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These are the stand-out properties of aluminum: low weight We’d be delighted to see you at our booth. There you can
combined with high strength, good electrical and thermal find out all about our full range of machinery and plants –
conductivity, corrosion resistance, and recyclability. for producing, processing, and refining aluminum as well
as aluminum products. Take this opportunity to talk with us
personally. Be our guest!
Visit us at
ALUMINIUM 2016
Hall 9, Booth No. 9C20 SMS group offers products customized to your require-
Nov. 29 to Dec. 1 ments. You also benefit because all our solutions are
Düsseldorf, Germany designed for top efficiency and resource saving. NEW ORDER COMMISSIONING e-Service
Eco-friendly steel complex for Largest extrusion press ever built by Platform prototype means: Industry
AFERPI in Italy. SMS group to start production. 4.0 you can experience.
42 98 128
SMS GROUP GMBH
Eduard-Schloemann-Strasse 4 Phone: +49 211 881-0 communications@sms-group.com
40237 Düsseldorf, Germany Fax: +49 211 881-4902 www.sms-group.com
sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
Contents
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12 The modernization experts. 18 ArcelorMittal Gent upgrades hot strip mill. 82 Pipe mill up to date. 106 Extrusion presses for Al Taiseer. 118 Future-oriented operation.
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Deep insights
The photo shows a Plug & Work test. In the
in-house test centers, SMS group automa-
tion experts set up a great portion of the
original automation system to be later in-
stalled at the customer’s site including con-
trol cabinets, computers, control desks and
software. Then, prior to commissioning, the
automation system is thoroughly tested by
close-to-reality simulations, and the cus-
tomer’s operating staff is trained at this
early stage. Plug & Work is the name of
SMS group’s innovative proceeding which
will significantly shorten the actual com-
missioning on site. To reproduce and visual-
ize production processes, SMS group has
most recently been using a professional,
interactive 3D graphics application within
the scope of Plug & Work. 3D visualizations
permit the users to observe mechanical
components and movements even more
clearly. The Plug & Work method is well
suited for both new equipment as well as
modernization projects.
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For 50 years, Drever has been establishing plants for steel product After 34 years of employment, 20 thereof as Managing Director,
heat treatment. Jointly with SMS, it is the market leader in annealing, Jean-Marc Raick has retired. On July 1, 2016, his position was
hot-dip galvanizing and stainless steel processing lines. assumed by Jean-Pierre Crutzen (photo).
On fire for
SMS INNSE – FOR 20 YEARS building furnaces
PART OF SMS GROUP 50 years of Drever in Belgium.
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SMS group has been recognized as “Best Supplier of MMK in technological detail of the plants and makes this know-how SMS digital GmbH to develop its own
available to its customers as service partners.
and non-standard equipment in 2015”. digital business models.
SMS group’s proficient approach to maintenance
guarantees highest plant availability.
EXCELLENT SERVICES
The award was presented to SMS onal performance as suppliers of plant technology and The SMS group services which MMK refers to as SMS group has founded a startup designed to develop
group in a ceremony held at Magnito- technical services. The ceremony concluded with a tour of being exceptional and for which they presented new digital models that complement the company’s core
gorsk Iron and Steel Works (MMK) in the Magnitogorsk worksite. the recent award relate particularly to services business. Operating independently in terms of finances
Magnitogorsk, Russia, on June 2, 2016. for the No. 6 continuous casting plant. For that and management, SMS digital GmbH
Pavel Shilyaev (CEO of Magnitogorsk UNIQUE APPRECIATION casting plant, which produces slabs up to 300 is a subsidiary affiliated with SMS
Iron and Steel Works) handed over the Pino Tesè, Executive Vice President Technical Service of millimeters thick and has a maximum casting Holding GmbH.
award to Fulvio Michelutti and Grigory SMS group: “We are proud to be recognized by our custom- width of 2,700 millimeters, the SMS group’s ser- “SMS digital will interact directly
Smolin (both from SMS Metallurgical ers and are indeed very happy about this award. It will be vice team performs the complete routine main- with customers to identify the digital
Service LLC) in recognition of excepti- motivation to us to continue striving to improve our prod- tenance as well as regular maintenance and re- products they need or want. Then it
ucts and services for our customers and responding to pairs to the molds and segments. will develop and market the right
their requirements as efficiently as possible. The award MMK rates its suppliers on a scale of points products in close cooperation with the
honors our proficiency and professionalism as well as the based on a number of criteria, which include the Business Units of SMS group,” says
high quality of our products. It will foster the partnership service scope, quality of work, timeliness and Burkhard Dahmen, CEO of SMS
between SMS group and MMK – one of our most important compliance with contract agreements. This open group. The new digital subsidiary will Maximilian Wagner
customers for 80 years.” supplier selection system provides MMK and build on findings from last year’s “In-
As early as in 1936, SMS group supplied the first revers- their business partners an objective assessment dustry 4.0” studies conducted by interdisciplinary project
ing rolling mill to MMK. Since then, MMK has been pro- of competitiveness. The “Best Supplier of the teams at SMS group. Maximilian Wagner has been ap-
ducing and processing steel on numerous state-of-the-art Year Award”, presented for the first time in 2016, pointed Managing Director of the new company with im-
plants and machines from SMS group. SMS group has been makes quality of performance openly visible. mediate effect.
supporting MMK extensively as a service partner. Starting
in 2009, service teams from SMS group have been perform-
ing various activities at facilities of MMK, including service
tasks ranging from individual solutions through to complete
service and maintenance packages. As plant manufactur- Reinhard Reddel Maximilian Wagner
er and systems supplier, SMS group is familiar with every reinhard.reddel@sms-group.com mw@sms-digital.com
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Joint venture
partners: Dr.
Andreas Filzwieser,
Managing Director of
PolyMet Solutions
GmbH, Dr. Rolf The merger helps SMS group expand its QuinLogic GmbH runs several locations around Joseph Dzierzawski, President and CEO SMS
Degel, Dr. Iris product portfolio. the globe. USA LLC, proudly holds the award trophy.
Filzwieser, Dr. Guido
Kleinschmidt,
Member of the
Managing Board of
assurance award
(from left to right).
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The modernization
experts
Identifying keys to success with SMS group.
Diligent planning
is a key element of Since the turn of the millennium, world steel capacity has ramp-up and making the plant “Indus-
fast revamps.
more than doubled. Due to the fact that the steel demand try 4.0-ready” with intelligent compo-
has not increased in accordance with development, steel nents, today! SMS group opens up new
producers worldwide are facing problem of overcapacity. competitive opportunities for plant
The Organization for Economic Co-operation of Develop- operators by implementing target-
ment (OECD) Steel Committee expects excess capacity of oriented, customized modernization
steel to reach 750 million tons, alone in 2016. Consequent- strategies.
ly, the cost pressure on the plant operators has been grow-
ing. However, there are indeed profitable market niches
and growth markets. For example, high-strength steel
grades for automotive light-weight construction are still
much in demand, as well as large-size components for
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wind power plants or gear components, or special formats,
like thicker gage sheet or special long products. Most plant
operators have therefore been increasingly concentrating
on modernizing their facilities and asking questions like:
Which is the best modernization strategy for me to remain
competitive? What kind of modifications are needed to max-
imize the efficiency and sustainability of existing plants?
The future of the plant owners is at stake. Therefore,
modernization today is much more than the mere replace-
ment of old parts with new ones. Integrative and foresight- years is the age of the PAO Severstal plant.
With the revamped plant, the customer can
ed concepts are needed in order to be able to reduce to a
now produce premium cold-rolled strips for
minimum the downtimes associated with a revamp, while
the automotive industry.
speeding up the commissioning activities, achieving a fast
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Forward-thinking revamps solution will be derived outlining how the production pro- market in terms of practical experience as well as innova- the same time, a modernization will also reduce the envi-
proximity is not only a geographical group provide higher cost-efficiency and allow our custom- have intelligent components in place which are capable of Realizing success
SMS Group
term, but an entrepreneurial mission. ers to reach their targets in a more sustained manner. communicating more intensively and effectively with high- A look at recent modernization projects reveals the advan-
With 14,000 employ- The SMS experts actively approach er-level systems. tages of modernization concepts by SMS group. At Arcelor-
ees worldwide, the the plant operators, suggesting ways Implementing customer requirements Mittal in Gent, Belgium, SMS group is revamping the me-
group can offer their to implement efficient modernization The fact that SMS group operates its own in-house manu- Leveraging expertise chanical equipment of the hot strip mill. The objective of
customers bespoke, measures that will open up new mar- facturing facilities enables us to manufacture components There are basically three options for revamping a produc- the project is to expand the product portfolio to include
technologically and ket opportunities for them. As a mat- perfectly tailored to the specifics of the modernization tion plant: revamping the mechanical equipment, revamp- high-strength and multi-phase steels. To this end, SMS
economically con- ter of course, customers also directly project on hand. This, of course, would not be possible ing electrics and automation or revamping both the me- group will install new finishing stands, new gears and new
vincing solutions for turn to SMS for concrete revamping without our highly qualified and, above all, long-time em- chanical equipment and electrics & automation. As OEM, high-performance spindles. Installation will take place
any challenges and requests. In both cases, the SMS spe- ployees who have the necessary knowledge and expertise SMS group boasts in-depth know-how for all three op- during two scheduled mill shutdowns. The functions of the
tasks. cialists will first conduct a fact-find- to master the challenges and complex mechanical engi- tions. However, the task is not only to bring an obsolete preassembled components will be checked in comprehen-
ing process based on which an engi- neering tasks we encounter in our industry. SMS group plant back to the state-of-the-art, but above all to increase sive pre-installation tests in the SMS group’s manufactur-
neering concept will be elaborated. has been active in the modernization business for many the product range, the product quality and the flexibility of ing workshops in Hilchenbach together with specialists of
From such a concept, a well founded decades. That gives us a clear competitive edge in the production – while decreasing the costs of operation. At ArcelorMittal. One advantage of this procedure is, for
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With this modernization ArcelorMittal is preparing its hot Sieflex® HT spindles (high torque spindles) and supplied now attainable, SMS group retro-fitted oil film bearings of ARCELORMITTAL PERFORMING TESTS IN
strip mill in Ghent, Belgium, to be able to meet future re- a new profile, contour and flatness control system (PCFC®) the SMS brand X-Roll® Oil Bearing. In the course of that SMS group WORKSHOP
quirements. The most important objective is the enlarge- for the finishing mill. shutdown, too, the electromechanical looper downstream Since March, big preparations have
ment of the product portfolio in the field of high-strength F6 was replaced by a hydraulic one. The new hydraulic been underway for the next conversion
grades and multi-phase steels. At its Ghent location, Arce- HIGHER ROLLING FORCES IN F3 AND F4 loopers for mill stands F3 to F5 will be installed in autumn shutdown. To ensure minimum down-
lorMittal is enhancing the production of strips of the newly An essential reason for awarding the contract for this com- 2016 during short downtimes. time, almost no remachining work at
developed Fortiform® series which covers new steel grades prehensive and complex modernization project to SMS mill stands and a fast ramp-up, both
for the automotive industry and comes with a considerable group was the convincing conversion concept. To keep the REPLACEMENT OF MILL STANDS F1 AND F2 new mill stands were pre-assem-
reduction in weight, at the same time providing an increased
level of safety. In addition, ArcelorMittal is striving for more
need for restricting the production process as little as pos-
sible and to ensure a reliable production start after comple-
The main conversion work in the hot strip mill will be per-
formed at the end of 2016 and comprises the removal of
bled in the SMS group’s Hilchenbach
workshop and the mechanical and i
flexibility in production and wants to be able to increase its tion of the conversion work, a modernization concept pro- the existing mill stands F1 and F2 and their replacement hydraulic equipment tested for proper
hot strip capacity at the Ghent site, if and when necessary. viding for two shutdowns was prepared. by new and stronger ones which come with powerful ac- functioning. Manufacture
The upgrade focuses on the finishing mill of the plant, The first shutdown was in December 2015 and lasted tuators such as hydraulic adjustment and CVC® plus, in- In June and July, ArcelorMittal Gent
which was commissioned in 1967, and comprises the instal- 14 days, as scheduled. Measures primarily focused on mill cluding work roll shifting and bending systems. These ac- had the opportunity to test the mill At its Hilchenbach
lation of new finishing stands F1 and F2 as well as modi- stands F3 and F4 which received new hydraulic adjust- tuators will be integrated in the existing PCFC® model and stand functions such as adjustment location, SMS group
fications to boost the rolling forces of mill stands F3 and ment cylinders able to produce an effective rolling force thus permit the strip geometry to be influenced right from and balancing systems or the entry is able to assemble
F4 plus the integration of hydraulic loopers throughout the of 45 MN. The mechanical adjusting equipment was re- the first finishing stand. Thanks to a rolling force of 50 MN and exit guides by itself. This was ac- complete machines
complete finishing mill. In the recent past, SMS group al- inforced. The internal faces of the mill housings were re- per mill stand, it will be possible to attain high reductions complished by involving the automa- up to a weight of 400
ready strengthened the drive trains of mill stands F1 to F3 by milled, and the housing clearance was adapted by install- in the first mill stands even when high-strength steel tion system installed at the hot strip tons per unit. The
installing new main and mill pinion gear units and powerful ing new wear plates. To absorb the higher rolling forces grades are rolled. mill and thus permitted the mechanical immediate vicinity of
equipment and the automation system design and manufac-
to be harmonized already in advance. ture ensures a close
Once the tests will have been com- interaction of both
pleted, the mill stands will be trans- fields and hence the
ported to Ghent and, in September, consistent advance-
be assembled adjacent to the mill. ment of rolling mill
The customer will test the equipment technology.
again before the second shutdown in
mid-November. The first step will be to
remove the old mill stands F1 and F2
and then to shift the pre-assembled
new ones to these positions in the fin-
ishing mill. The new mill stands will be
installed with a minimum number of
changes to the environment and re-us-
ing existing plant components such as
the media pump station. The hot strip
mill is scheduled to roll its first coil at
the beginning of December 2016.
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Interview
Mr. Haverbeke, would you please tell us about the project What kind of tests are you going to perform?
from your point of view and also why it is so important to We are trying to perform as many tests as possible. All the
ArcelorMittal Gent? equipment will be installed in the mill stands, this means
We are implementing this modernization project with SMS all actuators, sensors, loopers, guides and much more.
particularly with an eye on the automotive industry. Arce- Then, we will bring in the roll set together with SMS and
lorMittal takes a leading position in the market of high- test the interaction of the different components with the
strength steels for the automotive industry, which we of- aim to save time during the conversion shutdown. In addi-
fer under the brand name Fortiform®. Thanks to its high tion, we will test our automation system. This way, we hope
strength and excellent deformability, Fortiform® allows to learn more about the new mill stands – the way they op-
the bodywork of cars to be up to 20 percent lighter. Con- erate and what we have to observe in our new plant. To us
sequently, cars consume less fuel and emit less CO2 . This these tests will be very beneficial.
series supports our customers in the development of new
products and new concepts to meet future environmental How do you assess the cooperation of your team and the
standards, for example. team of SMS?
We appreciate to have a partner who is concerned and de-
Why did you choose SMS group to be your partner for this velops concepts jointly with us, who closely cooperates with
project? us, one who shares our ideas and with whom we can share
In the first place, we considered it important to have a part- our ideas. Together we will then try to find the best possible
ner capable of implementing such a project and experi- solution. The cooperation with SMS is very fruitful to us.
enced in the design and manufacture of strong mill stands.
Secondly, we were looking for a partner who, after the in- Standing in front of the mill stands, can you imagine that,
stallation of the mill stands, would optimize the hot strip in a few months, they will operate in your plant?
mill jointly with us to make rolling of our new products pos- Yes, of course it is great to have the mill stands here. It is
sible. This means that our cooperation will not terminate really impressing to enter the hall and see the completely
after the modernization activities, but SMS will support us, assembled mill stands. To me, it is an honor to participate
for instance, in introducing new products, improving prod- in this project, and I am looking forward to installing the
uct quality or reducing emissions. mill stands together with the teams of ArcelorMittal Gent
and SMS and later to benefit from the modernization.
Why is pre-assembly of such a high significance to Arce-
lorMittal Gent?
Pre-assembly in the workshop was an explicit demand. The
main objective behind is, of course, to shorten the shut-
down period needed for conversion. SMS was the only com-
pany able to pre-assemble the mill stands in its workshop
and also to install the work and backup rolls.
