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Vol. 16 No. 04

February 2014

Editor & Publisher

NIRMALYA MUKHERJEE Director

SHAMPA MUKHERJEE

Slow Consumption Trend Creates Doubts over Steel Production Target

Executive Assistant

World Steel Association estimated that steel steel demand in India would grow at

ANKIT MUKHERJEE

3.4 per cent in 2013 and touch 74 million tonnes, higher than the 2.6 per

Editorial Advisor

cent growth rate recorded recorded in 2012. In 2014, the demand is poised to grow at

MANORANJAN MUKHERJEE

even a higher rate of 5.6 per cent helped by efforts to implement structural

Sub-Editor

reforms.

ARNAB MONDAL DGM - PR

PRADIPTA SENGUPTA Sr. Executive - Business Development

Also a research shows that steel consumption is expected to grow at an average rate of 6.8 per cent to reach 104 million tonnes by 2017 driven by rising infrastructure development and growing demand for automotives.

AYAN BHUIYAN Production Manager

DEO KANT JHA

However, However, steel consumption in India continued to languish at 0.7 per cent growth Y-o-Y d uring April -February period of current fiscal at 67.25 million tonnes over the same period last fiscal

Design & Layout

SUMALENDU BASU Scanning & Processing

STEEL & METALLURGY

Regd. Office

at 66.78 million tonnes. Typically steel consumption rises by 1.1 times of the GDP growth rate for an economy. It remained largely subdued so far in the current fiscal considering India's slow GDP growth.

6,Upendra Nandy Road,

India's economy grew below expectations at 4.7 per cent in October-December on falling

P.O. Sheoraphuli, Hooghly

output in the manufacturing s ector. ector. The country's GDP had expanded 4.8 per cent in the July-

Pin : 712223, Ph.: 2632-3313 Corporate Office

September quarter and 4.4 per cent in April-June. Growth in the first nine months (AprilDecember) was 4.6 per cent.

#1A, SHAKTI 166, Rajdanga Nabapally,

The poor consumption scenario is in contrast with the latest figures by World Steel

EM Bypass Rashbehari Connector

Association which has revealed that India's steel production increased by 3 per cent to 59.62

(Behind State Bank Of Indore),

million tonnes in the first nine months of 2013, as against 57.90 million tonnes in the

Kolkata 700 107, INDIA

corresponding period last year. Moreover, the data showed that India's rate of production

Tel : +91-33-4061 4092

growth was the second-best following China among the major global producers.

Telefax : +91-33-2441 4780 / 5700 Email : [email protected]

India's steel production capacity is expected to increase to around 13 5 million tonnes in next

Web Site :  www.steelmetallurgy.com

1-2 years from the current level of about 90 million tonnes per annum as all steel producers

Printed by Nirmalya Mukherjee at

have taken up capacity addition projects. So, in all likelihood, an oversupply situation looms

Aparajita Print House

afar owing to this disparity in consumption growth and production growth.

91A, Baithakkhana Road, Kolkata-700009

So, which are the overseas markets to for this surplus volume? How to increase domestic

and published by him from

consumption?

6, Upendra Nandy Road P.O. Sheoraphuli, Hooghly, West Bengal

Subscription Amount w.e.f. 1st January 2013 Annual Subscription 1 year Rs. 6,000/= € 400 Annual Subscription 2 years Rs. 11,000/= € 700 Annual Subscription 3 years Rs. 14,000/= € 900 Single Copy Rs. 600/- €40

It is high time for one and all associated with this industry to take up a cohesive approach to find answers to these questions. Else, the coveted production figure will remain a mystical figure with no reason to step up production for long term viabil ity.

From The Desk

1

Product

4

Analysis

Profile Risk More Weight With igus ‘‘Drylin W’’ System

Realising India’s Steel Dream: Some Suggesons

ECOFLUX * Corrugated Tube Heat Exchangers

Industry

Special

14

Feature  A Look Through The Saga Of Essar Steel Technology

20

Update Most Modern SBQ Producon Technology  Rolling Mills Modernizaon Soluons  for Long Product Rolling Mills to Increase Producvity, Ulizaon and Product Quality 

Company

45

49

Profile Precision Speed and Length Measurement (down to Zero) Laser Sur face Velocimeters LSV 1000 / 2000 

 Zumbach At Tube 2014 News Desk

51

Statistics

66

32

INDUSTRY  A NALYSIS

Realising India’s Steel Dream- Some Suggesons S.S. Beriwala Chairman, Shyam Steel Industries Ltd.

T

he fortune of steel industry is intrinsically linked with the economic growth and development of any country. India is the 4th largest steel producer logded 5.86% growth in producon in FY : 2012-13, the largest among the major global producers. India Steel Vision 2020 or 2025 proposes to draw a roadmap for the Indian Steel Industry, the next decade to produce 300 million tonnes of steel by 2025. Whether it will remain a dream or we will fetch the target, is the main queson before the country. The Government expects the country to become the 2nd largest steel producer by 2015 on the back of capacity addion. But the experts take it oth erwise. Following points may be taken and considered sincerely to reach the target:

1)

Raw Material Sourcing.

2)

Technology Status.

3)

R&D Facilies.

4)

Logiscs and Infrastructure.

5)

Market Demand.

Ore, the basic raw material required for

and the Steel industry and the above

Steelmaking. But the easy availability of Iron Ore to the actual consumers at a fair price and right quality specially to the small players of Steel, who produce

agencies started running behind mak-

about 50% of the total Steel in India is far from reach. Even some quanty of Iron Ore was imported from abroad to feed the actual consumers, last year.

On the one hand Government wants

The reason mainly goes to mismanagement of the Steel Ministry, Government of India and factual policies. The large blocks of Iron Ore mines were alloed to mostly main Steel produc ers for capve mines and to NMDC,

Let us compare one by one.

Raw Material Sourcing Iron Ore India has abundant quanty of Iron

ing money by auconing and exporting Iron Ore at the exorbitant prices.

the Steel industry to grow and give proper compeon to the world and on the other hand the main raw material available here in India started to be diverted out of India. This point should be considered very sincerely by the apex bodies, the media and the Government i.e. States as well as Cen tre. The Government Agencies should

OMDC, OMDC and JMDC as merchandise mines to feed the domesc small

rst feed the domesc industry charg-

Steel players. With the passing of me Government of India as well as

do not agree, their leases should be

states have forgoen the main principle of development of the country

auconed globally. The Government

STEEL & METALLURGY

4

FEBRUARY 2014

ing Cost +20-25% premium. If they withdrawn and the Mines should be will receive a good exchequer at least.

INDUSTRY  A NALYSIS Here in India, we have no such ins tuons even aer such a long me of independence. The largest pro ducer of Steel i.e. SAIL/TATA/RINL even whenever establishe their new Steel Plant, they go in joint venture with the Plants in abroad and claim it their modernisaon. Research and Development work is negligible.

R&D Facilies The suitable instuon should be equipped with full facilies for R&D and should be opened by the Govern ment and then autonomous status should be provided to such instuon with strict laws and terms & condions.

Coal I am not taking the maer of Coking Coal, which is not easily available in India. We should consider about the availability of Non-Coking Coal, which is available plenty in India, but owing to mismanagement of Coal India Limited, negligible eorts for underground min ing since a long me and the faulty poli cies towards the supply of Non-Coking Coal to the actual Steel Consumers, by Government of India. Non-Coking Coal has also become a scarce raw ma terial and the huge quanes of NonCoking Coal are being imported to feed the actual Consumers. The large blocks should be alloed to some big Government agencies whether State or Central with the complete environment and forest clearance to feed only domesc small manufacturers of Steel in India at fair prices with the quality as per the declaraon in the invoices.

726.33 million tonnes, whereas India produced only 78.12 million tonnes during the same scal. The consider able point is that China produces each so much of Steel, which is the total producon in India. But we are very happy on the pretext that we are the 4th largest Steel Producer. Actually China has established several ins tuons, who research the technol ogy regularly. Steel producers and the manufacturers have no other choice but to be aliated with one or the other instuons for the technology.

Technology Status The Government should adopt prac cal policies pertaining to the technol ogy towards the development of the Steel industry. China had produced the Steel during the scal year 2011-12 at

STEEL & METALLURGY

6

FEBRUARY 2014

Logiscs & Infrastructure It is unfortunate part of India that the Government had been following whimsical populist policies and disburses the funds to unproducve sectors. Paucity of funds and some other faulty policies of land acquision etc. have not allowed the Government to bring the logisc and infrastructure, according to our needs. We are always lagging behind with the target in infrastructure and logiscs. This situaon is so bad that we have to pay much more freight from Odisha to Kolkata in comparison

INDUSTRY  A NALYSIS to the freight from Odisha to Colombo. It is a surprising fact; we fail to feed even our power projects with the proper coal through exisng logiscs. What will be the posion in 2025, if we will have to cop up with the ve mes more requirement of raw materials; nished goods and power. The logiscs and infrastructure can not be created overnight. We should take praccal policies and iniave should be given to infrastructure and logiscs so that industry as well as ag riculture growth may happen properly.

Suggeston a)

There should be single Ministry comprising of Steel, Power and Commerce and Industries, also comprising of the Secretaries from Fi nance, Logiscs and Infrastructure.

b)

A single window channel should be set up for the necessary clearance for logiscs and infrastruc ture planning inclusive of necessary clearance from environment, land acquision and forest etc. The Government should adopt very strict rules for land acquision towards the public interest for logiscs and in frastructure and payment to the land owners should be made immediately at fair market prices. No polical par es should be allowed to raise the voice for increase in land price, aerwards in favour of original land owners, which may occur with passing of the me.

the demand in India on the lame excus-

of its small industries. But the Steel

es as it has been done in recent Gadget

Ministry appears to perish this sec -

Nocaon No. 4(8)2010-SD-1 dated

tor, which produces about 50% of the

12.12.2013 issued by Government of

total Steel in India. This will result to

India, Ministry of Steel. It appears from

cartelizaon of a few big ones and

the Nocaon that the Government

the projects will have to bear the ex -

has instructed the Steel consumers to

orbitant prices of Steel unnecessary.

purchase Steel only from the integrated Steel Plant. The denion of integrated Steel Plant has been given having the minimum capacity of 1 million tonne per year as per the said nocaon. It appears that only such producers are capable to feed those consumers. It seems that the Nocaon has been issued in ha. It is pernent to state that since independence not a single infrastructure project has issued the tender or xed aucon for even 1 lakh tonnes Steel at a me, not to speak of

Being a core sector, the Steel indus try reects the overall growth of the economy in the long term. Consump on of Steel has taken to an indica tor of economic development. The demand of Steel is also derived from

various sectors such as infrastructure, automobiles, consumer durable, en gineering industries, housing & real estates etc. each sector of produc ers should be given equal preference.

10 lakhs tonnes as menoned in the Nocaon. If the Steel producers,

With the Steel consumpon of only

large or small, failed to supply the Steel

approximately 70 million tonnes, sky

Government should adopt such poli -

as per the relevant quality and within

is scope for development of Steel

cies, which may create Steel demand in

the me schedule towards supply, it

industry in India. We should for-

the market. A minimum of 70% of the

is automacally be blacklisted. The

mulate such policies so that we can

Steel produced in India should be con-

Steel Ministry has no authority to as-

feed the world with the cheapest

sumed domescally in India itself and

sess the capability of supply of Steel.

Steel, which we have, the capacity.

ported worldwide. It should not be le

The backbone of every developed

Some of the following points may

over the large producers only to feed

country stands on the development

be

Market Demand 

the rest should of 30% should be ex -

STEEL & METALLURGY

8

FEBRUARY 2014

reckoned,

as

given

below:

INDUSTRY  A NALYSIS

1)

Logiscs

should

be

prop -

er in such way that the mines and

queries should be linked with the sucient railway tracks and roads to all the cies in India. The administraon both, at 2) the State and Central level, should be strict against an-social acvies in the name of local syndicate for logiscs. GDP of 8% sustainable in next 3) decade-Higher growth requires mo bilisaon of higher resources and the sucient number of use; US$1 trillion investment in infrastructure in the next 5 years through Public Investment Plan (PPP), recommendaon of non-plan expenditure, higher ow of FDIs and ofcourse full ulisaon of such money. Empowered co-ordina4) on process on clearances for high impact Infrastructure Projects.

