smart steel plant

142 Pages·2017·6.12 MB·English

Leading partner
in the world of metals
T HE SMS GROUP MAGAZINE
ISSUE 01 / 2017
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New digitalization strategies facilitate manufacturing
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processes according to the principles of Industry 4.0.
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Plug & Work: automation pretested by simulation
Plug & Work: That’s the tried-and-tested method we apply SMS group is a global, leading partner for the metal
to run your systems thoroughly through their paces and industry. As a family-owned business headquartered in
optimize them even before commissioning. Germany, quality and innovation is in our DNA. We are
What you gain: Installing pre-tested automation systems committed to the success of our customers and strive
ensures rapid run-up curves for new plants as well as to add value along the entire value chain of the global
revamps. Even more, shorter assembly times give you a metal industry.
faster return on investment.
SMS group GmbH
Eduard-Schloemann-Strasse 4 Phone: [phone]
40237 Düsseldorf, Germany Fax: [phone]
[email protected] www.sms-group.com
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SMS group newsletter 01 / 2017
Contents
10 New rolling mill for Shandong. 42 New digital solutions for the metal industry.
PROCESS CHAIN FOCUS MAIN TOPIC
60 IRONMAKING PLANTS 04 O RDER 34 D IGITALIZATION
Demanded know-how Geared to implementable
61 M ETALLURGY AND ENVIRON-
M MPZ-group orders produc- and fast solutions
MENTAL TECHNOLOGY
tion complex for high-quality S MS digital introduces itself.
73 FLAT ROLLING MILLS tinplate.
36 DIGITALIZATION
88 S TRIP PROCESSING LINES
10 O RDER Data Challenge
AND FURNACE TECHNOLOGY
Continuous caster and N ew prediction models for
100 LONG PRODUCT PLANTS
Steckel/plate mill continuous casting process-
120 FORGING TECHNOLOGY S handong Rizhao relies on es.
equipment and kow-how from
128 TECHNICAL SERVICE
SMS group. 42 D IGITALIZATION
Big Data in steel plants
14 O PENING H ow steel plants can be au-
Big River Steel opens North tomated in line with Industry
America‘s latest steelworks 4.0 standards.
O n March 1, 2017, the steel-
works was officially commis- 50 D IGITALIZATION
sioned. Virtualization in automation
technology
G rowing trend of decoupling
hardware from its software.
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68 Commissioning at Tata Steel. 88 SSAB modernizes entry section. 114 VCC® for long products.
PROJECTS
60 IRONMAKING PLANTS 96 S TRIP PROCESSING LINES 20 P HOTO HIGHLIGHT
New blast furnace secures the AND FURNACE TECHNOLOGY
22 RETROSPECT – OUTLOOK
use of steel capacities Festive mood in Jesenice
58 PERFORMANCE MODULES
E VRAZ counts on equipment S IJ Acroni inaugurates heat
from Paul Wurth. treatment line with MultiFlex- 136 EVENTS
Quench®.
141 IMPRINT
68 M ETALLURGY AND ENVIRON-
MENTAL TECHNOLOGY 108 L ONG PRODUCT PLANTS
Special steels for the aero- Exclusive key technology
space industry I n its manufacturing shop
T he new VIM X-eed® unit from SMS group produces exclusive
SMS group meets all of Tata PQSC® tools.
Steel’s requirements at the
The SMS group newsletter app is
Stocksbridge location. 132 T ECHNICAL SERVICE
available in the App Store and at
Service which attracts
Google Play.
80 F LAT ROLLING MILLS I n cooperation with Wuxi, SMS
A strong set of teeth! group designed a new tool
S MS group will supply three holder.
spur-wheel mill-pinion gear
units to the U.S.A.
Cover: Hot strip mill at Big River Steel
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FOCUS SMS group newsletter 01 / 2017
TECHNOLOGY AND KNOW-HOW
FROM SMS GROUP IN DEMAND
IN BELARUS
REPUBLIC OF BELARUS. MMPZ-group orders production complex for
high-quality tinplate.
RCM
ECL
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DCR
BAF
ETL
RCM: Reversing Cold Mill
ECL: Electrolytic Cleaning Line
BAF: Batch Annealing Furnaces
DCR: DCR-Rolling Mill
ETL: Electrolytic Tinning Line
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FOCUS SMS group newsletter 01 / 2017
Group photo on occasion of contract signing on March 12, 2015. Participants (from left to right), sitting: Dieter Rosen-
thal (Member of the Managing Board SMS group), Aliaksei Kavalionak (Chairman of the Board of Directors MMPZ-
group). Standing: Falk Töpfer (Vice President SMS group), Helmut Lantzsch (Senior Specialist Financial Services East-
ern Europe SMS group), Reinhard Reddel (Head of Commercial Sales Europe, Russia, Americas SMS group), Marina
Keller (Senior Project Manager SMS group), Claas Sachteleben (Project Director SMS group), Dmitrij Slaunikau (Fi-
nancial Director MMPZ-group), Natalya Zavrenko (Co-Owner MMPZ-group), Dmitrij Brenko (Member of the Board of
Directors MMPZ-group), Aliaksei Shimukovich (Chairman of the Board of Directors MMPZ-group Moscow).