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On May 11, 2016, SMS group commissioned rolling mill efficient cooperation of all those in-
“2100” of the Russian steel producer PAO Severstal after a volved in the project, the main con-
comprehensive modernization. PAO Severstal awarded SMS struction activities, which included the
group an order to revamp the four-stand tandem cold mill dismantling of existing equipment, in-
“1700” at the Cherepovets works in Northwest Russia. The stallation of the new equipment and
objective of the project was to increase the capacity of the the commissioning phase until suc-
mill, expand the product range and improve product quality. cessful rolling of the first strip, were
The tandem mill was also to be prepared for being coupled performed during a mill downtime of
with a new pickling line at a later stage. only 88 days. The first strip was rolled
SMS group completely renewed the entry section and the just ten days after the first mechanical
four stands of the tandem mill. This involved equipping the equipment had been commissioned.
mill stands with the latest of CVC® plus 4-high technology Hence, PAO Severstal’s comprehen-
(Continuously Variable Crown). Effective work roll bending sively modernized rolling mill “2100” is
systems, CVC® work roll shifting also under rolling load, all set for new tasks. It is well prepared
highly dynamic adjustment systems, multi-zone cooling in to meet the customers’ growing re-
the last mill stand, an exit-side dry strip system of the latest quirements regarding the properties
generation as well as other proven plant components en- of quality carbon steels as well as
sure that the strip will meet the customer’s exacting quality high-strength and micro-alloyed sili-
requirements. High reductions per pass are made possible con steels. Including the capacity of
by effective roll and interstand cooling. Automatic work roll 200,000 tons added by this moderniza-
changing and the new, optimized coil preparation station tion project, PAO Severstal now has a
reduce non-productive times. total capacity of 1.3 million tons.
PERFECT INTERACTION
In order to be able to roll a wider range of products, the first
rolling stand received a completely new drive train. The per-
formance of the other stands was enhanced by integrating
new control systems into the existing drive units.
SMS group also supplied the X-Pact® automation sys-
After the revamp by SMS group, PAO Severstal now has a state-of-the-art
rolling mill “2100” which produces very efficiently.
tem, complete with level 1and level 2 as well as the mea-
suring equipment which includes the X-Shape flatness
i
measuring and control system. Robust and precisely oper-
ating X-Shape flatness measurement rolls have been in-
stalled behind the first and the last mill stand. An assis-
OBJECTIVES
tance system, specifically developed for tandem mills, opti-
READY FOR PEAK mizes threading and tailing out of the rolling stock at each
mill stand. This reduces off-size lengths at the strip head
and tail ends and increases the yield. All those components
The revamp focused on the
objectives below:
PERFORMANCE
are harmonized and perfectly coordinated to make sure the Minimize plant downtime
highly exacting demands on the strip quality in terms of Boost the product range
thickness, flatness and surface quality are met and the Improve strip quality in terms of
plant operates in an economically efficient way. thickness and flatness
The auxiliary facilities, which have also been brought to Increase output
the latest state-of-the-art, and the powerful filter systems Reduce non-productive times
The tandem mill at PAO Severstal was modernized in record time. reduce the consumption of emulsion, boosting the economic Enhance economic efficiency
efficiency and environmental compatibility of the plant, last
SMS group renewed the mechanical equipment as well as the electrical
but not least by the fume extraction system with advanced
and automation systems. exhaust air discharge between the rolling stands.
Thanks to the proven Plug & Work concept of SMS group Reinhard Reddel
in addition to diligent project planning and the extremely reinhard.reddel@sms-group.com
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Manufacturing site at the SMS Mönchenglad- Every step fits: Fitter during final touch of Intermediate step, opened case with a view
bach location where the wire rod blocks were repaired units. to the gearbox.
overhauled.
At ArcelorMittal in Sosnowiec, Poland, SMS group has and production capacities ensuring its
brought a finishing block of a more than eight year-old two- customers quick and uncomplicated
strand wire rod mill to “as new” condition in a very short services everywhere.
time. It took the metalworkers of SMS two weeks in the In the case of ArcelorMittal the plant
Mönchengladbach workshop to replace the anti-friction technicians dismantled the plant on
bearings and remachine the bores of the stands such that site and sent the parts to Mönchenglad-
wire rod blocks as good as new were available in the end. bach. The bearings were then renewed,
The plant originally supplied by SMS group in 2007 is a ten- bores repaired, and stands reassem-
stand finishing block arranged in K-shape on which Arce- bled and appropriately adjusted. After
lorMittal is producing wire rod of special quality. Main cus- return shipment and reassembly at Ar-
tomer of these grades is the automotive industry, producing celorMittal, cold commissioning was
safety components from it, such as helical springs, high- carried out. While the stands were in
strength connection or steering parts. Mönchengladbach for rework, the plant
Parts arranged on the car chassis are exposed to par- technician team stayed on site over-
ticular stress. Therefore, only quality steel is used. The hauling the transfer case and chang-
feedstock for automobile customers is produced by Arce- ing all drive couplings.
lorMittal on the wire rod mill in Sosnowiec at speeds up to In Sosnowiec, production now runs
ArcelorMittal delivers wire rod to the automotive industry worldwide e.g. for safety components. 100 meters per second. This enables the company to sell again as with a new plant. “The toler-
about 1,000,000 tons of material produced on the wire rod ances which we promise for these
mill to the international car industry. ArcelorMittal thus op- grades are between +/- 0.15 and 0.2
erates the plant in 20 shifts per week. millimeters,” says Frank Isken from
SMS group Service. “After our modern-
ization the unit can again be operated
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EFFICIENT MODERNIZATION
WITH CONCEPT ENGINEERING
Concept engineering is an efficient tool to develop the best
possible solution for the modernization of a plant. Through this holistic approach
Outokumpu improves the competitiveness of its hot rolling mill in Tornio. To ensure high surface quality Outokumpu will
receive a new descaler.
To cope with the increasing market demands in terms of nomically efficient solution. The examination further in- After the revamp had been completed, the close coopera- Simultaneously, the production process was analyzed in de-
quality, productivity, operating costs and product portfolio, cludes items like plant technology, production process and tion of the two companies was continued within the frame tail. By adapting the profile and flatness control, modifying
every plant must be upgraded at regular intervals in the maintenance. Process technology, mechanical and hydrau- of a cooperation agreement. This liaison has led to concept the CVC® contour of the work rolls and changing the strip
course of its lifetime. Accordingly, the requirements to be lic equipment, electrical and automation systems are con- engineering on the basis of which Outokumpu pursued the tensions it was possible to significantly improve the rolling
satisfied by the equipment manufacturer are often grow- sidered in the overall context also taking into account such following objectives: stability and to reduce output losses by up to 80 percent.
ing along with the plant life and the specialization in the aspects as consumption figures, safety and environmental
product range. standards. The tools SMS uses to prepare such all-round Improve product quality ROLLING MILL MODERNIZATION
analysis comprise the entire range of state-of-the-art meth- Enhance plant availability Along with concept engineering, targeted modernization
HOLISTIC ANALYSIS ods like FEM or CFD analyses or simulation programs. It is Expand the product portfolio measures were developed for upgrading the mill equipment
To meet the customers‘ demand for complex moderniza- absolutely vital here that customer and equipment supplier Simplify maintenance and spare parts management to produce strips with higher maximum strength and to im-
tions and a continuous improvement in performance, SMS cooperate very closely and respect their partner’s know- prove the surface quality.
group developed concept engineering. It means a system- how and operating results. ENHANCEMENT OF PLANT AVAILABILITY Still this year, SMS group will install a new descaler and
atic analysis of a plant on the basis of which SMS develops, Concept engineering provides coordinated measures The measures to be taken for the enhancement of plant new pumps to improve the surface quality. Like the old one,
jointly with the customer, the optimum technical and eco- for maintenance, plant engineering and production tech- availability were developed on the basis of a detailed inves- the new descaler operates at a pressure of 180 bars, but,
nology. Hence, the customer is given a comprehensive and tigation of the unexpected plant downtimes over a period of thanks to its improved design, will have a better surface
Outokumpu’s Steckel mill stand and the finishing detailed basis for his future planning at a comparatively more than two and a half years. In the course of these stud- cleaning effect.
stands installed in the exit section in 2005. low investment. ies, particularly vulnerable areas were identified and the The Steckel mill stand will be equipped with new Sieflex®
measures in the fields of maintenance and plant engineer- HT gear-type self-aligning spindles to transmit the higher
OUTOKUMPU IN TORNIO ing defined accordingly. rolling torques needed for the production of high-strength
One example of a successful application of this approach is steel grades. New wheel sets for the mill pinion gear unit had
the concept engineering for the hot rolling mill of Outokum- PASS SCHEDULES FOR NEW PRODUCTS already been supplied by SMS group. In addition, new bend-
pu, a market and technology leader in stainless steels. The Over the last few years, Outokumpu has been continuously ing blocks will be installed in the Steckel mill stand, which
company’s rolling mill in Tornio, Finland, comprising one expanding its product portfolio to even better meet the are less susceptible to failure and easier to change.
reversing rougher, a Steckel mill stand and a coiler, was demands of its customers for new steel grades and dimen-
commissioned in 1987. To increase production, SMS group sions. SMS group supported Outokumpu in the develop-
extended the facility by three finishing stands and one coiler ment of these new products and of the design criteria of Karl-Friedrich Müller
within a spectacular modernization project in 2005. its facility. karl-friedrich.mueller@sms-group.com
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NLMK relies on
Paul Wurth
The modernization of blast furnace No. 6 and auxiliary plants in Lipetsk,
Russia, will be carried out in cooperation with Lipetsk Gipromez.
Series of Modernization Services Accom-
plished at Blast Furnace Plant in Brazil
per cooling boxes, tuyeres and tuyere coolers), low energy
tuyere stocks and a completely new bustle pipe. The origi-
nal Bell Less Top®, Paul Wurth’s first ever reference in the Within the past months, Paul Wurth has successfully planned and executed a
former Soviet Union and in operation since 1978, will be
number of repair jobs helping our customer Vallourec Tubos do Brasil (VBR).
replaced completely by a new, parallel hopper type charg-
ing system (60 m3 hopper volume) including the pressure
equalizing and bleeder valves. Furthermore, Paul Wurth
will supply the cooling water pump house, the complete in-
strumentation, general electrical and control equipment.
On the process side, Blast Furnace control will be sup- Within the past months, Paul Wurth has successfully Wurth’s organisation and the performance of the execut-
ported by TMT’s stockline recorders, the SOMA acoustic planned and executed a number of repair jobs helping our ing teams helped to fully catch up with some delays which
temperature measurement system and the 3DTopScan customer Vallourec Tubos do Brasil (VBR) to fulfil a lifetime occurred during the idling activities.
profilemeter. extension programme for No. 1 Blast Furnace (BF) at their On the hot blast stoves side, stoves No. 13 and No. 12
For the casthouse, four sets of TMT’s fully hydraulic clay Belo Horizonte works in Minas Gerais. The interventions have been repaired in 2012 and 2013 already. Finalizing this
View over Ironmaking Shop No. 2 with Blast Furnaces No. 6 and No.7. guns and taphole drills as well as radar level probes for were related to the refractory systems of the blast furnace reline programme, the partial repair of stove No. 11 started
torpedo ladles became part of the order. itself and of the hot blast stoves. with the furnace’s temporary shutdown in November. Also
NLMK’s new BF6, with a hearth diameter of 12.0 meters, for this project, Paul Wurth has designed the new stove and
In preparation of a complete reline of No. 6 Blast Furnace an inner volume of 3,818 m3, 32 tuyeres and 4 tapholes, will Cost-optimized solution engineered the repair technology and sequences. The com-
(BF) at Lipetsk/Russia, NLMK recently signed a contract be designed for nominal production of 3.38 million tons of Currently, VBR’s BF1 is running in a campaign which plex task consisting of cooling down, demolition of the ex-
awarding to Paul Wurth engineering, supply of equipment hot metal per year. Some important auxiliary plants related started as early as in 2001. Last year, a decision was taken isting refractories, erection of the new material and heating
and technology as well as site supervision related to the to this furnace are already subject of orders to Paul Wurth: to extend this campaign until the next total reline up to the up was completed on 20th of February 2016 when the new
rebuild of the BF’s central unit, i.e. the blast furnace proper improvement of the top gas cleaning system, energy recov- year 2018. For the furnace, which underwent taphole re- stove could start cycling automatically. One week ahead of
and directly attached systems and equipment. ery turbine (TRT) and the Pulverised Coal Injection (PCI) pairs in 2009 and 2014, an intermediate repair of the schedule, it was handed over back to VBR, who started op-
Paul Wurth will adapt the Basic Engineering (delivered plant for BFs No. 6 & 7 are currently under execution. hearth and the tuyere area, with insertion of new carbon erating it together with the hot blast stoves No. 12 and 13 as
at an earlier stage) to the final technical solutions chosen blocks, became inevitable. In accordance with the cus- a complete plant again.
with the customer, and will be further in charge of the over- tomer’s desire for a cost-optimized solution, Paul Wurth Both modernization projects combined specific, tailor-
all engineering which will be executed in close collabora- designed the new hearth and engineered the related re- made design, repair-related engineering, worldwide pro-
tion with local design institute Lipetsk Gipromez. pair activities. These took place in November/December curement and expediting as well as on-site management
2015. Paul Wurth and its subcontractors executed sala- and supervision services, which have been accomplished in
Extensive Scope mander tapping, solid burden excavation and the removal time and to customer’s satisfaction.
Paul Wurth’s scope of supply comprises the BF shell, of a “bore”. This was followed by removing refractory re-
hearth lining with super-microporous carbon and ceramic Contact mains and subsequent installation of the new carbon
www.paulwurth.com
cup, all cooling elements (copper and cast iron staves, cop- paulwurth@paulwurth.com blocks and high-alumina bricks. In this phase, Paul
30 31
JSW Toranagallu, blast sms group newsletter 03 / 2016
furnace 1: The completely
new furnace vessel and
revamped auxiliary plants
ensure higher production.
Blast Furnace of
Jindal South West Steel
restarted
After a complete rebuild with modernisation, size increase and capacity
expansion by Paul Wurth, No. 1 Blast Furnace at JSW Steel, Vijayanagar Works,
Toranagallu, Karnataka, India has been blown-in in February.
This was achieved after a very short phase of cold and hot gas cleaning, slag granulation, water
commissioning which started 12 days in advance with a first
furnace leak test followed by pressure test, furnace drying,
heating and first filling. A smooth and safe blow-in and
treatment and PCI plants. A new hot
stoves plant with waste gas heat re-
covery system has been installed.
i
ramp-up allowed achieving 83 percent of nominal produc- The furnace has now an inner vol-
New No. 1
tion level within the first week of operation. The target pro- ume of volume of 2,307 m3 (instead of Blast Furnace
duction has been surpassed for the first time on the 9th of 1,250 m3), an increased hearth diame-
March 2016. ter (enlarged from 8 to 10.4 m) and in- JSW´s new No. 1
Paul Wurth’s contractual obligations covered design, en- creased number of hot blast tuyeres BF replaces its pre-
gineering, procurement and supply of equipment for the (from 18 to 28). The daily hot metal rate decessor which has
entirely new Blast Furnace and all its main auxiliary plants, is 5,250 tons for a total yearly iron pro- been in operation
basic engineering for the erection and its planning as well duction of about 1.7 million tons, some for one campaign
as supervision of erection and commissioning for the major 89 percent more than before the mod- from 2004 till August
plant units. ernisation. These figures represent 2015. It is sup-
one of the largest capacity expansions ported on the old but
capacity increase by 89 percent ever seen from one single blast fur- reinforced founda-
The new furnace features a modern profile, all-staves thin- nace rebuild. tions and fits into
wall cooling system, extensive instrumentation and pro- the existing square
cess recording devices, a parallel-hopper Bell Less Top® tower.
with a MIDI type gearbox, a completely modernised cast-
house with new and displaced equipment, adjusted runner
design, access ramps and platforms as well as de-dusting
facilities. The existing auxiliary plants have been upgraded
for the new production parameters: improvements and ca-
www.paulwurth.com
pacity increasing measures have been applied to the top
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
A view into a coke oven chamber. ROGESA was founded in 1981 and currently produces up to 4.6 million The static coal distributor is part of both static and dynamic distribution systems. BF No. 3 of Rashtriya Ispat Nigam Ltd. with
tons of hot metal each year. an annual capacity of 2.5 million tons.
Order from For modernising the BF4 Record coal injection rates at Successful
Shandong Hot Stoves Plant Tata Steel in Jamshedpur tests
Paul Wurth designs coke ROGESA places more orders. Successful upgrade to higher capacity for blast Robust blast furnace for
batteries for China. furnace “H”. RINL in India.
