Celsa Barcelona: Modernization of medium-section mill
Cooling bed with aerosol system; Source: SMS group
Celsa Barcelona has contracted SMS group to revamp the section mill at its Castellbisbal location in Spain.
Since 2000, Celso Barcelona has been producing I and H beams on a medium-section mill supplied by SMS group. The mill was originally designed for an annual production of 500.000 tons.
The German supplier first expanded the initial range of products rollable on the mill during a revamp in 2007. According to the company, continuous plant optimization has raised the mill’s annual capacity to 1 million tons since then.
The recent contract for SMS group now covers the replacement of the existing cooling bed with a new, higher-capacity one and the upgrade of the CRS (Compact Roller Straightener), making it capable of straightening heavier products. These measures will require adjustments to and upgrades of the existing electrical and automation systems, all of which will be performed by SMS group.
The new cooling bed will come with an aerosol cooling system that will boost the cooling efficiency and, consequently, the mill’s productivity. Another special feature of the new cooling bed will be a turning device designed to turn I and H beams through 90 degrees into or out of the upright position. This device will further increase the through-put rate of these products. The planned revamp will enable Celsa Barcelona to add HEA y HEB de 600 to its portfolio and further enhance its production efficiency.
The work on the straightening machine is planned to be performed during the 2020 summer break. The new cooling bed is to be installed and commissioned during the 2021 summer break.
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Dr. Florian Geiger will take over as CEO of the bright bar producer Steeltec on January 1, 2020. Source: Steeltec
From January 1, 2020, Dr. Florian Geiger will be the new CEO of the bright bar producer Steeltec. The graduate in business administration will take over from Gerd Münch, who is leaving the Schmolz + Bickenbach Group. Until 2013, Geiger worked as a management consultant in the field of efficiency improvement for international companies. He then moved to the Schmolz + Bickenbach Group, where as Vice President Business Development he was responsible for strategic projects and mergers & acquisitions. (Steeltec)
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Ningbo Powerway Alloy Material, subsidiary of Ningbo Powerway Group, has contracted Amova, a company of SMS group, to supply a logistics system for the complete works complex at its Yinzhou site in China. Ningbo Powerway Group is an important producer of non-ferrous metals bars, wire rod and strips in the Chinese economic region. The finished products made from these primary materials are used for a wide range of applications in the electrical and electronic industry.
Logistics system for aluminium coils; Source: Amova
Amova designs a complete, all-encompassing logistics concept for the facilities in Yinzhou with the intention to assure maximum efficiency of the material flow. Amova is going to link all process stages from the raw material storage area down to the dispatch area, including the higher-level materials control and tracking systems. The containers, which are manually filled in the raw material storage area with scrap blends for the different copper alloys, will be transported to the melt shop by means of rail-bound vehicles. There the containers will be stacked for intermediate storage until they are taken to the melting furnace by crane. Operation of the crane will be fully automatic, including the emptying of the containers.
Downstream of the melting and milling shop, the strips are intermediately stored in the flat product storage area which will be served by an automatic gantry-type crane. Freely navigating vehicles will transport the strips from there to and between the downstream processing stages – rolling, annealing, cleaning, cutting and slitting – and finally to the buffer store from whether they are taken to the packaging area. The packaged finished products will be intermediately stored in an automated high-bay store until they are dispatched.
Optimized plant logistics
Amova is also going to supply two transfer cars, each designed to autonomously pick up or put down three
containers at a time and transport the three containers as a set from the filling area to the intermediate storage area of the meltshop. The supply scope additionally includes a fleet of six freely navigating vehicles for the transport of the coils and the scrap containers, two additional buffer storage areas equipped with automatic cranes, a coil stacking device for the annealing plant, and the automated high-bay store, which – depending on the type of stored items − can accommodate up to 2,064 pallets. Also the management software for the various storage areas, including an integrated material flow control system, is part of the supply.