5) egy

Mul pronged stratto boost manufacturers.

to come in power or to contest the elecon so that hang Parliament can be avoided and elected Government

Very low rate of interest should 6) be imposed for purchase of land, Plant and Machineries and installaon charges for manufacturing units. No industry can be established or run compevely on the higher rate of interest, which at present comes to 15/16% globally.

can liberally work at least for 5 years. Administraon should ii) be free of any polical interference. The Ruling party/Ministries should only be permied to formulate rm and stable policies and

To create an atmosphere 7) Strict acon may be takiii) where workers and sta are promoted to produce at par with the workers and en against the authority of whatsta abroad. Though it is stated that ever posion it is, if found guilty. cheap labour is available in India, but This will automacally reno Government tries to verify the pro - iv) ducvity of workers and sta in India, duce the day-to-day interference of in comparison with global producvity.  judiciary, which is not the healthy trend for any democrac country. Last but not least, the Government should make proper amendment in the Apex bodies, the local Chambers and AsConstuon of India in such a way to sociaons should come forward to bring the facts before the Ministers in place Allow 2/3 polical pares only of praising every policy wrong or right. i)

STEEL & METALLURGY

10

FEBRUARY 2014

SPECIAL  FEATURE

 A Look Through The Saga Of Essar Steel Genesis & Evoluon

F

or the young Essar Group that was born with a vision to match the step of developing naon that was in the making, it was a giant leap to ven ture into the steel producon sphere. The journey started in 1989 by setng up two DRI modules at Hazira in the state of Gujrat with capacity of 0.9 million tonnes (MT). Then, the company advanced to build a pellet plant in Visakhapatanam, and eventually a fully integrated steel plant in Hazira.

Aerial view of the Essar Steel complex at Hazira, Gujarat, India

Today with a producon capacity 14 MTPA and footprint in India, Canada, USA, Indonesia and the Middle East and signicant presence in the key markets of Asia, Europe, Africa and North America, Essar Steel is a world class at steel producer to reckon with.

iron-making, steel-making, and down-

like a power plant and a port that can

The company has specied plants for

Current Operaons

handle 30 million tonne cargo annually.

value added steel products such pipes



ira

stream facilies including cold rolling mill, galvanising, pre-coated facility, steel processing facility, extra wide plate

Apart from this it operates an 8 MTPA Pellet Plant at Bailadila and is seng up a 12 MTPA Pellet Plant at Dabuna in Odisha.

mill and a pipe mill. The Hazira Steel

Product Basket 

Complex has modern infrastructure

and plates. It has leadership posion

Essar Steel India Limited, Hazwith capacity of 10 MTPA

Essar Steel Algoma, Canada with producon capacity with 4 MTPA •

PT Essar, Indonesia with a downstream producon capacity of 0.4 MTPA •

Essar Taconite Plant, USA under construcon with a pro ducon gure of 7MTPA •

Essar Steel India is an integrated steel producer with an annual producon ca pacity of 10 million tonnes which com prises ore beneciaon, pellet-making,

Essar Steel, Canada is an integrat-

in the cold rolling, galvanising and pre-

ed steel producer with a exible

coated segments. Apart from that Es-

manufacturing process and special-

sar Steel has the ability to provide all

ises in the producon of hot and

kinds of steel with versale produc -

cold rolled sheet steels in carbon

on lines — cut to length, sling, shot

and high strength low-alloy grades.

blasng, burnt to shape, trapezoidal, and factory-welded beams through

Essar Steel Minnesota LLC, with an ac -

Essar

Processing

cess to over 1.4 billion tonnes of iron ore

and

Distribuon.

Milestones

reserves, is Essar’s ambious project.

In its 25 years of existence Essar has PT Essar Indonesia is the largest pro -

many encouraging accomplishments

ducer of cold rolled steel in Indone-

to its credit. In 2011 Essar Steel com-

sia’s private sector with a current

pleted expansion and modernisaon

rolling capacity of 0.4 MTPA along

of its Hazira Steel complex with a cost

with a galvanising line of 0.2 MTPA.

of around

STEEL & METALLURGY

14

FEBRUARY 2014

Rs. 37,500 crores which

doubled the capcity to 10MTPA making Hazira the single largest locaon at steel producer in India and the fourth

Sustainable Run

largest in the world. Essar Steel incurred

Sustainability is of

a cost of just $750 per tonne of steel as

utmost importance to Essar Steel that

compared to industry standard of US $1 billion for a million tonnes of steel. In 2007 Essar Steel achieved another milestone by laying 267km slurry pipeline which is the second largest in the worl d. Essar has commissioned a 6MTPA ca pacity pellet plant at Paradip, Odisha in the rst phase of 12 MTPA plant. This pellet plant Paradip along with Visakhapatanam pellet plant will provide 20 MTPA pellet capacity to Essar Steel.

Technological Devolopment  Essar Steel has adopted three iron making technologies: HBI/DRI, CO REX and BF. These technologies of fer exibility in raw material inputs: •

The

complex

uses

varying

grades of iron ore including lump ore, nes, slimes, sinter and pellet •

energy

The complex uses dierent sources,

including

natu-

has been ensured with safety and environmental

aspects that are given due importance in the design, construcon and operaon of the plant. The steel complex reiterated this eort with adopon of COREX process which has beer environmental compability. This eort has resulted

in

mak-

ing Essar Steel the lowest emier of greenhouse

gases

and zero waste among the Indian

steel

producers.

Processing & Distribuon Network 

ral gas, coking coal, COREX export

Essar

gas, BF gas and non-coking coal.

cessing

Steel and

Pro Dis-

tribuon is India’s Also in its expansion and moderni -

largest steel solu-

saon eorts, Essar Steel installed

ons chain with a

world’s rst 3-stand CSP plant by

capacity of 5MTPA,

SMS Siemag with an annual capacity

located

of 3.5 MTPA of hot rolled strips and a

key industrial hubs

range of products that cover carbon

in India — Hazira,

steel as well as pipe grades silicon

Pune, Chennai, In-

and duel phase steels. The CSP Mill is

dore, Bhuj, the NCR

capable of producing HR strips down

region, Kolkata and

to 0.8mm thickness, lowest in India.

three internaonal

in

seven

SPECIAL  FEATURE

locaons- Dubai, UK and Indonesia.

Essar Steel is focusing on the comple -

Odisha Government to allocate iron

on of its remaining capacity expan -

ore mines as promised in the MoU.

Essar Steel has laid country’s rst and

sion by 2014, a plan that is expected

The steel rm has also seen rise

largest supply chain in the country

to boost earnings three-fold and stave

in demand for exports in recent

with its retail distribuon brand Es -

o liquidity crisis. The immediate chal -

months and expects the momen-

sar Hypermart with 520 outlets which

lenges before the company are raw

tum

provide customised services to origi -

material crisis, parcularly drop in gas

nal equipment manufacturers (OEMs)

availability and delay in construcng

Essar Steel is taking all measures to

and retailers, along with meeng the

the slurry pipeline from Dabuna Ben-

shrug o the dilly-dallying in its nan -

requirements of small and medium

eciaon Plant to Paradip Pellet Plant.

cial and operaonal front to ensure

enterprises (SMEs) with transparency

However, the company is taking vari -

that all producon capability come

on pricing, availability and quality.

ous

complet-

on stream. Once the economy picks

ing the slurry pipeline and connec -

up enough pace, Essar Steel will be

vity to the naonal grid to reduce

a major contender in India’s coveted

power costs, besides compleon of

run up to touch steel producon tar-

its coke oven plant.

get of 300 million tonnes by 2025.

The Journey Ahead  Essar

Steel

look

for

has its

ambious future

out-

growth.

measures

STEEL & METALLURGY

including

18

It also expects

FEBRUARY 2014

to

connue

in

the

future.

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TECHNOLOGY 

M ost Modern SBQ Producon Technology  Guenther Schnell, General Manager Proposal and Sales, Wire Rod and Bar Mills, SMS MEER GmbH

Introducon

I

n 2006 the world wide rst 3-roll block for SBQ producon with ad justment under load feature went into operaon at Deutsche Edelstahlwerke (DEW) Siegen-Geisweid/Germany. The great opportunies of the advanced 3-roll technology with the hydraulic adjustment under load feature were obvious. The adjustment under load feature opened up possibilies in most modern SBQ producon which were so far not available on the market. The achievements and results aer im plemenng the PSM® set a new technol ogy standard. Aer years of successful operang experience with the ad vanced 3-roll technology a precise on line measuring system in combinaon with the closed loop size control was added in order to achieve an even higher process transparency. The fully auto mac control system is interacng with the hydraulic gap adjustment system of the PSM® and thus able to directly react online under load on real me mea sured deviaons from the target size. In combinaon with the advanced 3-roll technology for most modern SBQ producon the 51st pouring reel line of SMS MEER will go in operaon in 2013. This pouring reel line is based on 62

years operaonal experience and rep resents the most modern pouring reel line technology. Demands such as improved coil formaon and scratch free pro ducon of sensive SBQ prod ucts is part of the advanced state of the art pouring reel technology. The advanced rolling technologies for most modern SBQ producon are introduced in the technical pa per and operaonal results shall un derline the great potenal of this most modern rolling technologies.

PSM® - The Advanced 3-Roll Technology

ducon technology. The rst advanced 3-roll block for wire rod and special bar quality produc on went into operaon at Deutsche Edelstahlwerke Siegen/Germany (DEW Siegen). DEW Siegen is part of the SCHMOLZ + BICKENBACH Group, which with around 11,000 employees are the world’s largest manufacturer, processor and distributor of special steel long products. They are rolling at their Siegen works up to 460.000t quality steels, ball bearing steel, spring steel, cold heading steels, high alloyed stain less steels and tools steels per year. DEW Siegen has a long experience in 3-roll technology since they were the pioneer in 3-roll technology when they started up in 1979 the rst industrial used 3-roll blocks for SBQ producon.

A new innovave rolling technology has been introduced in 2006 for spe cial bar quality (SBQ) producon and is represented by the Precision Sizing Mill (PSM®). This advanced 3-roll technology is already appreciated at several leading SBQ producers in Germany, USA and China and set with its features a new benchmark in the eld of SBQ pro - Figure 1. PSM® 3-roll sizing technology at DEW Siegen/ Germany

Keywords: advanced 3-roll technolog y, hydraulic adjustment under load, PSM®, closed loop size control, MEERgauge®, special bar quality (SBQ), sizing technology, free-size rolling, pouring reel technology, bar in coil producon

STEEL & METALLURGY

20

FEBRUARY 2014

TECHNOLOGY  From their start-up experience followed by 25 years operang experience of three 3-roll blocks of the rst generaon, DEW Siegen immediately iden ed one of the great key features of the advanced 3-roll PSM® which was so

(NOT ONLY discrete sizes) - requires less cas-

see/roll changes

far not available in the market: the hy-

- leads to less in-

draulic adjustment under load feature.

ventory (e.g. rolls, guides)

Well aware that, at that me, a pilot installaon has some risk and is also challenging, however, due to the outstanding advantages of the PSM® and the great potenal for further improvements of size tolerance they decided for

the advanced 3- roll sizing technology supplied by SMS Meer. The rst 3-roll PSM® went into operaon at Deutsche Edelstahlwerke Siegen/Germany 1) in 2006 replacing two of the three existing 3-roll blocks of the rst 3-roll generaon (Fig. 1). Today all sizes (Ø22mm  – Ø85mm) are nished successfully with the 6-stand 3-roll PSM® fullling all market requirements with tolerances much beer than required. The PSM® is oering all typical features of the 3-roll sizing technology such as: •

Single pass family rolling (Fig. 2) - for all diameters

- for all steel grades, - at any me



Quick cassee

changing

- 5 min for individual or all cassees

Figure 3. CARTA® PSM® - network structure

And beside all the typical features of a 3-roll system, one of the outstand ing key features in addion to the before menoned is the real me hy draulic gap adjustment capability under load which makes this machine

inimitable. Thanks to the advanced closed loop Technological Control System (TCS) which is also used in other applicaons such as secon mills. Instead of having a “black box” where only the entry and exit size of the bar can be measured, the TCS oers full process transparency since each individual roll posion and in addion, the individual roll force can be detected. Furthermore the system is able to com-



Free size rolling (9% of dia. / max. 3mm) - for innite sizes

pensate individual mill spring, feeder variaons and bar entering impacts but also is able to balance temperature variaons along the bar. Based on the TCS closed loop control system, the system can adapt to dif ferent rolling condions in order to immediately

opmise the system for achieving maximum yield on highest availability.

