120-t ladle furnace, the material handling system for alloying agents and a gas cleaning system. In addition to the mechanical and hydraulic equipment, SMS Siemag supplied the complete X-Pact® electrics and automation system, including the drives and the measuring and automation equipment, as well as the technological process models.
Scrap charging into the EAF.
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Newsletter of the SMS group 4/2011
From left: Friedrich Busenius, General Site Manager, SMS Siemag; Abdellah Samir, Member of the Board of Maghreb Steel; Fadel Sekkat, President of Maghreb Steel; José Portillo, Technical Project Manager of SMS Siemag.
Treatment of the first heat in the ladle furnace.
» Newsletter of the SMS group 4/2011
15
STEELWORKS AND CC TECHNOLOGY FOR FLAT PRODUCTS | Report
secondary cooling system using the process model for Dynamic Solidification Control. The maximum casting speed is 1.8 m/min. By adding two further strand guide segments, the maximum casting speed can be increased to 2 m/min.
Flexible production concept Via a roller table, the slab caster is directly linked with the downstream Steckel mill and the heavy-plate mill. As the roller table system is arranged as a “T”, the product flow downstream of the caster bifurcates into the two rolling mill lines. This arrangement enables Maghreb Steel to very quickly and flexibly react to any market requirements or customer requests, by adjusting the product range as needed in a speedy manner. The combined capacity of both rolling mills
Start-up with four slabs
first casting sequence was produced using
The new continuous casting plant can make
Casting). ISC® assures high quality of the cast
General Manager Othman Benmlih
slabs up to 200 mm thick. Slab widths range
slab and high plant productivity. The mod-
comes to a positive conclusion:
from 900 mm to 2,150 mm. The width can
ules include technologies such as the “trans-
be varied during casting. The slab lengths
parent mold” using the Mold Monitoring
“During the four years of collaboration, we had very good relations – both in human and in technical respects. SMS Siemag was our integral systems supplier and performed convincing work at all levels. We would like to collaborate closely with SMS Siemag in the future also.”
amounts to 1.5 million tpy.
SMS Siemag’s ISC® modules (Intelligent Slab
range between 6 and 12.5 m. They can be
System, hydraulic resonance mold oscillator,
further cut to variable lengths between 2
casting width adjustment as well as Cyber-
and 5 m by a second inline cut-to-length
link strand guide segments with Dynamic
system. During commissioning, four slabs
Soft Reduction for improved internal slab
200 mm thick and1,250 mm wide were pro-
quality. Metallurgical adjustments and opti-
duced. The length was 9.0 m. Already the
mizations are additionally achieved by the
16
Newsletter of the SMS group 4/2011
Use this QR code to watch the video about the commissioning at Maghreb Steel.
The first-ever slab cast in Morocco.
Positive economic environment The expansion strategy pursued by
a growth promoting program for the in-
the exacting requirements of the automo-
dustry. Plans are to double annual GDP
tive industry. Therefore the new Renault
from 1.6 to 3.2 % by 2015.
works to be built in Tangier may become a
Maghreb Steel coincides with a favorable
potential future customer of Maghreb Steel.
economic environment. In 2008, Morocco
The new steel mill complex of Maghreb
The French automobile producer plans to
was granted advanced status by the EU, fa-
Steel is an integral element of these plans. It
set up the world’s first CO2-neutral car mak-
cilitating trade and economic relations for
will enable the country to make all products
ing facility near the city of Tangier. The
the export and import of commodities.
from the liquid steel through to sheet or
“world’s cleanest car factory” is scheduled to
Since 2005, the Moroccan government has
strip products domestically. The expanded
be completed in 2012. In the initial stage, it
been implementing the “Emergence Plan”,
range of flat products will be able to meet
will produce 170,000 automobiles per year.
Newsletter of the SMS group 4/2011
17
STEELWORKS AND CC TECHNOLOGY FOR FLAT PRODUCTS | News in brief
➤ New order | Gallatin Steel, located in Ghent/KY, U.S.A., has placed an order with SMS Siemag LLC from Pittsburgh/PA for the modernization of one position of their twinshell electric arc furnace.
➤ Plants in operation | Over the past two years, SMS Siemag built and commissioned various facilities at MMK in Magnitogorsk, Russia. The most recent example is the combined pickling line/tandem cold mill installed at a new cold rolling complex. The new pickling line/tandem mill was officially inaugurated in July 2011. Also for the steelworks, SMS Siemag supplied new equipment.
Gallatin Steel, U.S.A.:
Modernization of DC electric arc furnace The project scope includes the supply of a new tilting platform, gantry, lower shell and roof. The new furnace shell will incorporate latest SMS Siemag technology. Detail engineering including three-dimensional modeling and finite element analysis of the new shell was completed earlier
The S-shaped ladle turret with a payload of 2 x 535 t.
this year. Equipment delivery is scheduled for installation and commissioning activities to take place during a production outage in the third quarter of 2012. Upgrade of the second shell of the 190-sht EAF will be done at a later date. Gallatin Steel is a joint venture between ArcelorMittal and Gerdau. The facility produces approximately 1.6 million sht of hot strip per year. Gallatin Steel’s facility features a 190-sht DC twin-shell EAF, a ladle metallurgy facility and a CSP® plant with a single-strand caster and a six-stand hot strip mill.
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Newsletter of the SMS group 4/2011
Two years of successful operation
RH degassing plant and slab caster at MMK
RH vacuum degassing plant.
Continuous casting plant for extra-wide slabs.
370-t RH-TOP plant
Slab caster for 2,700 mm casting width
At the MMK steelworks in Magnitogorsk,
Prior to the RH plant, MMK had commissioned the continuous slab
the 370-t duplex RH-TOP plant supplied by
caster supplied by SMS Siemag. The caster, which is designed for
SMS Mevac has been operating success-
the production of slabs with up to 300 mm thickness, has a maxi-
fully and reliably since its commissioning
mum casting speed of 2.0 m/min. The maximum casting width
at the end of February 2010 (see report in
amounts to an impressive 2,700 mm. Width changes can be made
Newsletter 2/2010). The RH plant is used
during casting. A highlight is the turret which, having a maximum
above all for the production of micro-al-
payload of 2 x 535 t, is the largest S-shaped ladle turret in the world
loyed steel for heavy plates.
built by SMS Siemag so far.
High-grade products. MMK is one of Russia’s leading steel producers. The recent investments have expanded MMK’s capacities for the production of premium cold-rolled and galvanized strip. The high-grade products are planned to be used mainly for the manufacture of automotive sheet and interior car parts and in the appliances and construction industries.
Newsletter of the SMS group 4/2011
19
SECONDARY METALLURGY | News in brief
Ellwood National Steel, U.S.A.: Order for VOD facility
Mechanical pumps instead of steam injectors ➤ New order | Ellwood National Steel in
First VOD facility in the U.S.A. with me-
Irvine, PA/U.S.A., which is part of the Ell-
chanical pumps.The plant will be equipped
wood Group, placed an order with SMS
with mechanical vacuum pumps rather than
Siemag LLC in Pittsburgh for the supply
a steam ejector system for the generation of
of a VOD facility (Vacuum Oxygen Decar-
the vacuum required for the treatment. The
burizing).
use of a gas cooling and bag filter system minimizes environmental pollution.
The project is undertaken to enable the production of low-carbon stainless steel
The scope of supply is comprised of all of
forgings, with a special challenge being
the mechanical process equipment, includ-
the attainment of a demanding combi-
ing the alloy addition system, as well as the
nation of strength, toughness and cor-
complete electrical and automation sys-
rosion resistance of the steel. Ellwood
tems with level-1 and level-2 controls.
National Steel plans to begin production of stainless steel at the Irvine plant as
SMS Mevac involved as center of compe-
early as in December 2012.
tence. Essen/Germany-based SMS Mevac, the competence center for VOD technology within the SMS group, provides the
with a leading German stainless steel pro-
process know-how, training and the basic
ducer. SMS Mevac will also be closely in-
engineering based on a license agreement
volved in the entire project execution.
NLMK, Russia: Start-up of a 320-t duplex RH-TOP plant
More than 4 million tpy of vacuum-treated steel ➤ Commissioning | At the metallurgical
Key equipment. To meet these require-
ment position provided with a wire feeding
combine of Novolipetsk in Russia, NLMK
ments, the plant is equipped with a power-
machine, devices for applying insulating
recently successfully commissioned an
ful, specially tailored vacuum pump system.
powder and special sampling equipment
RH-TOP plant supplied by SMS Mevac.
Both treatment lines use a very reliable hy-
for hydrogen measurements.
The duplex plant can treat heats of
draulic rocker-type system for lowering the
nominal weights up to 320 t. It will be
snorkels into the steel bath. The plant is
Scope of supply. SMS Mevac supplied the
used predominantly for the production
completed by devices such as metallurgical
complete basic engineering, core compo-
of ultra-low-carbon steels and low-alloy
TOP lances, a common alloying system with
nents, all of the basic and level-2 process
grades, among others for ship building.
double-chamber vacuum locks and auto-
automation systems and was responsible
It is planned to vacuum-treat more than
matic sampling devices with slag breakers.
for the supervision of installation and com-
4 million t of steel annually.
Each line is fitted with an additional treat-
missioning.
20
Newsletter of the SMS group 4/2011
Bhushan Steel, India: 180-t RH-TOP plant on stream
Lowering of hydrogen and carbon contents ➤ Commissioning | On June 18, 2011,
deep drawing, interstitial-free (IF), API X72 and higher, and bake-
Bhushan Steel commissioned the new
hardened steels.
