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Advanced pulsating spray cooling system from Primetals started up at Hyundai Steel continuous slab caster

  • DynaJet Flex system reduces appearance of corner cracks when casting advanced steel grades
  • Highest discretization of cooling zones in width direction
  • Pulse-width modulated cooling widens operation window with higher turn down ratio
  • Operational cost reduction by reduced scarfing losses and air consumption

In November 2018, the newly introduced DynaJet Flex spray cooling system from Primetals Technologies has been started up at the two-strand continuous slab casting machine CC2 in the Dangjin, Korea plant of Hyundai Steel. DynaJet Flex allows for pulse width modulated cooling, thus enabling highest discretization of cooling zones in width direction and widening the operation window with higher turn down ratios compared to cooling systems currently in use. This minimizes the appearance of corner cracks especially for advanced high-strength steels (AHSS). Consequently scarfing losses and in addition air consumption are reduced. This is the first industrial application of DynaJet Flex technology. The order for the new system for the first strand was placed in late November 2017. After a successful test, the application of the system on the second strand was ordered immediately.

Caster CCM2 has a rated capacity of 2.8 million metric tons of slab per year. It has a machine radius of 9.5 meters and a metallurgical length of 43.5 meters. Slabs are cast in a width range of 800 to 1,650 millimeters and a thickness of 250 millimeters. Hyundai Steel is producing special steels for the automotive industry, e.g. Hyundai Motors, such as AHSS of the second and third generation. Such crack sensitive steel grades require a width- adjustable secondary cooling to avoid overcooling of the slab corners.  In order to adjust spray cooling in the bender area for slab width ranges from 800 to 1,650 millimeters, a 4-step margin control with the Dynajet Flex system was installed on CCM2.

Today, secondary cooling of continuous casting machines is typically equipped with air-mist nozzles to achieve a wide turn down ratio which is the highest to lowest water flow without jeopardizing the spray pattern uniformity. To prevent corner cracks the zones are additionally split into center and margin strips across the casting direction. DynaJet Flex is the new cooling system to put the discretization of cooling zones at casting machines to the next level. By using water only nozzles, which are driven with a pulse width modulated signal, it is possible to increase the turn down ratio compared to air mist systems and significantly reduce the operating costs by reduced air consumption. The system can be installed on a segment during a planned maintenance cycle. After reinserting the segment into the machine DynaJet Flex is immediately activated. From then on the segment is ready to operate and provides the drastically refined cooling control for an optimal slab temperature, both longitudinally and transversely.

DynaJet Flex pulse-width cooling system from Primetals Technologies mounted in bender zone at Hyundai Steel

DynaJet Flex pulse-width cooling system from Primetals Technologies mounted in bender zone

Source: Primetals Technologies


Rizhao Baohua - Black Coil

Rizhao Baohua orders continuous hot skin pass mill with tension leveling line from Primetals Technologies

Chinese steelmaker Rizhao Baohua New material Co., Ltd (Rizhao Baohua) awarded Primetals Technologies a contract for the process supply of a continuous hot skin pass and tension levelling line (CHSPM). The new line will be installed at the company´s production facility in Rizhao, Shandong Province. The objective is to process black coil with good flatness characteristics and to ease the downstream tube fabrication and welding for applications in the construction and pipe industries. The CHSPM line is designed to process 1.2 million metric tons per year. The completely integrated equipment and automation solution offers Rizhao Baohua precise control of productivity, product quality and availability, thus improving profitability. The line is scheduled to start operating in February 2019.

Primetals Technologies is responsible for the process supply of the CHSPM line especially designed for the processing of incoming black coil, including engineering, manufacturing, and commissioning. The complete drives and automation technology for the line is also part of the project, ensuring the seamless interplay of all components. Specifically, the CHSPM is composed of a double coil charging and entry section design for heavy incoming black coils, a 6-strand horizontal looper 6, a skin pass mill with a maximum roll force of 1,500 tons, a 60 tons tension leveler, inspection facilities and an exit and coil dispatching system. The line is equipped to process strip with thicknesses ranging from 0.6 to 4 millimeters and widths between 900 and 1,600 millimeters at a process speed of 370 meters per minute. Maximal coil weight is 35 tons.

All equipment is based on the proven Primetals Technologies processing lines solution which ensures good flatness and exit strip surface roughness, and is designed to operate efficiently with minimal downtime in order to achieve a low cost per ton. In addition, the overall solution has been optimized to reduce costs for the associated civil works, which will be carried out by Rizhao Baohua.

