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Primetals Technologies to replace BOF converter at HBIS Serbia in Smederevo

Primetals Technologies has received an order from HBIS Group Serbia Iron & Steel LLC (HBIS Serbia) to replace BOF converter #2 at its production site in Smederovo, Serbia. The aim of the project is to improve the process and to raise production capacity. This will be achieved by increasing the converter vessel´s shell volume. At the same time, the critical outer dimensions will remain the same, so that adjacent interfaces may be kept. Modifications of the BOF pedestal or revamping of civil works are not required. The new converter will have a tapping weight of 105 metric tons and will receive, among other equipment, a Vaicon Link 2.0 suspension system and a new tilting drive. Start-up is expected for the second quarter of 2020.

HBIS Serbia is a producer of steel, hot and cold rolled products and tin plate in southeast Europe, and its facilities are located in the village Radinac near Smederevo, in Šabac and Kučevo. The plant in Smederevo produces iron at two blast furnaces, then converts blast furnace iron to raw steel at a three-furnace converter shop and continuous casting complex. Steel processing includes a hot strip mill, sheet cold reduction mill, annealing and tempering units. The converter #2 vessel shell and trunnion ring had reached the end of their useful lifetime

(Steel Price Data)

For the new BOF converter #2, Primetals Technologies is responsible for the engineering to increase the vessel shell volume, while keeping supporting bearing distances the same in order to avoid the necessity for civil works. The scope of supply includes the new vessel with detachable BOF bottom part, the trunnion ring, the Vaicon Link 2.0 suspension system, new supporting bearings with housings a new tilting drive including a pneumatic emergency drive system, bottom stirring system, a dart machine for slag retention as well as the implementation of slag splashing.technology. Primetals Technologies will also supply the electrics and the new basic (level 1) automation system for the new tilting drive and existing melt shop equipment, e.g. ferro-alloy system, transfer cars, etc. Furthermore, the scope covers the execution of the erection works and related advisory services. Dismantling of the old BOF equipment and installation of the new one are planned to be executed within approximately 55 days.  Installation will be carried out jointly with a local Serbian company.


BOF Converter meltshop of HBIS Group Serbia Iron & Steel LLC (HBIS Serbia) in Smederovo, Serbia. Primetals Technologies will replace BOF converter #2 (Image courtesy HBIS).

Source: Primetals Technologies


Continuous caster and secondary metallurgy facilities by Primetals Technologies receive FACs from MMKI

  • Annual production capacity increases to four million metric tons of slabs
  • Project included two-strand slab caster, twin ladle furnace, alloying station and dedusting system
  • Expands product portfolio of MMKI
  • Cross-section heat-pacing solution to coordinate steel production with casting operation
  • Reduction of dust content in cleaned gas

In late March, Ukrainian steel producer PJSC “Ilyich Iron and Steel Works of Mariupol” (MMKI) issued the Final Acceptance Certificates (FACs) for a two-strand continuous slab caster, a twin ladle furnace with an alloying station, and the associated dedusting system, all supplied by Primetals Technologies. The two-strand caster CC4 is designed to produce 2.5 million metric tons of slabs per annum. This increases MMKI’s annual production capacity to around four million metric tons, as well as enhancing and expanding its product portfolio to include, for example, HC, UHC and ULC steels. A level 3 heat-pacing solution coordinates the steel production with the casting operation.

MMKI produces steel with three LD (BOF) converters. A new 150 metric ton twin ladle furnace from Primetals Technologies and the associated alloying station help to set the desired steel grades and the correct casting temperature. Due to an Industry 4.0-ready automation on Level 1 and Level 2, this can be done via pre-selectable process models. A transformer with a rated power of 28 MVA provides the electrical energy for the ladle furnace, enabling a heating rate of 4.5 °C per minute. This heating rate and the guaranteed energy consumption value have been over-fulfilled during start-up.

Primetals Technologies designed a dedusting system to clean the off gases from the ladle metallurgy facility. This improves the environmental situation in the city of Mariupol, where MMKI is located. The dedusting system reduces the dust content in the off gases to a level of 12 mg/m3 (maximum), whereas the Ukrainian standards require up to 50 mg/m3 and the European standards up to 30 mg/m3.