180-t RH-TOP vacuum degassing plant in Meramandali in the Indian state of
TOP lance with double function. The RH-TOP vacuum recircula-
Orissa. The plant, set up in steelworks
tion degasser features a rocker-type treatment station equipped
No. 2, had been designed and supplied
with a multi-function TOP lance, which combines oxygen blowing
jointly by SMS Mevac UK and SMS India.
under vacuum and the function of an oxygen-gas burner for heat-
Reduction of hydrogen content and car-
comprehensive ferro-alloy addition system.
ing the vacuum vessel. The treatment station also comes with a bon removal. The new plant is used for a combination of hydrogen removal and
First of its kind in India. This RH plant is the first in India equipped
carbon removal treatments. It is part of the
with a powder-blowing TOP lance for desulphurization.
new steelworks No. 2 built by SMS Siemag and treats liquid steel produced in the re-
Scope of supply. The supply package of SMS Mevac UK comprised
cently commissioned Conarc furnaces.
core components such as the vacuum pump system, the multi-
Premium steel grades. Bhushan Steel in-
gical model for level 2. SMS India provided the main fabricated
function TOP lance, the vacuum rotary bearings and the metallurtends to use the new RH degasser to pro-
items such as the vessel platform, rocker structure and alloy sys-
duce high-value steel grades such as extra-
tem, as well as the complete electrical and automation system.
The RH-TOP degassing plant at Bhushan Steel during commissioning.
Newsletter of the SMS group 4/2011
21
HOT ROLLING MILLS | News in brief
Nanjing Iron & Steel ordered 4.7-m heavy-plate mill ➤ New order | Chinese steel producer Nanjing Iron & Steel Co. (Nisco) contracted SMS Siemag in August 2011 for the construction of a new heavy-plate mill. The supply package covers the finishing stand with CVC® plus technology and a rolling force of 120 MN, a pre-leveler, a hot-plate leveler and the shear line. All equipment will be supplied inclusive of the associated technological X-Pact® automation systems such as proDuring contract signing: Xiaochun Jiang (left), Vice President Nanjing Iron & Steel, and Dieter Rosenthal, Member of the Managing Board of SMS Siemag.
file and flatness control systems and the leveling model.
Renewal of coiler station ThyssenKrupp Steel
Morgoil® KLX® bearings in heavy-plate mill OMK, Russia
➤ Correction | Concerning: Publication of a letter from
➤ Commissioning | Sixth heavy-plate stand with 80"-86 bear-
Dr. Andreas Zaum, ThyssenKrupp Steel Europe AG, to the
ings. The 5.0-m heavy-plate finishing stand is in operation at Rus-
Electrical & Automation Division of SMS Siemag in a pre-
sia’s OMK – Vyksa Steel Works. For this stand SMS Siemag installed
vious issue of the SMS Newsletter.
heavy Morgoil® bearings of the size 80"-86 KLX®. The heavy-plate stand is already the sixth mill that uses bearings of this type.
In his letter, Dr. Zaum exclusively and expressly refers to the handling of the optimization phase of the coiler station comprising three UNI plus coilers for high-strength hot strip in the finishing mill of ThyssenKrupp Steel’s hot strip mill 2 in Duisburg-Beeckerwerth, and expresses his
Morgoil® KLX® bearings in CSP® plant with top performance Essar Steel, India
gratitude for the work implemented in this final phase of the project.
➤ FAC issued | The seven-stand rolling mill of Essar Steel’s CSP®
The publication of this letter in connection with an article
54"-76 KLX®.
plant was equipped with modern Morgoil® bearings of the size on the entire revamp of the Beeckerwerth hot strip mill was by no means meant to create the impression that the letter
It is already the second CSP® rolling mill to feature this bearing
reflected a valuation of the complete project transaction.
type. The bearings of roll stands F1 to F3 are additionally fitted with hydrostatic lubrication systems. With the bearings performing to the customer’s fullest satisfaction, Essar Steel has meanwhile issued the Final Acceptance Certificate (FAC).
22
Newsletter of the SMS group 4/2011
Layout of heavy-plate mill for Nanjing Iron & Steel.
Scheduled to start up in Nanjing in 2013, Nisco’s new mill is already
heavy plates. In keeping with today’s market demands, the product
the tenth SMS Siemag heavy-plate mill built in China in less than a
spectrum will cover plates of all steel grades, including pipe & tube
decade. Nisco wants to attain an annual production of 1.6 million t of
steels, shipbuilding grades, and high-strength steel grades.
New gears installed in FG0 and FG1 Voestalpine Stahl, Austria: Hot strip mill back in service ➤ Commissioning | Shut down for a period of several weeks for a comprehensive revamp, the hot strip mill of Voestalpine Stahl in Linz, Austria, went back on stream on August 19, 2011. SMS Siemag’s scope of supply for this project contained the reducer and pinion gears for the two finishing stands FG0 and FG1. Also during this revamp, stands FG0 and FG1 were completely replaced by stands provided by Voestalpine Stahl. This means that all stands of the finishing mill meanwhile have been replaced. While the pinion gears were delivered to
Pinion gear of the new stand FG0.
Reducer gears of FG0 and FG1.
their mounting locations as completely assembled units, the reducer gears could be
to the modular design of the gears. Thanks
SMS Siemag’s Hilchenbach manufacturing
assembled from individual units only in
to suitable preparation of the foundations
shops, the correct alignment of the gears
the customer’s mill for reasons of weight.
by the customer and the proven pre-set-
was quickly achieved. Now the hot strip mill
However, everything went smoothly due
ting of the contact patterns of the teeth in
is producing according to specification.
Newsletter of the SMS group 4/2011
23
ELECTRICS AND AUTOMATION
Xiangtan, China
Automation upgrade for heavy-plate mill ➤ New order | Enhanced material model, new passschedule strategies and new recrystallization model
neering at Xiangtan, finds words of
The Chinese firm of Xiangtan Iron & Steel Group Co. in the
by SMS Siemag:
Guo Wang Chen, Vice President Engipraise for the heavy-plate mill supplied
province of Hunan has requested SMS Siemag to upgrade the process model for the 3.8-m heavy-plate mill supplied by SMS Siemag in 2005. Xiangtan is one of China’s largest producers of heavy plate and its product spectrum includes high-quality plates for shipbuilding and for tubes & pipes. For plate produc-
“e mill equipped by SMS Siemag offers the best product quality in comparison with our other heavy-plate mills.”
tion, the company located in southern China operates three heavy-plate mills.
SMS Siemag’s supply package at that time comprised the complete mechanical equipment of the mill as well as the X-Pact® automation.
➤ Acceptance
Aluminum reversing hot rolling mill Elval issues FAC for new pass-schedule computer Elval Hellenic Aluminium Industry has granted to SMS
Hardware of the X-Pact® electrical and automation systems.
Siemag the official acceptance of a new pass-schedule computer for the aluminum reversing hot rolling mill.
Upgrade with latest innovations. With the upgrade of the exist-
The order covered the supply and installation of an X-
ing X-Pact® automation system SMS Siemag is helping Xiangtan
Pact® level-2 model server.
Iron & Steel to safeguard its leading position in terms of product
SMS Siemag’s scope included the supply of the hard- and
ical innovations in plate rolling. These include an enhanced mate-
quality. The upgrade incorporates SMS Siemag’s latest technologsoftware for automatic generation of pass schedules ac-
rial model, new pass-schedule strategies, particularly for thin
cording to special customer rules or requirements as well
sheet, a new recrystallization model for exact determination of the
as the setting of the process parameters needed to
pass reductions, and an extension of the gage control system for
achieve optimum product qualities and geometries such
optimization of the head-end thickness.
as thickness, profile and strip flatness. Revamp without plant stoppage. The upgrade will be implemented in shadow mode so that production need not be stopped.
24
Newsletter of the SMS group 4/2011
ALUMINUM ROLLING MILLS
➤ New order | Shandong Weiqiao Aluminium & Electricity Co. has contracted SMS Siemag to build a complex for the production of hot- and cold-rolled aluminum strips. The new works will be erected in Zouping in the Chinese province of Shandong. The up-andcoming company is a member of China’s Shandong Weiqiao Pioneering Group which ranks among the country’s top 500 enterprises.
SMS Siemag’s supply package for the Zouping complex includes a 1+4 hot rolling mill, a threestand tandem cold rolling mill and two singlestand cold rolling facilities for aluminum strip. The customer will use this production site mainly for the fabrication of material for alu-
»
minum cans.
Major order for hot and cold rolling mills
Shandong Weiqiao Group, China: Extension of aluminum flat products division
Design of the hot-strip finishing mill.
Single-stand cold rolling mill (reference mill).
Layout of the complete aluminum hot rolling mill.
Newsletter of the SMS group 4/2011
25
ALUMINUM ROLLING MILLS
Cold rolling facilities with a total capacity of over 500,000 tpy To be able to roll the aluminum strips coming from the hot rolling mill into thin final gages, the Zouping location will be equipped with three cold rolling facilities, i.e. two single stands and a three-stand tandem mill, all of them in CVC® plus sixhigh design. The three mills will have a combined annual capacity of 533,000 t. The cold rolling facilities will also go on The delegation from Shandong Weiqiao headed by Lu Tianfu, Advisor to the Chairman, to the left of Dieter Rosenthal, Member of the Managing Board of SMS Siemag, during a tour of SMS Siemag´s Hilchenbach workshops on October 7, 2011.
stream in 2013. Mill No. 1 for minimum final gages of 0.2 mm
Hot rolling mill for 2,200-mmwide aluminum strip
Coil weights of up to 30 t
The single-stand cold rolling mill No.1 will
The four-high roughing stand will operate
handle strips with widths of up to 2,150
in reversing mode to roll the incoming alu-
mm and large ingoing thicknesses of up to
The key components
minum ingots down to starting-strip thick-
10.0 mm. It is able to attain a minimum
The main equipment of the 1+4 aluminum
ness. These ingots are up to 2,200 mm
final gage of 0.2 mm.
hot strip mill comprises: edger, roughing
wide, up to 620 mm thick and weigh up to
stand, heavy crop shear, light crop shear,
32 t. In the finishing mill, four CVC® four-
four-stand finishing mill, exit-end equip-
high roll stands then roll the up to 45 mm
ment including trimming shear and coiler.
thick and up to 2,150 mm wide (trimmed)
For this scope, SMS Siemag will supply the
starting strips down to final gages be-
engineering and the core components that
tween 10.0 and 2.0 mm. The maximum
are decisive for the product quality. In addi-
rolling speed in the last stand is in excess
tion, the SMS Siemag’s package contains
of 670 m/min.
hydraulic adjusting systems, roll bending systems, CVC® equipment & technology, hy-
In the exit section, a coiler winds the strips
draulic valve stands and media systems. The
into coils with a maximum weight of 30 t.
hot strip mill will be equipped with an of-
Next in line are extensive facilities for coil
fline inspection line. Commissioning of the
storage and transport, in particular the lat-
Zouping hot strip mill is slated for H1 2013.
est-generation high-bay storage system, which will be supplied by SMS Logistiksysteme GmbH.