The contract with Shandong Prov- Further to earlier received turnkey or- which have now been transformed into After the PCI (pulverised coal injec- Along with the economic savings In the spring of 2016 all necessary
ince Metallurgical Engineering Co., ders for relining the hot blast stoves this order. In 2015, testing of the weld- tion) plant capacity expansion which gained by a high injection rate, the Performance Guarantee tests for the
Ltd (SDM) – an engineering company plant, including two additional pre- ing seams at the checker chambers of Paul Wurth designed and executed for plant upgrade provides for a reduction blast furnace No. 3 of Rashtriya Ispat
associated to the Chinese Shandong heating stoves and the new main to stoves 4.1 and 4.2 showed that the in- the customer, Tata Steel, operators of CO2 emissions over the entire iron- Nigam Ltd. (RINL), Visakhapatnam,
Iron & Steel Group – came into force No. 4 blast furnace of ROGESA Ro- stallation of a double shell becomes brought the coal injection up to 200 making chain, as well as for the relat- Andhra Pradesh, India, were suc-
in January 2016. It includes Paul heisengesellschaft Saar at Dillingen/ necessary. Paul Wurth’s double shell kg/t of hot metal. ed specific energy savings. cessfully performed.
Wurth’s design, engineering and site Germany, Paul Wurth Refractory & (also: double skinning) technology is The PCI plant´s capacity expansion These tests were related to hot
supervision services for the con- Engineering has now secured addi- known as a reliable and most proven increased flexibility and availability for metal production (average produc-
struction of four jumbo oven batter- tional orders. method on a global scale. BF “H” while the high injection rates tion and peak production rates), fuel
ies of top charging type, with 58 ov- These do cover a double shell repair improve the overall performance of rate, gas cleaning efficiency and pol-
ens per battery and an oven height of of the hot blast stoves 4.1 and 4.2 as ironmaking. lution; cast house and stock house
7.3 meters. These will form the cen- well as nozzle repairs for all three In particular, injection rates of more stack emissions, ambient dust con-
tral part of the coke making plant at main stoves. The projects comprise than 200 kg/t have been achieved on a centration and noise level parame-
Shandong’s Rizhao Iron & Steel new design and engineering, supply of all stable, sustained basis between July ters. Thus the robustness and quality
integrated works on the eastern related materials as well as supervi- and October 2015, even at a relatively of the blast furnace designed by Paul
coast of China. sion services for installation and com- high slag rate due to the high ash con- Wurth were demonstrated.
This engineering contract ensues missioning. tent of the injected coal. Paul Wurth´s Vizag Steel’s No. 3 blast furnace
from the cooperation agreement The order for the nozzle repairs is a Bell Less Top (BLT®) and TMT´s pro- can produce 2.5 million tons of hot
signed in 2013 between Paul Wurth result of a durability analysis of the hot filemeter and in-burden probe are metal per year. Its operating data
and SDM. blast stoves, which had been per- helping to optimize the burden layer indicates a reduced operating cost,
formed by Paul Wurth in 2013/2014. formation. This results in a high gas thus allowing RINL to increase its
Based on the results, specific repair utilization rate ( CO ›50%); at the overall production at Visakhapatnam
concepts were developed jointly with same time, good coal combustion to 6.5 million tons per year of final
ROGESA and TÜV (a German technical helps reaching a high coal/coke re- products at competitive performance.
supervision and certification body); placement ratio.
34 35
sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
Long-standing
cooperation with
customer ILVA
SMS group will install two hot-metal desulfurization
units at ILVA S.p.A., Italy.
In order to reduce the emissions arising from its opera- units will be equipped with de-slag-
tions, Italian steel producer ILVA S.p.A. has awarded SMS ging and fume extraction facilities. HMD unit of
group the order to install two hot-metal desulfurization Two possible injection options will be typical design.
units (HMD 1 and HMD 2) at its steelworks No. 1 and No. 2 provided: lime only (mono-injection)
in Taranto. The project will be handled on a semi-turnkey or lime together with magnesium (co-
basis by two SMS group companies, SMS INNSE and SMS injection).
Mevac. Commissioning of both units is planned to take At HMD 1, prior to the treatment,
place in early 2017. the overhead ladle handling crane
Hot-metal treatment stations are usually located be- will place the weighed hot-metal
tween the blast furnace and the BOF meltshop. The hot transfer ladle on a tiltable self-pro-
metal is transported by torpedo cars from the blast furnace pelled transfer car. The car will drive »We are very proud to work with ILVA again,
to the steel plant and poured into hot-metal ladles at a sep- into the treatment enclosure, which is
installing two hot-metal desulfurization units at Taranto.«
arate pouring station. clad with refractory coated panels on
Today, it is common practice in integrated steel plants to all sides. A sliding door will seal the
desulfurize the hot metal in a ladle in order to reduce the enclosure while the car is in the treat- Mr. Alberto Bregante, CEO, SMS INNSE.
high sulfur content originating mainly from the blast fur- ment position in order to prevent
nace coke. It is more economical to reduce the sulfur con- fumes from escaping.
tent in the hot metal rather than doing it later on in the At HMD 2, the hot-metal ladle will
steel. Desulfurization agents in powdered form, for exam- be placed into a ladle lifting stand by
ple lime, calcium carbide or magnesium, are deep-injected the shop crane. To prevent fume es-
through a refractory-lined immersion lance. It is possible to cape, a movable doghouse will be
either inject just one reagent, or two reagents simultane- transferred to the treatment position tube inside a refractory coating – will be located directly will be measured by the load cells un-
ously. These processes are called mono-injection and co- as enclosure. above the ladle treatment enclosure and lowered through a der the powder injection dispensers
injection respectively. Before the treatment starts, a sam- port in the enclosure roof. and calculated by the control system.
The desulfurization process implemented at ILVA will be ple taken beforehand from the transfer Any difference between the measured
based on the co-injection of lime and magnesium. The de- ladle will be analyzed. The result will CO-INJECTION WITH A HIGH DEGREE OF AUTOMATION and the required rate will be compen-
sign of the plant has been adapted to the plant configuration be used to calculate the amount of Before the tip of the lance enters the hot metal surface, the sated by the automatic flow control
and the local site conditions without compromising quality. lime and magnesium required to powder transport gas will be switched on. Firstly, just the valves below the dispensers.
achieve the necessary amount of de- lime powder flow will be started. Once the powder flow has When the lance has reached its full
DESULFURIZATION BY CO-INJECTION sulfurization based on the initial and become established, the lance will be lowered into the hot immersion depth, magnesium will be
Each plant will consist of a single treatment station, with the required final sulfur levels. The in- metal to a predetermined position above the refractory bot- added to the powder stream. Then, the
dedicated powder storage and injection equipment. The jection lance – a thick-walled steel tom of the ladle. During injection, the actual injection rate lime injection rate will be automat-
36 37
sms group newsletter 03 / 2016
HMD unit
comparable with that to be supplied to ILVA.
Fume
extraction
Ducting
ically reduced to keep the total rate of material injection ILVA chose SMS group not only for the
constant. When all required magnesium has been inject- efficiency of the process provided but
ed, this process will be executed in reverse until almost all also for its excellent technical solu-
CaC2 the required lime has been injected. Then the lance will be tions using Best Available Technique
Transport
retracted. (BAT) and ensuring best environmen-
dispenser
When all the powder has been discharged from the tal protection and compliance with the
lance, the transport gas will continue to flow for a short most stringent regulations.
period of time to ensure the powder line is clear. Then the
Hydraulic ladle Ladle support/ slag deflector Slag de-slagging
tilting unit Tilting stand plate pot machine line will be shut off. The lance will be retracted to its top
position. For maximum flexibility, the unit will be equipped
with independent injection dispensers, one for lime and one
for magnesium. Between the treatments, these dispensers
will be refilled from day silos mounted directly above them.
The day silos will be refilled as required by the powder stor-
i Scope of supply
age facility situated outside the plant.
Once the injection process has been completed, a sam-
ple will be taken and the hot metal temperature measured
by an automatic sampler through a separate port in the
The scope of supply basically includes:
fume enclosure. Loading and unloading of the sample
Reagent storage probes can be handled by a robot.
eagent handling and pneumatic transportation
R Finally, the carry-over slag plus the slag formed on top
system of the ladle during injection will be removed by a de-slag-
Injection system with automatic lance handling ging machine. This is done by tilting the ladle in the tilting
Hot metal handling frame mounted on the car (HMD 1) or in the fixed ladle tilt-
Slag pot handling ing stand (HMD 2). The removed slag will be collected in a
De-slagging station slag pot placed on a transfer car and parked in the rear of
Robot for temperature measuring and sampling the enclosure. When the slag pot is full, the car will transfer
Electrical instrumentation and automation it from the building to the slag bay where the slag pots will
Process control be handled by mobile carriers for appropriate disposal. Riccardo Sigoni
Once the de-slagging process has been completed, the la- riccardo.sigoni@sms-innse.it
dle will be moved back into its vertical position and taken to Markus Hüllen
the BOF shop by the shop crane. markus.huellen@sms-mevac.com
38 39
sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
i i
Algerian Qatari Steel (AQS) has award- its production to produce hot direct re-
ed Midrex Technologies, Inc., and its duced iron (HDRI) and/or cold direct
consortium partner Paul Wurth, a con- reduced iron (CDRI) simultaneously
tract to supply Equipment, Engineering without stoppage of production.
Paul Wurth Midrex
and Technical Services for one of the HDRI will be fed via an Aumund hot
world’s largest direct reduced iron- transport conveyor to a new EAF melt- Headquartered in Midrex Tech-
making (DRI) plants. The new natural shop located adjacent to the MIDREX® Luxembourg since nologies, Inc. is
gas-based MIDREX NG™ DRI plant will DRI Plant allowing for greater EAF its creation in 1870, an international
be located in Bellara Algeria, 375 km productivity and energy savings; CDRI Paul Wurth, now a process engineer-
east of Algiers. AQS is a joint venture can also be produced for additional member of the SMS ing and technology
between Sider Co. and National Invest- onsite use. group, has trans- company providing
ment Fund (51 %) and Qatar Steel In- formed itself over steelmakers with
ternational (49 %). The MIDREX® Plant Benefits of HDRI the last decades commercially proven
will be part of the overall steel complex With the new direct reduction plant into an interna- solutions for greater
that will produce 2.0 million tons of re- AQS is more flexible in the production tional engineering profitability and has
bar and wire rod finished products. of high quality steels with high de- company. As a result been the leading
AQS’s new MIDREX NG™ DRI Plant gree of purity. In addition, the need of its consider- innovator and tech-
will be designed to produce 2.5 million for imported scrap is also reduced. able know-how and nology supplier for
tons of DRI with the capability to vary Plants installed with the MIDREX® di- its effective policy the direct reduction
rect reduction technology, distinguish of innovation, the of iron ore for more
themselves by fact that they annually Paul Wurth Group than 40 years.
not only transport large quantities of
i
is today one of the
MiDrex® plant at hot DRI as any other technology avail- world leaders in the
Lion DRI in Malaysia. able on the market, but that the trans- design and supply
Advantages portation takes place at higher tem- of the full-range of
Additional benefits of charging peratures. technological solu-
hot DRI (HDRI) to the EAF are There are two main benefits of tions for the primary
charging HDRI to the EAF: lower spe- stage of integrated
ess energy required to heat the
L
cific electricity consumption and in-
Algerian Qatari Steel to build 2.5 million tons per year MIDREX® plant. www.paulwurth.com
www.midrex.com
40 41
sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
eco-friendly plant
wire rod mills. The SHARC (Shaft Arc furnace)
The new rail and section mill will produce 120-meter-
long rails as well as various beams, sections and sheet The SHARC is a DC electric arc furnace featuring two pre-
piles. Designed for quick program changing, the mill will heating shafts for scrap drying and pre-heating. One of the
comprise a tandem reversing mill with Compact Cartridge shafts is located at the front, the other one at the rear side of
the furnace. The electrode arm swivels between the two
Stands (CCS®) and a Compact Roller Straightener (CRS®)
shafts. This design is superior to conventional furnace de-
SMS group receives contract from AFERPI for the supply of as are already successfully in operation in numerous rail
signs as it provides for uniform and symmetric distribution of
and section mills. The CCS® mill stands will be equipped
a new steel complex in Piombino, Italy. the scrap. In combination with the even distribution of the flue
with hydraulic adjustment systems to allow rolling at very gas between the shafts, this makes for reproducible results
close tolerances. The scope of supply will also include a and smooth and highly efficient furnace operation during the
RailCool® rail head hardening line. meltdown and liquid phases.
The rail finishing line will process long and short rails Thanks to the use of the proven DC high-voltage technology
and the air-cooled pin-type bottom electrode developed by SMS
Acciaierie e Ferriere di Piombino S.p.A. (AFERPI) has award- characterized by highly economic and eco-friendly opera- and feature testing facilities, cutting and drilling machines
group, it was possible to give the pre-heating shafts their highly
ed SMS group the order to supply steelworks equipment for tion due to efficient pre-heating of the charge material. The as well as gap presses. A separate finishing line will be
compact design and arrange them in a very effective way.
their facilities in Piombino, Italy. The new plant will comprise SHARC furnace will be charged with a high rate of direct supplied for the sections. The scrap is charged into the shafts from above by scrap
an electric steelworks, secondary metallurgy facilities and reduced iron (Hot Briquetted Iron) in addition to scrap in This project will enable AFERPI to produce steel and rails baskets. The flue gas is extracted from the SHARC furnace
two long-product continuous casting plants of more than order to consistently meet the required cleanness of the in Piombino with latest state-of-the-art equipment. just below the lockable charging port. This arrangement
one million tons annual capacity. SMS group has also been steels produced. allows for the hot flue gases to be continuously drafted
contracted to supply a rail and section mill of 700,000 tons through the entire cross-section and the complete height of
capacity per year. Highest level of technology the scrap column. This makes pre-heating extremely efficient.
The new facilities will feature future-oriented technology The steel plant will also have a twin-ladle furnace and a
designed to produce premium steels at high productivity twin vacuum degasser. Those facilities will make it possible Jan Bader
and with environment-friendly solutions that ensure low to adjust the liquid steel precisely to the required target jan.bader@sms-group.com
energy consumption and low emissions. analysis before the steel will be cast either on the new
The Piombino works will receive a 140-ton SHARC (Shaft bloom caster or on the new billet caster for SBQ (Special
www.sms-group.com
Arc) direct-current electric arc furnace. This furnace type is Bar Quality) products. Both casting machines will be
42 43
sms group newsletter 03 / 2016
New steelwork
with high strategic value
The electric arc fur-
SMS group successfully commissions energy-efficient electric nace can be charged
with scrap, HBI and
steelworks and continuous caster for quality slabs. hot metal.
At PT. Gunung in Indonesia, SMS group cluding level 2, were part of SMS groups supply package.
44 45
sms group newsletter 03 / 2016
Tailor-made revamp of
the slab caster
Increase of the production of high-quality automotive sheet,
tinplate and heavy plate grades at ArcelorMittal Avilés.
ArcelorMittal Asturias (Avilés), Spain has placed an order lurgical length will increase from 34 to
able logging function Total Cost of Ownership) and the maintenance costs (TPM production can be performed without measurement software developed by SMS. Thanks to the
and the thorough – Total Productive Maintenance) for the plant. having to reduce the casting speed. In high quality of the measurement, the exact and reliable re-
assessment of the The modernization concept and the technologies devel- this context, the steel grade and the cording and the meaningful evaluation of the measured ob-
measured objects oped by SMS group represent the most cost-efficient solu- current casting speed will be taken jects, HD LASr is far superior to the systems used up to now.
make HD LASr tion for the customer. To keep the revamp time as short as into account. The mechanical oscilla- The slab caster will be prepared for the integration of
superior to previous possible, the existing foundation and anchor bolts of the tor will be replaced by a hydraulic os- Dynamic soft reduction. Furthermore, SMS group will im-
systems. continuous casting plant will be retained. cillator by means of which the stroke plement various level 2 process models of the X-Pact® elec-
length and frequency can be changed trical and automation package. A HD moldTC system will
Improving slab quality during casting. monitor the temperature distribution. In this way, possible
The two-strand slab casters were originally supplied by Furthermore, SMS group will im- strand shell stickers can be detected and breakouts pre-
SMS group in 1987 and each is able to produce approx. 1.9 plement a new secondary cooling con- vented at an early point in time. The DSC® (Dynamic Solidi-
million tons of slabs per year. Main reason for this revamp- cept with a width-dependent spray fication Control) metallurgical process model calculates
ing is the increase in quality required to cope with the grow- cooling system (water cooling) in the the solidification process of the strand and controls the
ing demands of the market. Besides, after the conversion, machine head. The cooling circuits for various secondary cooling zones. The two-strand continu-
the production capacity of both plants will additionally be the mold, the machine and the sec- ous caster No. 2 will be equipped with the same scope of
increased in order to deal with future challenges. ondary cooling system will be com- supply and features. The integrated steel plant ArcelorMit-
The new continuous caster No. 1 will produce slabs with pletely renewed; the hydraulic equip- tal Asturias produces high-quality steel grades for the au-
a thickness of 235 millimeters and widths of between 800 ment will be adapted and enhanced. tomotive sheet and tinplate industries as well as for heavy
and 1,600 millimeters. From mold to the run-out area, the ArcelorMittal Asturias will receive plate production.
caster will be rebuilt completely as a vertical bending cast- new workshops, which will be equip
er. The new continuous caster will have a radius of 8 me- ped with the HD LASr plant assistant Lothar Fischer
ters, the vertical length amounts to 2.4 meters, the metal- developed by SMS group. With this lothar.fischer@sms-group.com
46 47
sms group newsletter 03 / 2016
China Steel Corporation (CSC), Taiwan, has requested SMS quence in the mold is provided by
group to revamp its Continuous Slab Caster No. 4 at the
Kaohsiung location.
