SMS group Press releases2020-06-04T22:58:41+02:00 /typo3conf/ext/bm_atomfeed/Resources/Public/Logo/smsgroup_logo.png <![CDATA[MMK and SMS group managed to implement targeted commissioning despite extremely difficult conditions]]> 2020-06-04T15:36:21+02:00 2020-06-04T15:29:00+02:00 Example of an extraordinarily good cooperation

In 2018, Magnitogorsk Iron & Steel Works (MMK), Russia, has awarded an order to SMS group covering the extensive modernization of the finishing mill mechanical equipment and the fundamental revamp of the electrical and automation system of hot strip mill 2500 at the Magnitogorsk site. The modernization of the hot strip mill, established in the 1960s and supplied by a Soviet manufacturer, was scheduled to be implemented during several shutdown periods until mid-2020.

Within the modernization scope, SMS group equipped the finishing stands with new hydraulic adjustment systems and work roll bending systems. These powerful actuators enable MMK to produce strips within close geometrical tolerances. In addition, SMS group installed new equipment for changing work and backup rolls and a new high-pressure hydraulic system for the finishing stands. The modernization allows MMK to expand the portfolio of the plant, to improve product quality and reduce operating and maintenance costs. The rolling mill capacity will rise by 500,000 tons per year.

Also part of the large-scale project was a completely new X-Pact® automation system from SMS group, which was first installed in the SMS group test center for testing and pre-optimization under realistic conditions in line with the Plug & Work concept. The automation system includes basic automation elements and process models such as X-Pact® Pass Schedule Calculation for roughing and finishing stands, the Profile, Crown and Flatness Control X-Pact® PCFC, the X-Pact® Cooling Section Control model for strip cooling, a pacing system for the entire hot strip mill, the X-Pact® Vision operating and visualization system as well as a wide range of measuring equipment.

SMS group furthermore renewed the drive technology of the finishing mill and supplied six main drives including converters, two new spur gears and six mill pinion gear units as well as new drive spindles.

The revamp strategy provided for the modernization to be implemented during several shutdowns until mid-2020. Due to the present crises caused by the COVID-19 pandemic, great demands are made on all parties, not least the companies fighting to maintain the economic performance, and hence for a speedy return to normality.

MMK used the lower sales volume to be expected due to the crisis and decided, at the end of February 2020, to realize the great repair shutdown in its hot strip mill 2050 despite adverse circumstances and while respecting the health measures required by law.

Existing travel restrictions in Russia and the European Union presented additional obstacles. However, at the end of March, based on an almost 100-year-old trusting relationship, the CEOs of both Management Boards agreed per video conference to initiate allnecessary steps to procure, by means of special permit, visas for a group of selected experts and to grant them entry to the region by charter flight. The group was joined by a team from GE Power

Conversion, the supplier of the main drive converters and a long-term partner of SMS group, who provided maximum support in this situation.

In cooperation with customer MMK, additional options for remote support and augmented reality assistance were implemented. Thanks to the infrastructure established with the X-Pact® Service Portal, the customer could contact software experts and technologists at numerous SMS group locations for the solution of his problems.

Both, work performance and the smooth handling of the project have only been possible thanks to the trusting cooperation of all parties involved. So, SMS group would like to take the opportunity to express its sincere thanks here.

<![CDATA[Garner Aluminium Extrusions awards FAC to SMS group for HybrEx<sup>®</sup>35 extrusion line]]> 2020-05-28T12:15:57+02:00 2020-05-28T12:07:00+02:00 Higher productivity and energy efficiency with hybrid drive concept for aluminum extrusion presses

Garner Aluminium Extrusions, also known as Garnalex, based in Denby, United Kingdom, has awarded SMS group  the final acceptance certificate for the extrusion line it supplied. Together with OMAV S.p.A, consortium leader SMS group installed an integrated line with the HybrEx®35 as the core machine. OMAV S.p.A supplied a billet heating system with billet furnace and billet saw, a runout system including an intensive profile cooling station, a profile stretcher, and a finishing saw. The addition of an ageing furnace rounds off the production chain.

The company, founded in 2018, plans to use the new press to manufacture aluminum profiles for a fully integrated door and window system. "The philosophy of our newly established business is to offer excellent products at high quality standard and competitive prices. With this HybrEx® extrusion line, we are not only investing in advanced technology from the market's leading plant constructor, but also benefiting from lower investment costs at the same time," emphasizes CEO Roger Hartshorn.

The new HybrEx® technology will enable Garner Aluminium Extrusions to boost its productivity by up to 20 percent, depending on the relevant application, and to continue manufacturing high-quality products for its customers in an environmentally-friendly and resource-efficient way thanks to significantly lower energy consumption levels. With the hybrid drive concept developed for the HybrEx® extrusion press, the hydraulics are only used to generate the required forming forces. The ancillary movements of the extrusion press are performed by dynamic, electric servo drives.

The installed HybrEx®35 is capable of extruding billets with a diameter of up to 9" (228.6 millimeters) and a maximum length of 1,400 millimeters to produce aluminum and aluminum alloy profiles. The aluminum billets are loaded quickly and precisely into the center of the press using a patented linear loader. What’s more, the HybrEx® boasts a deflection-resistant, three-part triple-layer counter beam and patented precision guide for the container and moving crosshead, thus enabling the production of high-precision profiles with extremely thin walls. Its really compact design is possible thanks to the hydraulic system concept developed for the HybrEx®. The entire hydraulic drive unit has been integrated in the machine's soundproof enclosure. The enclosure design not only looks state-of-the-art, it also takes into account all aspects of operational safety while also ensuring better machine accessibility.