Last but not least, Amova will be responsible for the implementation of the Level 1 and Level 2 automation. The WMS (Warehouse Management System) will be set up as a redundant server system with virtualization. Until the MES (Manufacturing Execution System) will have been commissioned, the input terminals of the WMS will be used for the exchange of information with the various processing and cutting lines, and with other important constituents of the production process (e.g. the storage and buffer areas, and the Vehicle Management System of the freely navigating cars). In addition to acquiring process and material data, the WMS performs functions such as material tracking and plant performance analyses, which may be used as a basis for the independent calculation of Overall Equipment Effectiveness (OEE). The use of customized and animated graphics will make the system user-friendly, as a matter of course, also via mobile devices.
Commissioning of the entire works logistics is scheduled to be completed by early 2020. (Amova)
Recently, at the production site of Brazilian steel producer ArcelorMittal Monlevade a 130-ton-hot-metal desulfurization station (DeS) and a new dedusting system supplied by Primetals Technologies commenced operation. The desulfurization station represents the first installation of Primetals Technologies combining a volumetric dosing device for Magnesium (Mg) and a pressure dispenser for Calcium Oxide (CaO). Low sulfur levels of lesser than 0,005% (50ppm) can be achieved, Primetals states. The consumption of desulfurization agents is significant reduced and processing times are reduced to less than 30 minutes compared to treatment in a torpedo car. The associated level 2 system supplied by Primetals predicts the end sulfur content with high accuracy, deviations of real from predicted value is below 5ppm on average. The dedusting system installed in the melt shop processes approximately 900,000 m3/h. A handling system for 130-t-hot-metals ladles was also part of the project. The new equipment is part of an expansion and quality improvement program at ArcelorMittal Monlevade.
Low sulfur level, significant reduction of desulfurization agents, short processing time
Volumetric dosing device for precise feeding of Mg with rates between 3 and 15 kg/min; Source: Primetals Technologies
For the desulfurization station, Primetals was responsible for the engineering, supply and advisory services for reaction and start-up. Equipment encompassed a volumetric dosing device for dosing of Mg, a pressure dispenser for dosing CaO, lance and injection systems, the material handling system, including an unloading station, silos for storage, and material transport. An important part of the project is the complete level 1 and level 2 automation system with process models, enabling precise process control and dosing as well as reliable prediction of end sulfur content. This allows for flexible and optimum injection ratios of CaO/Mg from 2:1 to 10:1. The co-injection takes places with fully decoupled control of the conveying of Mg and CaO. The DeS station is designed to operate with fluidized CaO or CaC2 (Calcium Carbide) as well. Pure Mono-injection of CaO or CaC2 is possible, too.
The volumetric dosing device has two collateral pistons for the continuous and precise injection of Mg. The Mg flow rate is determined by the piston speed only and does not depend on the pressure in the system – there is no interaction with the pressure dispenser. With this mechanical system, the conveying rate of Mg can vary in a wide range of 3 to 15 kg/min. Powder materials like lime and calcium carbide are injected via the high performance pressure dispenser. All installed valves and control devices are designed for highest safety standard.
The new desulfurization station from Primetals replaced an existing desulfurization preformed in torpedo cars, reducing both the consumption of desulfurization agents and processing times. In addition, the effort for cleaning of torpedo cars is also lowered, deslagging simplified and metal losses during deslagging reduced.
New dedusting system covers two BOF converters, the DeS and slag skimming stand as well as the HM mixer. Primetals engineered, supplied and installed charging coolers for BOF charging evacuation, pulse jet filters with eight chambers and a filter area of 11,270 m2, and two induced draft (ID) fans with a power rating of 1,500 kW each. The filtered dust is discharged to containers. A handling system for the 130-t-hot metal ladles completed the scope of supply, including ladles, a transfer car with integrated ladle tilting device and a deslagging machine. (Primetals)
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North Star BlueScope Steel cooperates with SMS group
A thin-slab caster of comparable design in operation; Copyright: SMS group
North Star BlueScope Steel, located in Delta, Ohio, U.S.A., has selected SMS group as the supplier for its new single-strand thin-slab continuous caster. The new casting machine will have a thickness range of 95 to 110 millimeters and a width range of 900 to 1,595 millimeters. It will allow North Start BlueScope Steel to increase thin-slab production from 2.2 million metric tons (2.4 million short tons) to over 3.3 million metric tons (3.6 million short tons) per year.