26
Newsletter of the SMS group 4/2011
COLD ROLLING MILLS
20-roll cold mill on stream ahead of schedule Mills No. 2 and No. 3 for minimum final gages of 0.1 and 0.15 mm The single-stand cold rolling mill No. 2 and the three-stand tandem mill both will process strips with ingoing thicknesses between 0.3 and 3.5 mm. The single-stand cold rolling mill No. 2 is able to achieve min-
Hunan Xiangtou Goldsky Titanium Metal, China: Mono-Block mill rolls 1.0-mm titanium strip
imum final gages down to 0.1 mm, while the tandem mill will roll the material down
On June 25, 2011, eight days earlier
sential mill components that had been man-
to final thicknesses of 0.15 to 1.6 mm.
than agreed, the first coil was produced
ufactured in the shops of SMS Siemag were
at Hunan Xiangtou Goldsky Titanium
delivered to the site in the form of pre-as-
CVC® plus, HES and DS
Metal. The new 20-high cold rolling mill
sembled and function-tested units. The cold
The proven CVC® plus equipment & tech-
of the MB 22B-52" series rolled a tita-
rolling mill uses the latest Supafine® filter
nology in combination with work- and in-
nium strip from its initial thickness of
technology made by SMS Siemag which
termediate-roll bending systems enables
2.5 mm down to a final gage of 1.0 mm.
makes sure that even micro-size abraded
a wide roll-gap adjusting range. To prevent
particles from the rolling process are re-
excessively tensioned strip edges, which
A key factor which contributed to erection
moved from the rolling-oil circuit. This en-
typically occur in aluminum rolling, all of
and start-up ahead of schedule was that es-
sures excellent strip surface quality.
the cold rolling mills feature SMS Siemag’s proven HES system (Hot Edge Spray). Together with the multi-zone cooling system, the HES system ensures top strip flatness.
More information on this will be
The DS system (Dry Strip) minimizes oil
provided in Newsletter issue 1/2012.
residues on the surface of the rolled strip. Numerous ancillary systems In addition to the coil preparation stations, SMS Siemag is supplying further important secondary equipment, including the exit-side offline strip inspection stations for cold rolling mill No. 2 and for the tandem mill. These stations serve to check the quality of the end products. Particularly trendsetting are SMS Siemag’s eco-friendly and cost-efficient filter systems. The mills will be equipped with a total of six MultiPlate filters for cleaning the rolling oil plus two Airwash™ filter systems for exhaust-air purification. Festively decorated: the First Coil.
Newsletter of the SMS group 4/2011
27
COLD MILLS AND STRIP PROCESSING LINES | Photo story
2.1 million t of cold strip also in automotive quality
The coupled pickling line/ tandem cold rolling mill at MMK
In July 2011, the “red button” was pressed to officially commission MMK’s metallurgical complex in Magnitogorsk. In the weeks thereafter, an SMS team of photographers visited the works to take photos of the pickling line/tandem cold rolling mill. By courtesy of MMK, SMS is pleased to present some of the photos of the plant.
Control pulpit overlooking the entry group of the pickling line.
28
Newsletter of the SMS group 4/2011
The PL-TCM is the first stage of a complete cold-strip complex which SMS Siemag is building at MMK.
Material feed to the pickling section.
The pickling section, with the tension leveler in the foreground.
The starting stock is hot strip between 1.2 and 6.0 mm thick which runs into the pickling section at speeds of maximum 700 m/min.
The facility processes strips of carbon steel and high-strength steels in widths of 880 to1,880 mm. The maximum processing speed in the pickling line is 280 m/min.
Trimming shear.
A look onto the pickling tanks.
Tanks in the regeneration plant.
Pickled hot strip on its way to the tandem cold mill.
» Newsletter of the SMS group 4/2011
29
COLD MILLS AND STRIP PROCESSING LINES | Photo story
After pickling, the strip runs at up to 350 m/min into the five-stand tandem cold rolling mill where it is rolled at final speeds of up to 1,500 m/min. Final gages after rolling are
between 0.28 and 3.0 mm. Thanks to its technical equipment and the annual capacity of 2.1 million t of cold strip, the PL-TCM ranks among the world’s most powerful plants
The drive unit of the tension reel group.
30
Newsletter of the SMS group 4/2011
of its type. The continuous tandem cold rolling mill is equipped with five four-high roll stands incorporating SMS Siemag’s CVC® plus technology.
One of the four-high stands during roll changing.
The exit area.
The “Rotary Inspect” inline inspection line.
All mill stands feature equipment for positive and negative work-roll bending. Strip flatness and a drop-free strip surface are ensured by the multi-zone cooling system and the DS (Dry Strip) system in the last mill stand.
SMS Siemag’s Rotary Inspect inline inspection line permits prompt, reliable and easy checking of the quality of the rolled strip. In addition to the mechanical equipment, SMS Siemag supplied the complete X-Pact® electrical and automation package, the coil handling systems and the roll shop.
Interface and function tests using the customer’s production planning system could be carried out already in the test field with the completely installed X-Pact® automation system. These preparations and the holistic operating concept create the basis for quick ramp-up of the plant.
Coil haul-off.
Hardware check.
X-Pact® electrical and automation systems.
Newsletter of the SMS group 4/2011
31
COLD MILLS AND STRIP PROCESSING LINES
At MMK, SMS Siemag is currently building a cold strip complex including a whole range of strip processing lines. Project implementation takes place in several stages. After the start-up of the PL-TCM, which marked the successful completion of the first construction stage, two of MMK’s top executives were kind enough to grant SMS Siemag the following interview.
Interview
MMK: Integration test ensures high product quality Interview with: Sergej Laskov, Rolling Mill Manager at MMK Sergej Lipovsky, Head of Commissioning at MMK
Sergej Laskov.
Sergej Lipovsky.
Newsletter: Mr. Laskov, why did MMK
this also goes for the rolling mill we recently
choose SMS Siemag to supply, build and
put on stream. It is for this reason that we
commission a completely new cold strip
placed our order with the company that of-
complex?
fered the best overall concept.
Laskov: We already cooperated with SMS
NL: How do you judge the start of produc-
Siemag on several projects in the past and
tion of the pickling line/tandem cold mill?
gained a lot of positive experience. In addition, we once again analyzed the market and
Laskov: I think that both the first and the
took a close look at the supply and service
second month of rolling mill operation
spectrums of other plant builders. The over-
showed that we can achieve high-quality
all package offered by SMS Siemag met our
products. In these two months alone, we
expectations and requirements.
produced some 6,000 t of steel specifically for the carmaking industry. In the second
Sergej Laskov talking with Wolfram Schael (right), SMS Siemag’s general site manager.
32
Equipment made by SMS Siemag is per-
month, the rolling mill handled virtually all
forming very well around the globe. And
of the specified widths and thicknesses.
Newsletter of the SMS group 4/2011
NL: In this connection, how important was the integration test carried out beforehand?
ever question or situation came up, every-
NL: Once again for this project, SMS Siemag
thing was clarified quickly and to our full
acted as full-line supplier. In your opinion,
satisfaction.
how important is it to receive mechanical
Laskov: The commissioning of this rolling
equipment plus E&A from one source?
mill shows that the Plug & Work test we car-
NL: Which other aspects of commissioning
ried out largely benefited both sides. That’s
did you find particularly positive?
Lipovsky: I think it’s the optimal solution
Lipovsky: The HMI as implemented fea-
ment plus electrics plus automation come
for a customer when mechanical equip-
because during integration testing all the little things can be corrected which inevitably occur in the planning phase of such
tures a very high quality standard. All infor-
from one supplier. With his constellation,
major projects. And the training which our
mation relevant to the production process
the customer achieves the best results in
operators received as part of the Plug &
is available on the screens. Signals or mes-
terms of production quality. The interfaces
sages given out by the automation system
of all systems involved are optimally harmo-
are adequately displayed, and it’s quite easy
nized, from the level-2 process monitoring
NL: Mr. Lipovsky, what do you think of SMS
to diagnose a trouble or the failure of a
system to the basic automation system and
Siemag’s Plug & Work concept and were you
plant section or component.
the sensors to the mechanical equipment.
Work test has definitely paid off.
satisfied with the general cooperation between the staffs of MMK and SMS Siemag? Lipovsky: I was personally involved in integration testing and also headed MMK’s group of automation experts who participated in the programming activities. So I can confirm that the integration tests were successful. Without these tests, we would definitely not be able at this time to attain such a high production. Our cooperation on this project was very positive. Whenever differences of opinion came up, we managed to find a compromise. Because it’s simply not possible to consider each and every small detail in the contract. So when you handle a project of this size, you have to deal with unexpected questions every now and then. But what-
Sergej Laskov thanking Wolfram Schael for his excellent performance.