<![CDATA[SMS group to supply two annealing and coating lines for electric steel strip to Shougang in China]]> 2020-05-27T16:14:05+02:00 2020-05-27T16:01:00+02:00 Non-grain-oriented electric steel strip

Shougang Zhixin Qian’an Electromagnetic Material, China, has awarded an order to SMS group for the supply of two annealing and coating lines for electric steel strip. The lines will expand the annual production capacity of fully-finished non-grain- oriented electric steel strip with high silicon content at the existing production location in Hebei province by 360,000 tons. In both annealing and coating lines, the internal microstructure of the cold rolled material will be adjusted during the annealing process and the material then be provided with an insulating layer. The steel will mainly be used for the production of motors and generators to meet the increasing demand for efficient and effective electrification in China. SMS group is thus making a contribution to the mobility of the future. The contract was completely negotiated and concluded via digital media, due to travel restrictions. Commissioning of the lines is scheduled for 2022.

In addition to designing the mechanical and process equipment and to the manufacture of various core components, SMS group’s supply package also includes the supervision of part of the local manufacturing scope and of equipment installation and commissioning. Furthermore, SMS group is to supply the electrical and automation system.

Due to its magnetic properties, electric steel strip, also called silicon steel strip, is widely used in electrical engineering. With its advantageous magnetic properties, it contributes to improve the energy efficiency in electrical systems and thus helps to save resources. In non-grain-oriented strip, the grain orientation is irregular so that the material features isotropic properties. It is therefore used in rotating machines such as electric motors and generators. The material is especially used for electric vehicles, where high-quality electric steel strip determines the efficiency of the drives.

In both lines, the process includes cleaning, annealing, coating and drying of the material. Therefore, the lines will feature, besides the terminal equipment, cleaning sections, annealing furnaces, coating sections and drying ovens. The terminal equipment will comprise entry and exit sections as well as horizontal loopers.

<![CDATA[Salzgitter Flachstahl places order with SMS group for upgrade of No. 1 and 2 coilers in Salzgitter hot strip mill]]> 2020-05-19T14:09:37+02:00 2020-05-19T14:04:00+02:00 Increased productivity and improved plant safety

Salzgitter Flachstahl GmbH has awarded SMS group the order to upgrade the Salzgitter hot strip mill. This revamp concerns the coiler section of the hot strip mill (HSM), which has been in operation since 1963. The main objectives of the modification of the No. 1 and 2 coilers are to increase pinch roll life and dramatically reduce the maintenance requirement of the pinch roll unit. During its 57 years of operation, the HSM has been systematically modernized, keeping it continuously at the state of the art. SMS group has actively supported this process as supplier and technology partner.

About ten years ago (2010 to 2011), for example, SMS group carried out essential upgrading work on various sections of the HSM, including the installation of a third hot strip coiler, configured as a UNI plus coiler. This coiler is capable of coiling pipe grade strip up to 25.4 millimeters thick. This and the other measures implemented during that upgrade boosted the hot strip mill’s productivity and product quality.

Salzgitter Flachstahl GmbH’s experience with the latest No. 3 coiler has been excellent. Particularly, the maintenance effort is very low, among others thanks to the polishing devices integrated into the pinch roll unit. The polishing devices keep the pinch rolls clean, thus significantly reducing maintenance in this area. Manual grinding, for example, is usually no longer required. Salzgitter Flachstahl GmbH now intends to transfer these benefits also to its hot strip coilers 1 and 2.

For these coilers, SMS group is now supplying new rocker arms equipped with the latest generation of polishing devices. For the bottom pinch rolls, new polishing devices will be fitted to the pinch roll housings. The existing switch gates will be equipped with hydraulic position and force controllers. This integrated solution will increase the life of the pinch rolls and significantly reduce pinch roll maintenance.

SMS group's scope of supply includes the delivery of the mechanical components, the X-Pact® electrical and automation systems, and the installation of the equipment.

To minimize interruptions during ongoing production, the revamp will take place in 2021 during the main scheduled maintenance shutdowns.

<![CDATA[Second copper cold rolling mill from SMS group started operation at Jintian Ningbo Copper]]> 2020-05-07T16:28:06+02:00 2020-05-07T16:18:00+02:00 Intermediate and finish rolling in one and the same mill

SMS group has commissioned another new copper cold rolling mill at the Chinese copper manufacturer Jintian Ningbo Copper Co., Ltd. in the Chinese province of Jiangsu. The plant is designed for intermediate and finish rolling of cold strip made of copper and copper alloys. The success is linked seamlessly and quickly to the start of production of the breakdown mill in mid-March 2020. With this, Jintian Ningbo Copper Co., Ltd. has increased the production capacity by further process levels.

Intermediate and finish rolling is carried out by the new reversing cold mill in CVC®plus six-high design. The maximum strip width is 650 millimeters with a maximum ingoing thickness of up to 3 millimeters. The minimum strip thickness that can be achieved with this rolling stage is 0.1 millimeters as a final product or as semi-finished product for further processing.

The six-high cold rolling mill is provided with the latest rolling technology, which offers maximum flexibility in production planning and ensures excellent quality for the rolled products. Beside the hydraulic adjustment system, the proven CVC®plus technology (Continuous Variable Crown) for the precise setting of the roll gap is applied. Work roll shifting combined with the positive and negative work and intermediate roll bending ensures precise and economically efficient rolling operation. The exit side multizone cooling system finalizes the flatness results at high level.

The X-Pact® electrical and automation system from SMS group performs rolling process control and monitoring. Among other things, it includes Level 2 which is perfectly matched to the plant type and the product portfolio.

SMS group also supplied the fluid power systems. A Multi-Plate® filter ensures sustainable cleaning of the rolling oil.

The next important milestone will be reached in mid-May; the third cold rolling mill is scheduled to go into operation at that time. Jintian Ningbo Copper Co., Ltd. is already very satisfied with the performance of SMS group, which was delivered in a particularly challenging time.

<![CDATA[New Jintian Ningbo Copper cold rolling mill commissioned in China]]> 2020-04-03T14:42:56+02:00 2020-04-03T14:37:00+02:00 Extraordinary challenges mastered successfully

On March 19, 2020, SMS group successfully commissioned the new copper cold rolling mill of the Chinese copper manufacturer Jintian Ningbo Copper Co., Ltd. in the province of Jiangsu.

