Tag Archives: Primetals Technologies

Acciaieria Arvedi issues final acceptance certificate for electric arc furnace from Primetals Technologies

  • Production capacity up to 1.4 million metric tons per annum
  • Integrated dedusting and heat recovery system improve environmental balance
  • Commissioned in just 31 days, two weeks before the agreed deadline

Acciaieria Arvedi S.p.A., an Italian steel producer, has issued Primetals Technologies the final acceptance certificate for a new electric arc furnace. The furnace was installed in the Cremona Steel Works. The production capacity is 1.4 million metric tons of crude steel per annum. The order also included a dedusting system for primary and auxiliary dedusting, and for supplementary extraction points. This is combined with a heat recovery system, which uses the thermal energy in the furnace offgases to generate steam, which is then used in the works’ three pickling plants.

The new 150-ton electric arc furnace from Primetals Technologies increases the production capacity of Acciaieria Arvedi, and reduces conversion costs. The tap-to-tap time is just 36 minutes and is supported by single bucket operation. This enables around 200 metric tons of crude steel to be produced each hour. The electricity requirement of the furnace lies between 340 and 350 kilowatt hours per metric ton. The necessary energy is provided via a transformer with a power of 155 MVA. The furnace is usually charged with a mixture of 65 percent scrap iron, 25 percent pig iron and 10 percent HBI (hot-briquetted iron). The scope of delivery also included five refining combined burner (RCB) systems, burners for post-combustion , a newly developed electrode control system (Melt Expert), the FluidGuard system – a comprehensive water leakage control system, and a new type of automatic tap hole filling. This increases safety as no personnel need to be near the furnace. Primetals Technologies also supplied a level 2 process optimisation system, well prepared for Industry 4.0.

An existing dedusting system was modified for the new electric arc furnace. The total extraction volume has been increased by installing an additional filter for both auxiliary and supplementary extraction points on the new electric arc furnace. The dedusting system meets the strictest European environmental requirements, as it achieves residual dust contents of less than five milligrams per standard cubic meter of air.

To optimise the energy balance of the plant, the waste heat from the electric arc furnace is recovered and is used to generate steam. Some 17  tons of steam are generated per hour from the energy recovered from the waste heat. This steam is used for the three pickling lines in the steel works. The energy recovery system replaces the existing gas boiler in the steel works, thereby reducing gas consumption and thus energy costs.

Acciaieria Arvedi S.p.A. is part of the Arvedi Group based in Cremona, Italy. The works has two production lines for flat products. In addition to the steel works for the production of liquid steel, there are two casting-rolling lines in operation. One of these lines uses the innovative Arvedi ESP (endless strip production) process and was realised in collaboration with Primetals Technologies. Production is mainly concentrated on special steels, in particular high-strength steels and dual-phase steel (DP), as well as thin and ultra-thin sheet metal, which can replace cold-rolled products in many applications.

Electric arc furnace from Primetals Technologies at the Acciaieria Arvedi plant in Cremona, Italy.

Source: Primetals Technologies

Transfer bar cooling system from Primetals Technologies commissioned at Tata Steel Port Talbot hot strip mill

Cooling system increases production capacity by approximately 150,000 metric tons of hot strip per year

Recently, a transfer bar cooling system supplied by Primetals Technologies was commissioned in the hot strip mill of Tata Steel´s Port Talbot integrated steel plant located in South Wales, United Kingdom. The purpose of the cooling system, installed after the roughing mill, is the precise control of the strip temperature before it enters the finishing mill, without having to slow down the roughing mill. This results in an increase of production capacity by approximately 150,000 metric tons of hot strip per year. The system is based on Primetals Technologies´ Power Cooling technology. The order to install the transfer bar cooling system was awarded to Primetals Technologies April 2017.

Transfer bar cooling system from Primetals Technologies installed at the hot strip mill of Tata Steel´s Port Talbot integrated steel plant located in  South Wales, United Kingdom.
Transfer bar cooling system from Primetals Technologies installed at the hot strip mill of Tata Steel´s Port Talbot integrated steel plant located in  South Wales, United Kingdom.