MMPZ-group (Miorskij Metalloprokatnyj Zavod) has se- CQ and DQ. A future capacity expan-
lected SMS group to supply a new industrial complex for sion up to 240,000 tons will be possi-
the production of tinplate in Miory, Republic of Belarus. As- ble. The first plants are scheduled to
sisted by SMS group, a financing concept was developed for start operation at the beginning of
this project. The supply contract became effective in Janu- September 2018. MMPZ’s focus will be
ary 2017. SMS group will provide all technological equip- on the production of tinplate to satisfy
ment, comprising rolling mill and strip processing lines, the demand of the packaging industry
including pertaining X-Pact® electrical and automation and on cold-rolled sheet. The major
systems. In addition to supplying the plants, SMS group will share of the products is planned to be
support MMPZ by providing user know-how for commis- exported, in the first place to Russia
sioning and production. and other GIS countries, but also to
the European Union.
GROWING WITH THE MARKET SMS group will supply all rolling
MMPZ-group was founded in 2015 with the aim to produce and strip processing equipment, in-
electrolytically coated tinplate and cold strip in the Repub- cluding X-Pact® electrical and auto-
lic of Belarus to provide the regional market with high- mation systems. The scope comprises
quality cold strip products. To make this come true, MMPZ- a reversing cold rolling mill, an elec-
group relies on state-of-the-art, efficient and eco-friendly trolytic cleaning line, a batch anneal-
plant technology offered by SMS group. The new production ing facility, a two-stand DCR (Double
site will be established in Miory, a city in the northwestern Cold Reduction) mill, an electrolytic
part of the country. This location has good transport con- tinning line plus one packaging line
nections to the envisaged purchasing and sales markets each for sheet packages and coils. An-
including the countries Latvia, Lithuania and Russia in the cillary systems will be constructed by
close neighborhood. the Russian company MetProm. After
In the first construction stage it is planned to establish commissioning, SMS group will con-
plants with an annual capacity of 150,000 tons, producing tinue to support MMPZ by providing
tinplate grades T1, T2, T3, DR7 and DR8 and sheet grades user know-how.
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Miory
REPUBLIC OF BELARUS
Miory provides good
transport connec-
tions to the envis-
aged purchasing and
sales markets in the
EU and Russia.
PROCESS ROUTE ELECTROLYTIC CLEANING LINE
Priority here is on the production of starting stock for mak- The cleaning line comprises vertical
ing tinplate. To be able to respond to the market flexibly, the process tanks for spray cleaning and
plant concepts also permit non-coated sheet of material electrolytic cleaning, each being fol-
grades CQ and DQ to be produced as an alternative. The lowed by horizontal brush cleaners.
major part of the production, however, is planned to go A four-fold cascade rinsing system
through the complete process to the final product tinplate. and a hot-air drying system complete
The electrolytic strip cleaning section prepares the rolled the process. In addition to giving the
material for the annealing process in the batch annealing cleaned strip an excellent surface
facilities which set the required ductility. Thereafter, the quality, the line is characterized by low
strips are skin-passed in the DCR mill or, depending on the media and energy consumption. The
material grade, undergo a second reduction and are then vertical, electrolytic cleaning method
immediately skin-passed. This step is followed by tin coat- ensures that even fine impurities are
ing in the electrolytic tinning line. removed.
REVERSING COLD MILL BATCH ANNEALING FURNACES
The Reversing Cold Mill (RCM) is equipped with one payoff To be used as packaging material, the
and two reversing reels. In addition to the option of produc- cold-rolled strip must be subjected to
ing CQ and DQ sheet, the six-high mill stand with CVCplus® a recrystallization annealing process
is able to roll tinplate grades, that are to be finished in the to set the required ductility. The batch
tinning line, to a minimum final thickness of 0.15 millime- annealing furnaces serve to anneal
ters. The rolling mill complies with the new high-perfor- and cool the coils in batch mode. Thus,
mance design SMS group developed for cold rolling mills several coils, piled up to a maximum
and will be operated using particularly slim work rolls suit- height of 4.8 meters with a maximum
ed to attain high pass reductions at comparatively low roll- weight of 125 tons, can be processed
ing forces. This ensures the plant is running particularly simultaneously. The treatment per
cost-effective. Work and intermediate roll bending, multi- hood takes one or two days subject to
zone cooling and DS (Dry Strip) system in addition to the material and the volume of filling.