Against the background of the restrictions due to the current global spread of the COVID-19 virus, the commissioning was an extraordinary challenge successfully mastered in close partnership between the teams of SMS Siemag Technology Co., Ltd., China, and Jintian Ningbo Copper Co., Ltd.

The four-high reversing cold mill is used for the pre-rolling/roughing of thick strips with a maximum width of 650 millimeters and a maximum entry thickness of 18 millimeters. The copper and copper-alloy strips are transported as wound coils with variable inner diameters to the cold rolling mill and placed in the provided payoff stations.

Due to the great variability of the strip gauge, the payoff and recoiling stations consist of a combination of coiler gear and coiler drum of various reel diameters. The finished strips are wound onto the coiler drum and transferred to the downstream processing stations.

Maximum economic efficiency in processing the high-quality material is assured by the yield-maximizing SMS group design of the cold rolling mill. Proven actuators, as hydraulic roll adjustment, positive and negative work roll bending and multizone cooling, for example, assures the achievement of the required minimal strip thickness of 0.5 millimeters and the demanded high strip quality.

The complete scope of SMS group’s order from Jintian Ningbo Copper includes two further copper cold rolling mills, which will be brought on stream in the next few weeks.

<![CDATA[Successful INBA<sup>®</sup> Plant Reline at Rogesa’s Dillingen No. 4 Blast Furnace]]> 2020-03-23T14:38:21+01:00 2020-03-23T14:29:00+01:00 AG der Dillinger Hüttenwerke (Dillinger) and Paul Wurth completed recently the modernisation of the slag granulation plant at Dillinger’s No. 4 blast furnace. Paul Wurth’s INBA granulation and dewatering technology has been operating there since its initial installation in 2003. It is a cold water system with steam condensation designed for a daily capacity of 1,600 tons of blast furnace slag sand and a maximum slag flow of up to 8 tons/min.

After 16 years of operation, the plant was relined by Paul Wurth and Dillinger between March and September 2019. A special focus of this modernisation was on the cooling tower area as well as on the hot water tank, allocated below the INBA dewatering drum.

For the customer, it was a crucial criterion to minimise the loss of BF slag sand to one monthly production only. Therefore, Paul Wurth came up with the idea to reline the complete cooling tower gradually during uninterrupted, regular production and to use the four granted stoppage weeks in August to modify the hot water tank with a new water recirculation concept, which inevitably demanded a complete shutdown of the granulation operations.

In a first step, the existing water distribution of the complete cooling tower underwent a provisional modification. This was done during a short stoppage of a few days and allowed, for later on, that each tower cell could be shut down individually, while the remaining cells compensated the water losses of the cell under renovation. These consecutive modifications were executed between March 2019 and August 2019. Paul Wurth was in charge of the engineering, supply and erection of the new water distribution system itself, installation of a new pipe collector and its connection to the existing piping as well as of noise reduction panels.

The four-week stoppage in August was used to completely substitute the lower part of the old hot water tank as well as the connected process water recirculation system by a new design. Further works during that time were to finish the reline of the cooling tower, as well as to modernise the water pump reservoir and replace its clogged coke filters downstream the said hot water tank. At the same time, the Dillinger executed in their own responsibility partial replacement of several staircase structures as well as refurbishment of the granulation tank and the hot slag runner. During these 4 weeks, in average 80 workers were present during 24/7 shifts.

Finally, in January this year, Paul Wurth and Dillinger successfully tested the contractual process guarantee parameters of cooling tower performance and plant availability.

Paul Wurth’s design represents a new, specific concept of the cooling tower as well as a new process water handling within the hot water tank. This remarkably reduces the amount of suspended solids entering the cooling tower with the process water. Furthermore and up from now, the cooling tower can be flexibly used, which means that Dillinger will be able to use each cooling tower cell independently. This includes the possibility to shut down or by-pass one cell, based on the current production and maintenance needs without reducing any granulation capacity.

Paul Wurth’s cold water granulation system with steam condensation, pollution control and the dynamic INBA® dewatering technique is an officially recognised Best Available Technology (BAT) in the steelmaking industry.

About Paul Wurth

Headquartered in Luxembourg since its creation in 1870, the Paul Wurth Group is an established technology provider for the primary stage of integrated steelmaking. Paul Wurth is a leading market player for the design and construction of complete blast furnace and coke oven plants. Direct reduction plants, environmental protection solutions and recycling technologies complete Paul Wurth’s product portfolio. With more than 1 500 employees and entities in around 20 countries, the Paul Wurth Group has a strong presence in the significant iron and steel regions of the world.

<![CDATA[Tata Steel India orders slab conditioning line from SMS group]]> 2020-03-19T16:49:10+01:00 2020-03-19T16:44:00+01:00 Meeting the automotive industry’s requirements on slab surface conditioning

Tata Steel India has awarded SMS group the order to supply a slab conditioning line (scarfing line) for its Kalinganagar works.

Full-surface scarfing is a surface removal process used for eliminating surface and subsurface defects in slabs. Several car manufacturers specify this treatment as a requirement for steel used in car body applications. The new scarfing line will enable Tata Steel to open a new market segment for its Kalinganagar works by meeting the requirements of the automotive industry in the future. The slab conditioning line to be supplied by SMS group will be designed for approx. 1.02 million tons per year of scarfed slabs within a width range of 1,000 to 2,150 millimeters.

The scarfing line will be installed in the slab yard of the existing slab caster shop. It will scarf cold and hot slabs. The line will comprise a two-side scarfing machine - for the simultaneous processing of the upper and lower slab sides - and an in-line slab inspection system. Slabs charged into the line will be scarfed in two passes. Subsequently, they will run through a surface inspection system which checks them for any imperfections or defects.

An interface linking the X-Pact® level 1 automation system of the slab conditioning line with the production planning system assures the receipt of feedback on every slab that leaves the line after the treatment and before any further processing. The slabs to be processed will come from two SMS group-supplied continuous casters: a two-strand slab caster commissioned in 2016, and a brand-new two-strand slab caster to come on stream during 2020.