The equipment order for the continuous slab caster covered all the installations from the ladle turret and the tundish car through to the exit zone with its weighing, torch cutting, marking and deburring machines. The caster from Primetals Technologies has a machine radius of nine meters and a metallurgical length of 29.8 meters. It casts slabs with thicknesses of 170 and 250 millimeters in widths ranging from 900 to 1,550 millimeters. The maximum casting speed is 2.2 meters per minute. It processes peritectic and peritectic alloyed steels, low, medium, high and ultra-high carbon grades, as well as medium-carbon alloyed steel. The caster is equipped with automatic LevCon mold level control, a straight, cassette-type Smart Mold with the DynaWidth technology package to automatically adjust the width of the slab online, and the DynaFlex mold oscillator. The strand guide is equipped with Smart Segments and I-Star rollers. DynaGap Soft Reduction, the Dynacs 3D secondary cooling model, and DynaJet nozzles was also installed, making it possible for MMKI to produce a wide variety of high-quality grades with improved interior quality of the slabs.

MMKI is one of the largest iron and steel works in Ukraine. The company produces a wide range of flat products made of carbon, low-alloyed and alloyed steel grades for various applications. These include heavy plates for pipelines, shipbuilding, pressure vessels and the construction industry, as well as hot and cold rolled plates and coils.


Slab caster CC4 from Primetals Technologies at PJSC “Ilyich Iron and Steel Works of Mariupol” (MMKI), Ukraine.

Source: Primetals Technologies


Steel Coil produced by Hyundai Steel

Primetals Technologies optimizes pickling line-tandem cold mill for Hyundai Steel in just a few weeks

  • After a short refurbishment, all performance tests were successfully completed in just four weeks
  • The capacity of the pickling line-tandem cold mill has been increased to supply an additional strip galvanizing line
  • Prior analysis enabled targeted modernization with reduced investment sums

Primetals Technologies optimized the drive and automation equipment of the pickling line-tandem cold mill (PLTCM) no. 1 at the Dangjin plant of Hyundai Steel, a Korean steel producer, within a short period of time. After a refurbishment phase at the end of 2018, all the agreed proofs of performance for the production of more than 20 different product groups were completed by January in a period of just four weeks. The production capacity of the PLTCM was substantially increased at the same time, which now enables it to supply cold-rolled strip to an additional strip galvanizing line at the Suncheon plant. The refurbishment was preceded by a detailed analysis of the weak points of the entire plant and the development of a targeted refurbishment concept. This increased the production potential of the existing lines and minimized the investments needed for new equipment.

The analysis preceding the refurbishment showed that, instead of replacing the entire drive train, only the drive trains on stands two and three had to be replaced to eliminate the weak points. The available installed reserves of stands one, four and five were utilized and the load optimally redistributed to achieve the required increase in throughput for the complete plant. New transformers and cycloconverters were installed on stands two and three, and new motor and gear units were mounted on the existing foundations. The “Motor Utilization Model – MUM” newly developed by Primetals Technologies was used for the first time to make the maximum possible use of the installed performance reserves of the new and existing stand motors. The load was distributed optimally to adapt it specifically to the product mix and to obtain the best possible dynamic use of the forming forces of the individual stands. The objective was to achieve the maximum degree of forming along the complete line, and to come as near as possible to the load limits of the individual stands.

The continuous power of the new machines is around 36 percent higher and they allow the rolling work to be optimally redistributed in the tandem mill. Some of the low-voltage drives were also replaced. For example, the rollers on the infeed side are now equipped with motors and drives that are up to 50 percent larger in order to deliver the required pulling force at higher speeds. In addition to the renewal of the drive equipment, the technological controls in the basic automation and the Level 2 rolling regulations were modernized. The refurbishment of all parts of the plant was planned in great detail and completed right on schedule within the timeframe of 15 days. It was even possible to hold the first tests of the rolling operation one day earlier than scheduled. The first strip was successfully rolled as planned on December 14, and the plant was brought up to its previous throughput within three days.

All the verifications for more than 20 individual product groups – mainly interstitial free grades and other products for the automotive sector – were completed by the end of the first month. The plant also significantly surpassed the contractually agreed parameters within the first few weeks.

PLTCM no.1 at Hyundai Steel’s Dangjin site now has a capacity of around 1.8 million metric tons per annum. It processes cold steel strip in widths ranging from 600 to 1,800 millimeters. The entry thicknesses can vary between 1.2 and 6 millimeter, and from 0.25 to 3 millimeters on the exit side. The maximum strip speed is 1,400 meters per minute. The line consists of four four-high stands and one six-high rolling stand. Primetals Technologies had equipped the line with process automation back in 2006.

Steel Coil produced by Hyundai Steel

First coils produced at Korean steel producer Hyundai Steel’s Dangjin plant after the pickling line-tandem cold mill (PLTCM) no. 1 had been restarted. Primetals Technologies optimized the drive and automation equipment of the PLTCM within a short period of time.