Figure 2. PSM® - Single Pass Family Rolling Principle

The setup for achieving the required quality of

STEEL & METALLURGY

22

FEBRUARY 2014

the nal product will be planned by the SMS Meer Computer Aided Rolling Technology Applicaon System (CARTA®) for the PSM®. Set point se lecons for the rolling mill seng can be easily determined and trans-

mied to the rolling mill automaon system via the data network (Fig. 3). The core element of the CARTA® PSM® is a central high-performance server with databases for mill parameters and result values. The server is intercon nected with the basic automaon system and can be linked to an unlimited

number of workplaces, for example the rolling mill managers, technologists or the roll shop and operator sta 2. To quickly determine the rolling data the CARTA® PSM® system already in cludes the concepts of rolling technol ogy experience from SMS Meer as pre seng. For a wide range of special steel grades and individual requirements, the operator is even able to exibly adapt the seng values by means of a groove editor or create them complete ly new – from the diameter of the inial pass via the design of the actual groove form up to the calculaon of the relevant rolling speeds. Simulaons and visualisaons of the systems support the operator at the set-up planning stage (Fig 4).

SUCCESSFUL IMPLEMENTATION OF FIFTH SUBLANCE SYSTEM IN INDIA Recently, the fourth and fifth of a total of seven Sublance Systems were successfully commissioned at the SMS II operated by JSW Steel at Toranagallu, India. Operation of the three earlier systems commissioned at SMS I is stable and the remaining two will be installed at SMS II to become fully operational before the end of this financial year. This is the first successful implementation of Sublance–Based BOF Process Control in India. This market has been very reluctant towards installing sublances, but operations at JSW Steel are now proving the value for the Indian market. The reduction in tap–to–tap time, that may vary between 7 and 10 minutes, will allow for up to 20% of additional heats from the same steel plant. Additionally, the client will experience benefits from using the Sublance–Based System in terms of increased hit rates, reduced consumption of fluxes, optimized utilization of scrap and hot metal and improved health, safety and environmental performance. per formance. Typically, Typically, benefits of Sublance–Based Process Control for the SMS operator translate into value as follows: Your benefits:

Tap–to Tap –to–ta –tap p time time Hot meta metall consum consumpti ption on Scrap Scr ap consu consumpt mption ion Oxygen Oxy gen cons consump umptio tion n

Reduce Red uced d by 7–1 7–10 0 min. min. Reduce Red uced d by 10 kg/ kg/ton ton Increa Inc reased sed by by 10 kg/to kg/ton n Reduce Red uced d by 1.0 1.0 Nm³/t Nm³/ton on

Alumin Alu minium ium consu consumpt mption ion

Reduce Red uced d by 24 kg/hea kg/heatt

Ferromanga Ferro manganese nese consu consumptio mption n

Reduced Reduc ed by 60 kg/he kg/heat at

Energy Ene rgy sav saving ings s

Equiva Equ ivalen lentt to to 20°C 20°C

Refr Re frac acto tory ry wea wearr

Redu Re duce ced d by 20% 20%

Ergono Erg onomic mics s

Improv Imp roved ed worki working ng condi conditio tions ns

For these sublances, the newest generation of measurement computer, DIRC VI, is implemented. This new version allows for future additions to the measurement system. Phosphorous measurement will be implemented as well.

120 BLAST FURNACE PROJECTS 209 HOT BLAST STOVES 63 120 BLAST 63 PULVERIZED  PULVERIZED COAL INJECTION SYSTEMS 28 28 GAS  GAS CLEANING SYSTEMS 27 27 CASTHOUSE  CASTHOUSE PROJECTS 35 35 CHILLED  CHILLED FURNACE RECOVERIES 20 20 SALAMANDER  SALAMANDER TAPS 22 22 BLAST  BLAST FURNACE BLOW–INS 23 23 OPERATIONAL  OPERATIONAL IMPROVEMENT PROJECTS 41 PLANT AUDITS 114 SUBLANCE SYSTEMS 58 HOT 58  HOT METAL DESULPHURIZATION SYSTEMS Danieli Corus

Danieli Corus India Pvt. Ltd.

P.O. Box 1000 0 1970 CA IJmuiden The Netherlands T +31 (0)251 500 500 E info@danieli–corus.com W www.danieli–corus.com

S3 Level, E Block Intl. Trade Tower, Tower, Nehru Place New Delhi 110 019 T +91 11 4950 100 100 0 F +91 11 4950 1099 1099 www.twitter.com/danielicorus

TECHNOLOGY  3-roll cassees and 3-roll The MEERgauge® at the exit side of the guides in the roll shop. All PSM® operates on the basis of the light cassees and guides can cut technology(Fig. 7). Based on laser/ be transferred directly into image technology four sensors meathe PSM® roll shop by the sure synchronous and contact free the cassees changing device enre cross secon of the bar. With a and will be prepared o- scanning rate of 500 scans per second line shop during rolling (Fig. a true-shape cross-secon is estab 5). In case of very ght tol- lished of up to 400 measuring points erance requirements the and displayed with highest precision. rolls and rollers have to be aligned in the roll shop The essenal characterisc values of Figure 4. CARTA® PSM® - groove manipulaon possible by means of an opcal roll the individual measurements are sent For each bar the CARTA® PSM® system posioning/aligning device. The rolls to the Technological Control Centre stores the setup/calibraon data of and rollers can be axial and radial po - (TCS) of the PSM® via a direct prothe rolling mill and the most important sioned with a measuring accuracy of cess eld bus connecon in real me. rolling results. The data can be evalu- 0.002mm by means of a CCD-camera. The TCS logic analyses the values ated by tables and graphics. In addion, they can be deposited in an empirical In order to further database which ensures possible reuse. expand the capabilies of the advanced Another feature is the tool manage - 3- roll technology, ment funcon which is of tremendous SMS Meer and DEW support to the operators and mill man- Siegen successfully agement in order to opmise the tool/ implemented in joint roll ring costs. The roll ring sets and cooperaon a high3-roll cassees can be tracked with the ly dynamic closed CARTA® PSM® system and informaon loop size control sysabout e.g. wear is available. With the tem for the PSM®: Fig. 6: MEERgauge® at the exit side of the 3-roll PSM® aid of the CARTA® PSM® system, cus - the MEERgauge®. tomers are able to ne tune many de - This is another milestone with regard and assigns relevant adjustment set tails in case it is required. These excel - to the advanced 3-roll technology. points for gap correcons if required. lent features make the dierence to any other system available in the market. The MEERgauge® (Fig. 6) is installed Due to a combinaon of a highly dy down stream the 3-roll PSM® directly namic control system and a true-shape Furthermore the CARTA® PSM® system behind the last 3-roll stand posion and measuring system a fully automac roll supplies all data for the setup of the is replacing a convenonal laser mea - ing operaon of the PSM® coul d be sucsuring gauge which cessfully realised with the MEERgauge® was working on the - independent from the operator. shadow measuring method. The short- It is a fully automac size control syscoming of the conven- tem which is able to directly react ononal laser gauge is line under load on real me measured the number of mea- deviaons from the target size. It insuring points around teracts in closed loop mode with the the cross secon as hydraulic gap adjustment system of well as the measur- the PSM®. The basis for the closed ing method due to loop operaon of the rolling gap is Figure 5. PSM® - cassee quick change equipment swiveling laser heads. the adjustment under load capability.

STEEL & METALLURGY

24

FEBRUARY 2014

TECHNOLOGY  the whole size range can be reached in fully automac mode independent of the skill/experience of the operators. Recent achievements are shown in the following screen shots (Fig. 9).

Figure 7. Light-cut sensor arrangement and true-shape cross secon display

Figure 8. Advanced PSM® 3-roll cassee

This is realised by the advanced design of the 3-roll cassee (Fig. 8) in combi naon with the three hydraulic cylin ders. The hydraulic cylinders can adjust all three rolls concentrically but in case it is required the system is also able to adjust individually only one or two rolls. Thus symmetrical as well as un symmetrical posioning adjustments of individual rolls under load oer pos sibilies for ne opmisaon of the net shape tolerances. Another advantage of the design is, that during rolling operaon occurring rolling loads are transferred via hydraulic cylinders into the s hous ing of the PSM®. Due to the inimita ble design concept of the PSM® wear and maintenance of the cassees are reduced to an absolute minimum.

Operaonal Results3) Since the beginning of 2012 the closed loop size control system has been in successful operaon - interacng with the new precise true-shape measuring system. The commissioning was unevenul and shortly aer start up expectaons about the system have already been exceeded. Thanks to the advanced automaon level and reliability of the PSM® excellent results across

Required product tolerances are easily fullled and even exceeded – even for the most demanding applicaons tolerances up to 1/8 DIN EN 10060 are achieved reliably and regularly. It goes without saying, that the MEERgauge® does not necessarily help to produce even beer tolerances with the PSM®, but does support the operator to react on varying parameters such as feeder size tolerance, temperature variaons along the feeder, size and steel grade changes, wear of rolls or even operates the PSM® in a fully automac mode. The advanced 3-roll technology of SMS Meer pays o for their customers. Not only DEW Siegen/Germany benets since 2006 from the great features of the PSM®, since 2009 also Timken/ USA established several producon and quality records aer the installa on of the advanced 3-roll technology. Following the successful installaons at DEW Siegen/Germany and Timken/ USA three more 3-roll PSM®’s will be installed in 2013. One complete new state of the art SBQ rolling mill will be installed in China with pro cess and key equipment for the spe cialty steel producon of SMS Meer. Beside a new 3-roll PSM® including the CARTA® PSM®, Controlled Cool-

ing Technology systems (CCT®) with online thermo-mechanical rolling process control packages will be supplied. The complete new SBQ rolling mill at Xining Special Steel Co. Ltd., will be equipped in addion with an advanced quick cooling bed transport of straight bars which is considered for tempera ture sensive steel grades in order to avoid cracks during cooling procedure. Another 3-roll PSM® will be installed at Steel Dynamics. In summer 2012 Steel Dynamics (SDI), Indiana, USA awarded to SMS Meer the contract to supply a new roughing mill and a new 3-roll Pre cision Sizing Mill (PSM®) to their Pisboro works. The new rouging mill will be operated in semiconnuous mode consisng of a two-high reversing mill followed

by

eight

rigid

less stands in H/V conguraon which will feed the exisng mill. The advanced 3-roll PSM® will be installed at the place where a former 3-roll block of the rst generaon was installed (Fig. 10) and will nish all special quality bars in the range from diameter 19-76,2 mm. Those high-quality products are used in a variety of transportaon, industrial, energy and automove applicaons. The PSM® package consists of looper, two shear groups and in addion the automac 3-roll cassee change system, a roll shop for assembly of the 3-roll cassees and the 3-roller guides as well as the tech nology package CARTA® PSM®.