Newsletter of the SMS group 4/2011
33
STRIP PROCESSING LINES | News in brief
➤ New orders Hysco, Korea Laser welding machine for PL-TCM
Hysco, Korea Two strip processing lines Galvanizing line plus annealing & galva-
Already the fifth machine made by
nizing line. Hysco in South Korea will re-
SMS. SMS Siemag has been commis-
ceive from SMS Siemag the mechanical
sioned to supply a laser welder for the
equipment for two new strip processing
new coupled pickling line/tandem
lines. The hot-dip galvanizing line is to pro-
cold rolling mill which is currently
vide 500,000 tpy of strip with a zinc coat. The
under construction at Hysco in South
combined annealing & hot-dip galvanizing
Korea. This is already the fifth order for
line will make it possible for SMS Siemag’s
the laser welding machine developed
customer to produce either high-quality an-
by SMS Siemag.
nealed or hot-dip galvanized strips in keeping with the requirements of the market. It will be designed for a production of 300,000
Panzhihua, China Two annealing lines ordered
tpy of hot-dip galvanized and of 400,000 tpy SMS laser welder.
of annealed strips. Both lines will be equipped with air-knife systems made by
Altogether over 1.7 million t of high-
Fontaine and furnaces from Drever.
grade steel strips. China’s Panzhihua Iron and Steel Group Co., Panzhihua for short, chose SMS Siemag to supply two continuous annealing lines for a new works in Xichang in the country’s
New orders for SMS companies in China Tension levelers, trimming shear and post-treatment section with roll coater
southwestern province of Sichuan. The two CALs are to produce or process
In 2011, Strip Processing Lines Shanghai and SMS Siemag
over 1.7 million tpy of high-quality steel
Metallurgical Equipment, SMS Siemag’s manufacturing
strips for the automotive and electrical
and assembly location in Wujin, jointly received a number
appliances industries.
of new orders from Chinese customers for the supply of components for strip processing lines. Thanks to the operations in China, SMS Siemag is able to respond to and satisfy the demand of Chinese steelmakers for high-quality components directly from China. The orders cover for instance a tension leveler for Shougang Shunyi, a trimming shear for Shougang Qian’an, and another tension leveler plus a post-treatment section including roll coater for Ansteel.
34
Newsletter of the SMS group 4/2011
➤ Commissioning Tokyo Steel Pickling line on stream Annual capacity: 1.8 million t of strip. August 1, 2011, saw the production of the first coil on the continuous turbulence pickling line at Tokyo Steel, Japan. SMS Siemag’s supply package for this line contained all key components including the laser welding machine, all ancillary facilities plus an acid regeneration plant. The pickling line is able to attain an annual production of 1.8 million t in continuous operation.
Galvanized strip ready for shipment.
➤ Acceptance Shougang Qian’an, China Heavy shear line officially accepted
BSSB, China FAC for two special-steel lines
450,000 tpy of high-quality steel
Flexible configuration for 156,000 tpy
plates. On July 18, 2011, Shougang
of strip per line. Just recently, SMS Siemag
Qian’an issued the Final Acceptance
received the FAC for the strip processing
Certificate for the heavy shear line
lines supplied to Baoshan Special Steel
made by SMS Siemag. In addition to the
Branch, BSSB for short. For both lines, i.e.
mechanical equipment, SMS Siemag
an annealing line and a pickling line, each
also supplied the electrical and automa-
with an annual capacity of 156,000 t, BSSB
tion package. The shear is able to cut
chose a flexible configuration enabling a
450,000 tpy of hot strip into high-quality
broad product spectrum.
steel plates.
Newsletter of the SMS group 4/2011
35
STRIP PROCESSING LINES | Tinning technology
The project teams of Shougang Jingtang, SMS Siemag and the consortium partners after the signature.
During contract signing (from left): Wang Qing, Director of Shougang Jingtang Cold Rolling Plant; Cao Yuejin, Vice General Manager of Shougang International Trade Company; and Olaf Stalfort, Executive Vice President Strip Processing Lines Division and Vice President Market Development China.
➤ New order | China’s Shougang Jingtang United Iron & Steel commissioned SMS Siemag on August 16, 2011, to supply two electrolytic tinning lines for a total production of 475,500 tpy of high-grade tinplate. One of the reasons why SMS Siemag won the Shougang contract was that the technical concept offered by SMS Siemag provides for the use of soluble tin anodes. This concept entails significant economic benefits for the mill user.
For 475,500 tpy of high-quality tinplate
Shougang Jingtang, China: Order for electrolytic tinning lines with soluble anodes Design of the lines
Preparation cell
The two new lines for Shougang Jingtang will feature identical
A special process component provided by
equipment, the same direction of strip flow, and will be arranged
SMS Siemag is the preparation cell which is
alongside each other in one bay. In the entry section, they will be
filled with low-concentration sulphuric acid
equipped with two payoff reels followed by a welding machine, a
and through which the strip runs before it
side-trimmer unit and a vertical loop accumulator. The process sec-
enters the first tinning cell. It is here that the
tion starts off with an electrolytic cleaning section, a tension lev-
strip is pre-activated and perfectly cleaned
eler and an electrolytic pickling section. Next, the tin coat is ap-
from all iron-hydroxide particles. This en-
plied to the material in a total of nine vertical coating cells, with
sures that the iron content in the electrolyte
space already reserved for future installation of a tenth cell.
is reliably kept at a low level. In tinning lines
Arranged downstream of the strip drying section are an induction
without a preparation cell, by contrast, the
reflow unit and, finally, a passivating unit with a dryer. Another ver-
strip is activated in the first tinning cell; as a
tical loop accumulator provided in the exit section is followed by
result, the iron concentration in the elec-
an inspection station, a flying shear and two tension reels.
trolyte may rise to such a high level that the electrolyte is rendered unusable.
36
Newsletter of the SMS group 4/2011
Schematic representation of electrolytic tinning in a vertical cell.
Tinning section
Reflow unit
Tin-plating takes place in nine vertical cells, each equipped with
This line component serves to inductively heat the coating up to
four soluble tin anodes. Depending on the width of the strip to be
250 °C which is beyond the melting point of tin. This gives the
processed, the anode banks comprise up to 18 bars, each with a
strip a bright and shiny surface and allows an alloy layer to form
width of 70 mm. Because the width of the anodes will be adapted
which increases corrosion protection and improves the adhesion
to the strip width, no strip edge masks are required. Owing to its
of the tin layer on the strip surface. This heat treatment permits
better conductivity, Shougang Jingtan uses methane-sulfonic acid
to combine the benefits of electrolytic coating or plating (very
(MSA) as electrolyte in the tinning tanks. Thereby, energy costs go
thin layers) and those of hot-dip tinning (formation of an alloy
down while flexibility goes up due to the higher current density.
layer). By using high-frequency technology, heat treatment can
Since the electrolyte is substantially bio-degradable, it can be dis-
be implemented completely through induction. This means that
posed of in an eco-friendly manner.
no conductor rolls are needed on the strip surface which may produce surface defects. In addition, the formation of so-called wood
Replacement of the tin anodes
grains is precluded.
The state and condition of the anodes is continuously detected
Particularly worth mentioning is the highly efficient, simple and
and displayed by a monitoring system. In the lines SMS Siemag
precise control of the induction unit which also permits to modify
will supply to Shougang Jingtang, all the bars of an anode bank
the position of the unit in relation to the moving strip; in this way,
will be replaced simultaneously, thereby making sure that all bars
the formation of the desired alloy layer is always ensured.
of an anode bank have the same thickness at any point in time. This so-called parallel alignment of the anodes on the one hand
Numerous strip processing lines from SMS Siemag in the works
ensures high-quality and uniform plating conditions at any time,
of Shougang Jingtang. In addition to the two electrolytic tinning
and on the other hand prevents any impairment of strip travel due
lines and the tinplate annealing lines recently ordered, SMS Siemag
to defective anodes. The anodes will be produced on an anode
has already built and commissioned a number of further strip pro-
caster in the immediate vicinity of the tinning lines. The design of
cessing lines in Shougang Jingtang’s new works on Caofeidian Island.
this caster will also be provided by SMS Siemag.
In 2009 and 2010, two annealing lines were successfully started up, and the third annealing line will follow in the near future. Furthermore, a PL-TCM made by SMS Siemag went on stream in 2007.
» Newsletter of the SMS group 4/2011
37
STRIP PROCESSING LINES | Tinning technology
Fields of application of electroplated sheet (tinplate)
The electrolytic tinning process
Tinplate is a cold-rolled, recrystallization-annealed and pos-
In the process of electrolytic tin-plating, tin
sibly reduced thin sheet made from carbon steel to which a
is applied to the strip surface through elec-
firmly adhering tin coat was applied in an electrolytic process.
tro-chemical precipitation during which
This tin coat protects the base material against corrosion and,
process the strip runs through an acid-
subject to an adequate surface treatment, moreover is an ex-
type electrolyte. The electrolyte serves as
cellent primer for subsequent painting.
ionic conductor as during charge transport chemical processes occur at the electrodes
Mainly adopted as packaging material, tinplate is also called “pack-
due to the directed movement of the ions.
aging steel”. In fact it is used predominantly for the fabrication of
The thickness of the tin layer can be set
cans for food, beverages and pet food. In addition, it serves as
easily and exactly via the amount of the
packaging material for chemical-technical products as well as
electric current and the length of the pas-
spray cans for aerosols. Moreover, covers or lids and crown caps
sage time which depends directly on the
are often made of tinplate.
strip speed. In this way, also very thin layers by just a few µm can be applied with great precision. If required, it is also possible to apply layers of different thicknesses to the two strip sides.
Technical data of the lines Material
T2,5, T3, T4, T5, DR7, DR8, DR9, DR10
Capacity
each 237,500 tpy
Coating thickness
1.0 to 11.2 g/m2
Dimensions – Strip width
700 to 1,280 mm
– Strip thickness, ingoing
0.12 to 0.55 mm
Coil OD
max. 2,100 mm
Process speed
600 m/min
38
Newsletter of the SMS group 4/2011
Top economic efficiency through soluble anodes Electrolytic tinning lines may also be equipped in insoluble tita-
special metal coating, have to be restored
nium anodes in which case the electrolyte has to be continuously
in a cost- and time-consuming manner.
enriched with tin ions for the tin to deposit on the strip surface.
Furthermore, edge masks are needed for
This, however, requires a system in which tin granulate is dissolved
the insoluble anodes to adapt the width of
by means of oxygen. The substantial economic drawback of this
the anodes to the strip width when lighter-
method lies in the high price of tin granulate which is 5 to 10 %
gage strips have to be handled.
above that of tin bars as used for the production of soluble anodes. Moreover, at least 4 % of the dissolved tin are lost because tin
SMS Siemag’s electrolytic tinning lines use
sludge forms from which it is impossible to recover the tin. In addi-
soluble anodes. The width of these anodes,
tion, the active surfaces of the anodes, which are provided with a
which consist of several bars, can be adapted to the strip width. This ensures constantly good surface quality and high efficiency of the system. Another advantage is that no costs are incurred for the restoration of the anode surfaces. Plus, the costs of tin and the losses due to tin sludge formation are lower. And no money has to be spent for oxygen.