SMS group will be supplying a new hydraulic oscillator
temperature measurement via ther-
mocouples on the mold copper plates.
SMS group’s range of services also
i
drive, including the pump station and the pertaining includes the project management, on-
China Steel
Hebei Puyang Iron and Steel Co., Ltd. (Puyang Steel), Chi- With the new continuous caster sup- The video of this X-Pact® process control system, to replace the existing site training of the operating person-
Corporation (CSC)
na, has issued to SMS group the Final Acceptance Certifi- plied by SMS group, Puyang Steel has project can be electro-mechanical drive. For the mold, SMS group is sup- nel and the commissioning supervi-
cate (FAC) for the single-strand slab caster commissioned expanded its range of slabs produced, watched at: plying new thermocouples and the technological process sion. Start-up is scheduled for the end CSC operates
in 2015. above all by high-quality grades, such www.sms-group. models. The Level 2 models of the X-Pact® electrical and of 2016. Taiwan’s largest in-
SMS group met the customer’s high expectations by co- as peritectic microalloyed and high- com/nl2016-video- automation system contain Temperature Monitoring (Mold China Steel has placed this mod- tegrated steel plant
operating successfully with Puyang Steel and achieving fast strength steels, high-carbon and bo- hebei-puyang-en Monitoring System) and the Breakout Prediction System. ernization order as a follow-up to the and produces around
commissioning and a steep run-up curve of the plant. ron-alloy grades, premium steels and successful implementation of the Mold ten million tons of
Jointly with Puyang Steel and building on its profound expe- pipeline grades. Early detection of breakouts Monitoring System from SMS group in steel per year there.
rience and proficiency, SMS group developed a tailor-made The new hydraulic oscillator drive allows setting of the vari- Continuous Caster No. 7 in the same
and fully integrated concept that fits perfectly into the exist- able oscillation frequency, stroke length and curve shape. works.
ing structural situation of the works. The new caster was The breakout prediction system enables any possible stick-
integrated into the existing bay, using the available crane Lothar Fischer ers to be recognized already at an early stage and preven- Lothar Fischer
systems. lothar.fischer@sms-group.com tive measures to be taken. Monitoring of the process se- lothar.fischer@sms-group.com
48 49
sms group newsletter 03 / 2016
New continuous casting machine to produce Global Steel Wire optimized the
high alloyed steel grades and spring steel production process with the new
grades of highest quality. automation software.
of the new electrical and automation switchboards in a true Beat Kündig Francesco Fabris
www.sms-concast.com
record time. beat.kuendig@sms-group.com francesco.fabris@sms-group.com
50 51
sms group newsletter 03 / 2016
Successful commissioning In the first phase of Tata Steel’s ambitious investment pro-
gram at the Kalinganagar location in the district of Odisha
In the RH Degasser the steel is sub-
jected to vacuum treatment to perform
52 53
sms group newsletter 03 / 2016
Coiler No. 2 will be modernized to meet increased demands. Gear cutting in the SMS group workshop.
Top: Combined reversing and skin pass mill supplied earlier. Right, top: Four-high skin pass mill.
Right, bottom: Skin pass mill entry side.
water volume. passing capacity is 260,000 tons. n entry-side tilting chair for coils
A
steel drums in South
from the batch annealing furnace
East Asia.
Torsten Seeger
www.sms-group.com/plants/all-plants/csp-technology www.sms-group.com/expertise/drive-technology
torsten.seeger@sms-group.com
54 55
sms group newsletter 03 / 2016
i
Acerinox
LATEST 20-ROLL
SMS group is cur-
gauge of 0.15 millimeter. The maximum strip width to be rently installing a 20-
rolled here is 1,320 millimeters. Rolling can be performed Technical data high cold rolling mill
at a maximum speed of up to 800 meters per minute. Steel grades duplex steel, AISI 200, for the production
56 57
sms group newsletter 03 / 2016
As key supplier, SMS group delivered mation systems were thoroughly test- Specialized in top
quality thin strip down
and commissioned an ultra-modern ed, validating their reliable compliance to 0.05 millimeter is
twin-stand aluminum tandem cold with the stringent quality demands. the 20-roll mill.
mill newly installed at ALCOA Inc. near The automotive expansion at Tennes-
Knoxville, Tennessee, U.S.A. The new see will continue its ramp-up through-
cold rolling mill is part of Alcoa’s out 2016.
automotive growth project. The expan-
sion focuses on the production of
wide and durable aluminum sheets for
light-weight car body construction. The
China’s most advanced
copper cold mills
twin-stand rolling mill was supplied,
installed and commissioned by SMS Stefan Tammert
stefan.tammert@sms-group.com
group. The new equipment and auto-
The new cold tandem In early December 2015, Ningbo Xingye Copper completed the hot com-
mill is part of ALCOA’s
automotive growth missioning on two cold rolling mills supplied by SMS group.
project.
Ningbo Xingye Copper belongs to the Xingye Copper Inter- X-Pact® automation reduce off-gauge losses and allow
national Group Limited, a leading producer of high quality Ningbo Xingye Copper the maximum utilization of the
copper strip and plate products in China. SMS group sup- valuable material.
plied two reversing cold mills including X-Pact® electrical In addition, the 20-high cold rolling mill of SB23-26“size
and automation systems to Ningbo Xingye Copper. was equipped with a Multi-Plate® filter system for sustain-
able rolling oil usage. Not only regarding innovative rolling
WIDE MATERIAL RANGE technologies but also regarding environmental sustainabil-
On December 1st, 2015 hot commissioning has been com- ity both new cold rolling mills of Ningbo Xingye Copper offer
pleted and certified for the 4-high and the 20-high cold a new quality to the Chinese copper market.
rolling mill at Ningbo Xingye Copper facilities in Cixi. Both
the mills roll a large copper and copper alloy material
range. The 4-high reversing mill specializes in very thick Markus Gümpel
strips up to 16 millimeters entry thickness, whereas the markus.guempel@sms-group.com
20-high mill focuses on very thin strips down to 0.05 mil- Mehmet Caglayan
limeter final thickness. Special technologies of installed mehmet.caglayan@sms-group.com
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sms group newsletter 03 / 2016
Shandong Weiqiao Aluminium & Electricity is very content with the operating results of its new hot rolling mill.
Pursuing a strategy of downstream ex- tricity is entering the aluminum flat
pansion, Shandong Weiqiao Aluminium product market as a new player.”
& Electricity is setting up a new alumi-
num rolling mill complex at its site in
The hot rolling mill consists of an
edger, a roughing stand, a heavy and
i
Zouping in the Shandong Province, a light crop shear, a four-stand finish-
China. In addition to the hot rolling ing train and a run-out section in- Shandong Weiqiao
mill, SMS group supplied two single- cluding a side trimming unit and a Aluminium & Elec-
stand cold rolling mills, one three- coiler. Shandong Weiqiao can now tricity Co., Ltd.
stand cold tandem mill and a fully produce up to 2,200-millimeters-wide Shandong Weiqiao
automatic high-bay warehouse for alu- aluminum strips in a great variety of Aluminium & Electricity
minum coils for the new works. material grades. The main products is a privately-owned
are high-performance can end and company belonging to
MEETING CUSTOMER REQUIREMENTS body materials, CTP/PS sheets and the Weiqiao Pioneering
Zhang Yuedong, Deputy General Di- foil stock. Group, which is one of
rector of “New Material Branch, Shan- the Top 500 companies
dong Weiqiao Aluminium & Electrici- in China. Among the
ty”, which is the business unit in plants operated by the
charge, states: “Based on the achieved company are several
operating results, we are convinced coal-fired power plants
that the hot rolling mill supplied by and electrolytic plants
SMS group will allow us to fulfill all for the production of
and any requirements placed on our aluminum metal.
products by customers in China and
worldwide. Thanks to this investment, Rüdiger Roger Wiechmann
Shandong Weiqiao Aluminium & Elec- ruediger-roger.wiechmann@sms-group.com A coil being inspected in the offline inspection unit.
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sms group newsletter 03 / 2016
Stronger, faster,
more. The produc-
tion results of the
restarted finishing
mill are impressive.
COMPLETED EXTENSION OF After SMS group had hit the bull’s eye with the moderniza- the planning and designing phase of
tion of the roughing stand of Hot Mill 1 of Aluminium Norf the hot rolling line 50 years ago.
i
FINISHING MILL TERMINATES
GmbH (ALUNORF) at its Neuss location in Germany, the For the extension of the finishing
new finishing stand, too, was pre-assembled, tested and mill, SMS group supplied the mechan-
transported to the jobsite according to schedule in autumn ical equipment for the new, four-high
Extension
2015. Integration into the existing finishing mill was accom- mill stand, including hydraulic adjust-
MODERNIZATION PROJECT plished at the end of 2015. In early January 2016, the first
strip was produced on the extended finishing mill, which
completed the ambitious extension project of the biggest
ment, positive and negative work roll
bending system, pertaining drive tech-
nology as well as the gear components
The extension of
the hot rolling line
in three separate
aluminum processor worldwide. needed to upgrade the existing mill stages may serve
In the third and last modernization stage, ALUNORF has stands for running at higher rolling as a good-practice
The third modernization stage of the Hot Mill 1 at Aluminium Norf has been been adapting the finishing mill to the enhanced roughing speeds. example for the ef-
mill capacity which had been achieved through the mea- The new mill stand takes the first
successfully completed. The result: a more flexible production planning as well ficient modernization
sures implemented in the first and second project stages, position in the finishing line and per- of old plants.
as better utilization of the existing production facilities. comprising the upgrading of the roughing stand and the forms the major part of the shaping
renewal of the edger. The SMS group had considered the work as it rolls the incoming material.
option of extending the three-stand finishing mill already in New are the drive train with main
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
The completed
finishing mill with
entry-side new mill
stand. The first of the two annealing lines,
which SMS group supplied to Baotou
(BISG Baotou Iron & Steel Group – Rare
Earth Steel Plate Co. Ltd.), in Decem-
ber 2015 has been commissioned ac-
gear unit, mill pinion gear unit routine weekly downtimes, the major part of the installation cording to scheduled and has annealed
and Sieflex® HT gear-type spindles work was performed during a regular plant shutdown that the first coil as planned. Baotou had
A video on this proj- transmitting the high rolling torque in started on December 18, 2015. The first strip rolled on the awarded SMS group the order for the
ect can be viewed
under:
www.sms-group.
the first finishing stand to the work
rolls. In addition, the second and third
mill stands were each equipped with
finishing mill was seen on January 6, 2016. The regular pro-
duction process could be reassumed on January 8, 2016.
The result of the modernization of Hot Rolling Mill 1,
i supply of the two continuous annealing
lines including six-high inline skin pass
mills in October 2013. The second line
com/nl2016-video- new gear wheel sets. The extension of which was carried out in three stages, is an increase in ca- will be started up as scheduled in mid-
Strip control
aluminium-norf-en the available media systems and of pacity and ensures ALUNORF’s global leadership among 2016. Both lines will be of almost iden-
the filter equipment was also part of the producers of rolled aluminum products. Comprising EMG Automation tical design. Once on stream, the two
the supply package. two hot rolling lines, the aluminum rolling and remelt plant supplied the com- annealing lines will be able to produce The commissioning team of SMS group in front of the first annealed coil.
After several preparatory measures of ALUNORF in Neuss ranks among the biggest ones plete strip control more than 1.5 million tons of refined
which were implemented within the worldwide. The now completed extension offers a better system and, in additi- cold strip per year. The majority of the
utilization of the existing infrastructure and more flexibility on, integrated quality material, including grades for exposed addition to the design of the mechani-
in production planning. assurance systems. car body parts as well as high-strength cal equipment and the manufacture
grades such as DP and TRIP with ten- of various core components, the SMS
sile strengths of up to 980 MPa, will be group’s supply package also included
used in the automotive industry. The the supervision of part of the local
two lines will form an integral part of manufacturing scope and of equip-
the new cold rolling mill No. 2, which ment installation and commissioning.
Baotou is building in Inner Mongolia. The inline six-high skin pass mill
The recent commissioning of the first featuring CVC® plus technology en-
Guido Fick annealing line is an important mile- sures compliance with the contractual
guido.fick@sms-group.com stone of the overall project. strip flatness requirements. The Ex-
tended Bending System (EBS) provides
630,000 TONS ANNUAL CAPACITY for the targeted skin-passing of soft IF
The new line can handle strip widths steels even at low rolling forces.
between 830 and 1,580 millimeters In order to respond flexibly to the
Schematic represen-
tation of the new hot and strip thicknesses from 0.25 to 2.5 product range of the customers, the
mill concept includ- millimeters. The maximum process skin pass mill can additionally be
ing drive train. speed amounts to 400 m/min, the an- equipped with work rolls of different
nual capacity will be 630,000 tons. In diameters.
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sms group newsletter 03 / 2016
Reconstruction of a
pusher furnace for
slabs at VÍTKOVICE STEEL
SMS group received final acceptance certificate
for the reheat furnace revamp.
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
Simone Zussino, Head of Department, Reheating Furnaces and Heat Treatment Lines at SMS Meer S.p.A.
i
In February 2016, SMS group received the final acceptance With the revamped furnace Vítkovice The project was accomplished on a turnkey basis by SMS
certificate from Vítkovice Steel, a.s., Ostrava, Czech Repub- Steel, a.s. can take full advantage of a Meer S.p.A. in collaboration with the local firm BKB Metal,
lic, for the complete reconstruction of an old pusher-type modern control system which mini- a.s. The latter was responsible for the civil works and the Vítkovice
reheating furnace. The furnace feeds a plate mill at a max- mizes human supervisory work during construction activities. Particularly noteworthy is the engi-
imum hourly rate of 90 tons of slabs at reference condi- production, last but not least due to neering solution provided by SMS as the team of engineers Modernization of a slab
tions, reheated from ambient temperature to 1,250 °C. The the installation of the combustion opti- have succeeded in building a furnace of the most advanced reheating furnace
results of the comprehensive modernization are minimized mization system SMS PrometheusTM. design on the existing foundations, thus reducing the civil
Minimization of skid marks
skid marks, increased quality, an efficient control system The reconstructed furnace consumes works. The smooth interaction between the existing and the
Quality increase
and reduced fuel consumption. significantly less fuel compared to newly supplied equipment is one of the keys to the success
Optimized combustion processes
the old unit. The furnace meets the of this project, which was completed in one and a half years
Reduction of NOx emissions
FAST PROJECT HANDLING high safety requirements of the Euro- according to the customer’s requirement.
Lower energy consumption
A key technological aspect of the project had been to mini- pean standard 746-2. Also environ-
Modern control technology
mize skid marks on the slab bottom surface, which can mental aspects played major role in
cause noticeable rolling troubles. To ensure the fulfillment this project. An important target of
of the strict target given by Vítkovice Steel, a.s., SMS ran the reconstruction project was to
some test campaigns in a laboratory furnace before choos- achieve a significant reduction of NOx Pietro Della Putta
ing the final skid-riders shape and material. emissions. pietro.dellaputta@sms-group.com
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sms group newsletter 03 / 2016
With the successful production of the first coil in December martensitic grades and multi-phase
2015, Kobelco Angang Auto Steel, China, has commis-
sioned the new continuous annealing line. The strips were
steels. Both cooling systems are char-
acterized by very constant cooling so i
treated in the cleaning section, in the furnace and the final that strip geometry and surface quality
skin-pass stand and thus received its end properties. SMS of the plates produced satisfy high re- Line data
group as a system provider supplied the plant installed in quirements.
Anshan in the Province of Liaoning completely from a single With a rolling force of up to 18 me- The line has been
source. Besides the construction of mechanical, process ganewtons the six-high inline skin- designed for a strip
and thermal equipment and the manufacture of key com- pass mill is designed to reroll strips thickness range
ponents, SMS group is also responsible for the complete with high tensile strengths up to 1,600 between 0.5 and
electric and automation systems. MPa. The materials strengths require 2.5 millimeters and
After the completion of the commissioning phase the skin pass rolling under high strip ten- widths from 750 to
plant will reach an annual output of steel strips of around sion. The inline skin-pass mill realizes 1,650 millimeters.