 

The Power Cooling technology from Primetals Technologies is especially designed to reach highest cooling rates. This technology can be implemented as intensive cooling between the roughing and the finishing mill area. This leads to improved strip temperature control for increasing productivity.

Tata Steel Port Talbot’s hot strip mill has a nominal capacity of about 3.4 million metric tons of steel per year. The Port Talbot site is an integrated blast furnace based steel complex, which produces slabs, hot rolled, cold rolled and galvanized coils. The transfer bar cooling system installed after the roughing mill exit table employs a total of 18 spray headers in its initial configuration, nine top and nine bottom headers, and may be extended with additional headers at a later time. The total length of the transfer bar cooling system is approximately 10 meters. In order to cope with a large variety of steel grades and process requirements, especially the minimum surface temperature of the bar during cooling, the flow rates of the Power Cooling headers are adjustable over a wide range, so that a lower cooling intensity is also achievable as required for each individual product. Each header is flow-controlled by a separate ball segment valve.

Transfer bar cooling is based on Primetals Technologies´ Power Cooling

In addition to the transfer bar cooling system itself, Primetals Technologies´ scope of supply encompassed the affected roller table, including motors, drives and transformers, an overhead tank, a booster pump station and a cross-spray pump station. Level 1 and level 2 automation as well as the interface to the existing hot strip mill automation system was also provided.

The transfer bar cooling technology was tested for the first time at voestalpine Stahl in Linz, Austria in 2003. The first industrial installation was set up at Thyssen Krupp Bruckhausen in Germany in 2013.

Source: Primetals Technologies

EU Steel Buyers Grapple with Safeguard Implications

Primetals Technologies supplies new Arvedi ESP line to Henan Yaxin

  • Casting-rolling plant produces high-quality, ultra-thin strip to enter new market segments
  • Rolling of reproducible strip thicknesses down to 0.8 mm
  • Total production capacity of 1.6 million tons per year with potential for 2.5 million tons per year
  • Energy consumption and related costs are reduced by up to 45% compared to conventional casting and rolling processes
  • First mini mill combination of Quantum EAF and ESP with major reduction in CO2 and NOx emissions

Chinese steel producer Henan Yaxin Steel Group Co., Ltd. (Henan Yaxin) has placed an order with Primetals Technologies for the supply of an Arvedi ESP (Endless Strip Production) line. The casting-rolling facility will be part of a new steelmaking facility currently under construction in Fuding City, Fujian province . The liquid steel will be produced by two EAF Quantum electric arc furnaces ordered from Primetals Technologies earlier this year.

The Arvedi ESP line has a design capacity of 1.6 million metric tons per year with the potential to produce later 2.5 million tons per year. It is capable of rolling strip to a reproducible strip thicknesses down to 0.8 mm. This will enable Henan Yaxin to produce high-quality, ultra-thin strip to enter new market segments. Compared to conventional casting and rolling processes, energy consumption and the related costs are reduced by up to 45%. This also results in a major reduction in CO2 and NOx emissions, minimizing environmental impact. This is the first environmental friendly mini mill installation worldwide where EAF Quantum and Arvedi ESP are combined. The plant is scheduled to go into operation in 2020.

The privately-owned company Henan Yaxin operates integrated and compact steelmaking plants in five provinces and cities in China, and can produce more than ten million metric tons of steel each year. The Arvedi ESP plant will allow Henan Yaxin to better serve the highly attractive local and export markets for high-quality, thin-gauge strip products. The 180-meter-long plant is far more compact than conventional casting and rolling mills. The new plant is designed for an annual production capacity of 2.5 million tons of high-quality, ultra-thin, hot-rolled strip products with widths of up to 1,600 mm and thicknesses down to 0.8 mm. Carbon steels, high-strength low alloyed (HSLA) grades and dual-phase steels will be produced.

Primetals Technologies is responsible for the engineering of the Arvedi ESP plant and will supply mechanical equipment, media-control systems, technological packages and automation systems. The entire line is controlled by a completely integrated basic (Level 1) and process optimization (Level 2) automation, which fully controls all casting and rolling operations.