Figure 9. Screen shots of PSM® rolling in closed loop mode

STEEL & METALLURGY

26

FEBRUARY 2014

housing

TECHNOLOGY  nance requirements. Aer the water cool ing box an automac

each coiler drum on a li able plaorm. Aached to the li able plaorm is also the guid -

switch guides the bar

ing

towards the pouring reel guide trough. For an opmum coiling temperature a water cooling box is installed considering an ap propriate equalisaon

connecon to the spiral pipe lay -

length before entering Figure 10. SBQ mill upgrade for Steel Dynamics / USA

State Of The Art Pouring Reel Technology The ideal combinaon for most modern SBQ producon is represented by the advanced PSM® 3-roll technology and the state of the art pouring reel technology of SMS Meer. Based on 62 years experience in bar and coil tech nology the 51st pouring reel line of SMS Meer will be installed at Fujian WuHang Stainless Steel Co., Ltd./China (FWSS).

the pouring reel for the wide range of dierent steel grades. The water cooling box is integrated and controlled by the Controlled Cooling Technology (CCT®) system which can be either operated in o-line or in on-line closed loop control.

ing

trough system

which which

makes guides

the the

bar to be coiled to the boom of the water cooled coiler drum. The pinch roll arrangement, an ad vanced wobbling funcon as well as a s guiding steel structure assures a stable operaon procedure which forms very dense coils up to 400 0 kg/m³. In general special aenon has been paid for a scratch free transport and guiding of the rolled bar in order to as-

The bar feed line is

of

highly

resistant

wear mate-

rial. The U-shaped bar feed line with

The 51st  pouring reel line (Fig. 12) of

covers allows quick eliminaon of roll -

SMS Meer is arranged downstream the

ing

advanced 3-roll PSM®. It is designed to fulll not only today’s market de mands with regard to improved coil formaon and scratch free producon of sensive SBQ products but is also considered to oer highest exibility

case of a cobble.

and availability with minimum mainte-

switch is installed in order to guide the

material

in

For head and tail

Figure 12. Pouring reel line arrangement at Fujian WuHang

cropping as well as for sampling a shear is installed downstream the water

cooling box. Aer the shear a further bar than into the indi-

vidual pouring reel for the coiling process. Special aenon has been paid for the loca on of the pinch roll.

mechanical

damage

during

the formaon of the coil (Fig. 13).

is installed as close

as possible upfront

uct size or range of sizes to ensure

opmal supported coiling process, one individual pinch roll

STEEL & METALLURGY

vent

An elevang coil plate assembly in corporated in the pouring reel re moves the coil from the tub. The coil plate height is adjustable to provide opmum drum depths for each prod -

In order to have an

Figure 11. SBQ rolling mill at Fujian WuHang Stainless Steel

sure a smooth rolled material surface. Therefore the whole curved guiding system of the pouring reel line includ ing the spiral pipe laying system is equipped with air/oil lubricated rollers. The pouring reels are equipped with wear strips on the inner pins and outer rotang drum to pre -

28

FEBRUARY 2014

TECHNOLOGY  lied without harm out of the coiling

free

producon

of

sensive

SBQ

drum by a hydraulic cylinder which

products is considered to oer high -

is installed below each coil drum.

est exibility and availability with minimum maintenance requirements.

As soon as the coil is lied out of the coiling drum the discharging system

The installaon of the afore described

(Fig. 14), a so called sugar tong, hands the coil over to a pallet transport sys -

key technologies for special bar qual-

tem for further processing in one of the most complex coil handling systems.

on in demanding countries such

Various inline post treatment routes are possible at Fujian WuHang Stainless Steel Co., Ltd. as can be seen from the Figure 13. Water cooled pouring reel

the coil is formed at the highest pos sible level to minimize the tail end length at the top of the formed coil. Aer the coiling process has been start -

layout such as heat holding, quenching, online annealing and others. However, those are not further considered in this

paper.

ity and advanced wire rod produc as USA, Germany, China are indica ons for the huge potenal of these new technologies. They are installed at highly reputable steel producers which are in erce compeon in their individual market but also abroad. Those superior technologies are in venve soluons to follow the todays

Conclusion

and future demands of the individual

With pioneering spirit, courage and

markets. They are developed, de -

persistence revoluonary technologi -

signed, engineered and manufactured

In order to avoid scratches aer com -

cal milestones have been introduced

exclusively by SMS Meer based on a

pleon of the coiling process further measurements have been taken. Be -

by SMS Meer into the market. More

long experience in special quality steel

than 450 successfully installed wire

producon. This in combinaon with

fore the coil is lied out of the water cooled coiling drum, the inner sup porng and forming pins are collaps -

rod and bar mills represent trust and

the vast process know how oers to

great partnership of our customers.

our customers inimitable possibilies.

ing and thus the compact coil can be

The experience of the above men -

ed the spiral pipe laying system is lied according to the increasing coil height.

oned installaons in combinaon with the advanced 3-roll PSM® with hydraulic adjustment under load capability already smulated the SBQ market. The indisputable process transparency of the 3-roll PSM® oers a wide eld for

References 1) Jens Eisbach, Dr. Thomas Helsper, DEW

Siegen,

“Praccal

experience

with the world’s rst hydraulic adjustable 3-roll block for bars”, Internaonal Steel Conference 2011, Duesseldorf/ Germany, November 2011

further improving qualies of our cus-

2) Dr. Axel Koermer, Dr. Peter Thieven,

tomer’s products. The great potenal

SMS Meer, Publicaon in Stahl und

of the PSM®/MEERgauge® combina -

Eisen 131 (2011), Nr.5, p .51-58

on sll need to be further discovered.

3) Dr. Thomas Helsper, Jens Eisbach,

Figure 14. Coil discharging device

The SMS Meer state of the art pour -

DEW Siegen; Guenther Schnell, SMS

ing reel line is the perfect comple -

Meer, “The closed loop size control sys -

on of the advanced 3-roll technol -

tem in combinaon with the advanced

ogy for most modern SBQ producon

3-roll PSM at DEW Siegen-Geisweid”,

and an ideal combinaon. The im-

30th internaonal Steel Industry Con-

proved coil formaon and scratch

ference, Paris/France, December 2012

STEEL & METALLURGY

30

FEBRUARY 2014

ROLLING  MILLS

odernisaon Soluons For Long Product Rolling MMills To Increase Producvity, Ulisaon And  Product Quality  B. V. Kiefer and S. M. Shore Siemens Industry, Inc.

Introducon

W

ith the current economic pressures faced by the global steel industry, producers need to connually modernize their operaons to remain compeve. These modernisaons must be done selecvely in order to maximize the benets. Developments in equipment and process designs for rod and bar rolling mills have made possible signicant improvements in size control and mill producvity, mill ulisaon, operang cost and product quality. Through the intelligent combinaon of robust rolling stands and nishing blocks, high speed shears, pinch rolls, laying heads, ring distributors, coil handling systems and compactors, along with controlled temperature rolling and controlled cooling, many process im provements in rod and bar mills can be realised. Mill upgrades can be done with a phased approach to minimise downme, which minimises the eect on yearly capital expenditures and thereby maximises the return on investment. Long product rolling mills connue to provide an essenal segment of the industry with the capability for coiled and straight products in a wide range of sizes and steel grades for literally thousands of end-use applicaons. With the consolidaon across the industry in the last two decades, the long product mills that have survived have

been forced to streamline operaons and cut costs to remain compeve. This trend is expected to connue as the world economy experiences very slow growth or addional contracon occurs in well-developed countries. The recent evoluon in the industry has also led to a severe lack of skilled/ex perienced workers. The previous gen eraon of workers, because of their ex perience, may have been able to make best use of aging equipment and pro cess pracces. Now, the key to success in sustaining/improving opera ons is to selecvely replace the outdated equipment with new technology and increase the level of automaon. Modernisaons can provide consistent operaons with higher speeds, less maintenance and downme, longer wear part life for more up me between changes, and as lile operator intervenon as possible.

The Long Rolling  Process Line From starng billet to nished coil or bar bundle, the convenonal long rolling mill has many possibilies for improvement through equip ment and process modernizaon.

Roughing And Intermediate Mills In the roughing and intermediate mill area, modernisaons could be as

straighorward as stand and guide replacement to reduce maintenance

STEEL & METALLURGY

32

FEBRUARY 2014

and give beer secon control. In mul-strand mills, opons for stand replacement are limited. In singlestrand mills, product quality can be improved by replacing horizontal stands and twist guides with a horizontal/ vercal stand arrangement. Several opons are available for upgrades with xed or converble stands, using technology such as that available with the Red Ring family of stands. Oen of interest for modernisaon of older rod and bar mills is an increase in billet size. This change requires addional reducons that can only be achieved with more stands. One work able upgrade soluon is the addion of a breakdown mill ahead of the roughing mill, typically a three- to six-stand arrangement, depending on the new billet size. Of course, the addion of stands ahead of the roughing mill means changes to the furnace area, al though the new billet size may not be possible in the exing fur nace, so a new furnace may be needed. This could help with the logiscs of the project, since it may be possible to construct a new furnace and the breakdown mill upstream of the exisng furnace, so that much work can be done while the mill is sll running. Processing a larger bil let with breakdown mill stands will require a roller table between the breakdown mill and the exisng roughing mill, so that the rolled billet from the breakdown stands can be a free bar,

ROLLING  MILLS allows the mill to be congured with four, six, eight or ten roll stands, with any combinaon of 250mm, 230mm and 160mm housings. A relavely new development on No-Twist Mill technol ogy is that of the Modular No-Twist Mill, which ulizes many of the design features of the patented Reducing / Sizing Mill technology. This provides added improvements through com monality of rolling units, reducon in operang cost, and improvements in mill eciency, as well as signicant reducons in maintenance downme through extended component life.

Figure 1. Pre-nishing mill Vee Mini-Block

which can be decelerated to an acceptable taking speed for the exisng mill. Other common upgrades in the rough ing and intermediate mill areas are with shears, to improve reliability, speed and cung capacity. From up and down cut shears for billets and blooms to rotary and crank shears between sets of stands, several shear soluons are available for modernisaon proj ects. New laser speed measurement technology provides for improved cut accuracy and repeatability especially for bar mill divide shear applicaons for improved cut length opmizaon.

Pre-Finishing Mills For rod mills in parcular, the prenishing mill area can benet signi cantly from an upgrade to the rolling equipment. It is common to have lim ited rolling load capacity in the prenishing stands, which means that the stock temperature needs to stay relavely high and thus low tempera ture rolling and quality improvements become more dicult. Replacement of older stands with a heavier-duty stand is a straighorward soluon, but another successful approach has been upgrading the pre-nishing mill

area with one or more Morgan Vee No-Twist® Mini-Blocks. These blocks are well-suited to many upgrade situ aons, oering a small footprint, good secon control and ease of mainte nance. The compact size allows the addion of water cooling boxes ahead of the nishing mill or an increased

equalizaon distance for further im provements in processing capabilies.

Finishing And Post-Finishing Blocks The Morgan No-Twist® Mill (NTM) sll remains an essenal piece of equip ment for many new and revamp mill projects. With connued renement over more than 35 years to the present Vee conguraon, the NTM has proven to be capable of sustained, reliable operaon at speeds up to 120 m/s. In addion to high speeds, the mills are rated for higher loads, providing the ca pability to roll a wide range of grades from carbon steels through dicult heat-resistant alloys. These blocks can typically be supplied with pass reducon of anywhere from 12% to 23% per stand. Subsequent changes in pass re ducons are easily accommodated by a exible design that facilitates bevel gear changes. The exible design also

STEEL & METALLURGY

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FEBRUARY 2014

Increases in producon speed and operaonal reliability have also been aided by ancillary equipment and systems for the NTM. High-speed roller entry guides accurately direct oval secons into round passes while liming scratching of the rod surface. The reli ability and versality of these guides have evolved to allow for sustained op eraon for 5.5mm product up to 3,000 tons at speeds in excess of 100 m/s, for example. In addion, special cooling entry and delivery guides help control temperature in the process secon. One of the most signicant advance ments in high speed rod mills was the development of the patented Reducing/ Sizing Mill (RSM) in the early 1990 ’s. This specialized piece of equipment serves as a post-nishing mill block. More than 60 strands of RSMs have been installed worldwide, mostly as part of major mill modernizaon projects. The jusca ons for the installaon of the RSM in these mills are as varied as the benets provided by this technology (1, 2). For most mills, especially pre-1980 vintage mul-strand mills, the RSM has provided signicant increases in pro ducvity, especially on small diameter product where the maximum nishing speeds were previously limited to less

ROLLING  MILLS erance and ovality – typically ±0.1mm tolerance and 0.1mm ovality. On special steel products such as stainless steels, the ability to produce a closetolerance product has reduced the amount of peeling required, resulng in large savings from improved yield. In addion, experience with the ovalround-round-round pass sequence in many mills has shown that the overall pass life is double that of conven onal rolling, thereby reducing the downme for pass changes. This pass sequence is also benecial to wire drawers and other subsequent users, since it minimizes circumferenal surface variaons at the parng areas.