SMS group will supply the complete mechanical and electrical equipment of the slab conditioning line, including slab handling equipment and a fume extraction system that incorporates a wet electrostatic precipitator. Commissioning of the slab conditioning line is scheduled for the first quarter of 2021.

<![CDATA[SMS group and Semiotic Labs sign collaborate agreement]]> 2020-03-18T08:47:41+01:00 2020-03-17T15:00:00+01:00 SMS group takes predictive maintenance to an entirely new level by employment of AI solution

Semiotic Labs, a scale-up company based in Leiden, Netherlands, and SMS group have signed an agreement under which the two companies will cooperate in the field of predictive maintenance.

The innovative AI-based (Artificial Intelligence) technology developed by Semiotic Labs uses electrical signals and the data fingerprint of AC motors and other rotating equipment to monitor and analyze the condition of critical plant assets and enable reliable and early prediction of developing faults. In contrast to traditional, vibration-based solutions, SAM4 developed by Semiotic Labs operates based on sensors installed directly in the control cabinet - not on the asset itself. This solution is particularly useful for the monitoring of equipment in service under rough operating conditions as typical in the metallurgical industry.

SAM4 has already been implemented successfully on numerous hot wide strip mills and other applications in steel plants throughout Europe. The convincing results achieved by SAM4 under such highly demanding in-service conditions and tests at the SMS group workshops led to the decision to make this technology part of the SMS product portfolio.

“We continuously aim at expanding and enhancing the functionalities and capabilities of our Genius CM® condition monitoring system for the metallurgical industry,” says Christoph Häusler, Vice President Comprehensive Service Products, SMS group. “The integration of SAM4 into our portfolio is a very important step towards this end.”

"As part of the agreement with Semiotic Labs, SAM4 will be integrated as an App into the MySMS platform,” explains Dr. Eike Permin, COO, SMS digital. Further it is planned to integrate SAM4 into Genius CM®, SMS group’s condition monitoring system. Also cooperation in the field of data analyses and joint development activities between the two companies are planned.

The cooperation will become another important element of SMS group’s strategy of supplying Smart Maintenance Solutions that help their customers maximize uptime. Thus strategic predictive maintenance based on condition monitoring will become much more reliable and efficient than maintenance strategies based on operating times. And it will increase the components' lifetime and overall equipment efficiency.

<![CDATA[SMS group completes general overhaul of the converter gas recovery system at JSW Steel]]> 2020-03-12T11:10:44+01:00 2020-03-12T10:59:00+01:00 Recovering energies from the converter process and efficiently converting them into electricity in the in-house power station

At its works in Vijayanagar, India, Jindal South West Steel has resumed operation of the converter gas recovery system after it had been completely overhauled by SMS group.

Over the past 15 years, the gas recovery system supplied by SMS group has recovered more than 360 million Nm³ per year of high-energy gas from the oxygen blowing process of the 120-ton converter and efficiently converted this volume into electricity in the in-house power station. Without such a recovery process, the gas would have been burnt at the flare stack and the energy contained in the gas would have been lost.

The gas recovery system provides significant energy savings and reduces the emission of the carbon dioxide greenhouse gas produced in the steelmaking plant by approx. 155,000 tons per annum.

The overhaul became necessary since the gasholder seal had reached the end of its service life after 15 years of safe operation and, therefore, had to be replaced.

The scope of supply of SMS group comprised the delivery of all crucial components and the supervision of installation activities. The plant is now ready again for efficient gas recovery, thus saving millions of tons of carbon dioxide from being emitted into the atmosphere.

<![CDATA[Nucor Corporation places follow-up order with SMS group for the supply of slab and ingot reheat facilities and two heat-treatment lines for plate]]> 2020-03-10T13:34:05+01:00 2020-03-10T13:25:00+01:00 Quality-enhancing heat-treatment technology from SMS group

Nucor Corporation has awarded SMS group a follow-up order for the supply of reheat and heat-treatment facilities. The new equipment will be part of the new plate mill being built in Brandenburg, Kentucky. Nucor had already ordered the supply of a slab casting machine for the new mill from SMS group in 2019. “We are excited to be working with SMS group to have them supply critical equipment for our new plate mill in Kentucky, and to install their heat treatment line that utilizes the MultiFlex-Quench®,” said Johnny Jacobs, Vice President and General Manager of Nucor Steel Brandenburg.

The new casting machine will become the largest slab caster in the world. It will produce slabs of 200 to 305 millimeters thickness and up to 3,150 millimeters width. The follow-up contract now received by SMS group is for all of the new plate mill’s slab and ingot reheat equipment, for a heat-treatment line for heavy plate of up to 356 millimeters thickness and for a continuous heat-treatment line with MultiFlex-Quench® technology for plate between 4.8 and 102 millimeters thickness and up to 4,267 millimeters width.

Under the new contract, SMS group will supply a wide range of equipment, including:

A walking-beam furnace for the transfer of slabs from the SMS group casting machine to the rolling mill. The furnace will be designed for slab direct, hot and cold charging. Slabs of the maximal possible length of 15,240 millimeters will be charged in a single row - shorter ones in two or three rows. As a highlight, the walking beam furnace will be fitted with SMS-ZeroFlame burners, which are characterized by extra-low NOx emissions.

For ingot reheating, SMS group is going to supply bogie hearth furnaces. These furnaces will be able to reheat ingots of various sizes.

The combustion process in all the reheat furnaces will be controlled by the proven, advanced SMS-PROMETHEUS® Level 2 technology.

Further to these supplies, SMS group’s contract volume includes additional bogie hearth furnaces and a quenching facility, which Nucor will be using for a wide range of heat treatments – from low-temperature annealing through to normalizing. The connected quenching tank with water circulation will enable Nucor to precisely set the specific mechanical properties in heavy plate.