Source: Primetals Technologies


ANDRITZ

ANDRITZ to supply new hot-dip galvanizing line to Nucor Steel Arkansas, USA

International technology Group ANDRITZ has received an order from Nucor Steel Arkansas Division, USA, to supply a hot-dip galvanizing line for its facility in Hickman, Arkansas, USA. The new line will have an annual capacity of approximately 455,000 metric tons and is designed to produce high-strength steel grades, mainly for the automotive industry. Start-up is scheduled for the first half of 2021.

The ANDRITZ scope of supply and services comprises the complete hot-dip galvanizing line, in particular the furnace with the latest annealing technology for high-strength steel grades (Generation 3 AHSS), strip cleaning, mechanical equipment including strip transport and skin pass mill, electrical equipment, automation, and start-up of the plant.

Following the order to supply a pickling line and rolling mills for Nucor’s new cold-rolling mill in Hickman, AR, last year, ANDRITZ succeeded in convincing Nucor once again with its innovative technologies for the hot-dip galvanizing line.

Nucor Corporation, based in Charlotte, North Carolina, USA, is the largest US steel producer, with a production capacity of over 24 million tons per annum, and is also the largest “mini-mill” steelmaker (i.e. the company uses electric arc furnaces to melt steel scrap instead of blast furnaces for smelting iron).

Source: ANDRITZ

ANDRITZ is a globally leading supplier of plants, equipment, and services for hydropower stations, the pulp and paper industry, the metal working and steel industries, and for solid/liquid separation in the municipal and industrial segments. Other important fields of business are animal feed and biomass pelleting, as well as automation, where ANDRITZ offers a wide range of innovative products and services in the IIoT (Industrial Internet of Things) sector under the brand name of Metris. In addition, the international technology Group is active in power generation (steam boiler plants, biomass power plants, recovery boilers, and gasification plants) and environmental technology (flue gas cleaning plants) and offers equipment for the production of nonwovens, dissolving pulp, and panelboard, as well as recycling plants.

A passion for innovative technology, absolute customer focus, reliability, and integrity are the central values to which ANDRITZ commits. The listed Group is headquartered in Graz, Austria. With over 160 years of experience, 29,000 employees, and more than 280 locations in over 40 countries worldwide, ANDRITZ is a reliable and competent partner and helps its customers to achieve their corporate and sustainability goals.


Vacuum degassing plant and continuous bloom caster from Primetals Technologies brought into operation for Changzhou Eastran

  • VD twin vessel plant has a capacity of 75 metric tons
  • Objectives are further improvement of the steel quality and reduced working costs
  • Hydrogen content reduced to less than 1.3 ppm and nitrogen to less than 50 ppm
  • Continuous bloom caster produces 800,000 metric tons per annum for automotive applications
  • Dedusting system improves environmental quality

A twin vacuum degassing plant (VD) and a continuous bloom caster supplied by Primetals Technologies have been brought into operation at the Chinese special steel producer, Changzhou Eastran Special Steel Co. Ltd. (Changzhou Eastran). The VD plant has a capacity of 75 metric tons. The vacuum treatment reduces the hydrogen content to less than 1.3 ppm and the nitrogen content to less than 50 ppm. The objective is to improve the steel quality even further. The five-strand continuous caster is designed for an annual production of 800,000 metric tons of steel for applications in the automotive industry. It casts blooms for pipes, spring and bearing steels. A dedusting system improves the environmental conditions on site and the new plants also reduce operating costs. Primetals Technologies received the order at the beginning of 2017.

Changzhou Eastran is part of the Changzhou Eastran Group and operates a plant in the town of Changzhou in Jiangsu Province, Eastern China, producing special steels, including bearing and tool steels. The new plant replaces obsolete equipment.

Primetals Technologies designed all the mechanical and electrical equipment for the VD plant, and supplied core components, including the vacuum pump, filters and gas cooler. The vacuum pump itself was manufactured in Germany and procured from Leybold. The system was integrated in a Leybold workshop in Tianjin.

The five-strand continuous bloom caster is equipped with a curved pipe mold. The machine radius is ten meters and the metallurgical length around 20 meters. It casts high-carbon steels at speeds from 1.05 to 1.5 meters per minute and produces blooms with a square cross-section of 200 x 200 millimeters. Production can be extended to include other rectangular and round cross-sections.