600,000 tons, mostly for the automotive industry. By an- strip tensions up to 350 kilonewtons. The maximum
The first coil at Kobelco nealing, rapid cooling and subsequent skin-pass rolling the Included are working rolls with two process speed is
Angang in Anshan, China, strain hardening from the rolling process is reduced inside different diameter ranges, so that the 180 meters per
treated with the annealing the material and the mechanical high-quality properties product spectrum with regard to ma- minute, while at
line from SMS group.
are specifically set. Among others, ultra-high-strength ma- terial strengths and rerolling levels is the entry and exit,
terials shall be produced for the manufacture of light and at optimally covered. Equipment such as speeds of up to
the same time safe automotive structural components. work roll and intermediate roll bend- 280 meters per
ing, strip edge-oriented roll shifting minute may be
and strip blowing in the stand exit sec-
production of
ing system based on gas cooling is used among others for
high-strength TRIP, dual-phase, complex-phase and other
high-strength steels as well as drawing and deep-drawing
grades. By means of water as cooling medium the water-
automotive steel strips spray cooling system achieves even higher cooling rates.
This enables the production of also ultra-high-strength
Jörg Nix
joerg.nix@sms-group.com
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sms group newsletter 03 / 2016 sms group newsletter 03/ 2016
COST-efficient PROCESS
WATER CONDITIONING WITH
FOEN EVAP®
FOEN® offers a new system with patented polymeric heat
exchanger providing essential advantages when treating highly corrosive
process water as is incurred in pickling lines, for example. The FOEN EVAP® vaporizes process water and returns the conditioned water to the process
according to the mechanical vapor recompression principle using a polymeric heat exchang-
er and based on a temperature difference of less than 3 °C.
FOEN EVAP® is an efficient method for process water con- is well suited for rinse water from The treatment capacity of the systems
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
SMS GROUP TO
SUPPLY SIDE TRIMMING
UNIT TO SEVERSTAL
The pre-assembled and function-tested machine can easily be
integrated in the existing continuous pickling line.
Severstal contracted SMS group to supply a new ASC (Auto- strip, which is between 1.2 and 6.0
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sms group newsletter 03 / 2016 Rubrik — Unterrubrik sms group newsletter 03 / 2016
knife system with integrated EMG eMass® strip stabilization will be produced on the hot-dip galva-
Notable capacity
EMG emass®
because of its high layer accuracy and surface quality. nizing line is galvannealed strip for car
body shells. EMG eMASS® is a
PRECISE COATING system to stabilize
increase
The electromagnetic EMG eMass® system will be posi- fast-running steel
tioned at the shortest possible distance to the nozzle gap, strips and suited for
which is the actual point of technology, and stabilize the turnkey supply.
strip flow in the zinc air knife, hence improving the accu- Daniel Plätzer
racy of the zinc layer. In addition to its extremely high pre- daniel.plaetzer@duma-bandzink.com
Aperam Stainless awarded SMS group an order to mod- Furthermore, one of the existing air cooling modules will be
ernize the furnace of the direct rolling, annealing and pick- boosted, one air cooling module will be added, and the mist
ling line in Isbergues, France. The modernization will in- cooling module will be replaced. Since only very little space
crease the performance of the furnace by 50 percent. After is available in this furnace revamp heating and cooling are
the modernization Aperam expects to produce 380,000 designed stronger than usual.
tons per year of cold rolled, annealed and pickled stainless The furnace is heated up to 1,250 °C by low NOx burners
austenitic and ferritic grades (AISI 300 and 400 series) with with open flames. Subsequently, the strip will be cooled via
Direct integration this line. The material is used in the automotive industry air cooling from 1,100 to 220 °C within a distance of only
creates an optimum and for many other industrial applications. This new order maximal 35 meters. Mist cooling is then used down to 80 °C.
synergy of DUMA-
was awarded to Drever International, Belgium, a company At the maximum speed of 60 meters per minute a cooling
BANDZINK air knife
system and EMG of SMS group. The scope of supply consists of design, rate of 25 Kelvin per seconds will be reached in the cooling
eMass® strip stabili- manufacturing, assembly, erection and commissioning of section. In the final cooling section an even higher cooling
zation. the furnace. Drever International also built the original rate will be reached. The processed strip widths range be-
furnace in 1996. tween 800 and 1,580 millimeter and the strip thicknesses
The capacity of the horizontal direct-fired furnace will be between 0.8 and 5.0 millimeter.
increased with the revamp from 60.7 tons per hour (contrac-
tual data of the original furnace) to 91.0 tons per hour. There-
fore, 24 meters of the existing preheating section will be re- Serge Vanderheyden
placed by a 51 meter preheat and heating section. vanderheyden@drever.be
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
450,000 TONS OF HIGH- Apart from automotive structural components, strips with a
high-quality steel surface are produced for the production
of exposed vehicle parts.
or silicon contents to be galvanized without wettability
problems. A high-quality air knife system from DUMA-
BANDZINK is integrated for the galvanizing process. Due
to modern facilities such as a patented radial controller,
QUALITY STRIP PER YEAR HIGH COOLING RATES AND FAST GALVANIZING
To achieve high cooling rates, a vertical radiant-tube fur-
nace with ultra-fast cooling system from Drever is integrat-
an automatic air knife lip cleaner and a knife-gap width
adjustment, the highest surface qualities are achieved.
Drever and DUMA-BANDZINK are both companies of the
ed. A further highlight of the furnace is the pre-oxidation SMS group.
chamber which allows steel grades with high manganese Further important, quality decisive components of the
Angang produced first coil on new galvanizing line from SMS group. continuous galvanizing line are a high-performance clean-
ing section, a four-high skin-pass mill, a tension leveler, a
vertical roll coater with Drever drying and cooling system,
an ASC side trimmer with integrated scrap chopper and an
electrostatic DUMA-BANDZINK oiling machine.
The heat treatment and galvanizing of neering, process technology, furnace technology and gal- The line is designed for strips with dimensions of typical
the first coil on April 17, 2016, marked vanizing technology as well as electrical and automation car sheets. In the process section the strip is coated with
the start-up of the new continuous systems. zinc at a process speed of up to 160 meters per minute,
galvanizing line built for Angang (An- The line is designed to produce 450,000 tons of galva- whereas in the entry and exit sections speeds of up to 220
gang Guangzhou Auto Steel Co.) near nized or galvannealed steel strips per year and aims to meters per minute can be attained. The steel grades manu-
the city of Guangzhou in the province serve automotive and home appliances industries in South factured are CQ, DQ, DDQ, EDDQ, HS and DP.
of Guandong, China. SMS group sup- China and the Pearl River Delta. Most notably, deep-draw-
plied the complete plant from one ing grades and high-strength steels for the automotive in- The commissioning team with the first galvanized coil www.sms-group.com
source and was responsible for engi- dustry are produced, including modern dual-phase steels. on April 17, 2016.
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sms group newsletter 03 / 2016
TMK’s subsidiary Seversky Tube Works, located in Polevs- SMS quenching head, an SMS quenching inside lance, a
koy, Russia, has placed an order with the SMS group for a walking beam tempering furnace and a cooling bed. SMS
heat treatment line for tubes. The plant produces seamless group will also supply the complete water treatment sys-
and welded pipe mainly for oil and gas. With the installation tem in service to the heat treatment line. Heat treatment facility in process at Axis Pipe and Tube.
of this line, TMK is strengthening its presence on the Rus- The heat treatment line will be able to treat tubes up to a
sian market with tubes for oil and gas exploration as one of wall thickness of 40 millimeters. Thanks to the high prod-
At Axis Pipe and Tube, based in Houston, Texas, USA, SMS with a maximum test pressure of 15,000 psi, a finishing
The SMS group Quenching Head. group has successfully commissioned a heat treatment fa- section and all connecting transport equipment for the
cility and pipe threading line including two 4 axis CNC threading line were also supplied by SMS group. The con-
threading machines. necting transport pipe handling equipment is designed to
With the two new plants for its Bryan works in Texas, prevent pipe to pipe contact after threading. The tubes and
the company is capable of producing OCTG tubes (Oil pipes processed on the threading machines conform to
Country Tubular Goods) used for natural gas and crude oil manufacturing standards as per API 5CT.
production. With the new state-of-the-art equipment, Axis This project enables Axis Tube and Pipe to become even
Pipe and Tube is extending its product range and will be better at satisfying the ever more exacting demands of the
able to open up new customer segments. market relating to product quality and productivity, both at
SMS group supplied a heat treatment line, that includes present and in the future.
a natural gas fired walking beam hardening and temper-
ing furnace as well as a water quenching unit and a 10 roll
hot straightener, to produce tube grades of up to HCP110.
The supplied pipe threading line features two 4 axis CNC
threading machines which operate on the principle of sta- Sales
tionary tool and rotating tube. A hydrostatic pipe tester tubefinishing@sms-group.com
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sms group newsletter 03 / 2016
diameter pipe
age precisely con-
trolling the forming
via special sensors.
Possible negative
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
i
and a correspondigly
broad product range
with pipe diameters
ranging from 16 to
64 inches with wall
thicknesses of more Corinth
than 45 mm. Pipeworks
(CPW)
can be tack-welded in a safe and precise manner. A ro- and generally aims at optimally form-
bot-assisted laser measurement system precisely mea- ing longitudinally seam-welded large- CPW already suc-
sures the inner contour of the specially formed open-seam diameter pipes by the JCOE® process. cessfully operates
pipe. The 25-MN press is equipped with DVP hydraulics. “ShapeView” was used at CPW for the an HFI tube welding
For a customer first time in the world – enabling an line and a two-stage
statement from World’s first use of new ShapeView system optimized control of the forming pro- spiral pipe plant
Apostolos Papavasi- The state-of-the-art JCOE large-diameter pipe mill from
®
cess in real time. Therefore, the new from SMS group.
liou, CEO of Corinth SMS group enables highest technical requirements to be large-diameter pipeline at Corinth With the new JCOE®
Pipeworks, please met, and strictest environmental directives and demand- Pipeworks is the most modern in the large-diameter pipe
refer to: ing applications as are demanded by the most important world. mill, the company
www.sms-group. oil and gas companies in the offshore industry to be com- now completes its
com/nl2016-video- plied with. The plant is provided with the new automation production capaci-
corinth-pipeworks-en system Shape, precisely controlling the forming process ties in the field of
with the aid of special sensors. Possible negative influ- With the automation system Shape the customer is able to make use of the software welded pipes.
ences by the starting material or the operator are thus proposing standard machine settings. On the other hand, reliable start parameters are
calculated and output based on theses machine parameters.
minimized. The system consists of the three modular sub- Sales
systems “ShapeBase”, “ShapeView” and “ShapeControl”, LSAW@sms-group.com
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sms group newsletter 03 / 2016
Cost-efficient production of
premium SBQ products
Qingdao Iron and Steel successfully commissions
SBQ rolling mill from SMS group.
On February 19th, 2016, Qingdao Iron and Steel, based in Qin- Technology module. In addition to these, further modules
The plant will be built on a 200,000 square meters plot of land in gdao in the Chinese province of Shandong, rolled the first bar like the Technological Control System (TCS) and the Con-
Kizad and is expected to formally launch operations in 2018. on the SBQ (Special Bar Quality) rolling mill supplied by SMS trolled Cooling Technology (CCT®) module provide the pos-
group. The rolling mill is designed to produce premium sibility of online correction of the roll settings and ensure
SBQ products with excellent mechanical properties and op- optimized temperature control in the rolling line.
timized microstructure, while complying with most exact-
GROUND BREAKING AT ing dimensional tolerances. The first bars were already
rolled with a diameter tolerance better than 1/6 DIN.
The centerpiece of the rolling mill is a 3-roll precision
Al Gharbia Pipe Company (Al Gharbia), a joint venture be- Procurement, Construction) contract to a consortium formed
tween Senaat, one of the largest industrial holding com- by SMS group and Larsen & Toubro Limited, who will be re-
panies in the UAE, and two of Japan’s leading companies sponsible for constructing the complete LSAW (Longitudinal
in the steel sector; JFE Steel Corporation and Marubeni- Submerged Arc Welded) pipe plant on a turnkey basis.
Itochu Steel Inc. (MISI), broke ground in April in Khalifa
Industrial Zone Abu Dhabi (Kizad).
Al Gharbia will be the UAE’s first plant capable of man-
ufacturing large-diameter, thick wall, sour service, longi-
tudinally welded steel pipe to service the oil and gas
transportation sector, with the infrastructure and con-
struction sectors as secondary markets.
Once fully operational, production capacity is set to Ground
reach 240,000 tons annually, of which around 40 per cent breaking in
will be exported to neighbouring markets in the GCC and the Khalifa
Industrial
greater Middle East, as well as North and East Africa. The Zone Abu
new line will be designed to make pipes up to 12.2 meters Dhabi (Kizad).
long with an outside diameter ranging from 18 to 56 inch-
es. The maximum wall thickness will be 44.5 millimeters. Sales
In August 2015, Al Gharbia awarded its EPC (Engineering, LSAW@sms-group.com The centerpiece of the new rolling mill is the 3-roll precision sizing mill, type PSM® 380/5.
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
SMALL STEPS –
BIG IMPACT
An upgrade or elimination of a bottleneck in an existing rolling mill is a demand-
ing task. The challenge is to combine effective solutions with minimum
downtime. Such challenges SMS group accept not only for its own delivered
mills. Some examples show the competence and experience for such small Standard fan and
high velocity fan air
but effective modifications of the SMS group in the field of Long Products. velocity profile with
3-fan technology.
Customer benefits:
Improved operation & reduced
maintenance
Lower operating costs
Greater reliability
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
Successful produc-
tion of first section
on the upgraded
tandem reversing
rolling mill at Hyun-
dai Steel.
33
days of plant shutdown were needed during
the comprehensive modernization.
Hyundai Steel error messages of the whole rolling mill come together.
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
Low
investment –
high
efficiency
New continuous roughing line at Saarstahl. Economic rail production – thanks to univer- Continuous operation at Trinecke Zelezarny. World’s largest sheet piles produced at
sal rolling method. ArcelorMittal.
Particularly at the present time, new Renewed Revamped New bloom- Replacement
plants often do not suit the budget of a compa-
ny. In the course of modernization measures,
roughing line rail mill ing mill of straightener
existing facilities may be provided with state-
of-the-art technology. Customer: Saarstahl AG, Germany Customer: ArcelorMittal, Spain Customer: Trinecke Zelezarny, Customer: ArcelorMittal,
Czech Republic Luxembourg
Objectives: Major modernization goals Objectives: Changing the rolling Objectives: Extension of plant’s service Objectives: The new machine enables
are quality assurance and flexibility to method from the conventional two- life, maintaining continuous operation. the straightening of the largest sheet
But even smaller investments can be highly effective and make an ex- be able to respond to customer wishes high to a more economic universal piles worldwide und thus extends the
isting plant more efficient. Carrying out modernization work does not from the automotive industries and the rolling method. This reduces pro- Measure: Replacement of the existing product range. The twin-bearing con-
automatically mean to stop production for a longer period. Here, indi- mechanical engineering sector. duction costs and improves dimen- blooming mill by a new two-high re- struction achieves better straighten-
vidual solutions help to minimize production downtimes. sional accuracy and surface proper- versing blooming mill stand and instal- ing results for extra wide sections.
Together with the customer the possibilities of modernization mea- Measure: A new seven-stand roughing ties. In addition, the product range is lation of a hydraulic bloom shear with a
sures are discussed. Upgrade packages of SMS group range from line replaces the old blooming stand extended and rails up to 108 meters shear force of 1,100 tons. Measure: During a downtime period
technical upgrade up to complex revamping. SMS experts work closely built in 1962. A real challenge: large- are produced. of just four and a half weeks the exist-
with the customer on site to meet the challenges which such modern- scale modernization during ongoing ing straightener was dismantled and
izations involve. Please find below some examples of successful mod- production. Saarstahl and SMS have Measure: The core of the moderniza- the new CRS® straightening machine
ernizations for section and billet mills. jointly developed a concept managing tion is the installation of a working for sheet piles with double-sided
the upgrade of the rolling mill in Völklin- group, consisting of a universal and an bearings was set up. The supply
gen without production downtimes. To edging stand. They come with CCS® package included the mechanics, the
do this, a bypass was installed on the stands (Compact Cartridge Stand) electrics and the automation, the me-
i
site. Specially installed turntables and which are employed in numerous sec- dia systems and the complete chang-
roller tables directed the billets from tion and rail mills. The existing finish- ing facilities for the straightening roll
BENEFITS the furnace to the existing blooming ing stand is additionally replaced by a change. All nine rolls can be changed
stand. Shorter cycle times and faster universal stand. For the planned con- at the same time in less than 40 min-
Modernizations offer high efficiency product changes were made possible by version measures only standard down- utes by a manipulator. To achieve this,
a high level of automation. times are used. the column on the operating side can
Extension of complete plant’s service life be extended. The new facilities were
Extension of product range tested and examined beforehand by
Extension of maintenance cycles means of a simulation to make sure
Automation of processes
that commissioning was possible in
Saving valuable resources
this narrow time fame.