Source: Primetals Technologies, Limited headquartered in London, United Kingdom is a worldwide leading engineering, plant-building and lifecycle services partner for the metals industry. The company offers a complete technology, product and service portfolio that includes integrated electrics, automation and environmental solutions. This covers every step of the iron and steel production chain, extending from the raw materials to the finished product – in addition to the latest rolling solutions for the nonferrous metals sector. Primetals Technologies is a joint venture of Mitsubishi Heavy Industries (MHI) and Siemens. Mitsubishi-Hitachi Metals Machinery (MHMM) – an MHI consolidated group company with equity participation by Hitachi, Ltd. and the IHI Corporation – holds a 51% stake and Siemens a 49% stake in the joint venture. The company employs around 7,000 employees worldwide. Further information is available on the Internet at www.primetals.com.


Continuous billet caster revamped by Primetals Technologies started up at Feralpi Siderurgica in Italy

  • Production capacity was increased by 10 percent to 1.2 million metric tons per year
  • Billet cross section is raised to 150 x 150 millimeters with predisposition for 160 x 160 millimeters
  • Plant availability is increased

Recently, a six-strand billet caster revamped by Primetals Technologies was started up in the Lonato del Garda works of Feralpi Siderurgica S.p.A., part of the Italian Feralpi Group. The aims of the project were to increase production capacity from 1.1 to 1.2 million metric tons of billets per year, to produce billets with a larger square cross section of 150 x 150 millimeters with predisposition for cross section of 160 x 160, millimeters, and to improve plant availability.

Before the revamp, the six-strand billet caster of Feralpi Siderurgica in Lonato del Garda in the Brescia Province, had an installed annual capacity of 1,1 million metric tons of billets with a square cross sections of 140 x 140 millimeters. It produces medium carbon, carbon and low alloyed steels for the construction industry. Within the revamping project, the casting machine was equipped with new DiaMold high-speed casting molds, characterized by tapered mold tubes and open bottom-mold corners to reduce strand friction. The DynaFlex hydraulic oscillator with online and flexible adjustment of the mold-oscillation parameters serves to improve strand-surface quality. The scope of supply included a new secondary cooling and a dummy bar head and the existing straightener has been modified according to Primetals Technologies´ model of continuous straightening to optimize the straightening strains. Primetals Technologies was responsible for the basis, detail engineering and supply of the above components.

Feralpi Group is one of the most important steel suppliers to the European construction industry. The group operates four subsidiary companies in Italy and runs production and sales locations in Europe and North Africa. Feralpi Siderurgica was founded in 1968 and is thus the oldest member of the Feralpi Group. The company is today one of the leading suppliers of reinforcing steel, wire rod, reinforcement meshes and the associated derivatives in Italy.

Continuous billet caster modernized by Primetals Technologies in the Lonato del Garda, Italy works of Feralpi Siderurgica

Primetals Technologies, Limited headquartered in London, United Kingdom is a worldwide leading engineering, plant-building and lifecycle services partner for the metals industry. The company offers a complete technology, product and service portfolio that includes integrated electrics, automation and environmental solutions. This covers every step of the iron and steel production chain, extending from the raw materials to the finished product – in addition to the latest rolling solutions for the nonferrous metals sector. Primetals Technologies is a joint venture of Mitsubishi Heavy Industries (MHI) and Siemens. Mitsubishi-Hitachi Metals Machinery (MHMM) – an MHI consolidated group company with equity participation by Hitachi, Ltd. and the IHI Corporation – holds a 51% stake and Siemens a 49% stake in the joint venture. The company employs around 7,000 employees worldwide.

Source: Primetals Technologies



Primetals Technologies receives final acceptance for modernized continuous slab caster at Angang Iron & Steel

  • Modernization improves productivity and product quality
  • Greater flexibility for product mix and casting formats
  • Casting machine was revamped within just 30 days
  • Fast project implementation minimized downtimes
  • 1,700 heats equaling approximately 348,000 tons processed from start-up to FAC

In December 2018, Primetals Technologies received the Final acceptance Certificate (FAC) for the modernized two-strand continuous slab caster CCM1 in steel works no. 3 of Angang Iron & Steel Group Co. in Anshan, China. The caster was started-up in late October 2018 and processed more than 1,700 heats equaling approximately 348,000 tons within less than two months. The objectives of the project were to improve the product quality and productivity, and also to increase the flexibility of the processing of different steel grades and casting formats. The casting plant is equipped with modern equipment and technology packages, including DynaGap Soft Reduction to improve the interior quality of the slabs. In order to minimize shutdown times, the project planning attached particular importance to a quick implementation: the casting machine was revamped within just 30 days.