The modifications performed by SMS group to the existing casting strand – supplied by another manufacturer – and the ongoing maintenance of this equipment over the last decade differentiated SMS group for the supply of the new casting equipment. SMS group also developed a convincing, cost-efficient design that allows the new casting equipment to be interchangeable with the existing casting strand.
The scope of supply includes the complete cast floor equipment, including the ladle turret, the mold and the vertical-bending containment zone, and a pendulum shear to cut the strand into slabs.
To digitalize the casting process, SMS group is going to supply a range of innovative technology packages. The new casting machine will be equipped with X-Pact Width Control, X-Pact Solid Control that includes width-dependent air-mist secondary cooling and solidification control, Level 2 X-Pact Cast Optimizer and the HD mold monitoring system.
SMS digital will supply the SMS Data Factory digitalization package. The existing infrastructure will allow for immediate capability of data- driven Business Intelligence at the caster, allowing the caster data to be incorporated for ongoing enhancements in quality, production, and asset cost reductions.
The anticipated start-up of the new casting strand is set for 2021. (SMS group)
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Fives’ Stein Digit@l Furnace for long product reheating; Copyright: Fives
Fives has been awarded two strategical contracts to design and supply reheat- ing furnaces for Chinese steelmakers, both with very strict requirements on energy consumption and NOx emissions.
The first project covers an ultra-low NOx emission furnace to reheat long products, such as stainless steel bars, coils or wires for Yantai Walsin Stainless Steel, a subsidiary of Walsin Lihwa. Fives’ Stein Reheating WBF, a walking beam furnace, has a capacity of 85 tons per hour and will be equipped with the latest generation of AdvanTek burners, designed in France. The AdvanTek burners will guarantee energy efficiency and ultra-low NOx emissions, less than 100 mg/m3.
The second contract was signed with HBIS SHISTEEL – Shijiazhuang Iron & Steel Company within China’s HBIS Group for two reheating furnaces, each with a production capacity of 130 tons per hour. Fives’ Stein Digit@l Furnace, also a walking beam furnace, operating on natural gas equipped with patented wide flame burners and a combustion system with individual on/off control. The wide flame burners improve the crosswise and lengthways temperature profiles of the products, while the individual on-off control allows high thermal efficiency while reducing fuel consumption and NOx emissions. HBIS SHISTEEL is now relocating its steelmaking facilities 80 kilometers outside Shijiazhuang city to set up new standards for cleaner, more flexible and more efficient steelmaking in China.
The scope of both projects on EPC basis includes engineering, equipment supply, erection and commissioning, which will be completely executed by Fives Stein Metallurgical Technology (Shanghai), a Fives’ subsidiary in China. (Fives)
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Fabric filter at thyssenkrupp sinter plant makes progress
thyssenkrupp Steel in Duisburg: A crane is moving the 17 ton section of the filter into position. Copyright: thyssenkrupp
Since 2011, thyssenkrupp Steel has invested a total of around EUR 100 milion in a fabric filter project at its Duisburg site to clean the air from the sinter plant. The last of three fabric filters is scheduled to go into operation in spring 2020. In the course of the project another section of the filter has now been moved into position: with a weight of 17 tons, it took two 80- and 220-ton cranes to do the job.
The creation of dust in the sintering process is unavoidable, and electrostatic precipitators usually collect mostof this dust. thyssenkrupp claims it is setting new standards in air cleaning with its large fabric filters and collecting even the smallest dust particles.