SMS group is also going to supply a continuous heat treatment line incorporating a MultiFlex-Quench®, which will be arranged downstream of the rolling mill facilities. For hardening and normalizing, the plates will be heated in a high-temperature roller hearth furnace. The furnace will feature two chambers of different temperature ranges. The plates will be heated by radiant tubes in a nitrogen-based inert atmosphere. A large portion of the plates will be quenched or cooled to a defined temperature in the downstream MultiFlex-Quench®, providing Nucor extremely great flexibility in terms of cooling strategies. Switchable pressure ranges enable different cooling patterns, including slow cooling and quenching, and freely selectable cooling stop temperatures. This flexibility provides the possibility of producing a much wider range of products than would be achievable with a conventional quench. Especially when processing thin plates, the roller guides with hydraulic clamping devices will prove highly effective in achieving optimum product flatness.

A low-temperature furnace installed in the line will be used for plate tempering (warming-up). A specially designed gas recirculation system provides for optimal convection within the furnace chamber, resulting in maximum temperature uniformity.

The leveler integrated into the continuous heat-treatment line will be designed for plates of 4.8 to 25 millimeters thickness and a maximum plate temperature of 300 degrees centigrade. It will come with a roller actuation system that enables each leveling roller to be adjusted individually and the leveling strategies to be specifically tailored to the individual product. This assures minimum internal stresses and excellent flatness results. Thanks to the possibility of actuating all the rollers separately, optimum torque distribution is achieved.

SMS group will supply all equipment complete with the associated electrical and automation systems. This includes the motors and converters, all sensors and technological measuring systems, the complete Level 1 automation, and Level 2 process models.

The process model for the MultiFlex-Quench® is one of the quality-features SMS group will integrate in the heat-treatment line and which will play a key part in assuring the highest product quality. The target values for the product mix are set based on physical and mathematical models and temperature curves can also be simulated. The model adapts to the specific needs of production by optimizing process control accordingly. The model also promotes the development of new steel grades, as it enables simulations with varying parameters to be performed.

The Level 2 / Level 1 tracking system in the continuous heat-treatment line assures a continuous and smooth material flow and plate transport from the registration of the incoming material up to and including the discharge from the roller table to the dispatch area.

SMS group’s intuitive and ergonomically designed HMI concept ensures efficient control by operators with easy access to all relevant process information.

Commissioning of the plant is scheduled for 2022.

Nucor Corporation is the largest steel and steel products producer in the United States, with 27,000 teammates working safely at 25 steel mills and more than 300 operating facilities throughout North America. Last year, Nucor’s revenues exceeded $22.5 billion, and the company shipped more than 26.5 million tons of steel and steel products to outside customers. Nucor is also North America’s largest recycler, using scrap steel as the primary raw material in producing its steel and steel products. In 2019, the company recycled approximately 20 million net tons of scrap steel.

<![CDATA[Eurometal reduces ecological footprint by installation of high-efficiency multi-chamber aluminium melting furnace from Hertwich Engineering]]> 2020-03-06T16:12:01+01:00 2020-03-06T16:04:00+01:00 Casthouse expansion in Klomnice, Poland

Eurometal S.A., a company of the Eko-Świat group, has placed an order with Hertwich Engineering for the supply of an Ecomelt-PR100 multi-chamber melting furnace for the expansion of its aluminium casthouse in Klomnice, Poland. The plant, with a capacity of 30.000 tons per year, is scheduled to start operation in spring 2021. Hertwich Engineering, based in Austria, is a company of SMS group.

This year, Eurometal S.A., founded in 1990 as Eko-Świat, celebrates its 30th anniversary of market presence as a powerful supplier of high-precision rolled aluminium products (coils, strips, sheets), extrusion profiles, tubes, machined components and foundry alloys for the automotive industry.

The company operates three locations in Poland, which are being continuously extended and modernized to expand the market position of Eurometal S.A. within the automotive, transport, construction and electronics industries as well as on the market for renewable energy.

At its locations in Stalowa Wola and Bogumilow, Eurometal S.A. operates casthouses for the production of strips, extrusion billets and automotive alloys. In addition, Eurometal S.A. operates a cold rolling mill, strip processing lines and several extrusion presses. The placement of the order for the new Ecomelt PR-100 multi-chamber melting furnace is part of an extensive investment strategy aimed to increase the production capacity at the existing casthouse in Klomnice.

The low energy consumption values and the low emissions of this new melting furnace will reduce the ecological footprint of the Eurometal Group.

State-of-the art recycling furnace

Eurometal S.A. has chosen a multi-chamber melting furnace with preheat ramp designed for a capacity of 100 tons per day (approximately 30.000 tons per year). The furnace will be integrated into the existing production chain – beginning with scrap recycling through billet casting and extrusion down to machining of components. This furnace type is best suited for the melting of loose scrap with moderate organic content.

The new melting furnace will mainly process clean and painted extrusion and sheet scrap as well as smaller amounts of briquetted sawing and machining chips. To achieve the required alloy composition, charged material will be supplemented by clean primary and secondary aluminium as needed. Also liquid metal from crucibles can be added.

Scrap will be charged partially loose, shredded or briquetted onto the dry ramp in the melting chamber by means of a rail-guided charging machine. During the charging process the working environment is protected from the furnace atmosphere.

The scrap will be preheated for around 30 minutes to a temperature of approximately 500 degrees Celcius by an intense hot-gas flow. Thereby organic compounds are transformed into combustible gases to support the heating system of the main chamber. This way (using suitable scrap), some 50-70 percent of the energy otherwise supplied by natural gas can be substituted by the energy content of organic compounds.

After preheating, the decoated material is pushed from the ramp into the melting bath in the melting chamber. At the same time, the next scrap charge is placed onto the ramp by the charging machine. In the melting chamber, scrap is melted by the submerge-melting process to avoid oxidation and melt losses. An electromagnetic side channel pump provides the melt transfer between both furnace chambers as well as an adequate melt circulation in the main chamber to assure uniform temperature and alloy distribution.

Subsequently, the melt is transferred to the holding furnaces or crucibles by means of an electromagnetic tapping pump.