Angang Iron & Steel Group Co. is located in Anshan in Liaoning Province. It has an annual production of approximately 35.8 million metric tons (2017), and is one of China’s leading steel producers. Steel works no. 3 in Anshan employs a conversion route through a basic oxygen converter, ladle furnace and RH plant. It has an annual capacity of five million metric tons and supplies two casting plants. Continuous slab caster CCM2 has already been modernized by Primetals Technologies and has been back in successful operation since July 2015.

The two-strand continuous slab caster CCM1 in steel works no. 3 has a production capacity of 2.5 million metric tons per annum. Its machine radius is nine meters and metallurgical length 36 meters. The caster produces slabs with a thickness of 230 millimeters in widths ranging from 990 to 1,550 millimeters. The maximum casting speed is 2.1 meters per minute. The plant casts ultra-low carbon to high carbon steels, peritectic, deep drawn and HSLA steels, as well as micro-alloyed, low-alloyed and silicon steels.

The modernization project included equipping continuous slab caster CCM1 with a new tundish car and a new tundish with LevCon mold level control. The straight cassette-type Smart Mold is equipped with the Mold Expert breakout detection system, DynaWidth for automatic width adjustment, and the DynaFlex mold oscillator. Bender and Smart Segments as well as I-Star rollers are used in the strand-guiding system.

The Dynacs secondary cooling system dynamically calculates and controls the temperature profile along the entire strand. This enables the working points of the strand cooling, and thus the final strand solidification, to be determined precisely as a function of the casting speed, slab format and steel grade. DynaGap Soft Reduction is used to improve the interior quality of the slabs. The roll gap is dynamically adjusted during the final solidification in accordance with the operating points calculated by Dynacs. This minimizes segregation in the center of the strand. The secondary cooling uses DynaJet spray cooling with a center/margin setting.

In addition, Primetals Technologies handled the basic engineering of the tundish, the ladle shroud, the dummy bar system, the supporting structure and the maintenance stands, as well as the detailed engineering for the shroud manipulator, the tundish car, mold and mold oscillator, the segments of the strand-guiding system, the secondary cooling and the dummy bar. The automation system and the consulting services for the construction and commissioning were also part of the order.

Source: Primetals Technologies


twin ladle steel furnace

Primetals Technologies receives FAC from Severstal for ladle furnace supplied to Cherepovets converter steel works

  • Twin ladle furnace treats 4.8 million metric tons of liquid steel per annum
  • High degree of automation through Level 2 process models
  • Production capacity of converter steel works increases to almost 10.3 million metric tons per annum
  • Consolidation of liquid steel treatment significantly reduces operating costs

Russian steel producer PAO Severstal issued the Final Acceptance Certificate for a new twin ladle furnace supplied by Primetals Technologies to the converter steel works in Cherepovets. The ladle furnace is able to treat 375 metric ton charges of liquid steel with a treatment time not more than 45 minutes, and has an annual capacity of 4.8 million metric tons. This increases the production of converter steel from its previous maximum of 9.5 million to almost 10.3 million metric tons per annum. The additional ladle furnace also enables all the steel treatment to be brought together into a single section of the plant. This reduces annual operating costs by approximately 10 million euros.

The Cherepovets Metallurgical Plant in the Vologda region is part of the “Severstal Russian Steel” Division of PAO Severstal and is one of the world’s largest integrated iron and steel works. It produced around 11.65 million metric tons of liquid steel in 2017. The steel is used to make a large number of end products, including hot- and cold-rolled flat steel, galvanized and coated products, and long products. The Cherepovets converter steel works has three converters, each with a capacity of 350 metric tons. Until now, only one ladle furnace has been available for treating liquid steel supplied by Primetals in the past.

Primetals Technologies was responsible for engineering the twin ladle furnace, the alloying system, the dedusting system, and supplied key components. The scope of supply also included the associated electrical and automation equipment. The installed Level 2 system has been seamlessly integrated in the plant’s system and allows a high degree of automation due to the use of pre-calculated process models. In addition, Primetals Technologies supervised the installation and commissioning, and provided the staff training.

Severstal was responsible for the technical documentation development and the construction activities. The company invested approximately 43 million euros to expand of its treatment capacity. Severstal and Primetals Technologies can look back on many years of close cooperation.

Twin ladle furnace supplied by Primetals Technologies to the Cherepovets, Russia converter steel works of PAO Severstal

Source: Primetals Technologies