Vol. 16 No.

04

February 2014

Editor & Publisher

NIRMALYA MUKHERJEE
Director
SHAMPA MUKHERJEE

Slow Consumption Trend Creates Doubts over

Steel Production Target
World Steel Association estimated that steel demand in India would grow at

Executive Assistant
ANKIT MUKHERJEE

3.4 per cent in 2013 and touch 74 million tonnes, higher than the 2.6 per

Editorial Advisor
MANORANJAN MUKHERJEE

cent growth rate recorded in 2012. In 2014, the demand is poised to grow at
even a higher rate of 5.6 per cent helped by efforts to implement structural

Sub-Editor
ARNAB MONDAL
DGM - PR
PRADIPTA SENGUPTA
Sr. Executive - Business
Development
AYAN BHUIYAN
Production Manager
DEO KANT JHA
Design & Layout
SUMALENDU BASU
Scanning & Processing
STEEL & METALLURGY
Regd. Office

reforms.
Also a research shows that steel consumption is expected to grow at an average rate of 6.8 per
cent to reach 104 million tonnes by 2017 driven by rising infrastructure development and
growing demand for automotives.
However, steel consumption in India continued to languish at 0.7 per cent growth Y-o-Y during
April -February period of current fiscal at 67.25 million tonnes over the same period last fiscal
at 66.78 million tonnes.
Typically steel consumption rises by 1.1 times of the GDP growth rate for an economy. It
remained largely subdued so far in the current fiscal considering India's slow GDP growth.

6,Upendra Nandy Road,

India's economy grew below expectations at 4.7 per cent in October-December on falling

P.O. Sheoraphuli, Hooghly

output in the manufacturing sector. The country's GDP had expanded 4.8 per cent in the July-

Pin : 712223, Ph.: 2632-3313

Corporate Office
#1A, SHAKTI

September quarter and 4.4 per cent in April-June. Growth in the first nine months (AprilDecember) was 4.6 per cent.

166, Rajdanga Nabapally,

The poor consumption scenario is in contrast with the latest figures by World Steel

EM Bypass Rashbehari Connector

Association which has revealed that India's steel production increased by 3 per cent to 59.62

(Behind State Bank Of Indore),

million tonnes in the first nine months of 2013, as against 57.90 million tonnes in the

Kolkata 700 107, INDIA

corresponding period last year. Moreover, the data showed that India's rate of production

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growth was the second-best following China among the major global producers.

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Email : info@steelmetallurgy.com

India's steel production capacity is expected to increase to around 135 million tonnes in next

Web Site : www.steelmetallurgy.com

1-2 years from the current level of about 90 million tonnes per annum as all steel producers

Printed by Nirmalya Mukherjee at

have taken up capacity addition projects. So, in all likelihood, an oversupply situation looms

Aparajita Print House

afar owing to this disparity in consumption growth and production growth.

91A, Baithakkhana Road,

Kolkata-700009

So, which are the overseas markets to for this surplus volume? How to increase domestic

and published by him from

consumption?

6, Upendra Nandy Road

P.O. Sheoraphuli, Hooghly, West Bengal

Subscription Amount w.e.f. 1st January 2013

Annual Subscription 1 year Rs. 6,000/= 400
Annual Subscription 2 years Rs. 11,000/= 700
Annual Subscription 3 years Rs. 14,000/= 900
Single Copy Rs. 600/- 40

It is high time for one and all associated with this industry to take up a cohesive approach to
find answers to these questions. Else, the coveted production figure will remain a mystical
figure with no reason to step up production for long term viability.

From The Desk

Industry
Analysis

Realising Indias Steel

Dream: Some Suggestions

14

Technology
Update

20

A Look Through The Saga

Of Essar Steel

Risk More Weight With

igus Drylin W System

Company
Profile

49

Precision Speed and

Length
Measurement
(down to Zero) Laser Surface Velocimeters LSV
1000 / 2000

Zumbach At Tube 2014

Most Modern SBQ Production Technology

Modernization Solutions
for Long Product Rolling
Mills to Increase Productivity, Utilization and
Product Quality

45

ECOFLUX * Corrugated
Tube Heat Exchangers

Special
Feature

Rolling Mills

Product
Profile

32

News Desk

51

Statistics

66

Industry Analysis

Realising Indias Steel Dream- Some Suggestions

S.S. Beriwala
Chairman, Shyam Steel Industries Ltd.

he fortune of steel industry is intrinsically linked with the economic

growth and development of any country. India is the 4th largest steel producer logded 5.86% growth in production
in FY : 2012-13, the largest among the
major global producers.
India Steel Vision 2020 or 2025 proposes to draw a roadmap for the Indian Steel Industry, the next decade to
produce 300 million tonnes of steel by
2025. Whether it will remain a dream
or we will fetch the target, is the main
question before the country.
The Government expects the country
to become the 2nd largest steel producer by 2015 on the back of capacity
addition. But the experts take it otherwise. Following points may be taken
and considered sincerely to reach the
target:

1)

Raw Material Sourcing.