Primetals Technologies was responsible for the basic and detailed engineering, as well as for manufacturing molds, oscillators and segments. Primetals Technologies installed a number of technology packages to ensure not only a trouble-free casting process, but also blooms with high surface and interior qualities. The packages included the DynaFlex mold oscillator and straightening units with DynaGap Soft Reduction. Primetals Technologies also supplied the systems for the basic automation (Level 1). DynaGap Soft Reduction in combination with the Dynacs 3D cooling model enables blooms to be cast from high-quality pipe grades and other upmarket steels. Primetals Technologies also supervised the installation and commissioning of the continuous caster, and trained the customer’s personnel.

Vacuum degassing plant (VD) from Primetals Technologies not bloom caster

Vacuum degassing plant (VD) from Primetals Technologies

Source: Primetals Technologies


Bornay S.L. Trusts in High-Precision Tube Welding Line from SMS Group

Spanish welded steel tube specialist Bornay S.L. has ordered an HF (High Frequency) tube welding line, type RD 40, from SMS group for its Alicante works.

Bornay S.L. specializes in precision tubes and stainless steel tubes for the European, Latin-American and African markets and has over 50 years of experience working for different sectors, including the automotive, furniture and agricultural sectors

Spanish welded steel tube specialist Bornay S.L. has ordered an HF (High Frequency) tube welding line, type RD 40, from SMS group for its Alicante works. SMS group is the single-source supplier of all technical equipment from strip preparation to the cut-off-saw.

The new machine will produce round tubes with diameters from 10 to 40 millimeters and wall thicknesses from 0.75 to 4.5 millimeters, as well as squares in dimensions from 10 x 10 millimeters to 30 x 30 millimeters and rectangulars in dimensions from 20 x 10 millimeters to 40 x 20 millimeters with wall thicknesses ranging between 1.00 and 4.00 millimeters.

The tube welding line to be commissioned in the first quarter of 2020 will achieve a production speed of maximum 120 meters per minute. Here, Bornay can produce high-quality tubes with round, square and rectangular cross-sections. They can be used, among others, as precision tubes for the automotive sector, but also for metallic furniture or in the agricultural sector.

“Our requirements with regard to the new welded tube plant were very high since we produce tubes for mechanical applications that require a high level of precision in their finishing. The engineers from SMS group have designed a plant meeting our needs.” says Juan Bornay, Managing Director at Bornay S.L.

SMS group is a group of companies internationally active in plant construction and mechanical engineering for the steel and nonferrous metals industry. It has some 14,000 employees who generate worldwide sales of about EUR 3 billion. The sole owner of the holding company SMS GmbH is the Familie Weiss Foundation.

Source: SMS Group

Price Upturn Forecast in North American Stainless Steel Market in First Half of 2019


First Spooled Bar Coils for Japan and USA

Topy Industries Limited and Commercial Metals Company have now become the first Japanese and USA rebar producer to step ahead in the field of hot-rolled compact coils.

Rebar Coils

These two K-Spool Lines, perfectly on time started-up by Danieli, represent the state-of-art technology for the production of hot rolled compact coils with market-customized solutions: the layout configurations have indeed developed taking in to account the specific quality and productivity requirements.

The K-Spool Line at Topy’s Toyohashi Rolling Mill, Aichi Prefecture, has been designed for an output capacity up to 240,000 tpy of D10, D13 and D16 in compact coils from 1 to 3.5 tons for grades SD295A and SD345, by means of two Danieli horizontal spooler stations independently served by separate lifting forks.

A two-pass fast finishing block with a Hi-Profile measuring system have also been supplied to upgrade the finishing mill.

On the other side of the ocean, the K-Spool Line in Durant, Oklahoma, upgrades the CMC’s “environmentally responsible” micromill adding compact coils in the range #3 to #6, using a four-pass fast finishing block and two Danieli horizontal spooler stations, fed by the endless MI.DA® rolling mill.

With the application of the endless rolling process, the plant can produce compact coils in weights up to 11,000 lb (5.0 t).

Based on horizontal spooler coiling, Danieli K-Spool technology has reached an unparalleled level of reliability and quality in finished products, resulting in twist-free material, free of any residual tensions and stresses and very consistent in mechanical characteristics and surface quality.

Currently, depending on local market requirements, steelmakers produce spooled coils in different weights, up to 5 t (design capacity up to 8 t) in diameters up to 32 mm.

Workers in Japan, producing hot-rolled coils
Source: Danieli