Increase in plant performance
Reduction of emissions
Increase in plant availability
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The tension of all those involved in the project was high “The new cooling bed enables us to once again significantly
when the first rolled bars reached the cooling bed in the improve the quality of our rolled products so that we are
with simulations
bars were sliding through the roller table as planned example higher bar surface quality. “Especially in the auto-
where they were carefully slowed down and lifted onto the motive industry surface scoring is an absolute no-go,” adds
rake-type bed in a controlled manner. Premiere success- Dr. Helsper.
fully completed – the modernized cooling bed was taken
into operation. REVAMP IN ONLY SEVEN WEEKS
More safety, shorter conversion phases and well trained personnel – It took only two regular maintenance shutdowns to install For the extensive construction measures there was a total
the new cooling bed. The internationally operating producer of just seven weeks available to the project team of SMS
simulations make modernizations easier in many ways.
of special steel long products now runs a plant designed for group. “To make sure that Deutsche Edelstahlwerke was
bars in the size range from 20 to 90 millimeters. able to continue supplying its customer without any restric-
The new cooling bed allows closer length tolerances and tions the regular maintenance shutdowns had to be suffi-
higher quality surfaces of the produced steel bars and en- cient for the implementation. This means a tight schedule,
sures much better straightness of the products due to more because normally we rather calculate three months for
The modernization project at ArcelorMittal in Luxembourg
shows the advantages of simulating a revamp. In virtual re-
ality to visualize, design and evaluate machine components,
i BENEFITS
even cooling of the bars. Consequently, the expenditure in
the subsequent finishing section is reduced significantly.
such projects. Good planning was therefore in demand,”
project manager Stefan Schulte of SMS group reports.
During a three-week shut down in summer 2014 all ex-
SMS group adopts an approach allowing direct intercon- isting plant components of the cooling bed were dismantled
nection of virtual projects with planning and simulation Simulations are available for the following application and reassembled to be able to complete most of the foun-
tools. Therefore, it was possible to provide ArcelorMittal possibilities: Cooling bed on dation and cable duct work. During the summer shut down
with a comprehensive insight into the machines and the delivery side. in 2015 seven excavators were employed which demolished
whole production facility and to test real material flow pro- upport for layout planning. The design engineer inspects
S
the old facilities within six days. The foundations still miss-
the plant.
cesses with real force feedback. Simulation tests were ap- ing were built in parallel to the demolition. The individual
Material flow simulation. By means of modular modules
plied from the first discussion up to plant acceptance. (buffer sizes, roller tables, and others) the material flow in components of the new equipment reached the plant in
the production plant is examined and optimized. Siegen on 39 trucks and 18 heavy-duty transport vehicles
What will be offered by simulations for planning
upport for detail engineering. Design engineer is provid-
S – a logistical masterpiece. “We were glad to have SMS as an
activities: ed with in-depth information on arrangement of compo- experienced partner on our side,” praised rolling mill man-
nents. This particular three-dimensional visual impression
Safety in project planning and implementation ager Dr. Thomas Helsper.
is impossible in a conventional screen view.
Short conversion phase and fast commissioning Installation and assembly information. In particular, the This conversion demonstrates the competence of SMS
Tested and perfectly functioning software accessibility can be checked. group for most demanding reconstructions and moderniza-
Simulation of production operation and logistics. Process tions during ongoing production.
Training of plant operators in advance es and process chains can be mapped and varied.
raining and education. Operating, erection and mainte-
T
nance staff can be trained in advance.
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Largest front-load-
ing extrusion press
built by SMS group
with a pressing force
EXTRUSION ON AN
of 160 MN.
XXL SCALE
Largest extrusion press built by SMS has started production.
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»We have had very good experience with the availability, productivity and
precision of the tube press supplied by SMS group. That was one of the reasons
why we also decided in favor of SMS for the two new orders.«
The 160-MN press will be used in particular for the extru- All press lines supplied by SMS group at Jilin Liyuan have
sion of large profiles of medium-hard aluminum alloys that been equipped with up-to-date induction furnaces for billet
are used for new high-speed trains and other rail-bound preheating by IAS GmbH which also belongs to SMS group.
vehicles. The benefits: thanks to the large profiles, less Multi-zone IGBT converters of the latest generation have
welding work is necessary during wagon construction, sta- been installed in the 160-MN and 36-MN lines’ furnace in-
bility is increased whilst reducing the weight. The front- stallations to fulfill the high process requirements concern-
loading press processes billets with a diameter of 720 mil- ing temperature control in a precise way. This was an im-
limeters, a length of 2,500 millimeters and a weight of 2,750 portant aspect to receive the acceptances after a short
kilograms. They are used for the production of profiles with time. A loss-reduced coil design reduces energy consump-
widths of up to 800 millimeters and lengths of up to 35 me- tion of the high performance plants by up to 20 percent
ters. SMS group had already supplied a 45-MN direct/indi- compared to conventional installations.
rect tube press to Jilin Liyuan in 2011. Wang Min, owner of For the largest extrusion press built by SMS the installed
Jilin Liyuan, says: “We have had very good experience with capacity for each furnace installation is 2.4 MW and it pro- Ecomelt-PR80 Multi
the availability, productivity and precision of the tube press vides special billet handling to transport the unit weights of Chamber Melting Fur-
nace at TALEX, UAE.
supplied by the SMS group in 2011. That was one of the 2.75 tons within the plant in a surface-protecting manner.
reasons why we decided in favor of SMS for the two new With the two new presses, Jilin Liyuan, as one of the
orders. Of particular note are the vast experience and the leading producers of extruded aluminum profiles and
engineering know-how for the 160-MN press. Like us, SMS tubes, is expanding its product portfolio in China particu-
group has special knowledge of the process technology for larly in the high-grade and profitable special segments,
the production of extremely wide profiles. It is therefore the
right partner for us because we have very high expectations
and SMS has succeeded in converting our requirements
and is thus increasing its competitiveness. Project man-
ager Klaus Fußbroich SMS group says: “The cooperation
with the customer was very harmonious and marked by
TALEX casthouse –
successful start of
into solutions.” close partnership. Thanks to the good coordination, com-
missioning of both presses was successful and we received
INCREASING COMPETITIVENESS the final acceptance certificate already after a short time,
With the second new press – a 36-MN direct/indirect tube as all the agreed products and alloys as well as the quality
press – Jilin Liyuan is expanding its product spectrum in the
field of seamless tubes. The new press allows the processing
of billets of high-strength aluminum alloys weighing 300 ki-
and production targets were achieved to the fullest satis-
faction of the customer.” operation
lograms with a diameter of 322 millimeters and a length of
1,350 millimeters. They are used to extrude special tubes for
applications in power stations and in oil and gas exploration, The new TALEX extrusion plant in Abu Dhabi operates using its own extrusion
as well as profiles for the electronics and automotive indus-
billet. The casthouse, which started operating in February 2016, was built as a
try. The SMS press is also characterized by its high flexibility.
In direct extrusion mode, Jilin Liyuan can also produce nor- Klaus Fußbroich
turnkey plant by Hertwich Engineering, a subsidiary of the SMS group.
mal profiles. klaus.fussbroich@sms-group.com
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For more than forty years the industrial zone in Abu Dhabi
has been the country’s fastest-growing economic area. Its
current expansion projects include a new extrusion plant.
The operator of the new plant is Taweelah Aluminium Ex-
trusion company (TALEX) LLC, which was founded in May
2011 as a joint venture between SENAAT Industrial Holding
(formerly Abu Dhabi Basic Industries) and Gulf Extrusions.
The investment follows the trend for the high-performing
smelting industries in the Gulf Region countries to expand
into downstream activities (value added material). In fact,
and not least because of the dynamic building boom, the
Gulf Region has developed to become one of the centers of
worldwide extrusion production.
Vertical Casting
HIGH-QUALITY PRODUCTS FOR SPECIAL DEMANDS Machine in the
front, Continuous
In the first expansion stage TALEX set up two extrusion Homogenizing and
lines and a casthouse for extrusion billets. Besides stan- Sawing Plant in the
dard extrusion applications the new TALEX extrusion plant background.
will also produce high-grade extruded products for special
requirements in the automobile industry.
For the construction of the entire casthouse complex the
Austrian company Hertwich Engineering was awarded the
contract. After the first expansion stage (now completed)
the annual output of the casthouse will be around 30,000 to
40,000 tons of extrusion billets.
At TALEX an “Ecomelt-PR 80” (melting performance of 4
t/h) two-chamber furnace with a preheat ramp was in-
stalled, which is particularly suitable for melting post-con-
sumer scrap containing moderate amounts of Volatile Or- Before entering the homogenising fur- mogenising charge is achieved. Fur- there, finally, to a semi-automatic strapping station and on-
ganic Compounds (V.O.C). The concept is based on a nace, each individual log is checked for thermore, the heating of each individ- ward to a weighing machine. The scrap produced at the saw
multi-chamber furnace in which the processes of preheat- centre cracks by ultrasonic inspection. ual log can be accurately controlled. is also disposed automatically: the swarf is drawn off by
ing, gasification of organics and melting are combined in a Defective logs are rejected ahead of For cooling, an air-cooling station suction and briquetted while all the scrap is returned to the
single unit. the furnace. matched to the alloy mix is used. melting furnace. The plant has been designed for the sub-
The melt is transferred via a launder system from the In this first expansion TALEX opted sequent integration of a second casting furnace and a
Ecomelt melting furnace to the holding and casting fur- for continuous homogenising. In the AUTOMATED SCRAP DISPOSAL batch-type homogenising unit. With this equipment, the
nace. The molten metal from there is sent to the casting continuous homogenizing furnace, The cooling station is followed by the plant’s planned capacity and alloy variation will be reached
station via the I-60 SIR inline degassing and filtration units. since by virtue of the design, each saw for cutting off the head and butt in the final stage.
For degassing, filtration and the VDC casting process TAL- individual log is heated in exactly ends to produce long billets between
EX decided in favour of Hycast technology. The vertically the same way and thus a reliable, 4,000 – 7,500 millimeters. The cut bil-
cast logs are lifted out of the casting pit by a crane and laid uniform and controlled temperature lets are transported by a further roller
www.hertwich.com
down at a transfer station. adjustment throughout the entire ho- table to a stacking machine and from
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buntmetall amstetten
orders extrusion press
Left to right: Fadi Awadhalla (EGA), Mo-
hamed Nagib (EGA), Walid Al Attar (EGA),
Franz Niedermair (Hertwich Engineering).
90
Austria-based buntmetall amstetten GmbH, a leading pro- stream of the press, will consist of four Hertwich Engineering (HE) has become the technology and houses worldwide, decided to install the Hertwich Technol-
ducer of semi-finished and finished parts made of copper vertical induction furnaces, which will market leader in the business sector of melting, heat treat- ogy and showed the expected results, competitors followed.
and copper alloys in Europe, has placed an order with SMS be supplied by the SMS group company ment and recycling technology for aluminium. On the way This happened in 1994, when EGA Jebel Ali successfully
group for the supply of a 50-MN extrusion press for NF IAS, based in Iserlohn, Germany. Heat- to this success, the trustful collaboration with Dubai Alu- commissioned the first Hertwich Continuous Homogeniz-
metals and an inductive billet heater to be installed up- ing the billets in vertical induction fur- minium (DUBAL), now an operating subsidiary of Emirates ing Plant including two sawing machines. Thereafter, a se-
stream of the press. naces is an innovative approach which Global Aluminium (EGA) and referred to as EGA Jebel Ali, ries of notable aluminium producers ventured to invest in
The new 50-MN extrusion press will replace the existing allows to bring also difficult-to-heat has been extremely helpful. On the occasion of the 25th an- the new technology: Comalco and Boyne in Australia, NZAS
percent of the prod-
25-MN SMS-Schloemann extrusion press built in 1961. The alloys to the required pressing temper- niversary of the partnership, both parties met for a joint in New Zealand, ALCOA (previously Eastalco and Intalco) in
ucts made in Austria
new press and its ability to handle higher input weights will ature within a narrow tolerance range. celebration in Dubai. the USA, Alba, and others. Since then, more than 120 con-
are exported.
provide buntmetall amstetten the possibility to boost the Commissioning of the extrusion In the past two and a half decades, EGA Jebel Ali has tinuous homogenizing units have been installed, and around
productivity of its operations and further expand its range of press and the billet heater is scheduled become one of the largest and most efficient primary alu- 60 percent of all billets for extrusion produced today are ho-
“specialty” products. to take place in spring 2017. minium smelters in the world, producing more than one mogenised using these units.
At its Amstetten works, buntmetall million tonnes of aluminum per year. Together with Emir-
FULLY AUTOMATED OPERATION produces tubes, bars, rods, wires and ates Aluminium (EMAL), another EGA subsidiary referred to CONVINCING NEW BATCH FURNACE CONCEPT
The extrusion press will come with fully automatic handling profiles made of copper and copper al- as EGA Al Taweelah, EGA today has a production capacity of The development of the new batch furnace concept (reverse
equipment. All manual activities will in future be performed loys. The products are used in sectors 2.4 million tons per annum, accounting for around 5 per- air) by HE was not very different. Again EGA Jebel Ali was
by an industrial robot. The billet heater, to be installed up- as wide ranging as facilities engineer- cent of smelter production worldwide. Almost half of EGA’s the first company to venture onto this new ground. Having
ing, solar systems engineering, heating annual production is processed into billets for extrusion witnessed the advantages of the new batch furnace con-
and air conditioning equipment, me- and forging. cept, other notable casthouses have selected it as well. In
chanical and plant engineering, electri- 2016, three plants of this type are to be commissioned.
cal engineering, the aviation and auto- COOPERATION WITH EGA JEBEL ALI CONVERTS MARKET In total the production of the homogenising units installed
motive industries, ship building and For Hertwich, the collaboration with EGA Jebel Ali has been by HE at EGA’s two operating subsidiaries amounts to more
offshore technology, and even comput- valuable in many respects. In the field of Heat Treatment of than one million tons per year. A total of six continuous fur-
er technology and advanced supracon- extrusion billets, Hertwich has successfully developed new naces and the same number of batch homogenising fur-
ductors. The Austria-based company concepts to reduce energy consumption and thus also emis- naces have been installed, including numerous auxiliary
exports 90 percent of its products. sions, achieve a uniform temperature distribution inside the units such as charging machines, sawing and ultrasonic
furnace, which is a pre-condition for quality products; and inspection equipment, briquetting presses and much more.
inspect the material for center cracks and inclusions. The There are also two horizontal continuous-casting lines with
whole heat treatment process including Ultrasonic Testing, a total capacity of 130,000 tons.
Sawing and Packing has been integrated in a fully automat-
ed production process by Hertwich.
In order to establish these new technologies on the ini-
50-MN extrusion press for non-ferrous metals complete with fully Bernhard Steinert tially sceptical market, EGA Jebel Ali has been a helpful
automatic handling unit designed by the SMS group. bernhard.steinert@sms-group.com partner. Only when EGA Jebel Ali, as one of the leading cast-
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sms group newsletter 03 / 2016
03/ 2016
SMS group also supplies Since aluminum production started in the Gulf region in
the early 1970’s the GCC countries (Gulf Cooperation i
extrusion line No. 5 and 6
Council) very soon became a key market for aluminum ex- DatA
trusion presses in the range of 5 to 12 inch. First SMS
press lines have been delivered back in the 1980’s when The main data of the state-of-
the demand for extrusions for building & construction the-art front-loading presses are:
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sms group newsletter 03 / 2016 sms group newsletter 03 / 2016
Top: Discharge
table of the
extrusion line.
Bottom: Puller,
run-out and
cooling table.
One of the key account customers in the region is Al first press from SMS. In the whole
Taiseer Aluminium Company in Riyadh, Saudi-Arabia. This time we could rely on the good quality
modern, family-owned enterprise is one of the top-level and precision. Plus the service, which
extruders of the GCC countries. Operating already four is of course important. We all find
modern 8-inch SMS-Schloemann extrusion lines, Al Tai- this with SMS.”
seer ordered two additional 25/27 MN (8 inch) extrusion The run-out systems of the extru-
lines to fulfil the continuously growing demand from the sion lines as well as the energy effi-
market. Both lines are installed, commissioned and in op- cient log heaters are made by OMAV
eration now. S.p.A., Italy and meet perfectly the
high demands that a modern extrusion
RELIABLE PARTNER SMS GROUP handling system has to fulfil.