Figure 2. Morgan Reducing/Sizing Mill

than 70m/s. Installing the RSM aer an exisng 10-stand NTM and rolling 7.0mm in the last stand to feed the RSM can increase the nishing speed for 5.5mm from 65m/s to nearly 100m/s, as was the case, for example, at Global Steel Wire in Spain. For mills producing a large percentage of 5.5mm products, the addion of the RSM can result in a signicant increase in annual output. In the case of one Asian steel produc er, with 85% of the product mix being 5.5mm, producon was increased from 540,000 tpy to over 740,000 tpy, with an increase in mill eciency from 72% to 76.5% in conjuncon with an increase in nishing speed from 70 m/s to 94 m/s. Mul-strand mills already operang at, or close to, the maximum rolling rate on small diameter product have had lile to gain from this benet; however, the installaon of the RSM has sll provided producvity improvements with added rolling exibility. These improvements have been realized fol lowing the introducon of the single family rolling method inherent with the applicaon of the RSM technology. The single family rolling method al -

lows a single roll groove to be used in each stand from the rst stand in the roughing mill to the last stand in the NTM to produce the complete product size range through the RSM. The same concept is also extended to the Bar Re -

ducing/Sizing Mill providing a true inte grated rolling soluon for combinaon mills. This not only simplies the mill setup, but also improves yield through reduced number of cobbles and eliminaon of trial bars. It also signicantly reduces the roll and guide inventory. With the mulreducon external gear drive, the RSM can produce mulple nished sizes from a single feed secon. This, coupled with of ine roll units and the quick-change transfer car, allows size changes to be made within ve minutes. As a result, even though the rolling rate or nish ing speed has not been signicantly increased, the mill is sll capable of improving their producvity through increased operang eciency with the reducon in downme for roll changes. Other benets provided by the RSM include minimisaon of roll and guide changes, ability to increase rolling cycle frequency, and improved product tol -

STEEL & METALLURGY

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An addional opon for a post-nishing block is a Vee Mini-Block, which is usually congured as a 2-stand block to roll small sizes in a rod mill. In many cases, this block has been used to increase producvity on small sizes by as much as 50 percent, while also improving control of product dimensions when compared with older upstream equip ment. When used as a pre-nishing mill block, the Vee Mini-Block’s small footprint simplied retrot projects. The latest design of these blocks is modular, with two-stand units that allow for fast changes and help minimise mainte nance and spare parts inventory by of fering compability with Vee No-Twist Mill and Reducing/Sizing Mill units.

Water Boxes and Equalizaon Troughs A common limitaon in rod and bar mills is the control of product tempera ture through the process line. In many cases, there is lack of cooling capacity, making control of mechanical and metallurgical properes, as well as amount and type of scale, dicult. Product quality requirements have therefore prompted many mills to upgrade their water box systems, usually replacing

ROLLING  MILLS

Figure 3. Traversing Water Boxes

older systems with new technology with more ecient cooling that is easier to maintain. Depending on available space, more cooling can be provided to allow for an expanded range of prod uct qualies. A necessary component of a new water box line is that of a temperature control system, such as

the SIROLL LR Enhanced Temperature Control System, which provides the mill operator with the ability to closely control and monitor process temperatures on the nishing end of the mill. To maintain a high level of mill ulisaon with minimum personnel, while supporng a mulple cycle rolling schedule, mill owners need fast chang es of rolls and other parts throughout the mill, as well as quick changing of auxiliary equipment. The Siemens split bore cooling nozzle design allows op erators to quickly and easily open a nozzle for inspecon or cleaning and to remove cobbles. To avoid the neces sity of manually changing the nozzles in the cooling line for a new product size, mulple lines of dierent bore nozzles can be arranged in a traversing box that can shi posions for the dierent nozzle bores, requiring less man power an minimising mill downme.

High Speed Trimming Shears A challenge for every rod mill is trimming the head and tail ends of every

coil produced, to eliminate hot and outoolerance product on the ends of the coil. In most mills, the trimming is performed manually at a combinaon of locaons – on the cooling conveyor and at a trimming staon in the coil han dling system. To increase worker safety and improve trimming consistency and eciency, high speed trimming shears are available for the process line. These shears have the ability to cut front and tail ends at extremely high speeds, while controlling the amount of material trimmed in order to maximise yield.

The ability to roll small size product at high speeds, i.e., above 100m/s, is meaningless if the ring paern on the Stelmor® cooling conveyor is not consistent and the laying head pipe needs frequent changes. A bad ring paern can result in failure to achieve the spec ied tensile uniformies and addional personnel required at the laying head or reform staon to prevent cobbles in each coil. The Morgan High Speed Lay ing Head was developed to operate at those speeds and has achieved a good reputaon for reliable high-speed op eraon. Numerous mills have upgraded their laying head and pinch roll systems in recent years to increase producon, reduce manpower, improve yield and ensure consistent product quality. Re cent developments on the high speed laying head system have resulted in a new upgrade package. Design changes in the laying head and pipe support have led to even beer performance at high speeds, with extremely low vibraon levels. Also, a signicant advancement in the technology of the laying head pipe now enables many, many more tonnes of small diameter

For example, the shear shown in Figure 4 is a connuously rotang arrangement using two separate shears for trimming and cobble cung with a high speed servo drive switch sys tem, for improved cut length accuracy and repeatability. The system works in conjuncon with front-end orienta on at the laying head to insure that the new trimmed head end is placed at the desired locaon on the con veyor. The shear design can be used for a right or le hand mill, with a size range capability from 5mm through 20mm for speeds up to 120 m/s.

High Speed Laying Heads And Pinch Rolls

Figure 4. High Speed Trimming Shear

An area of the process line that commonly limits the success of a rod mill is that of the laying head and pinch roll.

products to pass through each pipe at high speeds – resulng in a dramac r educon in downme for pipe changes.

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ROLLING  MILLS The success of the laying head and pinch roll system is also dependent on the mechatronics package that is in tegral to an equipment upgrade. This system provides for consistent coor dinaon of speeds between the units, for repeatable front end posioning of each coil, ne control of ring diam eter and wobble adjustment for large sizes. The Morgan Intelligent Pinch Roll incorporates servo control of pinch force and posion, closed loop control of pinch force and speed, plus rapid and repeatable roll close mes.

Stelmor® Controlled Cooling Conveyors Conveyor processing is crical for mills producing high quality products, since it directly aects as rolled properes and indirectly aects properes of products that are heat treated aer rolling. The latest roller conveyor con guraon improves cooling uniformity and surface quality and gives a mill the capability to run connuously in a slow cooling, or retarded cooling mode. Im proved cooling air distribuon through the patented OpMesh system and nozzle deck design between the fan plenum and rod surface increases product cooling and uniformity. In addion, many conveyor upgrades in-

clude increased fan capacies. Higher air velocies improve cooling rates and thereby reduce the total fast cooling length requirement. This is parcularly advantageous for mills producing large diameter, fast-cooled prod ucts. The addion of a roller conveyor in combinaon with, larger fan ca pacity increases both average ten sile levels and tensile uniformity (6).

Coil Reforming The patented Ring Distributor system has for many years dened rod mill coil reforming technology by, oering a consistent approach to the reform ing of coils. With the Ring Distributor, coil rings from a Stelmor® Controlled Cooling system are collected high in the reforming tub and are distributed for opmal placement by a rotang blade. The resulng coil package is dense and well-shaped. When compared with systems without the Ring Distributor, coil heights can be reduced between 15 and 20% on 5.5mm rod, for example. Reducon in coil height and enhancements in coil shape translate directly into improvements in shipping by allowing more coils to be placed on the truck or rail car bed, as well as a decreased risk of loosened coil es or strapping during shipment.

Figure 5. Morgan High Speed Laying Head and Pinch Roll

STEEL & METALLURGY

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FEBRUARY 2014

A major benet for the wire drawer is that coils have a beer payo with re duced number of tangles. The system can be retroed into exisng mills and has proven very benecial in accommodang larger coil weights and reducing damage to coils in transit and in storage. Ring Distributors have been installed in more than 100 strands worldwide.

Coil Handling And Compacting Systems The coil handling and compacng system completes the process of making the best possible coil package, starting at the laying head and connuing on to the Stelmor conveyor and reform area. In most rod mills built before the 1980s, coil handling and compacng are in need of an upgrade. Many exisng systems use horizontal hooks for transporng cooling coils from the reform, through the compactor to the unloading staon. Some old er mills and many new installaons use vercal stem pallets. The latest designs of horizontal hook carriers and vercal stem pallets systems are of modular design with standardised components for ease of maintenance. They are usually custom-congured to t into the available space and to meet the specic needs for producon and coil process ing, while enabling future expansion. For compacng of coils, both horizon tal and vercal compactor systems are available for seamless interfacing with the upstream coil handling system and with the downstream unloaders to coil storage and shipment. Some of the key features of these compactors include the capability of handling coils with a maximum 1450mm outer diameter and 750mm inner diameter, the possibility of using binding wire in diameters from 6mm to 8mm as-rolled, with cycle mes for compacng and tying in the range of 30 to 35 seconds, depending on coil

ROLLING  MILLS Case Study 1 – Wire Rod Mill Laying Head And Reform Modernisaon NUCOR Nebraska wanted to improve their coil package in order to reduce delays in the mill and to provide a beer product for their wire drawing customers. Their modernisaon project focused on the laying head and the reform areas.

Figure 6. Vercal Coil Handling System

weight. The compactors are versale

For the overall management of the mill,

and can be oered with wire binding or strapping using hydraulic, pneumac or electric systems. The wire binding heads are designed to make a consis-

Siemens oers the XpertManager™ system, which provides seamless integraon of process data in real me, from the Manufacturing Resource

tent, high-strength knot for safe transport through storage and shipping.

Planning stage through to enre producon process, including billet yard and coil or bar bundle yard management. This system has been imple-

Automaon And Mill

Management Systems Mechanical equipment upgrades can by themselves result in improvements to the long product rolling mill process and products. However, their contribuon can be maximised when used in con-

mented in numerous mills, providing operators and mill managers with upto-date informaon on the mill pro cess and performance. Management of rolls and guides within this system can further improve its eecveness.

 juncon with upgrades to mill control, automaon and management systems.

Rod Mill Modernisatons

As menoned above, water box temperature control is a necessary ingredient in a cooling system upgrade and the

With the above advances in rod mill equipment and system technology,

mechatronics package is key to the success of the laying head and Stelmor conveyor performance. Other typical areas of upgrades include mill setup and speed control, tension and loop control, sequencing and tracking, plus other mechatronics packages for mill equipment components. Modernisa-

Siemens VAI has been able to successfully upgrade numerous mills around the world in recent years. Usually, the mill modicaons have included an RSM as the main component to improve producvity, mill uliza on and product quality. However, it is the combinaon of the RSM with

The new laying head equipment consisted of a Morgan High Speed Laying Head, which was to be the basis for consistently good ring formaon onto the controlled cooling co nveyor. The laying head was supplied with the patented tail end control deector plate to help with the consistency of head and tail ends. To ensure proper delivery of the rings to the conveyor, a new adjustable entry secon was added to span from the laying head to the exisng conveyor. The mean pipe diameter of the new laying head was chosen to match the coil dimensions previously made on the mill. On the reform end of the conveyor, a completely new reform staon was in stalled, with a Morgan Ring Distributor to further ensure formaon of a good coil package. The reform tub was custom designed to maintain the previ ous coil dimensions. A new sliding exit secon of the conveyor, designed to receive the rings from a drop o the exisng conveyor, enabled speed changes ahead of reform. A new secon of the coil handling system vercal stem pal lets was also provided, designed to in terface with the exisng pallet system.

Case Study 2 – Wire Rod Mill Reform And Coil Handling Modernisaon

on of these elements in the rolling mill can together help opmise the process

the other equipment and controls that has enabled the full realizaon of the producon and operaonal im-

The single strand rod mill at CELSA Atlanc in Spain was built in 2006, primarily to produce ribbed reinforcing products and industrial grade rod

and make the best possible product.

provements of these modernisaons.

in coil. The nishing end of the inial

STEEL & METALLURGY

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FEBRUARY 2014

ROLLING  MILLS Controls for the coil handling area were expanded to accommodate changes in the exisng equipment and manage the new pallet system, interfaces and compactor.

Case Study 3 – Wire Rod Mill Stelmor, Reform And Coil Handling Modernisaton The single strand rod

Conclusions Rolling mill equipment and process im provements by Siemens VAI during the last decade have enabled many mills to undergo successful modernisaons. Signicant increases in rolling speed, producon rate, mill eciency and product quality have been realised with these modernizaons. The combinaon of highly exible and reliable equipment, superior process design and automaon systems oer many possibilies for improving mill operaons.

mill at Sterling Steel in the USA was originally installed in 1983 and underwent various upgrades over the years. Figure 7. Vercal compactor

1.  Shore,

S.

M.,

“Developments

for High-Speed Rod Mills,” Iron & Steel Instute of Japan, Nov. 2001.