Additionally, Hertwich will supply a rail-guided skimming machine as well as a flue gas treatment plant to comply with emission regulations in place.

When the melting furnace, including the auxiliary equipment, will have started operation in spring 2021, Eurometal S.A. will own a state-of-the-art recycling plant that can be operated by one operator per shift (including charging, skimming and melt transfer). Along with the low energy consumption values (450 to 550 kWh/ton) and the notable, high-quality metal yield, this plant provides significant economic advantages.

<![CDATA[dnata awards AMOVA contract for the construction of a new cargo terminal at Manchester Airport]]> 2020-03-05T16:47:07+01:00 2020-03-05T16:39:00+01:00 Logistics and automation from one source

dnata, one of the world’s largest airport services provider, is moving its air cargo handling operations at Manchester Airport to a new purpose-built facility, the the “dnata City Northˮ cargo complex. After Heathrow, this is the second largest cargo terminal of dnata in their United Kingdom network. To make the new terminal fit for the future, dnata invested in an intensive planning phase. AMOVA, a company of SMS group, has developed an innovative concept which also takes future requirements of the facility into account.

AMOVA will supply the entire logistics system for the “dnata City Northˮ cargo complex. The heart of the new facility is a 15ft Elevating Transfer Vehicle (ETV) with a split roller deck. This universal vehicle can store and retrieve two 5ft ULDs (Unit Load Device) independently and additionally route 20ft ULDs through the racking system.

A special feature is located on the airside of the terminal, where the customer uses truck docks, which, thanks to their special design, also enable the use of dolly trains. On the land side, truck docks are planned to serve the Road Feeder Service (RFS). The facility is completed by several motor-driven roller decks, various work stations and cold storage cells for pharmaceutical products.

Besides the complete automation, AMOVA also supplies the WMS (Warehouse Management System), in cooperation with its long-standing partner Unitechnik. The WMS ensures an optimal material flow and coordinates and controls all transport orders of the ETV, the express line, the work stations and the truck docks. In addition, the WMS realizes the backup function of ULD identification should the higher-level Cargo Management System (CMS) fail. The WMS supports the operators with animated real-time visualization of the status of the automated transport equipment and the ULDs.

As a global technology leader in intralogistics, AMOVA supports the fast-growing trading market with its continuous development of technological advancements and innovations. This strategy combined with AMOVA’s air cargo expertise convinced dnata of AMOVA’s capability of handling this project. The contract was signed in November 2019, assembly will start as early as summer 2020 and the handover of the operational terminal is planned for late 2020.

<![CDATA[SSAB Relies on Paul Wurth Service for Strategic Renewal Project in Luleå]]> 2020-03-05T16:08:07+01:00 2020-03-05T15:56:00+01:00 EMISSION REDUCTION & COKE OVEN BATTERY LIFE EXTENSION

On 31 January 2020, SSAB EMEA AB has chosen Paul Wurth’s service team to carry out, on EPC basis, a revamp of its coke oven battery at Luleå steel works in northern Sweden, which focuses on battery life extension and emission reduction.

In line with the group’s motto to be a Leading Partner to its customers, Paul Wurth has first supported SSAB with a detailed feasibility study, which defined the most appropriate implementation scenario to extend the battery life. Secondly, SSAB being a front runner in environmental compliance, asked Paul Wurth as a leader in emission abatement for coke plants to study also the application of best available technology (BAT) in the frame of the revamp in order to come to furtherly cut emissions and improved coke quality.

In the successfully developed feasibility study, Paul Wurth included its patented technology of the Single Oven PREessure Control (SOPRECO®) system for emission reduction, evaluated the best implementation scenario for removing existing design constraints in relation to the by-products plant and, thus optimised the overall project cost taking into account both capital and operation expenditures along with minimum production losses.

As this proposal fitted into SSAB’s strategy, Paul Wurth was awarded the order in result of the subsequent official bid. This covers the replacement of the entire raw gas system including ascension pipes, goosenecks, the SOPRECO® system, gas collecting main (GCM) and off-takes. Furthermore, taking the occasion of empty ovens during GCM replacement, Paul Wurth will also renew the battery ovens roof by replacing the rails for charging machines, transversal tie rods and some refractory layers.

Since the Scandinavian conditions in wintertime are extreme, the replacement works will be carried out in two steps: preparation activities to remove any existing constraints will take place in summer 2020, followed by the main intervention for replacing equipment in summer 2021. Thanks to Paul Wurth’s approach tailored to SSAB’s specific needs, this intervention will lead the 54-ovens coke battery at Luleå to an extended and environmentally friendly life cycle, thus promoting future sustainability.

About Paul Wurth

Headquartered in Luxembourg since its creation in 1870, the Paul Wurth Group is an established technology provider for the primary stage of integrated steelmaking. Paul Wurth is a leading market player for the design and construction of complete blast furnace and coke oven plants. Direct reduction plants, environmental protection solutions and recycling technologies complete Paul Wurth’s product portfolio. With more than 1 500 employees and entities in around 20 countries, the Paul Wurth Group has a strong presence in the significant iron and steel regions of the world.

<![CDATA[Two new Multi-Plate<sup>®</sup> filters from SMS group enhance efficiency and sustainability of rolling operations at Hydro Aluminium]]> 2020-03-04T15:14:28+01:00 2020-03-04T15:01:00+01:00 Efficiency increase after conversion of rolling-oil filter system

Hydro Aluminium Rolled Products GmbH, a company of global Hydro Group, operates a facility for rolled aluminium products in Grevenbroich, Germany. There, SMS group has replaced two existing plate-type filters for the cleaning of rolling oil from aluminium foil production with new Multi-Plate® filters of types MPF 3-13 and MPF 3-16. Multi-Plate® filters from SMS group assure high efficiency and sustainability in rolling oil cleaning.

During the supplier selection process, SMS group stood out not only thanks to its high-quality filter technology, but also thanks to its highly convincing conversion concept, capable of complying with the very tight project schedule, even under the challenging space conditions on site.