Anode banks in a vertical electrolytic tinning cell.
Principle representation of the electrolytic coating lines for Shougang Jingtang.
Newsletter of the SMS group 4/2011
39
TECHNICAL SERVICE | Cost reduction
➤ Product presentation | For metallurgical plants and rolling mills
IMMS® and Condition Monitoring: Tools to reduce life cycle costs Life cycle costs are the cumulative costs a plant or system causes over its entire service life. These costs do not only include the price for acquisition but mainly also the expenses for operation and maintenance. For metallurgical plants and rolling mills, they mostly exceed the original investment costs many times over. Hydraulic adjusting cylinder.
For this reason, many of the SMS customers are striving for a reduction of life cycle costs as an important strategic means to keep up their competitiveness. The present state of the art offers a number of tools to achieve this goal.
Savings through design and maintenance Considerable cost savings can be achieved by appropriate measures in plant design as well as by targeted maintenance work during operation. There is a variety of examples successfully implemented by SMS Siemag for the reduction of life cycle costs through design modifications or new developments.
Flat-neck spindle.
Examples for cost reduction by means of design modifications n Torque, vibration, and temperature measurements for condition monitoring and to avoid overloads. n Modular hydraulic control columns which can easily be extended in line with plant adaptations to changing production requirements. n Practice-oriented inspection possibilities for large-size gear units to ease preventive maintenance and repair. n Flat-neck spindles with reliable oil lubrication system to increase the service lives and to obtain the best possible power transmission referred to identical dimensions.
40
Newsletter of the SMS group 4/2011
Additional tools for cost reduction
Systematic selection of components
Since the service life of metallurgical plants is normally much
It is easy to install a continuous monitoring
more than 30 years, significant expenses are incurred for opera-
system at various plant components, but to
tion and maintenance during the useful phase. As a rule, these
achieve the desired cost effect, it is necessary
easily exceed the purchase price of the plant. To give you an ex-
to select “suitable” components for continu-
ample of how to control these costs, two additional tools are pre-
ous monitoring.
sented below. One of these tools is the integrated maintenance management system (IMMS®), the other one the condition monitoring system which is an early warning system against failure. Both are effective means for efficient maintenance and hence for reduction of life cycle costs.
Maintenance Management System, IMMS® In a maintenance management system, data quality is the basis for success. Therefore, highest attention must be paid to obtaining meaningful data for transfer to a maintenance management system. Structured data generation on the basis of the RCM method (Reliability-Centered Maintenance) ensures that this demand is met. SMS Siemag developed a practicable approach by means of MERCM (Maintenance Engineering based on RCM). Rolling mill gear unit.
Genius Condition Monitoring System, CM Linking CM systems to the plant control system to generate process-
Advice on site
related monitoring data will provide the overview required for recording the actual plant condition. If these data are combined
SMS Siemag offers local advice services on these topics.
with the plant design knowledge, the step from a mere data display
For more information please go to:
to data evaluation will be successful.
[email protected]
Newsletter of the SMS group 4/2011
41
TECHNICAL SERVICE | Locations worldwide
Location: Germany Spare parts Technical customer support Know-how components repairs Zinc-pot equipment repairs
Location: USA Spare parts Warehouse management Know-how components repairs Zinc-pot equipment repairs Copper mold plating/segment workshop Roll workshop Work roll chroming Technical customer support
Location: Turkey Spare parts Technical customer support Copper mold plating/segment workshop
Location: Russia Spare parts Warehouse management Copper mold plating/segment workshop Know-how components repairs Technical customer support
Location: Middle East Know-how components repairs Technical customer service
Location: China Spare parts Know-how components repairs Zinc-pot equipment repairs Work roll chroming Copper mold plating/segment workshop
Location: India Spare parts Technical customer support Copper mold plating/segment workshop
Location: Brazil Spare parts Technical customer support Know-how components repairs Copper mold plating/segment workshop
➤ New openings | New and expanded workshops. Constant improvement of SMS Siemag’s customer service in the fields of
The SMS Siemag service workshops
Trustful partnership
maintenance and repair is a major concern to SMS. Thanks to service workshops in the Middle East, Brazil, China, India and Russia,
Workshop in Gebze, Turkey. This new site
Workshops in Tianjin and Zhangjiagang,
in Turkey and the U.S.A., SMS Siemag is a
is being equipped with the most modern
China. From the first and/or second quarter
direct and experienced contact partner
machinery and facilities for the repair and
of 2012, service workshops will be available
right on the doorsteps of many customers.
coating of mold plates as well as for gen-
to SMS Siemag’s Chinese customers in Tian-
Some of these locations are new facilities,
eral repair work. About 20 service techni-
jin and also in Zhangjiagang. The about 40
others have been expanded as this report
cians will be available close to the cus-
experts working in Tianjin in the north of
will show.
tomers from the first quarter of 2012.
China specialize in the repair of zinc bath equipment and the chromium-plating of
Repair of high-tech components also pos-
Workshop in Vespasiano, Brazil. In this
work rolls.
sible. SMS Siemag’s service staff is able to re-
location also, SMS Siemag will carry out re-
pair all equipment items including high-tech
pairs of demanding plant parts such as
In Zhangjiagang in southern China, about
components requiring special know-how
CVC blocks, HGC/AGC cylinders, coiler
90 technicians will offer general repair
such as AGC cylinders, CVC® systems, drive
mandrels and mold plate coatings as of
services, manufacture spare parts in situ,
spindles or even pinch rolls. The workshop
the first quarter of 2012. Such repairs at the
repair and coat mold plates, and make
personnel was trained in Germany and op-
customer’s site grant best possible consul-
rollers with special coatings.
erates according to SMS Siemag’s proven
tation and support in terms of mainte-
quality management system.
nance and optimization.
42
Newsletter of the SMS group 4/2011
Service workshop in Alabama, U.S.A. In spring 2010, SMS Siemag and Band-Zink GmbH established a workshop for the
Three-axis milling machine.
Box-plating process.
The process of mold nickel plating.
ice life of the mold. The resulting main ben-
maintenance of zinc bath equipment of hot-dip galvanizing lines in Alabama in the southeast of the United States on the premises of ThyssenKrupp Steel USA. All machin-
Nickel plating of molds is a technology to
efits are on the one hand lower mainte-
ing steps required for the repair of the gal-
increase and improve the overall service
nance costs and on the other higher plant
vanizing units including coating of the bath
life of molds.
availability and/or productivity through reduced downtimes.
rollers are performed in close vicinity to the galvanizing lines.
Service workshop in Orissa, India
SMS Siemag’s workshop in Bhubaneswar offers all process steps that are required
Moreover, the SMS method of mold nickel
for complete mold reconditioning: clean-
plating improves the quality of the final
ing, inspection in a test facility, welding
product as it helps particularly to avoid the
New central workshop in Bhubaneswar
shop, dismantling and re-assembly, as
formation of star cracks on the slab surface
opened. In the fourth quarter of 2011, the
well as all essential processes for mold ma-
and to reduce the pickup of copper parti-
new central workshop in India’s northeast-
chining and coating. Specially modified
cles as well as to obtain better slab dimen-
ern state of Orissa was opened in order to
three- and five-axis CNC machines allow
sions due to less surface wear.
offer SMS Siemag’s customers a variety of
the machining of workpieces with copper
services in a central location. These services
and nickel alloys.
Thanks to the favorable location of the
comprise mainly the maintenance and re-
workshop, transport times are quite short
pair of caster molds as well as nickel plating
The so-called box-plating process devel-
and machining work can be carried out
of mold copper plates. Besides the actual re-
oped by SMS Millcraft is highly efficient
quickly and efficiently.
pair service, the workshop personnel takes
since merely the wear surfaces to be
care of the complete logistical management
coated get in contact with the electrolyte
Know-how and experience. Assisted by
of the components from collection at the
solution and time-consuming dismantling
the experts of SMS Millcraft who dispose of
customer’s plant to re-delivery.
and re-assembly work is thus avoided.
many years of experience and a highly developed and worldwide reputed know-
The workshop has a size of approx. 2,000 2
The workshop is geared to machining
how in the field of mold machining and
m and is completely equipped with latest
molds of different sizes and for use in var-
coating, the new workshop was recently
coating facilities, CNC machines as well as
ious casting technologies, CSP® plants and
commissioned. As a consequence of the in-
testing instruments according to interna-
also conventional continuous casters.
teraction of effective technologies and processes and in due consideration of the
tional standard. The service team consisting of some 50 qualified technicians who
Cost savings and benefits. The SMS
experience of the local subsidiary SMS
were trained in the U.S.A. plus manage-
method of mold nickel plating offers sig-
India, a competent repair and maintenance
ment by SMS staff ensure the continuously
nificant process technological and eco-
service was born which is tailored to the
high-quality level of the services rendered
nomic advantages. Surface coating re-
specific requirements of customers in India.
by the workshop.
duces wear and leads to an extended serv-
Newsletter of the SMS group 4/2011
43
BUSINESS AREA SMS MEER | News in brief
Reduced operating costs
Annual capacity: 20,000 t of aluminum bars
ASAŞ orders homogenizing plant
Otto Fuchs, Germany:
for round aluminum bars
Homogenizing furnace ordered
➤ New order | ASAŞ Alüminyum Sanayi ve Ticaret A.S., Turkey, has ordered a plant for the homogenizing of round bars from Hertwich Engineering, Austria. The scope of supply comprises a helical ultrasound testing facility, continuous homogenizing, cooling, turbo cooling and a saw and packing station. With this equipment, about 80,000 t of round bars can be handled. Commissioning is scheduled to start at the beginning of 2012. With this new plant, ASAŞ will reduce its operating costs because the electrically heated continuously operating furnace has an energy consumption of only about 210 kWh/t. This is considerably
Hertwich Engineering supplies a similar plant to Otto Fuchs.
less than with conventional gas furnaces. In addition to that, ASAŞ will benefit from low downtimes and maintenance costs, assuring
➤ New order | Otto Fuchs KG in Meinerzhagen, Germany, has
high productivity of the downstream extrusion press lines.
commissioned Hertwich Engineering with the supply of a continuous homogenizing furnace for round billets with large diameters. The equipment will be used for the production of billets from special Al alloys for the automotive and aircraft industries and will be provided with a very precise temperature control. Operation will be fully automated. Commissioning is scheduled for the end of 2011.