Those included laying

2.

head modicaons in the

T. M., “New rod rolling technology for improved mill ulisaon and product quality,” MPT Internaonal, Aug. 1995.

mill consisted of a Morgan Vee NoTwist Mill, water boxes with interme diate pinch rolls for HYQST™ producon, Morgan High Speed Laying Head, Morgan Stelmor conveyor, reform with a two-arm mandrel and transfer car for interfacing with a horizontal

late 1990s, a new Stelmor conveyor in

hook coil handling system with a single horizontal compactor. Aer several years of operaon, shis in the product market and change of mill ownership resulted in the need for increased capacity in the coil handling system.

of the Stelmor conveyor, a new reform

The soluon included changes to the reform tub including a new nose cone

References

the early 2000s, changes in the nishing

Shore, S. M., Dyck, J. and Shore,

block area, and new water boxes with a temperature control system in 2008. The latest modernisaon, which was recently completed, included extension staon with a Ring Distributor, a new vercal stem pallet system and a newgeneraon vercal compactor with wire binding. This upgrade has enabled Sterling to increase mill ulisaon to more than 90% and to set several new producon records. The totally vercal

to improve coil formaon with the exisng Ring Distributor, plus modi caons to the lower reform area to replace the two-arm mandrel with

system, from reform through to com-

an interface to a new secon of vercal stem pallet coil handling. In addi-

age, shipment and customer use. Fewer

on, the horizontal hook system was extended with a new secon to pro vide more coil posions and to interface with the new vercal stem pallet system, incorporang a transfer car

or broken bindings. Also, coils have ex-

and trimming staons. A second horizontal compactor was also installed.

pacng, has resulted in less distoron of the coil during cooling, so that the nal coil package oers beer coil storcoils have to be re-worked due to loose perienced signicantly less scratching,

3. Kiefer, B. V., Vincent, J. C. and Varo, R. A., “Thermomechanical Process Improvements in High Speed Rod and Bar Rolling with Reducing Sizing Mills,” Proceedings, Internaonal Conference on Thermomechanical Processing: Mechanics, Microstructure & Control, Sheeld, England, June 2002. 4. Vincent, J. C. and Kiefer, B. V., “Modernisaon of Stelmor Conveyor Systems for Expanded Process Capability and Improved Product Quality,” Proceedings, Wire and Cable Technical Symposium – Interwire 2003, Atlanta, GA, May 2003. 5. Ichida, Y. et al, “Overview of the New Finishing Block Mill and Coil Handling Line at the No. 7 Wire Rod Mill,” R&D Kobe Steel Engineering Reports, Vol. 50, No. 1, Apr. 2000.

aributed to their less frequent manipulaon. All components of the systems

No-Twist

are easily accessible, improving worker

tered

safety, and the mechanical design has

try, Inc. XpertManager and HYQST are

resulted in reduced maintenance costs.

trademarks

STEEL & METALLURGY

44

FEBRUARY 2014

and

Stelmor

trademarks of

of

Siemens

are

regis-

Siemens

Indus-

Industry,

Inc.

PRODUCT PROFILE

Risk More Weight With igus ‘‘Drylin W’’ System

between sha centres. Compared to the other drylin W sizes, these new dimensions give a higher load capacity, up to two tonnes, as well as resisting higher moments. Stacally each of the four bearing housings made of zinc die-casng can take up to 480 kg. A gliding foil made of iglidur J200 is responsible for the lubricaon-free travel of high loads at low fricon val ues and most minimal wear, especially developed for the use with hard-anodised aluminium as fricon partner.

igus now introduces the fourth size in the “Drylin W” linear guide family: the size 25 (be low). With a load of up to 2 tonnes possible, it can easily move the load of a properly equipped middle class estate car linearly - maintenance-free and without lubricaon.

L

inear technology that is lubricaonfree and dirt resistant – now withstands the weight of a well-equipped middle-class estate car (up to 2 t). The new “Drylin W” linear guide size 25 from igus connects these characteriscs. Previously, a lubricaon-free and cheap alternave to linear guide sys tems that run on ball bearings was developed with the “Drylin W” system. As early as the construcon stage, the exible and modular design with its most dierent accessories allows more freedom of design. New elds of applicaon for the manifold linear guide systems such as in agricultural machines, automobile construcon, but also in the eld of medicine tech nology or packing industry, oers now the high-load version in the size 25. Like all members of the “Drylin W” family, the new version consist of

three simple basic elements: a guide rail made of hard-anodised aluminium, the housing bearings made of zinc die casng and the gliding foil made of the tribo-opmised plasc iglidur J200. The W25 double guide rail has a 25mm sha diameter and 120mm distance

All four sizes of the “Drylin W” system are easy to mount because the double rail makes the costly alignment of two parallel shas or guides un necessary. The rails are available up to a length of four meters. For longer travels, the rails can be easily placed in sequence. The factory-made attached bevel allows gliding of the glide elements from one rail to the other. The system is available from stock.

Also the new size has been designed according to the successful principle of the “Drylin W ” system: double guide rail made of hard-anodised aluminium. Its counterpart is the guide slide that consists of four zinc die c asng bearings, equip ped with a sliding foil made of the tribo-opmized plasc iglidur J200.

STEEL & METALLURGY

45

FEBRUARY 2014

PRODUCT PROFILE

E COFLUX * Corrugated Tube Heat Exchangers

thermal eciency and eliminates

product

channeling. Thermal ef ciency is so improved, that for typical thin lm applicaons heat transfer area can be reduced to less than half of that

required in a plain tubular heat exchanger.



Salient Fea-

DT - Series

tures / USP

Product Applicaon

Compact heat

tubular

exchanger;

K- Series •

C

orrugated Tube Heat Exchangers

Long running mes

due to turbulent ow

are shell and tube heat exchangers

which use corrugated tubes instead of



plain tubes. This kind of tube combines

mum spares requirement.

Very low maintenance costs, mini-

the best features of both the plain tube and the plate heat exchanger. The



Lower heat transfer areas.

bulence in both ows (product & ser-



Minimal fouling and hence high

vice) at lower velocies. This increases

response to CIP

tubes are corrugated to induce tur-

Wide choice of



MOC.

Heat

ECOFLUX* Corrugated Tube Heat Exchangers are used in varies industries for processing of pharmaceucal, chemical, petrochemical, ferlizers, ed ible oil, paper & pulp, cosmecs, steel, cement, power, rubber, paints, breweries & dislleries, waste & waste water management, sugar, automove, fruit pulp, beverage, parculate ready-to-eat foods, milk & milk based products, nutraceucals and probioc supplements. ECOFLUX* is used for an extensive range of applicaons like heater, cooler, condenser, reboiler, regenerator, hot water generaon, chiller, pasteurizer, sterilizer, asepc ller and evaporator.

exchang-

ers can be made in SS

304 / L, 316 / L, Cu Ni, Hastelloy,

Alloy 20,

Duplex, Titanium, etc. •

Uniform

thermal

processing. •

MI - Series

More exibility in annular space sizing.

STEEL & METALLURGY

48

FEBRUARY 2014

AS- Series

COMPANY  PROFILE

Speed and Length Measurement (down to Zero) P recision Laser Surface Velocimeters LSV 1000 / 2000 

Z

umbach Electronics ents new, high-tech and speed measuring

pres length gauges.

Precision speed and length measure ments are crical for opmisaon of connuous or quasi-connuous pro ducon processes. Proper ulizaon of these measurements can lead to lower producon costs and higher product quality. The ideal sensor must exceed tradional contact encoder performance, increasing reliability and accuracy while minimising maintenance requirements and material yield. The LSV Laser Surface Velocimeters have been designed as the ideal next generaon sensors for non-contact length and speed measurement. They provide precise length and velocity data quickly and reliably for both process control and cut-to-length applicaons.

LSV 2000 Velocimeter •

The LSV 1000/2000 measure reliably on almost any solid surface, whether con trolling processes ulising carbon steel, shiny aluminium or oily sheets, or pro ducing round wire and cable, or manu facturing paper, cardboard or ssue.

Benefts / Advantages / Main Features Zero speed, direcon detecon (model LSV 2000 only)

Aracve ROI, fast payback

All-in- one system, easy integraon into producon processes and control environments •

Reduced operang and maintenance costs

Includes two trigger inputs for addional light barriers or opcal switches for high precision edge detecon and oset length compensaon •

Easy to operate and no re-calibraon required •

Visible laser for easy alignment in the eld •





Fast, state-of-the-art signal processor with powerful command set for ecient system communicaon via se rial or Ethernet interface •

Robust sensor technology for reliable operaon even under harsh condions, protecon classes IP 66 and IP 67

Hardware status signals for remote diagnosc funcons available •



STEEL & METALLURGY

49

FEBRUARY 2014

User-selectable full quadrature pulse output and interfacing as LAN & RS 422/232 •

COMPANY  PROFILE

 Z umbach At Tube 2014

PROFILEMASTER® SPS 300-S 4

STEELMASTER Rotang SMR Gauge

Z

UMBACH – Swiss Prime Measuring since 1957 - will join the internaonal trade fair for tube products TUBE 2014 in Dusseldorf, Germany, 7-11 April. Novel and intelligent solu ons as well as cost ecient soluons for

in-line

measurement

and

con-

trol of tubes, pipes and proles are going to be the focus of Zumbach’s exhibion booth at Stall No. 5E17.

nicant advantages over other gauges,

also called light cut principle. Models

when it comes to fast and accurate

are available for any hot rolled prole

capture of dimensions in longitudi -

up to 500 mm (edge length). All models

nal and radial direcon. The mainte -

are also available for cold applicaons.

nance for SMR gauges is close-to-zero.

ECOGAUGE SystemsNew Compact And Low Cost Diameter/Width Gauges For Hot And Cold Processes

The mechanical concept is extremely simple and robust; no wear parts, no collector rings, no brakes,etc.



Excerpt Of The

on

Noveltes

Depending and

stac

the

the customer

STEELMASTER

os-

These new gauges feature, among

In addion to the exisng line of prole gauges for cold steel and metal proles, Zumbach exhibits this new version for hot applicaons. The gaugesare based on triangulaon by camera vision, oen

transmission from the laser heads. Addionally they oer novel and sig -

also

or

cillang

for fully contactless power and signal

are

needs,

STEELMASTER SMR Gauges - New Rotang Gauges For High Speed Dimension Measurement In Hot Rolling Mills others, a revoluonary new system

SMO

SMS

applica-

available

PROFILEMASTER® - New InLine Profle Gauge For Hot Rolling Mills

STEEL & METALLURGY

50

FEBRUARY 2014

On show will be one of the new up graded ECOGAUGE systems of single axis gauges. With new models, ECOGAUGE 160 and 550, the range of applicaons have been extended to a diameter of 500mm (20in.). Typical soluons are between roll ing stands for bar or for strips or in conveyors, aer hot extrusions, af ter radial forges or in peeling and grinding operaons. Mounng is very exible and possible in hori zontal, in vercal or any orientaon.

NEWS  DESK

Siemens Installs Three Contnuous Slab Casters At Tisco

S

iemens Metals Technologies in-

 The other two con -

stalled

nuous

casters

at

three

connuous

Chinese

steel

slab

casters,

produc -

CCM 01 and CCM

er Taiyuan Iron and Steel Group

04, were erected in

(Tisco) in the last quarter of 2013.

Steel Making Plant 2 South, which is

Two casters were installed in Tisco’s

Tisco’s carbon and

carbon and special-steel works and the

special-steel works.

third in the company’s stainless steel

CCM

works in Taiyuan. Each of the connu-

one of the two Sie-

ous casters is designed to produce one

mens

million tonne of slabs per year. The

casters which have

new casters increase Tisco’s capac -

been in operaon

ity for manufacturing high-quality car-

there

bon, silicon and stainless steels with

years.

a high interior and surface quality.

new casng plants are almost iden -

ic seng of the slab width, and Smart

cal in order to opmize maintenance,

Segments are installed in the strand-

operaon and spare parts stocks.

guiding system. DynaGap So Reduc-

Tisco, China’s leading producer of stain -

01

replaces

connuous

for

many

The

two

on enables the posion of the nal

less steel, have already put two singlestrand connuous slab casters, CCM

They have a machine radius of eight

solidicaon of the strand to be deter -

1 and CCM 2, from Siemens in opera-

meters and a metallurgical length of

mined with high precision, which means

on in Steel Making Plant 2 North since

27.6 meters. The thickness of the slabs

the roll gap can be controlled precisely

2007. Now with the third caster, CCM

ranges from 200 to 230 millimeters and

to ensure high internal slab quality. Dy -

0, having gone on stream, Tisco can

the width from 830 to 1,630 millime -

nacs dynamic secondary cooling and

now produce an addional one million

ters. The two plants cast a wide range

DynaJet nozzles, combined with inter-

tonne of stainless-steel slabs ever y year.

of carbon steels and special steels with

nally cooled I-Star Rollers, produce a

high silicon content, and each has an

slab surface of consistently high quality.