After an installation time of only two weeks, both new filters were put into operation. The customer was very pleased with the implementation of the project.

The limited space available on site called for the successfully preassembled and function-tested Multi-Plate® filters to be dismantled again in parts at SMS group’s manufacturing facilities in Hilchenbach and shipped to Hydro in modules.

<![CDATA[Five-strand caster supplied by SMS Concast successfully commissioned at Saarstahl AG, Germany]]> 2020-02-20T15:55:04+01:00 2020-02-20T15:43:00+01:00 Performance Modules enable the production of high-grade steel products

At their steelplant in Völklingen, Germany, Saarstahl AG has successfully commissioned a new five-strand billet caster, supplied by SMS Concast, a member of SMS group.

The caster is designed for a nominal annual production of 850,000 tons and the casting of 180-millimeters-square billets.

The new five-strand continuous casting machine – called S1 by Saarstahl AG – is equipped with latest technological features such as CONVEX molds, hydraulic mold oscillators, mold and strand electro­magnetic stirrers, mechanical soft reduction and an electrical & automation system prepared for the full implementation of Industry 4.0. The S1 casting machine at Saarstahl is the first caster in the world designed with mechanical soft reduction (MSR) technology for a billet cross section of 180 millimeters square. It produces billets in a wide range of steel grades, including bearing steel, spring steel, cold-heading and free-cutting steels.

Saarstahl AG was the first manufacturer in the world to apply mechanical soft reduction in billet casting. With the new S1 caster, Saarstahl AG is now even better positioned to further strengthen its leading position in this technology and to successfully cope with the volatile and increasing market demands.

In addition to the technological features, the caster is equipped with a complex discharge system, with a turnover cooling bed equipped with a forced cooling system to cool the billets down to 100 degrees Celsius.

Saarstahl AG is a world-leading producer of high-grade steels. The company has cooperated with SMS Concast AG for many years. In 2003 and 2008, SMS Concast had already supplied two casting machines to Saarstahl AG.

<![CDATA[Xinjiang Amer Qian Golding Cable has ordered a CONTIROD<sup>®</sup>*copper wire rod plant from SMS group]]> 2020-02-17T15:44:59+01:00 2020-02-17T15:38:00+01:00 High production output, efficiency and quality in the production of copper wire

Xinjiang Amer Qian Golding Cable Co., Ltd. from China, a subsidiary of Amer Group, has placed an order with SMS group for a CONTIROD®* casting and rolling plant to produce copper wire. In total, the new CONTIROD®* plant of the CR-3500 type has been the fourth plant for the Amer Group over the last decade. The new plant is destined to be installed at the Urumqi location in the Xinjiang Province. The technological know-how of SMS group’s copper specialists and the proven plant concept were the decisive factors for the order.

The high-performance wire rod line CR-3500 is designed for the production of up to 35 tons of ETP copper wire per hour corresponding to an annual production output of about 225,000 tons. ETP copper wire (Electrolytic Tough Pitch) serves as starting material for the production of conductors for the electronic and electrical industries. With the new CONTIROD®* plant, Amer Group expands its production capacities to meet the demand in the western Chinese regions consolidating its position as one of the leading Chinese wire rod producers.

The CR-3500 for casting and rolling copper wire in one process is modularly structured and consists of a shaft melting furnace, a holding furnace, a twin-belt caster, a twelve-stage rolling mill with separate individual drives, a deoxidation and cooling section as well as a wire coil station, strapping unit and foil packaging plant.

For the CONTIROD®* CR-3500 SMS group employs state-of-the-art technologies, for example Lambda control on the shaft furnace, frequency-controlled three-phase drives, and deoxidation and cooling line with separate media circuits. The above features enhance the comprehensive process efficiency while product quality is improved at the same time. Fuel, working material and power consumption can be significantly reduced. As a result, CONTIROD®* is marked with the SMS group ecoplants label.

In addition to the proven Lambda control, an improved charging and distributing system for cathodes and return scrap is employed on the shaft melting furnace. This technology minimizes the consumption of natural gas by efficient heat transfer and increases product quality.

Molten copper is continuously cast in an almost horizontal way via the Hazelett twin-belt caster to a casting ingot with a cross-sectional area of 6,510 square millimeters. A homogeneous casting structure and an even oxygen distribution in the casting ingot are key factors for a high-quality wire rod. A chamfer plane and a spraying unit optimally prepare the casting ingot for the additional rolling process.

In the rolling line with altogether twelve individually driven mill stands the rectangular casting ingot is rolled down to eight millimeters round wire. Due to a specific force control from the individual mill stands, a top wire quality with fine-grained homogeneous rolling structure can be attained.

In a two-stage deoxidation and cooling section a water-alcohol solution first of all reduces the oxide layer on the wire rod surface. In a second step the wire rod is cooled down with water until a configured target temperature is reached. A laser measuring system controls the final diameter of the finished wire rod.

In a wire coil station with automated strapping unit and foil packaging plant the finished copper wire is prepared for further transport. A previously applied wax coating ensures that an oxidation process by ambient air is prevented.

The CONTIROD®* CR-3500 is scheduled to go on stream at the end of the second quarter in 2021.

*CONTIROD® is a registered trademark of Aurubis Belgium.

<![CDATA[CELSA Barcelona places order with SMS group for modernization of medium-section mill]]> 2020-02-06T15:24:14+01:00 2020-02-06T13:32:00+01:00 Revamp expands product range

CELSA Barcelona has contracted SMS group to revamp the section mill at its Castellbisbal location in Spain.

Since 2000, CELSA 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. SMS group first expanded the initial range of products rollable on the mill during a revamp in 2007. Continuous plant optimization in cooperation with SMS group 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 and HEB up to 600 to its portfolio and further enhance its production efficiency.

Before placing this modernization order, CELSA Barcelona contracted SMS group with a study to determine the investment amount to add the new product sizes and SMS Concast with the order to add a further strand to the continuous casting machine that would enable the casting of heavier beam blanks for the larger cross-sections to be rolled in the future. That project was completed at the end of 2019.