2)

Technology Status.

3)

R&D Facilities.

4)

Logistics and Infrastructure.

5)

Market Demand.

Let us compare one by one.

Raw Material Sourcing

Iron Ore
India has abundant quantity of Iron

Ore, the basic raw material required for

Steelmaking. But the easy availability of
Iron Ore to the actual consumers at a
fair price and right quality specially to
the small players of Steel, who produce
about 50% of the total Steel in India is
far from reach. Even some quantity of
Iron Ore was imported from abroad to
feed the actual consumers, last year.
The reason mainly goes to mismanagement of the Steel Ministry, Government of India and factual policies. The
large blocks of Iron Ore mines were
allotted to mostly main Steel producers for captive mines and to NMDC,
OMDC, OMDC and JMDC as merchandise mines to feed the domestic small
Steel players. With the passing of
time Government of India as well as
states have forgotten the main principle of development of the country

STEEL & METALLURGY

FEBRUARY 2014

and the Steel industry and the above

agencies started running behind making money by auctioning and exporting Iron Ore at the exorbitant prices.
On the one hand Government wants
the Steel industry to grow and give
proper competition to the world and
on the other hand the main raw material available here in India started
to be diverted out of India. This point
should be considered very sincerely
by the apex bodies, the media and the
Government i.e. States as well as Centre. The Government Agencies should
first feed the domestic industry charging Cost +20-25% premium. If they
do not agree, their leases should be
withdrawn and the Mines should be
auctioned globally. The Government
will receive a good exchequer at least.

Industry Analysis
Here in India, we have no such institutions even after such a long time
of independence. The largest producer of Steel i.e. SAIL/TATA/RINL
even whenever establishe their new
Steel Plant, they go in joint venture
with the Plants in abroad and claim
it their modernisation. Research
and Development work is negligible.

R&D Facilities
The suitable institution should be
equipped with full facilities for R&D
and should be opened by the Government and then autonomous status
should be provided to such institution
with strict laws and terms & conditions.

Coal
I am not taking the matter of Coking
Coal, which is not easily available in
India. We should consider about the
availability of Non-Coking Coal, which
is available plenty in India, but owing to
mismanagement of Coal India Limited,
negligible efforts for underground mining since a long time and the faulty policies towards the supply of Non-Coking
Coal to the actual Steel Consumers,
by Government of India. Non-Coking
Coal has also become a scarce raw material and the huge quantities of NonCoking Coal are being imported to
feed the actual Consumers. The large
blocks should be allotted to some big
Government agencies whether State
or Central with the complete environment and forest clearance to feed only
domestic small manufacturers of Steel
in India at fair prices with the quality
as per the declaration in the invoices.

726.33 million tonnes, whereas India

produced only 78.12 million tonnes
during the same fiscal. The considerable point is that China produces each
so much of Steel, which is the total
production in India. But we are very
happy on the pretext that we are the
4th largest Steel Producer. Actually
China has established several institutions, who research the technology regularly. Steel producers and the
manufacturers have no other choice
but to be affiliated with one or the
other institutions for the technology.

Technology Status
The Government should adopt practical policies pertaining to the technology towards the development of the
Steel industry. China had produced the
Steel during the fiscal year 2011-12 at

STEEL & METALLURGY

FEBRUARY 2014

Logistics &
Infrastructure
It is unfortunate part of India that the
Government had been following whimsical populist policies and disburses the
funds to unproductive sectors. Paucity
of funds and some other faulty policies of land acquisition etc. have not
allowed the Government to bring the
logistic and infrastructure, according
to our needs. We are always lagging
behind with the target in infrastructure
and logistics. This situation is so bad
that we have to pay much more freight
from Odisha to Kolkata in comparison

Industry Analysis
to the freight from Odisha to Colombo.
It is a surprising fact; we fail to feed
even our power projects with the
proper coal through existing logistics.
What will be the position in 2025, if
we will have to cop up with the five
times more requirement of raw materials; finished goods and power.
The logistics and infrastructure cannot be created overnight. We should
take practical policies and initiative
should be given to infrastructure and
logistics so that industry as well as agriculture growth may happen properly.