Heating up to 20 %
Dubal, UAE, orders homogenizing plant for aluminum bars from Hertwich Engineering ➤ New order | Dubai Aluminium (Dubal) has awarded Hertwich
The furnace capacity is 55 t. Owing to a reverse air jet with vent flap
Engineering, Austria, the order for the supply of a chamber-
control the furnaces will be able to achieve even temperature dis-
type homogenizing plant and a cooling station for its Foundry
tribution as well as 20 % faster billet heating. The plant is fully auto-
No. 1 in Dubai. Processed will be billets with diameters ranging
mated and heating is controlled via the measured air and metal
from 125 to 410 mm and lengths up to 8 m. The plant is the sec-
temperatures. The same concept ensures also efficient cooling in
ond of its kind in Foundry No. 1 and altogether the third at
the air cooling station. Hertwich Engineering is part of the SMS Meer
Dubal. Commissioning is scheduled for September 2012.
Business Area.
44
Newsletter of the SMS group 4/2011
Service life of casting molds increased by 20 %
About 30 % higher productivity
Metallo Chimique, Belgium:
New bright steel center for
Casting carousel for Cu anodes
Flanschenwerk Bebitz , Germany
➤ New order | The Belgian recycling specialist Metallo Chimique N.V. in Beerse, less than 30 km east of Antwerp, has placed an order with SMS Meer for the supply of a casting carousel for anode plates made of copper. The casting carousel is designed for a production of 50 t/hour and provides a new casting device for smallest weight tolerances. Apart from that, the equipment includes a system for decreasing the thermal load on the molds, whereby operating costs are considerably reduced and productivity is increased. A peeling machine of the PMS 125 design.
”SMS Meer’s new system for minimizing the thermal load on the casting molds increases the mold service life by up to 20 %. Furthermore,
➤ New order | Flanschenwerk Bebitz GmbH in Bebitz, Ger-
less service is necessary,” says Thomas Schatz, Sales Engineer at SMS
many, has placed an order for a new bright steel center with
Meer. Commissioning of the plant is scheduled for summer 2012.
SMS Meer. The plant of the BC 120 design is able to process bars with diameters up to 120 mm and achieves a max. peeling speed of 40 m/min. With this capacity, the facility is approx. 30 % more productive than conventional equipment. The greater efficiency results from a particularly robust construction allowing high peeling speeds.
Principle of casting carousel.
The facility peels, straightens and inspects round bars from different stainless steel grades and it processes bars with diameters ranging from 25 to 120 mm and lengths from 3 to 6 m.The bar diameter can be reduced by up to 10 mm and less changing times will furthermore ensure Bebitz flexibility. “With the new facility, we will be able to fulfill the individual requirements of our customers even better,” says Udo Gebel, Bright Steel Production Manager at Flanschenwerk Bebitz. “From the SMS Meer plant, we also expect an excellent product quality.” Another bright steel facility will be supplied by SMS Meer to Viraj Profiles Ltd. in Mumbai, India. Viraj Profiles is the parent company of Flanschenwerk Bebitz GmbH.
Newsletter of the SMS group 4/2011
45
CC TECHNOLOGY FOR LONG PRODUCTS | Bloom casting plants
➤ Commissioning | In June 2011, Dongbei Special Steel Group Company, based in the Chinese harbor city of Dalian in the province of Liaoning, brought on stream a new continuous bloom caster supplied by SMS Concast. Successful casting of the first heats – on all three strands right from the start – was followed without delay by performance tests and subsequent ramp-up to full production.
Dongbei, China: High metallurgical quality Bloom caster in full production
Casting platform area with ladle turret and tundish.
46
Newsletter of the SMS group 4/2011
Sturdy strand guide segments ensure high dimensional accuracy.
The plant produces blooms of perfect dimensions.
Perfect design of the containment zone.
Technological features for high product
Part of a new steelworks complex. Thanks
The casting machine has a radius of 16.5 m
quality. For achieving the specified metal-
to the new caster, Dongbei Special Steel will
and is designed for casting cross-sections of
lurgical properties and grades, the casting
be able to produce blooms of higher met-
380 mm x 490 mm. For optimal strand sup-
machine is equipped with a series of tech-
allurgical quality and make production of
port from the mold exit down to the lower
nological systems:
final products on the downstream rolling
part of the casting machine, the cast strands
mill more efficient. The casting plant is part
are guided by sturdy segments until they
n Technology for low-superheat casting
reach the withdrawal and straightening
n Mold design for improved heat
units. These segments feature support
city of Dalian. The old steel mill facilities in-
extraction
side the city region have meanwhile been
rollers on all four sides to keep the strand
n Mold electromagnetic stirring (M-EMS)
precisely in position. The sturdy design of
n Resonance oscillation system
the strand guide segments is perfectly
n Intensive secondary cooling
suited to withstand high thermal loads and
n Position- and length-optimized
of a steelworks complex set up outside the
shut down. Saving of resources and reduced emissions. With this investment, Dongbei is
mechanical forces. This guarantees perfect
dynamic mechanical soft reduction
making a major contribution to resource
bloom dimensions along the complete con-
(DMSR)
saving and reduction of emissions. A key
n Dynamic control of DMSR through
factor in the success of this project was the
an online solidification model and
close collaboration and partnership be-
The withdrawal and straightening units are
individual support roller adjustment
tween the teams of Dongbei Special Steel
equipped with dynamic mechanical soft re-
for thickness reduction
and SMS Concast.
tainment zone.
duction DMSR. With DMSR, the strand thick-
n Reduction rates are individually and
ness can be reduced individually at each
automatically controlled by the DMSR
withdrawal and straightening unit in rela-
module, as a function of the steel grade,
tion to the internal condition of the strand.
steel temperature, casting speed and
Through this, the plant achieves best metal-
secondary cooling
lurgical internal quality.
Newsletter of the SMS group 4/2011
47
INDUCTION TECHNOLOGY | New technology
Induction technology from SMS Elotherm, Germany
GKN Driveline: Heating plant with iZone™ put into operation ➤ Commissioning | With a ceremonial handover, GKN Drive-
The heating plant provides a bar magazine
line Trier GmbH, Germany, has officially started the operation
with a loading capacity of about 25,000 kg
of an induction heating plant delivered by SMS Elotherm in a
enabling a continuous material flow for
newly built production building. Apart from the employees of
uninterrupted production of almost two
GKN in Trier and numerous personalities from politics and
hours. In addition, an integrated cooling
business, high-ranking group members were welcomed by Dr.
magazine, operating according to the FIFO
Roland Seidel, Managing Director of GKN Driveline. Among
“first-in, first-out” method provides single
them were for example Sir Kevin Smith, Chief Executive Officer
storage of bars already heated. Returned
of the British parent company GKN plc, and Dr. Helmuth
bars are raised from the transport roller
Rohregger, Managing Director of GKN Driveline North Europe.
conveyor by a lifting device which prevents
As from July 1, 2011, precision parts for constant velocity joints
ferred to the cooling chain.
bending of the bars and are then transwhich are used in the vehicles of all renowned automotive manufacturers are now manufactured at GKN Driveline Trier. The bar
The innovative "iZone™" technology enables
heating plant of the EloBar™ type built by SMS Elotherm operates
GKN Driveline to reheat bars while they are
in front of a multistage press of a Swiss manufacturer.
still warm and before they are cooled down at ambient temperature.
The bar heating plant of the EloBar™ type.
48
From left: Dr. Helmuth Rohregger, Dr. Roland Seidel and Sir Kevin Smith, GKN Driveline; Dirk Schibisch, Head of Sales/Marketing of SMS Elotherm.
Newsletter of the SMS group 4/2011
GKN Driveline produces precision parts for constant velocity joints on an induction plant supplied by SMS Elotherm.
FORGING PLANTS
Two conrods at the same time in 4.8 seconds
Dongfeng Nissan orders forging line for new plant in Guangzhou, China ➤ New order | The Chinese-Japanese joint venture company Donfeng Nissan Passenger Vehicle Company has placed an
Flexible plant for different conrod sizes
order with SMS Meer for the supply of a wedge press with forging roll. The machines are destined for the new forging mill
On this line, Dongfeng Nissan is going to
in the Guangzhou Province, Huadu District. With this plant,
manufacture conrods exclusively for its
Dongfeng Nissan will be able to produce different conrod sizes
own passenger car production. Conrod
for passenger cars within a short period of time in a flexible and
production via forging roll and wedge
fully automated manner. Commissioning of the new forging
press is fully automated. The transport of
line is scheduled for the beginning of 2013.
the parts in the wedge press is controlled via an automatic servo-electrical walking-
Reduces feedstock and thus also costs
beam system. A quick-change system for the die holder is also integrated in the
The wedge press of the AKP 2500 series has a forging force of 25 MN
plant.
and is characterized by its large eccentric loading capacity. With the wedge drive of the ram the forging tolerances can be kept at a constant low level. The forging roll of the ARWS 1 type preforms the forging material. In addition, the roll reduces the feedstock and thus the material costs.
“is ensures Dongfeng Nissan a high productivity. At the same time, the plant is flexible to produce different conrod sizes within a short period of time,” says Dieter Blom, Project Manager Sales Closed-Die Forges at SMS Meer. The plant forges two conrods simultaneously in a cycle time of 4.8 s.
Two identical plants at Nissan In Japan, Nissan is already successfully operating two identical plants of SMS Meer at the Yokohama site.