The work on the straightening machine is planned to be performed during the 2020 summer break. The new cooling bed will be installed and commissioned during the summer shutdown of 2021.

The upcoming project continues the longstanding and successful cooperation between the two companies.

CELSA Group operates various steel production facilities. At Castellbisbal, in the province of Barcelona, Spain, CELSA has been active since 1967. The facilities today comprise an EAF meltshop, a bar rolling mill, a wire rod mill and a medium-section mill. Annual production totals 2.4 million tons.

<![CDATA[SMS group to replace the largest converter in North America at ArcelorMittal Dofasco, employing latest technological features]]> 2020-01-31T15:33:08+01:00 2020-01-31T15:18:00+01:00 ArcelorMittal Dofasco (AMD), Canada, has awarded SMS group Inc. the contract to supply a replacement 320-ton KOBM converter and gear drive for its steel making plant in Hamilton, ON, Canada. The converter at ArcelorMittal Dofasco is the largest basic oxygen converter in North America.

The project goals are to replace the existing equipment, which is approaching its end of life, with new equipment incorporating the latest technological developments. One featured technology is the unique SMS group electro-hydraulic torque compensator, which is a system that actively reduces the resultant forces generated by highly dynamic bottom blown converters. This will reduce the dynamic loading on the entire system, with resulting increases in availability and life.

The patented SMS group torque compensator has been designed to operate with both the existing and new gear reducers. The new torque restraint system will be installed and fully commissioned on the reducer for the existing converter, during a vessel reline outage in May 2020. It will then be incorporated into the new reducer during the complete converter replacement, scheduled for the second quarter of 2021.

The overall project scope of supply includes the converter vessel, trunnion ring, the proven lamella-type vessel suspension system, trunnion bearings, gear reducer, hydraulic torque compensator system, the X-Pact® electrical and automation systems for the compensator, and supervision of erection and commissioning.

The high-performance gearbox, manufactured at the SMS workshop in Germany, will be designed for high reliability and a long service life under tough operating conditions. The gearbox will be equipped with a main gear having an optimized case hardening depth. With a diameter of 3,500 millimeters (137.8 inches), the main gear will be one of the largest applied in a converter drive system in the world. The advanced gear design results in a superior contact pattern in all loading conditions.

SMS group will ship the complete vessel and trunnion ring assembly in one piece, considerably reducing the overall assembly effort on site.

At the Hamilton plant, AMD annually produces 4.5 million net tons of high- quality steel used in a wide range of industries, including the automotive, construction, manufacturing, packaging, distribution and tubular segments.

<![CDATA[SMS group presents innovations, technology and services for the tube and wire industry]]> 2020-01-29T14:04:29+01:00 2020-01-29T13:47:00+01:00 Tube & wire 2020 in Düsseldorf, Germany

At the international trade fairs "Tube" and “wire”, taking place in Düsseldorf from 30 March to 3 April 2020, SMS group is going to present new plant concepts and innovations that meet the future demands of the tube and wire industry. Visitors to the SMS group booth (B03/04, Hall 7a) will also have plenty of opportunities to learn about the wide range of technologies and services by means of which SMS group optimizes its customers’ plants  ̶  during their complete life cycle  ̶  in terms of sustainability, efficiency, reliability and safety.

As a systems supplier, SMS group will present solutions for the full range of manufacturing materials for tube and wire products. For the copper industry, for example, SMS group is going to show its compacROD® technology for copper wire production. This technology package uniquely combines state-of-the-art technologies for gas-fired shaft furnaces, with a purpose-tailored casting system and a high-end rolling mill equipped with separately actuated individual drives. This modular plant concept is the perfect starting solution for producers wishing to take up the production of ETP- or FRHC-grade copper rod. The integrated production process, designed for a capacity of 5 to 7 tons per hour, is characterized by extremely low process costs.

For manufacturers of oil country tubular goods (OCTG), SMS group has developed the ThreadView measuring system. This gage checks in just a few steps whether the threads of pipes will be capable of withstanding the extreme stress acting on these pipes in the field. With ThreadView, the measurements are much faster and more accurate than was achievable in the past with a completely manual inspection process, and it is even possible to inspect premium threads. An additional benefit is that the acquired measuring data can be used for the evaluation and detailed analyses of the production process, and for documentation purposes.

SMS group’s PERFECT spray® impressively shows how advanced surface coating can sustainably enhance the long-time performance of tubes. By combining kinetic electric arc spraying with the digital current-voltage source PERFECT spray®, tube coatings become more resilient to wear and corrosion and thus longer lasting.

As the core element of an innovative automation concept for high-frequency tube welding plants, X-Pact® Quicksetting assures that – after a dimensions change – the rolls are automatically adjusted to their new positions. Customers benefit from this data-based adjustment process in the form of extremely short change-over times.

SMS group will also present its new digitalization app SMS-Metrics, a tool that captures and stores machine and process data inline, i.e. during running production. The collected data can be called up in customized form via smart phone, tablet or PC. With SMS-Metrics, operators and managers can view the production data at any place in real time.

Also presented will be the prototype of the SMS group eShop, which will allow customers to order spare parts or services conveniently via an online portal. eShop is another element of SMS group’s digitalization strategy and an integrated part of the digital “Smart Maintenance Solutions” product family. SMS group invites trade fair visitors to learn about the wide range of functionalities provided by the new eShop and the various links and communication channels to other modules of the product family, such as Smart Alarm (central alarm management), Genius CM® (Condition Monitoring), the electronic eDoc plant documentation system and IMMS®, the integrated maintenance management system.

This year’s Tube & wire trade shows will also see the continuation of SMS group’s “Leading Partner Talks”. During the fair days, customers and partners from industry will talk about current projects and give their assessments of future trends and developments at the SMS group booth (B03/04, Hall 7a). The program of the “Leading Partner Talks” will be available in March at