The sinter plant in northern Duisburg consists of three belts. A fabric filter for the smallest belt has been in operation since 2011. The filter unit on the largest of the three belts was commissioned in 2017. Now it’s time for belt number three. “The fabric filter system in Duisburg is among the biggest and most effective of its kind in the world,” says project manager Tibor Hänsel. (thyssenkrupp)
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Thyssenkrupp’s climate targets in line with global climate agreement
The Science Based Targets initiative (SBTi) has approved thyssenkrupp’s climate targets. At the same time the organization has confirmed that thyssenkrupp is acting in line with the goals of the 2015 Paris climate conference, where the international community agreed to limit future global warming to well below two degrees.
The SBTi is a collaboration between CDP, the United Nations Global Com- pact, World Resources Institute (WRI) and the World Wide Fund for Nature (WWF). Its aim is to establish science-based climate targets as standard business practice, by defining and promoting best practice in science-based target setting. To this end, the targets defined by companies are subject to an extensive independent assessment based on the latest climate science. There are currently only 10 German companies whose climate targets have been approved by the SBTi.
Thyssenkrupp recently announced that it aims to become climate-neutral by 2050. To achieve this, the company has set two binding medium-term targets which have both been validated by the SBTi: Compared with the base year 2018, emissions from production and sourced energy (scope 1 and 2 greenhouse gas emissions) are to be cut by 30 percent. This target is in line with an emission reduction pathway of “well below two degrees Celsius”. (thyssenkrupp)
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SMS digital and Voith to push IIOT platform development
Voith and SMS digital, the digital subsidiary of SMS group, announce plans to bundle competencies in platform development. The aim of the cooperation is to offer platform services for their Industrial Internet of Things (IIoT) solutions. The two companies are joining forces to digitalize business with smart applications and efficiently share development resources and competencies.
The joint platform by SMS digital and Voith is easy to use by smartphone. Photo: Voith
The joint platform provides both companies the opportunity to use new applications across different industries in the other’s worldwide core markets and speed up the development process of customer-relevant applications. For example, SMS digital can introduce its digital product Smart Alarm more efficiently in Voith’s core markets and the process industries. Meanwhile, SMS benefits from Voith’s OnCumulus apps designed for production efficiency enhancement and asset management.
While most of the platform services are industry-independent and can be jointly used by both companies, some that are app- or industry-specific will be reserved for the respective company. The customer gateways MyVoith and mySMS group still remain the central and cross-sector contact points for customers, partners and suppliers of each company. Additionally, these gateways serve as company-specific access points to the respective IIoT applications. The platforms and applications are accessible via all common mobile devices.
Building on deep domain knowledge in their respective industries, both the Voith Group and SMS group make effective use of these competences, developing highly efficient digital applications specifically for their customers’ needs. Both companies share not only this common background, but also a common vision. “Together, we provide platform solutions and technologies for the digital age that offer real added value to our customers,” states Dr. Benedikt Hofmann, CTO Voith Digital Ventures.
“SMS digital identifies and develops innovative products for the metals industry and we are very pleased to have the opportunity to take a further step in the digital transformation of key global industries together with Voith,” says Prof. Dr.-Ing. Katja Windt, CDO, SMS group GmbH. (Voith)
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Björn Rosengren, President and CEO of Sandvik, will leave Sandvik as of 1 February 2020. He will join ABB on February 1 2020 as Chief Executive Officer (CEO) and succeed CEO, Peter Voser, in this role on March 1 2020. At that time Peter Voser will revert to his position at ABB solely as Chairman of the Board. “Björn Rosengren has, since he joined Sandvik in November 2015, established a solid decentralized business model for the company and made the organization more flexible and efficient,” says Johan Molin, Chairman of the Board for Sandvik. “This has not been an easy decision. Sandvik is a great company with a lot of future potential and I will continue to lead the organization with a strong commitment until end of January”, Rosengren comments. (ABB)
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