Dongfeng Nissan produces conrods for passenger cars on new forging line.
Newsletter of the SMS group 4/2011
49
FORGING PLANTS
Operable after an assembly time of just nine months
China: Wuxi Turbine Blade take world’s most powerful screw press in operation With an impact force of 35.5 MN it is the world’s most powerful
The clutch-operated screw press supplied by SMS Meer combines
screw press. Since summer 2011, the clutch-operated screw
the benefits of forging hammer and hydraulic press with the ad-
press is operating at Wuxi Turbine Blade Company, in short
vantage to better satisfy the increased demands from the cus-
WTB, at its Wuxi site in Jiangsu Province. The large press has
tomers of the power plant and aircraft industries. The scope of sup-
been put on stream after an erection time of just under nine
ply of SMS Meer also included the training of the Chinese plant
months. More than 150 guests from the worlds of politics and
operators.
business were present at the opening ceremony at WTB.
In operation after an erection time of just under nine months: The clutch-operated screw press from SMS Meer.
50
Newsletter of the SMS group 4/2011
Yan Qi (right), Managing Director of WTB, and Norbert Gober of SMS Meer unveil a small present during commissioning.
During the opening ceremony, Norbert
The core of the plant is the screw with a di-
Gober, Vice President Closed Die Forges at
ameter of 1,320 mm and a weight of 82 t
SMS Meer, emphasized the good coopera-
and it requires a frequency-controlled driv-
tion between WTB and SMS Meer. Therefore,
ing power of only 500 kW which is 87 %
the plant could go on stream three months
less than for conventional screw presses
earlier than contractually stipulated.
whilst at the same time increasing the forming energy.
New forging inserted into press.
The flywheel with a diameter 7,500 mm in rotation.
With the new screw press of the Eumuco-Hasenclever type, WTB will be able to produce in future forgings from high-strength alloys for the power plant sector and the aviation industry.
Turbine blades for the low-pressure stage of the latest generation of powerplant turbines and turbine disks for aircraft engines can be manufactured on this plant.
Newsletter of the SMS group 4/2011
51
SERVICE – WORLDWIDE
➤ New service offer | SMS Meer can now offer its customers three service packages to make laser measuring devices on ring rolling machines fit for the future.
The goal is to reduce machine downtimes because a ring rolling machine without a properly functioning laser measuring device is mostly at a complete standstill which will cause high costs.
Service packages for ring rolling machines
Laser measuring devices made fit for the future The SMS Meer service packages offer quick help to plant users and thus ensure high product quality and full plant availability. In this way, the laser measuring devices are able to continually determine the surface structures on the rolled rings in a highly precise and contactless manner.
Package 1: Spare laser
Package 2: Maintenance of laser measuring device
Package 3: Upgrade and modernization of laser measuring device
Repair work mostly takes a few days, pro-
Regular maintenance makes it possible
Some measuring heads can be brought up
vided that all required spare parts are im-
that stable measuring results are achieved
to the latest technical standard by ex-
mediately available. This may cause prob-
even with older lasers. SMS Meer offers ma-
changing individual components and by
lems particularly in the case of older laser
chine maintenance at regular intervals to
performing a software update. By retro-
measuring equipment. The reason: due to
make sure that downtimes are minimized.
fitting for example an internal temperature
ever shorter innovation times of electronic
In this way, quality management regula-
control system higher stability of the wave
components older spare parts are often no
tions can be fully complied with.
length and improved beam stability can
longer available. A spare laser can be easily
be attained. A controlled laser impulse
replaced on demand which minimizes pro-
width and sensor exposure time result in
duction outage. Therefore, SMS Meer offers
higher dynamics and stability of the meas-
spare lasers.
ured values. This is of particular interest for manufacturers who want to measure e.g. descaled or even high-gloss surfaces.
52
Newsletter of the SMS group 4/2011
Turbine blades for aircraft industry
Forges de Bologne, France: Screw press with “new heart” Already 34 years old and still competitive with regard to productivity and product quality: this is the result of a modernization on a screw press of the HSPRZ type which SMS Meer performed at Forges de Bologne in France.
“is example shows: SMS Meer plants and machines achieve long service life and can be brought economically to the latest state of the art even aer decades,” says Hans-Dieter Niers, Head of Repair and Modernizations. From Germany to Russia and then to France. The machine has an interesting history. Originally, SMS Meer had supplied the screw
Component of 34-year old screw press prior to modernization.
press in 1977 to a Russian customer where it was in operation for about 20 years. With only little signs of wear, Forges de Bologne purchased the screw press approximately 12 years ago. Then, it
Already in operation for a while. Since the beginning of May
was disassembled and stored for some time. In 2008, SMS Meer
2011, Forges de Bologne has resumed forging with the old plant –
was finally commissioned by this French company to carry out a
in fact high-quality turbine blades for the aviation industry.
general overhaul of the press. New screw assembly as “new heart”. Most of the extensive modernization work has been carried out in the SMS Meer manufacturing workshop in Mönchengladbach where the new screw set of the forging machine was also manufactured: the “new heart.” In addition, SMS Meer equipped the press with a completely new hydraulic and electrical control as well as other new mechanical components. Special feature: Wooden oil-motor pinions. A special feature of the hydraulic screw press is the oil-motor pinion made of wood. The pinions are now operated by the hydraulic control which applies a very smooth drive concept. After modernization, the age of the screw press is no longer visible – neither from its appearance nor from its output.
Newsletter of the SMS group 4/2011
53
TUBE PLANTS
➤ Innovation | With SMS Meer’s new simulation concept for weldedtube plants, calculations become more realistic than with those methods common on the market.
Simulation calculation at SMS Meer which, already today, can be integrated in 3D design work is not only easy and logical in its application but is also completely and freely configurable. In this case, SMS Meer successfully combined three elements: 3D-CAD, FEM and the actual process.
Realistic plant calculations are possible
Welded-tube plants: New FEM-analysis concept Old procedure with limitations. For some time, SMS Meer has been calculating pipe forming processes with FEM tools (Finite ElTechnologically relevant 3D model of welded-tube plant.
ement Method), however, there were deviations between the computer model and the situation in practice. The reasons for this were limitations of the technologies available. Examples: calculations were performed with an optimized MSC.MARC solver. The equipment used was a hexahedron grid over several layers – depending on the strip gage. In practical application, single-layer models had proven to be a
Formation flower calculated with FEM.
good time/benefit compromise. Machine and roll data were entered via a 2D-CAD system, in some cases by means of prepro-
Here, the SMS Meer experts discovered that
a good basis, however, they should become
grammed masks and tables.
such calculation cannot represent the entire
noticeably more realistic by further technical
scope of the bending process.
development at SMS Meer. To verify this, SMS Meer had regular contact with plant
The rolls did not rotate and were defined as slide bodies. Since friction was basically only
A new, more advanced approach. SMS
operators and checked the calculation re-
taken into consideration via conversions it
Meer’s main goal was to create an FEM cal-
sults. Measurements on current products
was not often applied in practice because it
culation model which should be as realistic
and comparisons with simulation data had
led to relatively unfavorable and frequently
as possible just like it is required from each
already revealed that previous calculations
also to unrealistic results. The material data
FEM calculation. Therefore, more informa-
were pretty close to reality. Now it was a
of various steels had merely some influence
tion had to be processed than before to fur-
matter of optimizing this.
with regard to their yield strength and only
ther improve earlier simulation results con-
flow curves of standard material were used.
siderably. Previous results provided indeed
54
Newsletter of the SMS group 4/2011
Fin-pass stands.
Solution with connection to design
Finally, this concept offers numerous ben-
Unlimited flexibility during design
data. The complex parametric 3D design
efits which result in optimized plants and
work. For a machine or plant builder such
of welded-tube plants using the CAD sys-
processes.
as SMS Meer, it is particularly important to
tem ProEngineer Wildfire 3.0 (M230) from
be able to try out new ideas or even nonReal roll kinematics. In a calculation, the
realized ideas without requiring major ef-
ate collision analyses and an almost per-
rolls should behave just like in reality. There-
fort. The possibilities of a 3D system are un-
fect construction system, but this system
fore, the rolls were defined as rotating bod-
limited and now the possibilities of trying out these systems are also unrestricted.
PTC not only enables SMS Meer to gener-
also provides excellent interconnection ca-
ies, partly also driven. The rotary axes are
pabilities with FEM systems. Consequently,
defined directly in the simulation software.
the connection of FEM systems to design
For the roll surfaces the friction is also taken
Realistic material behavior. A realistic
into account with the Coulomb friction
simulation makes sense only with data
model. In this way, a realistic transport be-
from practical application. If not only a
data was a logical step. Early utilization. Beyond previously inde-
havior can be calculated, for example in the
qualitative but also a quantitative analysis
pendent FEM simulations, SMS Meer is
calibration distance.
is required the application of a proper flow
now able to incorporate this technology in
curve is indispensable. Plastic forming is
the CAD environment of design work. The
Simplified design work using “drag-
calculated with the plasticity model of a
advantage: the integration of FEM calcula-
and-drop”. With this step a method has
cold forming process using Ludwig's equation as follows:
tions can already be applied early during
been developed which allows transmitting
the development of new plants and the
the contact geometries directly into the
creation of new concepts.
simulation environment, i.e. the contact geometry of all rolls was transmitted in-
therefore the application of previously cal-
In doing so, SMS Meer has come to the con-
cluding the strip in relation to the dimen-
culated flow curves for currently used ma-
Another goal of the SMS Meer engineers is
clusion that a collection of simulation data
sions as well as to the position. This now
terials as the basis for the forming process.
particularly benefits from this procedure
makes a realization of flexible and unre-
Here, SMS Meer does not only rely on an ex-
since all required data are already available
stricted changes of machine properties
tensive data collection but also has long-
in a 3D format. ProEngineer directly inter-
possible – a major progress in design work.
standing contacts with institutions active in
connects geometrical data and positions
And it is no longer necessary to enter the
this field. In some cases, the material sam-
with special settings across various depart-
complete positioning and roll geometry pa-
ples are directly sent to SMS Meer by the
ments within SMS Meer. All data are avail-
rameters since these are already available in
customer.
able in real time and are already incorpo-
the CAD system. However complex the po-
rated via PDMLink 9.1 (M020). It therefore
sition of the forming elements may be – a
makes sense to implement these structures
single mouse click is sufficient for precise
and make them also available for simula-
positioning. Now, additional modules are
tions. SMS Meer performed an extensive
no longer required for complex or even ex-
benchmarking analysis and found that the
otic plant components and a time-consum-
simufact.forming system was best suited in
ing entry of coordinate values into the ta-
all areas. In addition, this system features a
bles can also be dispensed with. Transmis-
high integration capacity.
sion errors are thus safely ruled out.