In the Arvedi ESP process, hot-rolled coils are produced in a linked casting and rolling plant directly from liquid steel in a continuous and uninterrupted manufacturing process. The line commences with the casting of a thin strand that is subsequently rolled to an intermediate thickness of 8 to 20 mm in a 3-stand high-reduction mill positioned at the end of the caster. After reheating in an induction heater, rolling of the transfer bar to the targeted end thickness is performed in a 5-stand finishing mill followed by laminar strip cooling. Strip cutting is then carried out by means of a high-speed shear immediately prior to coiling to coil weights of up to 32 metric tons. The full range of steel grades can be flexibly produced on Arvedi ESP plants.

As a result of the endless strip-production mode of Arvedi ESP lines, repeated threading into the individual rolling stands is not necessary. This is the basis for the production of ultra-thin strip gauges down to 0.8 mm thicknesses. The tolerance values for the required strip geometry are fully met along the entire length of the rolled product. Endless production is also decisive for assuring the homogeneity of the steel microstructure, grain size, yield strength and tensile strength. Because the strip is continually under tension, the cobble rate is below 0.1%, even when producing more than 50% below 1.2 mm thickness. Yield values exceeding 98% are reached because cropping of the strip head and tail ends is not necessary.

Arvedi ESP plant in operation

Source:  Primetals Technologies

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Primetals Technologies to modernize automation system in Novelis Pinda aluminum hot strip mill

Voestalpine Stahl GmbH has given Primetals Technologies the final acceptance certificate for the Seku 3.1 secondary dedusting system in the Linz plant. The system was constructed during the course of voestalpine’s SEK MET 4 project and cleans up to 700,000 actual cubic meters of off-gas from secondary metallurgical facilities per hour. The expected clean gas dust content is less than one milligram per standard cubic meter, which is considerably less than the legally prescribed limit. The system was ordered from Primetals Technologies in the third quarter of 2014 with the aim of further increasing the capture rate and the separation of dusts in downstream metallurgy.

The new secondary dedusting system has a total of 24 new and two existing extraction points as well as an existing alloying group with multiple extraction points, which are combined into seven groups for the ladle furnaces, the alloying groups, the conditioning stand and the bunker extraction. A 2,300 kilowatt, induced-draught, speed-controlled fan enables the extraction capacity to be adjusted to match changing operational conditions. In normal operation, the system cleans 610,000 working cubic meters of off-gas per hour at temperatures up to 130 °C. The maximum capacity is 700,000 cubic meters per hour. The dust is separated by bag filters with a total surface area of almost 9,900 square meters. The expected clean gas dust content is less than one milligram per standard cubic meter. The filters are equipped with compressed-air cleaning developed by Primetals Technologies. This enables the bags to be cleaned gently but effectively with economical use of the compressed air. The electric motor of the induced-draft fan is partially enclosed to minimize noise emissions. Troughed chain conveyors and pneumatic conveyors carry the separated dust to either a silo or the granulation plant.

The scope of delivery also included the mechanical and electrical equipment, the instrumentation and control equipment, and the visualization. Primetals Technologies was also responsible for the engineering, installation and commissioning of the plant. SGS Industrial Services from Dorf an der Pram, Austria, performed the mechanical assembly work such as structural steel work, piping, raw and clean gas ducts, clean-gas stack, fan system and reconnection work on existing system sections.

Source: Primetals Technologies

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Power X-HI stainless steel tandem cold mill from Primetals Technologies produces first coil at Beihai Chengde

  • Plant capacity is 600,000 tons of cold strip per year
  • Designed to produce stainless steels of AISI grade series 200 and 300
  • Short cold test phase and first coil produced within three months

In late December 2015, a stainless steel continuous tandem cold mill (TCM) supplied by Primetals Technologies to Beihai Chengde Stainless Steel Co. (Beihai Chengde) produced the first coil at the Beihai plant in the Chinese Guangxi Province. The mill consists of a Power X-HI type, five-stand, continuous tandem cold rolling mill and a heavy laser welder. The rolling mill has a rated capacity of 600,000 tons of cold strip per year, and is designed to produce AISI grades series 200 and 300. The cold test was performed within 17 days and the first coil produced within only three months. The order was placed in the mid-2013. It was the second order for an X-HI and the third order for a continuous TCM for stainless steel that Primetals Technologies had received from China.