CVC®plus make strip thickness, flatness and surface meet The coil batches on each basis are
the customer’s quality requirements. A multitude of com- covered by a protective hood. The at-
ponents is identical to those of the DCR mill and contrib- mosphere within the protective hood is
utes to an extremely economical operation of the plant. 100 percent hydrogen to attain a
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»The recipe for success: cutting-edge, efficient technology paired
with an innovative financing concept.«
Harald Rackel, Member of the Managing Board of SMS group, about the new MMPZ-group project.
high degree of heat transfer and to reliably protect the that impress by their environmental
surfaces from oxidation. Depending on the respective pro- compatibility, efficiency, operational
cess phase, heating or cooling hoods are then put over this safety and flexibility. The entry section
inner cover. The heating hoods heat the material up to 640 integrates a side trimmer with edge
degrees Celsius. For the cooling process hoods with com- scrap wrapper. In preparation for the
bined air and water cooling are used. tinning process, the strips run through
a cleaning section, a tension leveler
DCR (DOUBLE COLD REDUCTION) ROLLING MILL and a pickling section. The tinning unit
The DCR mill is a multi-talent. To attain the required mate- comprises six tinning cells. After the
rial and surface properties, the stock (SR) which has already tin layer has been applied, it is treated
been reduced to final thickness, is skin-passed in the DCR in a fully inductive reflow heating sys-
mill. To meet the respective material grade requirements, tem to improve the surface quality. Fi-
however, the strips may be further reduced in the first mill nally, the strip is passivated, dried and
stand and skin-passed in the second one. This method oiled.
generates double-reduced (DR) material with a minimum Numerous measuring units are in-
thickness of 0.10 millimeters used to produce specific tin- stalled throughout the line to ensure
plate products. The rolling mill may also be operated as permanent process monitoring and
skin-pass mill for CQ and DQ sheet having a thickness be- control in co-action with the layer
tween 0.35 and 1.00 millimeter. thickness measuring system. This
The DCR mill is designed as four-high facility. The prov- makes sure the end product has best
en CVCplus® technology combined with the new power possible quality and the line operates
bending system increases the capacity of the intelligent ac- efficiently. The rinsing water from the
tuator systems and creates the pre-condition for excellent tinning process is conditioned in a
strip quality. The mill can be run in wet and dry skin-pass state-of-the-art evaporator system
mode depending on the required surface roughness. thus saving further operating costs.
The line is designed with respect to
ELECTROLYTIC TINNING LINE (ETL) a future extension to increase capacity
The purpose of the electrolytic tinning line is to provide the and improve process quality. So, it will
very thin steel sheet with a fine layer of tin to protect it be possible to subsequently integrate
against corrosion and thus to produce high-quality tinplate. a preparation cell, two additional tin-
MMPZ decided in favor of a line using soluble tin anodes. ning cells and a height adjustment for
Being the market leader in this technology, SMS has dem- the reflow unit, among others.
onstrated the economic, environmental and process-tech-
nological benefits by means of several lines built so far. USER KNOW-HOW
These benefits include a reduction of tin consumption and The process for producing high-grade
stable process conditions which, combined with precise tinplate will be accompanied by MET/
process control, result in a high-quality final product. The Con Metallurgical Plant & Process
line features numerous high-performance components Consulting GmbH, an enterprise of
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FOCUS
150,000
tons annual capacity in the first phase.
SMS group. MET/Con has the experience and expertise to
deliver comprehensive know-how specifically tailored to a
customer’s needs, and may flexibly resort to a wealth of
knowledge and a broad product portfolio in the steel and
non-ferrous metal sector to develop a complete metallurgi-
cal concept, including specifications of steel grades suited
to produce high-quality tinplate. The services cover, in addi-
tion to assistance in technological issues, also superordi-
nate organizational topics. MET/Con’s consultancy services
include optimized production planning, establishing an ef-
fective organizational structure including staff planning, and
the development of an efficient quality assurance system
including necessary laboratory equipment and staff training
measures. Thus, MMPZ will enjoy full support on its road to
efficiently producing high-quality product grades and to fur-
ther strengthen its position on the market as a reputed pro-
ducer of tinplate products.
HOLISTIC SYSTEMS COMPETENCE
With its X-Pact® electrical and automation package, SMS
group offers holistic systems competence for the planned
tinplate complex. X-Pact® makes sure all plant components
will perfectly harmonize: As systems solution, technology,
mechanical and hydraulic equipment, electrics and auto-
mation form an efficient and powerful unit. In addition to
the automation scope, including technological controls and
process models, the X-Pact® scope of supplies will com-
prise all drive equipment, instrumentation and plant opera-
tion systems. As an integral part thereof, the tried and
tested X-Shape flatness measuring and control system will
make sure the high quality requirements are met.
Falk Töpfer
[email protected]
Marina Keller
[email protected]
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Steckel/plate mill.
CONTINUOUS CASTER AND
STECKEL/ PLATE MILL
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