Tenova, a company of the Techint Group specialized in innovative solutions for the metals and mining industries, was recently awarded a new contract for the new furnace concept, the Flexible Modular Furnace (FMF®), for Pomina 3 steel plant, part of Pomina Steel Corporation in Ba Ria, Vung Tau region, Vietnam.
In the Pomina 3 steel plant, the steelmaker upgraded the 120 tons Consteel® EAF – supplied by Tenova in 2013 – into a Tenova FMF® (Flexible Modular Furnace). Adopting this new technology, Pomina 3 will also be able to charge the furnace with hot metal coming from the new blast furnace. This solution will allow Pomina 3 to adopt a hybrid electrical/integrated steelmaking technology minimizing CAPEX and gaining a savings on production costs.
The start-up of this plant is foreseen in early 2019.
“This project is the first one of this kind in Vietnam, following a trend of steelmakers for advanced solutions to decrease production costs and look for more flexibility to use different input materials into an EAF. In the last three years, Tenova signed four contracts (relevant to six furnaces) linked to the FMF® solution”
said Stefano Marelli, Tenova Global Sales Regional Manager.
Tenova FMF® is a modular concept of smelting furnace that can be developed from core equipment called base module with specific add-ons and has the flexibility of converting various charge mix of raw material (scrap, DRI, liquid hot metal, pig iron, etc.). Each module is designed with specific features in order to fit the requirements of the charge mix.
The FMF® solution is also suitable for those steelmakers that are looking for a transition from Basic Oxygen Furnace (BOF) to an EAF based steelmaking. Flexibility is the greater advantage of this solution for all the markets that are developing toward lower environmental footprint steelmaking operations, however this solution also provides the possibility to smelt a full range of metallic charges which can reduce costs to a minimum level.
Pomina Group (former Thep Viet) started the collaboration with Tenova almost 15 years ago, with a first contract for Consteel® EAF, ladle furnace and continuous caster, followed by another Consteel® EAF and, more recently, by a cold mill complex for pre-painted galvanized flat steel.
Steelwork is on a 4,000 mile journey from Dorset to the Caribbean for the reconstruction of a primary school, devastated by hurricane Irma and Maria last year.
Christchurch-based John Reid & Sons Ltd (REIDsteel) is leading a consortium of businesses in the UK which have joined forces to help rebuild the Enis Adams Primary School in the British Virgin Islands. The company, which has exported to the Caribbean for more than 30 years, has rallied its suppliers to provide support free of charge, in kind or at a discounted rate. They are Tata Steel, National Tube Stockholders, Joseph Ash Galvanising, Euroclad, Ayrshire Metal Products, BAPP, Powell Gee & Co Ltd, Kestrel Liner Agencies and Meachers Global Logistics.
Main contractor in Tortola, Newton Construction Co Ltd, with whom REIDsteel has worked for 34 years, is leading the construction work and will erect the steelwork. Virgin Islands businessman Peter Haycraft, who was a longstanding client of REIDsteel with his former business Road Town Wholesale, has pledged $1m of his own money for the school reconstruction to help the local community. REIDsteel – whose specialities include disaster-resistant buildings – designed and manufactured the steelwork to withstand any future hurricanes and to give something back to the islands. Now four 40ft cargo containers full of steel work are being shipped across the Atlantic for the project on the island of Tortola, with three more to follow in the coming months.
REIDsteel commercial director Tim Cook said:
“We have built strong personal and professional relationships over many years in the Caribbean.
“It was terrible to see the damage wreaked by the hurricanes last year so we’re very grateful to Peter Haycraft for giving us the opportunity to help him give something back to Tortola.
“Our thanks to our suppliers and business associates who rallied around immediately. It is great to see the first shipment depart and we’re looking forward to the school rising from the ashes.”
Others involved in the project are architect AEMC Architectural Services, civil engineers AEC Consulting Engineers Ltd, Electrical Barry’s Electrical Services, Reliable Plumbing, S&D Security, and the British Virgin Islands Ministry of Education and Culture.
Hesketh Newton, managing director of Newton Construction Co Ltd, said:
“We have made good progress so far and the new school will really begin to take shape with the arrival of the steelwork. As a local family-owned business of 40 years, we’re very pleased for the opportunity to give back by supporting this project.”
Peter Haycraft said:
“I have worked closely with REIDsteel and Newton Construction Co Ltd for many years. I am delighted that we are all able to do something for the community following the hurricane and look forward to the school children arriving on the first day of term.”
The first ground has been broken for the reconstruction of the school, which is due to open in September 2019.
It will have state of the art classrooms with smart boards, computer suites, library, solar panels, wheelchair access and therapeutic suite for instruction of specially gifted kids.
REIDsteel, which celebrates its centenary next year, designed the building to withstand 185 mile per hour winds and earthquakes based on Unified Building Code Occupancy Category III and IV. All of REIDsteel’s 26 buildings in the British Virgin Islands survived with only superficial damage after the hurricane which lashed the region last year.