The casng plant has a machine ra -

annual producon capacity of one mil

dius of nine meters and a metallurgical

lion

length of 27.4 meters. The thickness

All three Siemens casters feature a cas-

plete basic (level 1) and process

of the slabs can be varied between

see-type Smart Mold with a hydraulic

automaon (level 2) for the three

180 and 250 millimeters and their

DynaFlex mold oscillator. The plants are

casters

width from 1,000 to 2,150 millimeters.

equipped with DynaWidth for automat-

construcon

metric

STEEL & METALLURGY

tons

51

of

slabs.

FEBRUARY 2014

Siemens

also

and

supplied

assisted and

the

Tisco

com-

with

commissioning.

NEWS  DESK

Process Engineering Industry Calls For Greater T hermal Coordinaon To Enhance Energy Efciency  conserve energy through opmised, ap-

a mystery, it can be solved with the

plicaon-oriented and well-coordinat-

beer coordinaon with the end-user

ed heat exchanger designs by bringing all

since conceptualisaon. If that data is

the major players on a single plaorm.

shared with manufacturers - through

EPC Companies - it would be easy to HTRI is a Texas based industrial re search

development

consor-

um which serves the thermal pro -

TEMA India Ltd. is among the global

cess

more

leaders in manufacturing of Heat Ex-

member

changers and one of the major us-

than Mr. Haresh K. Sippy, Chairman and MD, TEMA India Ltd.

and

nail this obscurity”, he concluded.

engineering

1,400

needs

corporate

of

sites world-wide for over 50 years.

ers of HTRI technology in India. HTRI CC-India (Communicaon Com-

hermal process engineering in -

T

Speaking on the current challenges

dustry took a pledge for greater

faced by the industry, Chairman and

energy eciency eorts as design -

Managing Director, TEMA India Ltd. and

ers, engineering consultants, manu-

the oldest HTRI Member, Mr. Haresh K.

facturers, buyers, processors and EPC

Sippy said, “The coming years and de-

companies gathered at the HTRI-CC

cades will see reduced availability of

India meengs held at Delhi and Mum-

crude oil and hence Indian companies

bai recently to explore newer and

need to upgrade ideas and standards

innovave soluons to make Heat

to meet global requirements and re -

Exchangers

ecient.

sultantly help conserve environment.”

89 companies of India represenng

“Heat Exchangers are to be tailor-

sions, 19 presentaons, covering var-

all key stakeholders were brought to-

made as per the end-user’s require-

ied aspects on thermal, process and

gether by Heat Transfer Research Inc.

ments and not merely as specicaons

mechanical engineering, showcased

(HTRI) at the HTRI-CC India meengs.

and datasheets. Aer all, the wealth

the recent trends and future require -

of informaon comes only from the

ments. Also there were conducted two

end-users. Though heat exchanger is

panel discussions with the discussions.

more

energy

miee) is a formal “Users’ Forum” and it provides a non-business plaorm to collect feedback on various aspects related to HTRI technology and its usage. This forum regularly discusses the current relevant maers and sends feedback to HTRI – which gets documented and suggesons implemented for the future development. On the technical side of the discus-

The meengs highlighted the need to

Wins Order Worth Rs. 246.78 E lecon EPC Projects Crores From NTPC 

E

lecon EPC Projects Limited, one of the India’s largest Material Handling Equipments and Transmission Products manufacturers and a subsidiary of Ele -

con Engineering Company Limited, has bagged an order from NTPC LIMITED of Rs. 246.78 crores for Ex-works

STEEL & METALLURGY

52

FEBRUARY 2014

(India) supply for coal handling plant package of Gadarwara Super Thermal Power Projects, Stage – I (2x800MW).

NEWS  DESK

W orld Steel Associaon To Launch Steel Safety Day  he World Steel Associaon (world -

T

on safety and health pracces in the

steel) plans to launch Steel Safety

steel industry over the last ve years

Day, reiterang its commitment to

and has idened the main causes

the safety and health of the peo-

of serious safety incidents. The Steel

ple who work in the steel industry.

Safety Day is expected to reinforce awareness of the ve most common

This safety awareness day is aligned

causes of safety incidents and to cre-

with the World Safety Day held by

ate a safer working environment across

the Internaonal Labour Organisa -

the enre steel industry worldwide.

on on 28 April every year. In support of this global event, World Steel As-

“worldsteel is requesng all its mem-

sociaon and its members will carry

bers as well as all related organisa-

out an industry-wide safety audit.

ons within the steel industry to carry out a special audit on the ve main

worldsteel has carried out an analysis

causes of safety incidents in all plants

around the world. This should engage both employees and service provid ers involving as many as four million people in total.” Edwin Basson, Director General of worldsteel said. Andrew Page, Chairman of world steel Safety and Health Commiee said: “The steel industry has seen a steady and notable reducon in the rate of injuries since 2006 and the average lost me injury frequency rate has gone down by 50% in the last ve years. But our goal remains to cre ate an injury-free, illness-free and healthy workplace with zero incidents.”

S AIL Posts 7% Sales Growth In Feb ’14 C

onnuing its encouraging Q3 re sults, Steel Authority of India Lim-

ited (SAIL) maintained its upward trend in its sales and producon in February 2014. The company registered 7% growth in sales in Feb ’14 compared to the same month last year (SMLY). For the cumulave 11-month period Apr 13 – Feb 14, SAIL’s concerted ef fort

in

increasing

domesc

sales

as well as exports paid o as these grew by 8% and 33% respecvely. SAIL

plants

kept

pace

with

the

rise in sales, as the company pro duced 1 million tonnes (MT) of sale able steel in Feb ’14, marking a 7%

SAIL Chairman Mr. C.S. Verma ascribed

has given us the condence of re -

growth over SMLY. The month also

SAIL’s growth trend to consistently

porng a beer outcome in the

witnessed

growth

good performance throughout the  -

coming months, which will further

each in hot metal and crude steel, at

nancial calendar. “Consistent growth

pick-up with the expected strength-

1.12 MT and 1.04 MT respecvely.

in sales over the last few months

ening of the market,” he averred.

4%

producon

STEEL & METALLURGY

54

FEBRUARY 2014

NEWS  DESK

Steel Minister Asks Steel Producers To Set Up Rural Stockyards

G

overnment asked

A Parliamentary panel on Steel and

“Taking this concept a step forward,

major steel com-

Coal in December had expressed disap-

it has been decided that the stock-

panies

pointment over low steel consumpon.

yards would also have service centers

has

in

the

in their premises, where small fabrica-

country to set

up

stockyards

A high-level panel had asked the gov-

on jobs could be carried out,” he said.

in

rural

areas

ernment to issue necessary direc-

so

that

con-

on to all major steel producers to

The

sumers save on

set up processing units and stock-

tate small fabricators to manufac-

me and cost of

yards, parcularly in rural areas, to

ture steel products according to the

Steel Minister Beni transportation. Prasad Verma

boost the per capita consumpon.

needs of customers and at the same

“We have asked

The Steel Minister said a few play -

me

leading steel players, including SAIL and

ers

have

already

begun

RINL, to establish stockyards in rural ar -

up such stockyards in rural areas.

service

provide

centres

beer

would

facili -

infrastructure

to small entrepreneurs, he added.

seng

eas for providing products required in

India’s steel consumpon grew 3.3 per cent, the lowest in three years,

construcon and other applicaons.’’

“Latest in this series of iniaves is the

to 73.3 million tonne in 2012-13

Steel Minister Beni Prasad Verma said.

establishment of stockyards by Steel

on subdued demand due to slack-

Steel consumpon in India is barely

Authority of India Ltd (SAIL) and Rash-

ening

60 Kg per capita against the glob -

triya Ispat Nigam Ltd (RINL) in rural ar -

est rates. It grew by 5.5 per cent in

al average of 210 kg per capita.

eas of Gorakhpur and Gonda,” he said.

2011-12 and 9.9 per cent in 2010-11.

economy

and

high

inter-

 J SW Steel To Raise Dolvi Steel Plant Capacity to 5 Million Tonnes

J

SW Steel Limited plans to shi its focus to its Dolvi Steel Plant in Maharash tra, which is beer placed to support its expansion plans, compared with its agship plant in Karnataka, where diculty in raw material sourcing has curtailed growth, according to the company. As per report, the 3.3 million tonne Dolvi Steel Plant in the Raigad district of Maharashtra that came to JSW Steel from its acquision of Ispat Industries Limited in 2010 is seeing new investments.

A senior execuve in JSW Steel was quoted as saying: “There is a lot of acvity taking place there. A capac ity addion of 1.7 million tonne has been planned for Dolvi which will push up the total capacity at the plant to 5 million tonne. The plan is likely to be implemented in the next few months.” Mr. Prashant Jain, Head of Corpo rate Strategy and Development at JSW Steel, said, “We will be expand-

STEEL & METALLURGY

56

FEBRUARY 2014

ing capacity of Dolvi plant in fu ture as it a very good locaon for browneld expansion. However, we have not yet decided the melines.” The ocial said that JSW had made new investments for a pellet and a coke oven plant, which are in trial phase and almost ready for producon. The company has also invested in using are gas a byproduct to generate 25% to 30% of the power required by the plant.

                                                                                                                                                                                                                 

                                                                                                        

             

  

  

       

 

     

      

   

   

  

       

    

 

       

     

 



       

NEWS  DESK

Steel Producon At 135 Million S AIL Sees India’s Tonnes By 2015-16

S

AIL Chairman Mr. C.S. Verma said that with around 50% ca pacity increase in the ong, India’s steel industry is likely to face a temporary over supply situaon. Mr. Verma said that “Substanal ca pacity addions are lined up in the next 1 to 2 years in the country taking the capacity from the current

level of around 90 million tonnes per annum to around 135 million tonnes per annum by 2015 to 2016.” He added “The rise in producon may lead to a temporary phase of oversupply, this is because typically the in crease in capacies is in spikes, where as the increase in consumpon follows a relavely smoother trajectory.”

During the April-February period of the current scal, India’s steel consumpon expanded by just 0.7 per cent to 67.253 million tonnes (MT) over the same period last scal, mainly due to slow economic growth. Mr. Verma added that this increased capacity and subdued consump on might lead to more exports.

Steel Consumpon Inches Up 0.7% In Apr-Feb S

low economic growth weighed down on India’s steel consumpon which expanded by just 0.7% during April-February period of current scal at 67.253 million tonnes (MT) over the same period last scal. The coun try consumed 66.78 MT steel during corresponding period last scal,

Joint Plant Commiee, a Steel Ministry Unit, said in its monthly report.

the domesc economy and a sharp decline in imports,” the report said.

“India’s real consumpon of total nished steel was up by 0.7% yearon-year in April-February FY’14, impacted primarily by the slowdown in

“The low growth rate in domesc steel consumpon indicated that base level demandcondionsconnuedtobeweak during the current scal so far,” it said.

RINL Puts In All Round Performance In Feb’14 C

onnuing the good performance in Producon as well as in Sales, RINL recorded a growth of 11% and 20%, in Liquid Steel, Saleable Steel producon respecvely compared to February’13. The month of February also witnessed a growth of 5% in Power Generaon thus reducing dependency on state grid. A turnover of Rs 1382 crores was achieved in February with a sequenal growth of 7% over previous month. The cumulave of Rs 11,766 crores achieved in current FY, represenng a growth of 2% over CPLY. The exports re corded a growth of 72% at Rs 725 crores compared to CPLY of Rs 421 crores. The cumulave sales volume of Sale -

able Steel, Special Steel and Wire Rods registered a growth of 12%, 9% and 39% re specvely compared to CPLY. Sri P Madhusudan, CMD, RINL aributed the good show to the dedicated and commied employees steered by able leadership and asked to connue the ef forts during last month of this FY

STEEL & METALLURGY

58

FEBRUARY 2014

with more zeal and to make every eort in surpassing the set targets.