Al Taiseer’s vice president Nasser Al Fattouh justifies his IAS GmbH, a member of the SMS
repeated order to SMS: “22 years ago we received our group, delivered the two TEM-PRO
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Hindalco Industries
relies on Hertwich Contin-
uous HOMOGENIZING Ecomelt-PS 250
melting furnace at
Hulamin, Pieter-
maritzburg.
Extrusion billets have to pass a heat treatment process before they are
going to be extruded in a press. For this process, Hertwich Engineering supplies
Continuous Homogenizing Furnaces, which are established worldwide.
South Africa expands Aluminium recycling
115
Rubrik sms group newsletter 02 / 2016 sms group newsletter 03 / 2016
Pandolfo extends
its homogenizing capacity
Pandolfo Alluminio S.p.A., a leading Italian extrusion plant, has placed an order
Helical Ultrasonic Testing Station
at Impol d.o.o., Slovenia.
with Hertwich Engineering for the supply of a modern Batch Homogenizing Fur-
nace for extrusion billets. Its commissioning is scheduled for August 2016.
to the existing plant. In principle the two plants are operat- he saw for cutting off the head
T
and butt ends and if necessary for
ing independently of one another, but they are linked to cutting out defective sections
each other by a conveyor. A packing system, consisting
of a billet stacker and automatic
strapping
Sales
info@hertwich.com
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i
X-Pact® Vision – operation With this new Vision concept, SMS group is setting a semi-
nal benchmark in visualizing complex process interactions,
The structure is clear and the mask
layout purposeful. Thus the operators
Tom
and visualization
while focusing on the needs of the human operator. Plant can easily focus on and get a clear Based on new mo-
operation has been redefined in order to comply with the view of the production process. Pieces bile solutions, SMS
requirements of modern, highly automated plants. Process of information are grouped in a mean- group has developed
information is accessible at any place and time thanks to ingful way. This allows the screen the Technical Opera-
the web-based reporting function of X-Pact® Vision. With masks to be reduced to the essential tion Management –
mobile devices, the process results can be evaluated in a and create an intuitive structure, pro- TOM for short. This
Responding to the constant advance of digitization and the growing highly intuitive, secure and time-saving way, providing po- viding both high transparency and enables the operator
tential for process optimization. easy orientation.
degree of automation, SMS group has redesigned its operating and visualization to record notes and
Last but not least, intuitive naviga- peculiarities on the
concept, which is now called X-Pact® Vision. The concept is also conveniently X-Pact® Vision HMI: Plant operation made easy tion through the various available dis- production process
applicable to any plant configuration in a modernization project. Controlling the extremely complex production processes in plays and menus, the vast possibilities without paper, using
metallurgical plants and rolling mills demands a lot of the of customization as well as the con- an intuitive touch
operating personnel. In order for operators to be able to text-based operator guidance perfect display, which facili-
react swiftly and take the correct decision also in critical this concept. The outstanding user tates quick entries
situations, they must have access to all information rele- friendliness of SMS group’s HMI solu- by means of pre-
vant to them and their jobs. The innovative X-Pact® Vision tion provides additional efficiency and formulated texts and
HMI (Human Machine Interface) concept developed by SMS eventually enhances the motivation to icons. The recorded
group supports operators in performing their tasks. use the new system. events are stored in
The new HMI concept makes it much easier for the op- a database and may
erator to capture information about the production process X-Pact Process Guidance System
®
be further processed
that is relevant to him in his current situation – in an easy- With its new automation structure, at a later stage.
to-grasp, clearly structured and intuitive way. the X-Pact® Process Guidance
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X-Pact® Vision
Control Station.
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Web-based
reporting.
Operating elements which are not allowed to be imple- X-Pact® Vision Mobile Operation integrated into the quality control system. The software is
mented via touch panels or the HMI for reasons of safety The mobile solutions of the X-Pact® based on open web standards, making it suitable for use on
are arranged in a clearly structured, easily accessible man- Vision concept mean new freedom for any office or industrial tablet. By making quality manage-
ner in the area in front of the screens. In this way, it is en- managers and metallurgists, as they ment more efficient, the Product Inspector optimizes the
sured that measures are taken intuitively and correctly – can access the production processes production process.
even in emergency situations. in real time via mobile devices (tablet/
The operating area is completed by ergonomically opti- smart phone). Revamping with X-Pact® Vision
mized control room chairs designed for 24/7 use, reducing Thus, the feature of web-based re- The X-Pact® Vision systems form the link between the pro-
physical strain on the operators and supporting their power porting provided by X-Pact® Vision duction plant and the operator, visualizing all processes in
of concentration. from SMS group provides potential for a production-oriented fashion including all information
process optimization as the process relevant to the operator. All attributes and functions of the
The social or analysis area results can be evaluated in a highly in- X-Pact® Vision concept are implemented on the basis of
Located at the center of the control station’s social/analy- tuitive, secure and time-saving way. proven technologies. The upgradability of the systems guar-
sis area is the Data Analysis and Vision Desk – DAVID for Data safety is guaranteed by internal antees their compatibility. The control station is set up in
short. It has been consciously designed to stand out from Wi-Fi connection with access authori- modules, scalable and perfectly suited for revamps. The use
the other functional furniture as a stand-alone item in- zation and authentication. of standards ensures stability and makes for easy service-
tended especially for teamwork. Equipped with the latest Mobile quality control of e.g. slabs ability of the system. With the right operating concept in
communication technologies, the discussion desk “DA- by means of the X-Pact® Vision Prod- place, plant operators are on the safe side – and SMS group
VID” is the information center of the plant. Here, all infor- uct Inspector is another newly devel- has the ideal solution for it.
mation for production analyses, performance evaluations oped software application for tablets.
and shift meetings is compiled. To effectively support the As well as documenting the quality of
work in teams, a large multi-touch display is horizontally produced slabs at fixed locations, the
installed into the desktop and can be operated intuitively. operating personnel can now perform
Also for customer visits, the discussion desk with its a mobile check at any suitable location
great variety of features plays a central role, making it in the works. SMS group offers the
predestined to serve as a central meeting place in the Product Inspector as a cost-effective Stefan Luxenburger
plant. The large DAVID multi-touch display. stand-alone solution or as a solution stefan.luxenburger@sms-group.com
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In February 2016, SMS group received an order from the at a pressure of up to 1,000 bar, which
Serbian firm Impol Seval, Valjaonica aluminijuma Sevojno, ensures that deposits and adhering
for the comprehensive modernization of the aluminum hot
rolling mill supplied by Schloemann in 1972. The main ob-
jectives of the revamp are a considerable increase in pro-
aluminum residues are removed reli-
ably from the roll surfaces. i
duction and an improvement in quality of the rolled strips X-Pact® automation system
AluControl®
as regards thickness and profile tolerances. Thanks to the AluControl®
integration of the entry-side coiler into the production pro- The heart of the new mill is the new X- AluControl® has
cess, it will be possible in future to work with three coiling Pact® automation system, AluControl®. been developed at
passes rather than only one as previously, thus greatly en- It comprises the technological control SMS group over the
hancing the efficiency of the mill. systems and the Level 2 process past few years as an
To enable the mill to also roll large ingots, the entry and models. automation package
exit sections are being completely revamped. The posi- Via a link to the existing production that is specially
tions of both coilers are being shifted and raised, so as to planning system, Level 2 receives all suited to the require-
allow larger coil diameters to be wound. The belt wrap- of the product data and, depending on ments of the hot
pers, pinch rolls and side guards are being renewed and the thermal condition of the mill, cal- and cold rolling of
adapted on both sides. At the exit end, a new trimming culates the optimum pass schedule in aluminum. Alu
shear will be installed. It will be coordinated with the high- each case and the mill setting values. Control® has proven
er exit speed resulting from the reduced final gage of min- The Level 1 control systems ensure its value in more
At the moment the single-stand mill rolls the heated billets in reversing operation down to gages imum 3.5 millimeter. that the assured close tolerances for than 20 installations
of 8 to 15 mm and coils the strip in the final pass in gages between 5 and 10 mm. strip gage and profile will be achieved. since 2012, for new
New X-ray measuring unit All plant data and process informa- plant projects and
The strip gage and profile will be measured continuously tion are displayed in the new visual- revamps alike, and
over the width by a new X-ray measuring unit. The mea- ization system in a user-friendly
Modernization of
consistent improve-
sured data are the input variables for the technological con- manner. The hot rolling mill at IMPOL ments have been
trol systems. In the millstand itself new cooling headers Seval is being revamped in two stag- implemented in
will be installed, partly for the purpose of ensuring roll-gap es. An initial plant shutdown in the practical application.
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Klaus Lazzaro
klaus.lazzaro@sms-group.com
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Dirk Oedekoven
(left) and André
Peschen, both from
SMS group, present
the prototype of a
digitized solution.
Industry 4.0
provides significantly more advantages and more intelligent such as RFID technology or OCR recognition of writing are
functions than has been the case to date. It already started also usable.” The user may then select the respective
during the development phase. During visits to customers component on the drawing. Depending on the selection,
special needs and pain points were identified with a radical the associated bill of material is also directly displayed.
user-focused approach. Design thinking enhances collab- Photos and other additional information help to identify the
SMS group presents prototype for eService platform. orative creativity to solve problems holistically and to the proper component more easily. At the same time, avail-
customer’s best advantage. Using this methodology a so- ability (for example in a consignment warehouse) and costs
called rapid prototyping was possible and we are able to as well as delivery dates can be checked. Via the function
present initial approaches in the form of scribbles and click of the shopping basket the spare part can of course also be
dummies. Consequently, we always maintained a close dia- ordered comfortably.
At the Tube & wire 2016, plant owners were able to achieve Dr. Dirk Oedekoven, Vice President Technical Service, SMS log with the customer throughout the entire development.
a concrete idea of what the future holds with digital prod- group: “The visitors were impressed by our solution. On a Therefore, we could consider optimizations and customer A spare parts catalog that thinks along
ucts and smart SMS group services. concrete example of the exit guide of a peeling machine we ideas very specifically and at an early stage.” André Peschen: “Naturally, the user may quickly locate the
The Service Division presented a functional prototype of could show which advantages can be offered by digitizing respective part via the tree-like menu. One special feature
an eService platform with integrated electronic spare parts the service segment. It is a key module and SMS group is Mobile solution with assembly group recognition is that further parts which may be required for the spare
catalog which provides a number of smart functions and additionally working on further solutions.” Electronic spare One of the most important innovations of the SMS solution parts are shown, for example suitable seals for a bush. In
thus accelerates maintenance and spare parts procure- parts catalogs – also with online availability – exist already is that customers are able to determine the respective this way, the customer is directly provided with an overview
ment, and ensures more flexibility and transparency for ev- a long time; the question therefore is: what exactly makes component directly on the machine and to receive key in- of complete repair sets, saving on follow-up orders which
eryone involved in the process. the new system of SMS group so special? formation on ET packages, etc. immediately. With a tablet cost valuable time.”
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4. Wear or defec-
tive part can now be
ordered with just one
click and shopping
basket function.
3. Operator (main-
tainer) can only
select desired parts
– the parts list is au-
tomatically adapted.
It can already be noticed that the new digital eService ings for each customer plant – inclu- line platform “my SMS group” using any terminal device – convincing that the first pilot projects
product of SMS group is fulfilling the requirements of dif- sive of parts of our sub-suppliers. For even via desktop. Following his identification with individu- are going to start soon – together with
ferent customers. For the test version various plants were a minimill this may quickly amount to al security mechanisms, any personified information is the customer. I believe we thereby
mapped. Apart from the peeling lines, different cold pilger several hundred thousand BOM items displayed to him. This means, the customer may control prove as SMS group that we are on
mills and even a complete wire rod mill were cataloged. For and numerous drawings interlinked the access authorizations depending on the fields of activi- the right track to build linked service
the latter, an adjoined consignment warehouse with all in- with each other. It is about the same as ty, thereby also achieving a simplification in operation. De- intelligence and digital service trans-
formation was also generated in addition to the main plant. customers are accustomed to from the pending on the user, only the required modules are then formation.”
Since all plants of SMS group are structured individually, usability in the private sector when displayed – at present, there are for example the subject
each customer using the service is able to reach his equip- shopping online. The customer does areas “Equipment”, “Smart Alarm” and “Best Contact”. In
ment on the platform via a personalized and protected area. not see the complexity behind our the course of time, the modules shall be extended continu-
The aim was to map a so-called “Full Bill of Material”, virtu- eService, but it becomes much easier ally as digital products so that the entire service process is
ally the digital twin of the actual plant. and faster for him to reach the goal.” digitally mapped and supported.
Intelligent full bills of material Integrable service products First pilot projects for smart technology
André Peschen explains the background: “This is one of the Within the framework of Industry 4.0 Dr. Oedekoven: “With our service platform the customers
great challenges we can master using modern software and eService the electronic spare have a central information access which they can use any-
tools. Via interfaces, we unite the often very heterogeneous parts catalog is one of the first con- time and anywhere. User guidance is extremely simple
data and drawings in a unified user interface. This was also crete digital products of SMS group. It due to smart technologies directing the customer to the
one of the major requests of the customer who does not is by no means only limited to mobile right section respectively to the deposited information
want to locate the spare parts from different sources and tablet use. At a later stage, the user such as technical datasheets and operating manuals. Our André Peschen
methods. We provide homogeneous information and draw- shall have access to the protected on- digitization plan with eService at the Tube & wire was so andre.peschen@sms-group.com
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Automated die »With the automated die adjustment from SMS we are able to
attain clearly improved process transparency. Moreover, the adjustment of
adjustment for repro- the die is significantly improved which also has a positive effect on
the occupational safety of the machine operator.«
ducible quality Andreas Sieber, Plant Manager, Steeltec AG, Emmenbrücke, Switzerland.
i
Simple solution, pragmatic implementation
By installing a control circuit of the actual wire rod deflection
downstream of the shear to achieve the target deflection, a
BENEFITS
motorized die adjustment is automated. As a result, the
straightness of the drawn products is optimized by the auto- Customers benefit in more than one way
mated die adjustment, based on wire rod deflection already
before straightening. Furthermore, the process data for Reject reduction, even at coil head and tail end
quality assurance can be output to the operator. Improvement of material straightness already before
straightening
Reduction in operator workload
Increase in occupational safety
Reproducibility of setting parameters of die
Displaying quality fluctuations in primary metal
Enhancing process reliability
Johannes Kahlen
johannes.kahlen@sms-group.com
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Right: Innovative
coating of X-Roll® Oil
Bearing bush with
bearing metal.
90
way. If requested, our delivery program also provides vari-
INNOVATIONS FOR GREATER ous fastening systems as modernization package. For ex-
tending the inspection intervals of bearing systems, for ex-
ample the newly developed clearance-free bearing support
CUSTOMER BENEFITS
is a possible solution,” says Frank Benfer, Head of Oil Film
Bearing Product Unit at SMS group.
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Joining together
in preparing
Lively panel discussion: Holger Ade from the German Forging
Association moderated the event on the topic “How secure is the
for the future
competitiveness of the German forging industry?”
The number of suppliers of closed-die forgings on the world Challenges in today’s day-to-day business
market is growing continuously, the consequence is in- At the beginning of the event, Marc Hübbers, Head of Forg-
creased competition. German and internationally renowned ing Technology Service Europe at SMS group, introduced
forging companies still have a knowledge edge in terms of the history and the portfolio of the Service Product Unit
development but it is noticeably decreasing. And there is Forging Technology at SMS group. Then, practical exam-
the cost pressure by competitors with low labor costs and ples of current projects of participating companies formed
rising material and energy expenses. the starting points as regards contents. Whether with auto-
mation and cycle time reduction of an MP2000 (Hirschvogel
Answers to issues concerning the future Umformtechnik GmbH), with a general overhaul and mod-
The first Maintainers’ Day Closed-die Forging of SMS group ernization of an FPRN 500 (Märkisches Werk Halver) or
was a platform for exchanging views among specialists. with bringing together two machines during a just-in-time
The discussion focused on the following urgent issues: repair of a KSP 200 (Daimler AG): again and again it was
shown which exceptional measures were taken in part to
hich concrete challenges must be tackled by the forg-
W meet the huge demands with regard to time and costs.
ing technology industry already today? “Whereas in former times ten weeks were available for re-
Which developments are evident for the future? pair work, nowadays only six weeks are required,” summa-
Which possible approaches should already be pursued rizes Frank Dobus, Operations Manager at Hirschvogel
today more actively? Umformtechnik GmbH, in an illustrative manner. “We can
only be successful when we take a common and coopera-
More than 30 maintenance managers and technical ex- tive approach to our projects!”
perts of renowned companies accepted the invitation to
Mönchengladbach in April. Dirk Oedekoven, Vice President Panel discussion on the FORGING INDUSTRY’S FUTURE
Technical Service of SMS group, welcomed the audience The first day was concluded by a panel discussion around
and guided the participants through the two-day event. the question, how secure the competitiveness of the
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30
»Whereas in former times ten weeks were available for Experts exchanging
views: Frank Dobus,
repair work, nowadays only six weeks are required. We can only be successful Plant Manager at
Hirschvogel
when we take a common and cooperative approach to our projects!« Umformtechnik
GmbH, Denklingen,
in a conversation
with SMS Works
Frank Dobus, Operations Manager at Hirschvogel Umformtechnik GmbH.