Beihai Chengde is active in nickel mining and the production of narrow stainless steel strip. The company intends to use the new cold rolling mill to start producing wide strip. The continuous rolling mill handles hot-rolled, annealed and pickled stainless steel. It is able to achieve exit thicknesses from 0.3 to 3.0 millimeters from entry thicknesses of between 1.0 and 5.0 millimeters. The width of the strip varies between 800 and 1,300 millimetres.

The continuous rolling mill line comprises three main sections, each separated by strip accumulators. The entry section includes a double uncoiler station, each equipped with coil storage facilities, coil loading car and overhung mandrel uncoiler together with coil opening, flattening and shearing equipment. The Primetals Technologies welding machine is of heavy laser type (LW21H) and includes strip centering and strip cutting facilities as well as diagnostic systems.

The mill section includes five stands of Power X-HI type with associated high tension bridles and rinsing section to remove emulsion from the strip surface. The rolling speed is 400 meters per minute. The rolling stands are designed for a flying roll change, so production will not have to be interrupted to change the work rolls. This increases productivity and reduces output losses.

The exit section comprises exit bridle, inspection station, rotary shear, scrap and sample cutting, two recoilers, belt wrapper, paper interleaving feeding equipment, spool loading and coil unloading car with associated coil banding and storage. The strip looper between the rolling line and the exit section decouples the rolling process from the downstream activities, such as strip inspection and coil shearing. This means that these are no longer limiting factors on the mill throughput.

The scope of delivery also included variable-speed Sinamics drives with a total power of 22,000 kilowatts, and the basic (level 1) and process (level 2) automation. A Simatic WinCC-based solution handles operator control and monitoring tasks. It also enables distributed supervision, and features easy-to-use diagnostic and alarm functions.

X-HI is a registered trademark of Primetals Technologies in some countries.

Source: Primetals Technologies

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Primetals Technologies to engineer continuous caster and secondary metallurgy facilities for MMKI

  • Annual production capacity to increase to four million metric tons of slabs
  • Project includes ladle furnace, alloying station and dedusting system
  • Expanded product portfolio
  • Cross-section heat-pacing solution to coordinate steel production with casting operation
  • Reduction of dust content in cleaned gas

Primetals Technologies has received an order from Ukrainian steel producer “Iljitsch” Metallurgical Combinate in Mariupol (MMKI) to engineer a continuous slab caster, a twin ladle furnace with an alloying station, and the associated dedusting system. The two-strand caster CC4 will be designed to produce 2.5 million metric tons of slabs per annum. This will increase 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 will coordinate 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 will be used to help set the desired steel grades and the correct casting temperature. A transformer with a rated power of 28 MVA will provide the electrical energy for the ladle furnace, enabling a heating rate of 4.5 °C per minute. Primetals Technologies will design a dedusting system to clean the offgases from the ladle metallurgy facility. This will process around 206,000 standard cubic meters per hour, and reduce the dust content of the cleaned gas to less than twelve milligrams per standard cubic meter.

The engineering order for the continuous slab caster covers all the installations from the ladle turret and the ladle car through to the exit zone with its weighing, torch cutting, marking and deburring machines. The caster from Primetals Technologies will have a machine radius of nine meters and a metallurgical length of 29.8 meters. It will cast slabs with thicknesses of 170 and 250 millimeters in widths ranging from 900 to 1,550 millimeters. The maximum casting speed will be 2.2 meters per minute. It will process peritectic and peritectic alloyed steels, low, medium, high and ultra-high carbon grades, as well as medium-carbon alloyed steel. The caster will be 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 will be equipped with smart segments and I-Star rollers. DynaGap Soft Reduction, the Dynacs 3D secondary cooling model, and DynaJet nozzles will also be installed, making it possible for MMKI to produce a wide variety of high-quality grades. The interior quality of the slabs will also be improved.

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. Primetals Technologies previously supplied continuous slab caster CC3 to Mariupol, where it has been in operation since 2005.

Source: Primetals Technologies

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