Straightedge forming section.
Newsletter of the SMS group 4/2011
55
TUBE PLANTS
➤ Commissioning | On August 15, 2011, the first tube was rolled on a 159-mm (6 ¼“) PQF® seamless-tube plant at Baotou Iron & Steel Company in the Autonomous Chinese Republic of Inner Mongolia – only five months after start of erection.
Assembly of the key components had commenced in mid-March 2011. The quality of the tubes produced until now was fully according to the technical specifications and the official performance tests will be completed in January 2012.
Baotou Iron & Steel, China
PQF® tube plant has started production In March 2009, SMS Meer together with SMS Innse have been awarded the order for the supply of a PQF® seamless-tube plant with a production capacity of 400,000 tpy. The engineering has been prepared by SMS Innse in cooperation with SMS Meer. The scope of supply included the design and manufacture of the tube rolling line comprising cone-type piercer, PQF® plant, extractor and stretch-reducing mill plus supervision of erection and commissioning. The PQF® plant with new mechanical
Discharge of the first tube.
equipment was manufactured in Italy, while the cone-type piercer and the stretch-reducing mill were built in Mönchengladbach. SMS Innse and SMS Meer also sup-
Main technical data of the plant
plied the Carta® automation equipment, the control engineering and the automa-
External tube diameter
Ninth PQF® plant in China. The PQF®
Wall thickness
2.9 to 25.0 mm
Productivity
150 pcs/h with offline
seamless-tube plant for Baotou is the ninth plant of this type which has been installed
mandrel insertion Steel grades
by companies of the SMS group in China. Two more plants are presently being erected or are in the manufacturing phase.
56
38.0 to 159.0 mm with 2 different PQF® grooves
tion system (level 2).
Newsletter of the SMS group 4/2011
Carbon, low/medium/ high alloy
LONG-PRODUCT MILLS
➤ Commissioning | At Jiexiu Xintai Iron & Steel Co. in Jiexiu, Shanxi Province, China, a rolling mill for heavy steel beams supplied by SMS Meer has been successfully taken into operation.
Already the first four I-beams rolled with dimensions of 400 mm x 400 mm were within the tolerance range.
Jiexiu Xintai, China
Heavy-section mill succesfully started First four beams already within tolerance range In future, beams with web heights up to 1,000 mm shall be produced. The mill is designed for 1.2 million tpy of such products and the plant at Jiexiu Xintai is the ninth section mill which has been supplied to China by SMS Meer.
Technology for highest flexibility and top quality The beam mill is equipped with universal
Finish-rolled beam on transport roller table. Owing to rigid CCS® mill stands, the rolled products achieve close tolerances.
mill stands of CCS® design (Compact Cartridge Stand). These highly rigid mill stands with hydraulic roll adjustments
XH® rolling method
allow final dimensions to be rolled within a very close tolerance range. In addition, a
This mill also operates according to the XH® universal beam rolling
nine-roller CRS® straightener with hydraulic
principle developed by SMS Meer. This process allows particularly
adjustment and automatic roller change
large beams to be rolled with close tolerances and thus increases
ensures high flexibility and optimum
the quality of the products at Jiexiu Xintai. In the meantime, this
straightening quality with minimum resid-
technology is used in 16 section mills worldwide.
ual stresses.
Newsletter of the SMS group 4/2011
57
LONG-PRODUCT MILLS
➤ New order
China: Baotou orders another section mill 1.2 million t of beams, rails and sheet piles per year Inner Mongolia Baotou Steel Union, China, belonging to Baotou Iron & Steel, has placed an order with SMS Meer for the supply of a heavy-section rolling mill. This means that Baotou will receive another rolling facility of this type after a section mill had been supplied by SMS in 2006. Commissioning of the mill is intended for the end of 2012.
Finish-rolling group of the section mill put into service at Baotou in 2006.
Broad dimensional range and high capacity In future, the mill will produce heavy beams with a web height of 200 to 1,000 mm, rails with meter weights between 52 to 75 kg/m and U-shaped sheet piles with a span width of up to 600 mm. The annual capacity is 1.2 million t. With this mill, the capacity of parallel-flanged beams and rails for high-speed traffic in China will continue to increase.
Rails manufactured on the section mill at Baotou built by SMS Meer.
Supply including training. The supply
CRS® straightening machine for good
Cold saws with high throughput. The
package of SMS Meer includes planning
straightening results. A 9-roller CRS®
rolled product is cut into finished lengths
and engineering, technological core equip-
straightening machine (Compact Roller
by cold saws of SMS Meer. This technology
ment, customer training as well as supervi-
Straightener) serves as straightening unit.
from SMS Meer is characterized particularly
sion of erection and commissioning.
To achieve particularly good straightening
by low cutting costs, a high throughput rate
results for beams and rails the machine is
and a high level of plant availability.
Benefits from CCS® mill stands. The
equipped with straightening rolls sup-
heavy-section mill is equipped with uni-
ported at both sides, and with hydraulic
Economical XH® rolling process. The
versal mill stands of the CCS® type (Com-
adjustment. For the production of rails, a
heavy section mill operates according to
pact Cartridge Stand). Hydraulic adjust-
vertical straightener is additionally used
the universal XH® rolling principle, making
ment control and rigid stand design en-
which is also provided with individually-
rolling on a compact tandem group possi-
able section rolling with end dimensions
driven rolls.
ble. This means that all stands are used
within narrow tolerances.
with each pass. With the XH® rolling process, Baotou is able to e.g. produce beams very economically since this rolling method is highly productive and roll wear is very low.
58
Newsletter of the SMS group 4/2011
➤ New order
China: Xining oders two new rolling mills More than 1 million t of billets and bars per year Xining Special Steel Co. from Xining City in Qinghai Province has placed two orders with SMS Meer for a semi-continuous billet mill and a bar mill for quality and specials steels (SBQ grades). Commissioning of the two plants is scheduled for the end of 2012.
Representatives of Xining Special Steel and SMS Meer after signing of a contract for a billet and a bar mill for quality and special steels.
components of the new billet mill and close rolling tolerances are ensured by an automatic roll gap control and the sizing technology
The mill trains of the billet and the bar mill will be designed for
HSC® (Hydraulic Sizing Control).
close tolerances to be achieved by the use of hydraulic underload adjustment systems. The overall dimensional range of the two
The bar mill. This plant provides a three-roll sizing block, type
trains is from 16 to 280 mm in diameter.
PSM® (Precision Sizing Mill). With the hydraulic adjustment under rolling load, any customer-specific dimension can be produced-
The billet mill. Compact stands with hydraulic adjustment mech-
from one pass series, i.e. economically also in small batch sizes
anism of the HCS® (Hydraulic Compact Stand) type are the key
and with close tolerances.
Three-roll sizing mill, type PSM®.
Newsletter of the SMS group 4/2011
59
TRADE FAIRS | EVENTS
Düsseldorf, Germany: March 26 thru 30, 2012
SMS Meer at wire and Tube 2012 These trade fairs are the world’s key events for the tube and wire rod industry. In 2012, the fairs will run in Düsseldorf from March 26 to 30, giving the industry an opportunity to discuss
Source: Presse-Service Messe Düsseldorf.
trends and issues relating to the production, processing and use of tubes, wire rod and cables. More than 2,000 exhibitors and some 65,000 visitors from around the globe are expected
Aachen, Germany: September 25 thru 30, 2011
to come to the wire and Tube 2012.
ICTP – Conference on Technology of Plasticity
Visit SMS Meer in Hall 7a, Stand B16. SMS Meer’s stand will be the largest single presentation at the event. Covering a floor space of over 700 m2, it will be about 20 % larger than SMS Meer’s stand in 2010. And for the first time, SMS Concast will join SMS Meer at
The ICTP 2011 in Aachen attracted some 600 of the leading
the stand. As a full-line supplier, the SMS Meer Business Area will
scientists in the field. Characterized as “The Olympics in the
showcase its spectrum of products and services as well as sustain-
technology of plasticity and metal forming” by the organizers,
able innovations for the production of tubes and wire rod. The
the ICTP offered an excellent platform for exchanging the latest
focus will be on innovations, ecology and customer relations.
scientific findings and recognitions. The event was managed by the Institut für Bildsame Formgebung (Institute of Metal University) of Dortmund. SMS Siemag and SMS Meer have maintained a close scientific cooperation with RWTH Aachen for many years and were the main sponsors of the event. Many of the participants used the breaks between the conference sessions to visit the SMS stand to gather information
For more information on wire and Tube 2012 please go to:
on the products and services as well as the career opportunities that
www.wire.de and www.tube.de
the companies of the SMS group have to offer.
Imprint Newsletter 4/2011 SMS group December 2011 Volume 18
Publisher and responsible for the contents SMS group: Dr. Thomas Isajiw, Düsseldorf Business Area SMS Meer: Dr. Peter Heimerzheim, Mönchengladbach www.sms-group.com ·
[email protected] Editors: Jürgen Hoffmann and Edmund Stabel, Corporate Communications, VIM P.O. Box 230229 · 40088 Düsseldorf, Germany, Phone +49 (0)211 881- 4604 · Fax +49 (0)211 881- 4386
“The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as 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.”
Published on December 12, 2011 | © SMS group | Circulation in English 9,000, in German 6,000 | Printed in Germany
Forming) of RWTH Aachen University and the TU (Technical