Manager Jochen
Gerards about
service concepts.
German forging industry is. Holger Ade, Head of Busi- manufacturing and assembly. Because however, additional requirements to flexibility and cost tics of energy consumption meet the current challenges of
ness Administration of the German Forging Association, of the proximity of design and manuf structure are resulting from day-to-day maintenance op- the industry. Particular advantages are low maintenance in
provided a keynote speech and moderated the discussion. acture both areas are able to work erations. Accordingly, the concept of the new, independent combination with less costs for spare parts, high energy ef-
It quickly became clear which transformation the forging closely together. and complementary SMS Service workshop was very well ficiency and prevention of current peaks. Accordingly, the
industry is undergoing. Apart from quality, speed and cost Since the completion of a plant received, which enables minimal lead times and costs with possibilities were directly discussed in an intense way,
reductions are required above all. To achieve this, new but modernization at the beginning of maximum flexibility. With its own workshop only for servic- namely how this concept can also be translated into exist-
practicable approaches are needed for press technology, 2015, a new assembly hall with 4,000 es and with OEM knowledge SMS group is able to provide ing machines.
digitalization and partnership. Particularly the topic of dig- square meters is available offering a much faster and better assistance. Qualified personnel and
italization was lively discussed in the present context of crane capacity of 180 tons. In addition, machines are exclusively available for service tasks. Many modules for new competitive opportunities
Industry 4.0. Dirk Oedekoven emphasized that “digitaliza- 15 new machine tools of the latest After presenting the concept of the new service work- In general, it has become apparent that many promising
tion cannot be the answer to our problems but only a con- generation were installed in the area shop, possible efficiency improvements for commissioning concepts and approaches exist to enhance the competitive-
temporary formulation of our homework.” of the previous mechanical workshop. were demonstrated by SMS group simulation on the basis ness of European forging companies. The participants saw
Uwe Schumann, Head of Maintenance Massive Forming A master computer-controlled MC of project examples. For this real-time function simulation the right approach in the topics that were introduced to re-
of Daimler AG: “Even SMS group as our service partner processing line with fully automated the real control hardware is linked to the simulation com- act properly to growing future requirements. The challeng-
has to support us with these challenges. The events and a workpiece feeding and a tool for unit puter. Advantages of such “virtual start-up” are a reduction es facing the industry can only be mastered together.
continuous dialog with SMS show us that new and tougher weights up to ten tons, a boring mill of commissioning period and total cost, a steeper ramp-up
conditions have been recognized and that adequate solu- line for machining cubic workpieces curve according to SOP and potentials for carrying out
tions are already offered and developed. Here, thinking and up to a unit weight of 120 tons and a functional tests without interfering with the real plant. Sim-
working are highly practical.” five-axis turning/milling center with ulation models are useful whenever the risk of “failure” is
maximum possible machining capac- particularly high, i.e. when for example conversion work or
Solutions for future challenges ities of a workpiece weight of 60 tons modernizations have to take place within a short time inter-
On the second day the discussion of solution approaches to and a workpiece length of 20 meters val with little time for preparation or when a new automa-
the aforementioned challenges was in the focus. The day are further key figures. tion hardware and/or software is applied.
started with visiting the manufacturing and assembly In the course of discussions it be- Furthermore, the maintenance-friendly drive concept of
workshops of SMS group in Mönchengladbach. At the came clear that such manufacturing the innovative MEERtorque® series was presented and dis-
Mönchengladbach location, 42,000 square meters out of a possibilities are a precondition for ma- cussed intensively. Properties such as the wear-free cou- Heinz Zacharia
total space of 124,000 square meters alone is provided for ny repair and modernization projects, pling, the recovery of braking energy and the characteris- heinz.zacharia@sms-group.com
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Robot enhances
efficiency
SMS group modernized 40-year-old extrusion press at
SG Extruded Products Group in Bittterfeld, Germany.
Last year, SMS group modernized a 42.5-MN extrusion Bitterfeld plant was absolutely new to
press from 1972 of customer ST Extruded Products Group the customer. “Looking back, the de-
Outokumpu from Finland has ordered from SMS group a In early 2016, ArcelorMittal Eisenhüttenstadt, Germany,
press were not an option. The seven-axis robot cares for
billet loading and ensures that the billets are safely and i PLANT
new work-roll bending and shifting system for its Tornio has commissioned SMS group to upgrade a drum shear quickly positioned in the press center. Due to shorter dis-
based Steckel mill. Furthermore, the blocks will be cassette of its hot strip mill. To achieve this, SMS group tances and quicker loading, temperature losses in the bil-
STEP-G in Bitterfeld
equipped with an additional lubrication system for the wear staff members dismantle the shear weighing about 82 let are minimized and energy efficiency of the whole pro-
plates. So far only manual relubricating of the wear plates tons into its individual parts. In the course of this, they de- cess is enhanced. Using a robot for billet loading in the ST Extruded Products Germany
during roll changes has been possible and caused relatively termine which components remain unchanged, or have to GmbH
fast wearing down of the plates. For the additional lubrica- be refurbished or replaced so that the shear fulfils its Manufacture of extruded
aluminum profiles
tion, the new wear plate and the CVC® block will be equipped function in the production process after the overhaul. Rust The robot at the Bitterfeld plant.
In 1916, establishment of
with additional lubrication holes through which grease is and deposits are removed and anticorrosive is re-applied.
Bitterfeld site
pumped during operation. The system will be connected to Delivery of the upgraded shear is scheduled for December
Approx. 120 employees
the existing millstand grease supply system. The grease 2016. For its customers, SMS group repairs all shears in
2 presses: 20 MN/ 50 MN
metering blocks with four outlets currently existing on the steel or aluminum lines. Shears are core units – if they do
Final applications in the automo-
mill stands only have to be replaced with metering blocks not function properly the complete production process is tive industry, trade, mechanical
that have six outlets. With this new equipment Outokumpu affected. At ArcelorMittal two shear cassettes are there- and structural engineering
will increase the service life of its mill. fore alternately used between overhauls. On the hot strip
mill in Eisenhüttenstadt steel is produced for special ap-
plications in the automotive industry.
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i BENEFITS
Benefits of Clean Lance System
The Clean Lance System against the rough environmental conditions at the convert-
er. The modularly designed system enables easy mainte-
nance. Since the nozzles are closed again after each coat-
of SMS group
ing procedure clogging is prevented and permanent coating
material circulation is realized.
Already the first coatings under production conditions
when using manual sprayguns have convinced pilot cus-
tomers of the advantages of oxygen lance coating on BOF Oxygen blowing lance with typical skull accumulation (left), and
converters without vapor barrier. With the semi-automatic after coating with ThixoGuard by the Clean Lance System (right).
Spray ring of Clean Lance System with guardrail and blowing
More safety for processes, environment and employees. coating system an industrial solution has matured from lance with ThixoGuard coating.
one prototype.
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To make sure production is running smoothly and reliably, sion protection treatment like carboni-
media systems used in plant engineering have to be a triding, nickel coating or galvanizing
combination of precisely harmonized components. Hy- make sure the valve units can be used
draulic controls, oil lubrication systems and machine pip-
ing take care that, for example, the energies or lubricants
needed for the production process are accurately distrib-
over a long period. All controls are
completely factory-wired and tested by
SMS group. The only thing to do on site
i Setup
uted. For many years, SMS group has been mastering this is to connect to the terminal box.
The pump stations are modular and comprise:
interaction of all sub-components. SMS group provides its
wealth of experience in media systems for new facilities PUMP UNITS
and modernization projects and offers the pertaining port- Based on the most common load and ank unit
T filter, water cooling via plate heat block with full-flow pressure filter,
folio of products and services regardless of which type of performance demands in SMS group The size is graded in steps from 2 to exchanger, filling and draining pos- individual shut-off and relief option,
18 cubic meters according to the tank sible by means of integrated pump and mounted on a baseframe for one or
plant is concerned. applications, a series of pump units volume. The tank is of two-chamber, filter. two pumps, and, optionally, with noise
was developed able to cover all re- rectangular design with direct-priming protection.
VALVE UNITS IN HYDRAULIC SYSTEMS quirements. The individual, but funda- pumps, heating elements and mani-
ain pump unit
M
fold.
SMS group specializes in hydraulic controls and associated mentally standardized units offered by The product range of SMS group eturn-flow filter unit
R
valve units. The company designs and manufactures valve SMS group are a low-cost alternative includes different pump sizes depend- The SMS standard scope includes three
ecirculation unit
R ing on their displacement: 125 cm³, filter sizes depending on the respective
units in line with the customers‘ demands up to a length of and, combined in a reasonable and In line with the gross tank volume and 180 cm³, 250 cm³. Sizes 355 cm³ and return-flow volume. The unit compris-
two meters in different configurations (control columns, function-oriented way, meet the de- the demand, SMS developed different 500 cm³ are under way, other pump es a double filter with nonreturn valve
valve tables, media supply rails, individual blocks). Since mands of plant users. Thanks to the performance stages with a recircula- sizes may be supplied on request. The on a baseframe.
tion capacity between 170 and 1,000 unit consists of pressure-controlled
the SMS workshop is able to perform multi-axis sloping large number of reference sets, SMS
dm³/min. The unit comprises a gear axial piston pumps of swash-plate
boreholes and to use cartridge valve technology an ex- group also has extensive knowledge type or screw spindle pump, 3-μm design (control alternatives on re-
tremely compact design can be implemented. This helps and experience in the use of special filtration with SMS-certified double quest), modularly equipped pump
satisfy system requirements up to the highest dynamic fluids. As a unit, the pump stations are
control level. In-house painting and state-of-the-art corro- completely factory-wired.
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Controls configured
as valve table.
i
SUPPLY OF ACCUMULATOR UNITS HYDRAULIC SYSTEMS TEST FIELD
Bladder accumulators of the following At its Hilchenbach location, SMS group has one of the most
sizes are available from the SMS stan- modern testing facilities for hydraulic systems. At the end
dard portfolio: 2 x 32 dm³, 4 x 32 dm³, of the hydraulic systems manufacturing and assembly line,
Portfolio
2 x 50 dm³ up to 8 x 50 dm³. The ac- all of the hydraulic controls produced by SMS are subjected SMS group media systems
cumulators are of single- or double- to an extensive test. For this purpose, three test stations are
imensioning and calculation of
D
row design, with separate safety and available. They satisfy all requirements imposed by today’s
the facilities
shutoff blocks and with a common safety and environmental standards. The progress and the
Valve block design
baseblock including fluid energy sep- results of the exactly defined, reproducible and partly auto-
(Detail) Design pump stations
aration. mated test procedures are electronically recorded and so iping concepts based on modular
P
are the valve presets. components
SUPPLY OF OIL LUBRICATION SYSTEMS Hydraulic consumer groups, combined with the possi- Assembly drawings
When oil lubrication systems are or- bilities of modern measuring and control technology, en- anufacture of all kinds of valve
M
dered, SMS group generally takes care sure optimum function tests to be performed for the mul- control stands
of the basic and detail engineering. titude of different hydraulic controls. This effort pays off as Pump stations
Here, too, a great variety of standard- flawless hydraulic controls only will be supplied to con- ccumulator stations /accumulator
A
units
ized components is available, and the struction site, and commissioning will be shortened sig-
lectrical controls as required for
E
company can present a multitude of nificantly.
the respective facility
references. This ensures savings in ench tests of the valve control
B
time and money. stands
ervice and commissioning
S
MACHINE PIPING worldwide
The design of machine piping suitable
for pre-fabrication on the basis of iso-
metric drawings and of piping mod-
ules adapted to the machine permits
Controls in column
exactly fitting units to be shipped, design for media
which are easy and fast to install at modules. Andreas Löhr
the jobsite. andreas.loehr@sms-group.com
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SMS group at
products, Acciaierie
e Ferriere di Piom-
bino S.p.A. (AFERPI),
commissioned SMS
group with the sup-
540
group,(left) after
In April, about 70,000 visitors from 130 signing the contract
countries visited the trade fairs for the with Fausto Azzi,
CEO, AFERPI.
tube and wire industries organized in
the Düsseldorf exhibition halls. SMS
group was also represented at the Tube
& wire. Apart from many discussions
with the customers, SMS group pre-
sented the latest developments (de-
tailed information were already pre-
square meters was the size of this year’s
sented in Newsletter 02/2016) and stand of SMS group at the Tube & wire.
could register new orders.
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sms group newsletter 03 / 2016 Rubrik — Unterrubrik
Metal + Metallurgy
in China
Seminar in Brazil For more than 20 years now, Metal + Metallurgy has been
ranking among the leading trade fairs for the steel indus-
try in Asia. This year, too, SMS group had its own exhibi-
In Belo Horizonte, SMS group provided tion booth in Beijing. On the very first day, Yin Ruiyu, the
former Chinese Vice Minister for Metallurgical Industry,
information on integrated service.
and Dieter Rosenthal, Member of the SMS group Manag-
ing Board, met at the stand. The following days were gov-
erned by numerous interesting talks with customers. Olaf
Stalfort, Manager Commercial Sales and responsible for
After two successful events organized by Paul Wurth do with high interest. SMS group do Brasil has a long tradition China at SMS group, says: “This time, we put the focus of
Brasil in 2008 and 2013, SMS group held an integrated ser- in serving the clients in Brazil and also assisting other mar- our presentation and the symposium on the subjects of
vice seminar in May 2016 in Belo Horizonte, Brasil. About kets in South America by its offices and workshops. efficiency increase and modernization of existing plants
150 delegates from the entire steel industry of Brasil joined SMS group’s objective of organizing this seminar was to as these are the issues our customers are currently deep-
the event. SMS group demonstrated the competence of its further strengthen its presence on Brazilian and South ly involved with. And we support them as a reliable and
Technical Service division through various presentations American market for technical services. loyal partner.”
covering local Brazilian and also global service projects. In
the current, difficult market situation of the Brazilian iron
and steel industries the solutions shown to improve pro- Contact Olaf Stalfort In conversation (f.l.t.r.): Yin Ruiyu, Dieter Rosenthal, Stefan Leser
duction and quality and to minimize costs were perceived service@sms-group.com olaf.stalfort@sms-group.com (CEO SMS group China) and Olaf Stalfort.
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Imprint
SMS group newsletter
Issue 03/2016
Publisher
In the middle: Pino SMS group Corporate
Tesé, Management Communications, Eduard-
Schloemann-Straße 4
Technical Service of 40237 Düsseldorf, Germany
SMS group, opened Responsible under Press
the industrial forum Law: Thomas Isajiw
in Chelyabinsk. Phone +49 211 881-0
E-mail: communications@
sms-group.com
www.sms-group.com
Published on
August 25, 2016
© SMS group / circulation
in German 6,600, in English
14,000 / printed in Germany
The 8th International industrial forum “Recon- the metallurgical sector. SMS group was present
struction of industrial enterprises – break- during the exhibition and the forum. The experts
Publications and
The information provided
in this magazine contains
through technologies in metallurgy and ma- of SMS group presented their newest develop- a general description of the
performance characteris-
chine-building” was held in April 2016 in ments and achievements. About 2,000 special- tics of the products con-
Chelyabinsk. At the same time the 16th Interna- ists from the large, medium and small business cerned. The actual products
10th International Rolling Conference insight into the range of products. pressly agreed in the terms
of the contract.
154 155
WE TRANSFORM …
THE WORLD OF ALUMINUM
T H E S MS G R O U P MAGA Z I NE
I SS U E 03 / 2016
These are the stand-out properties of aluminum: low weight We’d be delighted to see you at our booth. There you can
combined with high strength, good electrical and thermal find out all about our full range of machinery and plants –
conductivity, corrosion resistance, and recyclability. for producing, processing, and refining aluminum as well
as aluminum products. Take this opportunity to talk with us
personally. Be our guest!
Visit us at
ALUMINIUM 2016
Hall 9, Booth No. 9C20 SMS group offers products customized to your require-
Nov. 29 to Dec. 1 ments. You also benefit because all our solutions are
Düsseldorf, Germany designed for top efficiency and resource saving. NEW ORDER COMMISSIONING e-Service
Eco-friendly steel complex for Largest extrusion press ever built by Platform prototype means: Industry
AFERPI in Italy. SMS group to start production. 4.0 you can experience.
42 98 128
SMS GROUP GMBH
Eduard-Schloemann-Strasse 4 Phone: +49 211 881-0 communications@sms-group.com
40237 Düsseldorf, Germany Fax: +49 211 881-4902 www.sms-group.com