NEWS  DESK

Minds From Tata Y oung Steel Clinch Industry World Champions Title  At 8 th Steelchallenge ausik Tamuli and Animesh Kumar Singh from Tata Steel India

K

billets at the lowest total cost using sec-

bagged the Industry World Champions at the World Steel 8th steelChallenge, held on 19 February 2014 in Brussels .

ondary steelmaking simulaon tools at steeluniversity. org. An applicaon of this steel is the cables of suspension bridges which can span greater distances than any other type of bridge and typically

The two young minds from Tata Steel in India won in the category for young steel industry employees. A team Ezio Agusn Casalini and Francisco Branas from Universidad Nacional del Sur in Argenna won in the student category.

use less material, leading to lower construcon costs.

The regional champions from the rst round vied for the World Champions -

Dr. Karl-Ulrich Köhler, Chairman of

tle of the 8th steelChallenge where the task was to produce high strength steel

worldsteel Educaon and Training Commiee and CEO Tata Steel Europe, an-

nouncing the winners said: “This global compeon, simulang the manufacturing of steel, provides a unique opportunity to young professionals from steel companies and universies to test their skills.” Mr. Joon-Yang Chung, Chairman of worldsteel and CEO and Chairman, POSCO, commented upon presenng the trophies and cercates to the champions: “The steel industry requires connuous

Two Winners Kausik Tamuli and Animesh Kumar with Dr. Karl-Ulrich Köhler in the middle

STEEL & METALLURGY

60

FEBRUARY 2014

innovaon and creavity and, in exchange, oers a rewarding and challenging career. This industry boasts connuous technological innovaons making a vital contribuon towards the sustainable growth of society.”

NEWS  DESK

I ndian Steel Consumpon To Expand By 2-3% In Fy14: INSDAG 

2013-14, according to Mr. Sushim Ba nerjee, Director General, Instute for Steel Development & Growth (INSDAG). “The steel industry is facing slug gish consumpon growth. We expect some improvement in Q4 period and the sector may see a growth of 2-3% in 2013-14,” Sushim Banerjee said. The steel demand in the 10 month period (April 2013- January 2014) increased by only 0.5-0.6%.

Sushim Banerjee

S

teel consumpon in the country might register a growth of 2-3% in

Mr. Banerjee menoned tradionally in the Q4 period (April-March) de mand and price remained bouyant, but this year long products were witness -

ing price pressure aer slump in steel scrap price in the internaonal market. He said crude steel producon in April 2013-January 2014 period was 4.6% and for the full scal FY’14 it was projected to remain at around 5%. On the nal report on the steel pol icy that aimed to increase Indian steel producon capacity to 300 mil lion tonnes by 2026 from 96 million tonnes now, Mr. Banerjee said he was not sure and it might come sooner as elecons were knocking on the doors. Despite sluggish demand and producon outlook in FY’14, the scenario was likely to improve in 2014-15.

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NEWS  DESK

Siemens Meros Plants To Clean Sinter Ofgases For Italian Steel Producer Ilva S.p.a • • • •

Cuts ne dust emissions to below ten milligrams per standard cubic meter Reduces dioxins and furans to less than 0.1 nanograms per standard cubic meter Substanally reduces acidic gases and volale organic compounds Plant design allows for major reducon of sulfur dioxide emission

talian steel producer Ilva S.p.A. has placed an order with Siemens Metals Technologies to supply four turnkey Meros plants for the two sinter plants in

I

come down from the actual emission load of 12 grams per year at the ac tual limit of 0.4 nanograms I-TEQ per standard cubic meter to a level less

and nely distribung adsorpon and desulfurizing agents, such as acvated carbon and sodium bicarbonate, into the ow of ogas. This eciently binds

its Taranto steel mill, which is the single largest producon unit in Europe with a capacity of 11 million tonnes per year.

than 3 grams per year. The design of the plant is also featuring installaons for major sulfur dioxide reducon.

and removes heavy metals, harmful and hazardous organic components, as well as sulfur dioxide and other acidic gases. The use of sodium bicarbonate

Siemens Meros process will clean all the ogas from the sinter process – totaling more than 2.6

Siemens recently won an order in summer 2013 to equip the sinter plants with

to reduce the amount of sulfur dioxide also eliminates the need for a condioning reactor. The pro-

million cubic meters per sinter plant per hour. This will reduce emissions of sulfur dioxide, ne dust, organic compounds, heavy metals and acidic gases to levels signicantly below the

cess is water-free, which avoids steam plumes coming from the smoke stack. The dust parcles are deposited in a specially developed, energy-ef cient bag lter, which is suitable for temperatures

usual limits in Europe. The rst two Meros plants are scheduled to

of up to 250°C and very low cleaning pressures. The greater part of the

go on stream in April 2015 and the other two will follow in September 2016. The value of the order lies in the mid double-digit million euro

Meros plant from Siemens

range.

In the future, the ne dust emission via the smoke stack of Ilva´s sinter plants in Taranto will be reduced by more than 1,000 tonnes compared to the legal emission level, which is actually set at 4 0 micrograms per standard cubic meter.

two new secondary dedusng systems. The Meros plants will replace the existing outdated MEEP electrostac precip itators, which can only remove dust. The new units will be installed and integrated into the ogas system of the sinter plants during ongoing operaon, which will only require brief shutdown mes.

Furthermore, the dioxin emission will

The Meros process involves injecng

STEEL & METALLURGY

62

FEBRUARY 2014

dust removed by the precipitator is recycled back into the ow of ogas to further opmise the ef ciency and cost-eecveness of the gas puricaon process. Any remaining unulised addives are then once more in contact with the ogas, so that they are nally almost completely ulised. The process automaon system ensures stable operaon, even during uctuaons in the volume and composion of the ogas. Emission limits can therefore be observed at all mes.

2-DAY INTERNATIONAL CONFERENCE

STEEL CONCLAVE 2014 Raw Materials, Technology, Energy Management & Logistics in Steel Industry 28 - 29 October 2014 Bombay Convention & Exhibition Centre Goregaon (East), Mumbai, India Organised by:

Concurrent to:

Technical Focus: • • • • • • • • • • • •

Coke making Future supply of coal & iron ore New coke making technologies Iron ore production and handling Iron ore beneficiation technologies Sinter plant operation and automation Pelletisation Blast furnace iron making New blast furnaces Direct reduction: production and use of DRI Environmental control in iron making CO2 reduction and energy saving in steelmaking • Alternate Fuel • Waste Heat Management • Water Treatment

• Primary and secondary steelmaking • Continuous Casting technology • Refractories developments in casting additives • Special technologies for high performance steels • Automation, maintenance, on-line machine control • New plants and updating of conventional plants • Safety and environmental aspects • Downstream processing of CC products and of ingots (interactions with successive working processes, i.e. rolling, forging, wire drawing, extrusion, etc.) • New casting processes, novel casting technologies, new products

• Product quality (surface defects, internal quality) • Near-net-shape casting / thin and medium slabs • Strip casting, beam blank casting • Finishing • Testing technology (cleanliness, gas content, surface quality) • Casting, solidification and phase formation • Metal forming processes and thermomechanical treatment • Coating and finishing • Integrated modelling of process chain and production • Materials transportation and handling logistics

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STATISTICS

W orld Steel Associaon Monthly crude steel producon in the 65 countries included in the report, in thousands of tonnes.  January 2014 January

January

% change

1 month

2014

2013

Jan-14/13

2014

2013

% change

Austria

681

672

1.5

681

672

1.5

Belgium

580 e

627

-7.5

580

627

-7.5

Bulgaria

45 e

43

3.7

45

43

3.7

Croaa

20 e

3

546.6

20

3

546.6

Czech Republic

458

443

3.5

458

443

3.5

 Finland

330

300

9.7

330

300

9.7

 France

1 350 e

1 351

0.0

1 350

1 351

0.0

 Germany

3 663

3 585

2.2

3 663

3 585

2.2

Greece

110 e

87

26.4

110

87

26.4

 Hungary

80

78

2.6

80

78

2.6

2 245

1 756

27.8

2 245

1 756

27.8

186

7.6

200

186

7.6

Italy Luxembour g

200 e

Netherla nds

620 e

612

1.4

620

612

1.4

Poland

640 e

649

-1.4

640

649

-1.4

Slovakia

393

388

1.3

393

388

1.3

Slovenia

54

42

28.2

54

42

28.2

1 111

1 000

11.1

1 111

1 000

11.1

387

371

4.4

387

371

4.4

1 083

824

31.5

1 083

824

31.5

417

-13.6

360

417

-13.6

14 409

13 433

7.3

14 409

13 433

7.3

75

61

22.1

75

61

22.1

5

10.3

5

5

10.3

49

52

-5.9

54

0

..

Spain Sweden United Kingdom Other E.U. (27) (e) European Union (28) Bosnia-H erzegovi na Macedonia

360 e

5e

Norway

49

52

-5.9

Serbia

54

0

..

Turkey

2 829

2 854

-0.9

2 829

2 854

-0.9

Other Europe

3 013

2 972

1.4

3 013

2 972

1.4

 

Byeloruss ia

175 e

226

-22.6

175

226

-22.6

Kazakhstan

300 e

198

51.3

300

198

51.3

45 e

0

..

45

0

..

Moldova

 

 Russia

5 935

5 704

4.1

5 935

5 704

4.1

Ukraine

2 490

2 878

-13.5

2 490

2 878

-13.5

58

2.6

60

58

2.6

9 065

-0.7

9 005

9 065

-0.7

Uzbekistan C.I.S. (6)

60 e 9 005

STEEL & METALLURGY

66

FEBRUARY 2014

STATISTICS

Monthly crude steel producon in the 65 countries inc luded in the report, in thousands of tonnes.  January 2014  January

January

% change

2014

2013

Jan-14/13

2014

2013

% change

1 050 e

1 096

-4.2

1 050

1 096

-4.2

Cuba

35 e

20

72.6

35

20

72.6

El Salvado r

10 e

8

25.0

10

8

25.0

Guatemala

40 e

26

53.8

40

26

53.8

1 550 e

1 552

-0.1

1 550

1 552

-0.1

45

59

-22.8

45

59

-22.8

7 328

7 362

-0.5

7 328

7 362

-0.5

10 058

10 122

-0.6

10 058

10 122

-0.6

397

320

24.1

397

320

24.1

2 738

2 776

-1.4

2 738

2 776

-1.4

Canada

Mexico Trinidad and Tobago United States

 North America Argenna Brazil

1 month

Chile

110 e

141

-21.8

110

141

-21.8

Colombia

125 e

89

40.0

125

89

40.0

Ecuador

60 e

46

30.6

60

46

30.6

Paraguay

5e

1

354.1

5

1

354.1

110 e

87

27.1

110

87

27.1

10 e

0

..

10

0

..

110 e

175

-37.0

110

175

-37.0

3 634

0.9

3 665

3 634

0.9

19

80.8

35

19

80.8

677

-27.8

489

677

-27.8

Peru Uruguay Venezuela South America

Algeria Egypt

3 665

35 e 489

Libya

70 e

41

72.8

70

41

72.8

Morocco

58

53

9.3

58

53

9.3

615 e

615

0.0

615

615

0.0

1 267

1 405

-9.8

1 267

1 405

-9.8

1 350 e

1 111

21.5

1 350

1 111

21.5

165

197

-16.2

469

463

1.4

South Africa

 Africa Iran Qatar

165 e

197

-16.2

Saudi Arabia

469

463

1.4

United Arab Emirates

157

216

-27.5

157

216

-27.5

2 141

1 987

7.7

2 141

1 987

7.7

China

61 573

63 622

-3.2

61 573

63 622

-3.2

India

6 954

6 955

0.0

6 954

6 955

0.0

Japan

9 401

8 863

6.1

9 401

8 863

6.1

South Korea

6 040

5 928

1.9

6 040

5 928

1.9

Taiwan, China

1 840 e

1 776

3.6

1 840

1 776

3.6

85 809

87 144

-1.5

85 809

87 144

-1.5

339

408

-17.1

339

408

-17.1

77

83

-7.1

77

83

-7.1

416

491

-15.4

416

491

-15.4

129 783

130 253

-0.4

129 783

130 253

-0.4

Middle East

Asia

Australia New Zealand

 Oceania Total 65 countries*

 

* - the 65 countries included in this table accounted for approximately 98% of total world crude steel producon in 2013e - esmated

STEEL & METALLURGY

67

FEBRUARY 2014

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