Tata Steel is helping with the supply of ComFlor® floor decking and providing Colorcoat® pre-finished steel including Colorcoat Prisma®, whilst Cardiff based Euroclad are giving finished roof systems. Thirsk-based National Tube Stockholders has given steel tube and steel hollow sections, Joseph Ash Galvanising is hot- dip galvanising the structural steelwork and Ayrshire Metal Products has given secondary steel – cold rolled purlins Barnsley-based BAPP has supplied industrial fasteners and bolts, Powell Gee of Shrewsbury has supplied fixings for floor decking and the external cladding envelope. Kestrel Liner Agencies, a global Caribbean shipping specialist which offers weekly sailings from more than 145 ports to the Caribbean basin, is helping with shipment and Meachers Global Logistics with shipping services.
Andy Thorne, Kestrel group chairman, said:
“In the immediate aftermath of Hurricane Irma and Maria we were able to get people on the ground and provide specialist logistical and financial support to the region. A year on we are delighted to team up with our customers and partners to help rebuild the school. Our mission statement says it all, ‘Global reach – local focus’.”
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.
The partnership of Nucor and Danieli teams will bring the Gallatin casting and rolling plant to the next level of high-quality production and competitiveness. This is the first time that a classical compact thin slab casting and rolling plant is fully reconfigured into an ultra-modern QSP® (Quality Strip Production) plant.
Both Nucor and Danieli teams are committed to set a new benchmark in Casting and Rolling Technology. Formerly known as the Gallatin Steel Company, the thin slab rolling plant located in Ghent, KY has a name plate capacity of 1.6 million shTPY of hot rolled coils having a thickness range from 1.4 to 12.7 mm, widths up to 1,625 mm and maximum coil weight of 35 shTon.
The existing plant operates a 185 t twin shell DC EAF, a single LMF, a vertical caster, 206 m tunnel furnace, a six-stand close-coupled rolling mill, traditional laminar cooling and one down coiler. The current capabilities of the steel plant are mostly structural steel, micro-alloyed grades and thin line pipe grades. Like similar compact plants, Gallatin was originally designed for doubling the annual capacity by means of a second meltshop, second vertical caster and tunnel furnace connected by a swivel ferry system to the in-line HSM.
The new equipment was originally meant to be a copy of the existing one. In October 2014, Nucor became the owner of the Gallatin Steel Company and has recently approved an investment to advance the technological capabilities and competitiveness of the Nucor Steel Gallatin Sheet Mill. Danieli is the selected technology supplier for the complete equipment and automation system, from raw materials to hot rolled coil.
In full partnership spirit, the Nucor and Danieli team of specialists agreed to re-engineer the plant by changing the original concept into an advanced QSP® plant having improved thermomechanical rolling capabilities thereby expanding production of AHSS grades, API line pipe steel grades and a number of other value added grades.
The revamped plant includes a high performance DC EAF and Twin LMF, and future provision for vacuum degassing. Being equipped with state of the art technology, the new meltshop will make use of the most recent process management tools, including Q-MELT, which is a key aspect to optimizing the transformation costs. After the upgrade, the complete production will be delivered by a single strand vertical curved caster having a total capacity of up to 3.0 million shTPY. The new caster represents the 5th generation of Danieli high production slab casting machines.
The slab will be delivered to the rolling mill by a new tunnel furnace via a swivel-type ferry system. The layout allows for the installation of the new caster and first portion of the tunnel furnace and swivel system without affecting the mill’s production. Furthermore, two new roughing mills will be added to expand rolling capabilities. The six-stands finishing mill will be retained but will be widened and upgraded with new interstand guides, loopers and new bending and shifting system. This will enable rolling strips as wide as 1,870 mm.
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).
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.
Two more orders from Valin Xiangtan and Hengyang Valin Steel Tube
Following recent orders from Maanshan Iron & Steel for a new bloom caster and Huaigang Special Steel for a caster upgrade with the Q-SOFT technological package, another two Chinese top steel producers, Valin Xiangtan and Hengyang Valin Steel Tube, chose Danieli casting technology to improve their steelmaking plants.
Valin Xiangtan awarded Danieli with the order for a new bloom caster to be installed in their Hunan steelmaking facility. It will be a 14-m radius, 5-strand machine for 280×280-mm and 350×430-mm blooms in a variety of special carbon steel grades, from low carbon up to high carbon, such as bearing steel. The caster will be equipped with two electro-magnetic stirring systems, soft and hard reduction packages, and run by Danieli Automation L1 and L2 systems. The Liquid Pool Control (LPC) system will provide accurate and balanced secondary cooling, with controlled stirring and reduction processes for each type of steel produced.
Hengyang Valin Steel Tube ordered “Eco Power Moulds” to increase caster productivity.
Eco Power Mould is the latest evolution of Danieli Power Mould technology which allows fast casting thanks a highly efficient thermal exchange.
The installation of this revolutionary mould will allow Hengyang Valin to enlarge the casting section and increase productivity without adding an additional strand.
Further, this solution will allow Hengyang Valin to incur lower CapEx and a short shutdown.
The revamping project also will include the supply of spiral-design, secondary cooling system for more uniform and gentle heat removal, and the Danieli Automation Q-Mould package to monitor the status of the mould and oscillation to continue guaranteeing top-quality cast blooms.