Suggestion
a)

There should be single Ministry comprising of Steel, Power and

Commerce and Industries, also comprising of the Secretaries from Finance, Logistics and Infrastructure.

b)
A single window channel should
be set up for the necessary clearance for logistics and infrastructure planning inclusive of necessary clearance from environment,
land acquisition and forest etc.
The Government should adopt very
strict rules for land acquisition towards
the public interest for logistics and infrastructure and payment to the land
owners should be made immediately
at fair market prices. No political parties should be allowed to raise the voice
for increase in land price, afterwards in
favour of original land owners, which
may occur with passing of the time.

Market Demand
Government should adopt such policies, which may create Steel demand in
the market. A minimum of 70% of the
Steel produced in India should be consumed domestically in India itself and
the rest should of 30% should be exported worldwide. It should not be left
over the large producers only to feed

the demand in India on the lame excuses as it has been done in recent Gadget
Notification No. 4(8)2010-SD-1 dated
12.12.2013 issued by Government of
India, Ministry of Steel. It appears from
the Notification that the Government
has instructed the Steel consumers to
purchase Steel only from the integrated
Steel Plant. The definition of integrated
Steel Plant has been given having the
minimum capacity of 1 million tonne
per year as per the said notification. It
appears that only such producers are
capable to feed those consumers. It
seems that the Notification has been
issued in haft. It is pertinent to state
that since independence not a single
infrastructure project has issued the
tender or fixed auction for even 1 lakh
tonnes Steel at a time, not to speak of
10 lakhs tonnes as mentioned in the
Notification. If the Steel producers,
large or small, failed to supply the Steel
as per the relevant quality and within
the time schedule towards supply, it
is automatically be blacklisted. The
Steel Ministry has no authority to assess the capability of supply of Steel.

of its small industries. But the Steel

Ministry appears to perish this sector, which produces about 50% of the
total Steel in India. This will result to
cartelization of a few big ones and
the projects will have to bear the exorbitant prices of Steel unnecessary.

The backbone of every developed

country stands on the development

Some of the following points may

be reckoned, as given below:

STEEL & METALLURGY

FEBRUARY 2014

Being a core sector, the Steel industry reflects the overall growth of the
economy in the long term. Consumption of Steel has taken to an indicator of economic development. The
demand of Steel is also derived from
various sectors such as infrastructure,
automobiles, consumer durable, engineering industries, housing & real
estates etc. each sector of producers should be given equal preference.
With the Steel consumption of only
approximately 70 million tonnes, sky
is scope for development of Steel
industry in India. We should formulate such policies so that we can
feed the world with the cheapest
Steel, which we have, the capacity.

Industry Analysis

1)

Logistics should be proper in such way that the mines and

queries should be linked with
the sufficient railway tracks and
roads to all the cities in India.

2)

The administration both, at

the State and Central level, should be
strict against anti-social activities in the
name of local syndicate for logistics.

3)

GDP of 8% sustainable in next

decade-Higher growth requires mobilisation of higher resources and the
sufficient number of use; US$1 trillion
investment in infrastructure in the next
5 years through Public Investment Plan
(PPP), recommendation of non-plan
expenditure, higher flow of FDIs and
ofcourse full utilisation of such money.

4)

Empowered
co-ordination process on clearances for high
impact
Infrastructure
Projects.

5)
egy

Multi
pronged
stratto
boost
manufacturers.

6)

Very low rate of interest should

be imposed for purchase of land, Plant
and Machineries and installation charges for manufacturing units. No industry
can be established or run competitively
on the higher rate of interest, which
at present comes to 15/16% globally.

7)
To create an atmosphere
where workers and staff are promoted
to produce at par with the workers and
staff abroad. Though it is stated that
cheap labour is available in India, but
no Government tries to verify the productivity of workers and staff in India,
in comparison with global productivity.
Last but not least, the Government
should make proper amendment in the
Constitution of India in such a way to

i)

Allow 2/3 political parties only

STEEL & METALLURGY

10

FEBRUARY 2014

to come in power or to contest the

election so that hang Parliament can
be avoided and elected Government
can liberally work at least for 5 years.

ii)
Administration
should
be free of any political interference. The Ruling party/Ministries
should only be permitted to formulate firm and stable policies and
iii)

Strict action may be taken against the authority of whatever position it is, if found guilty.

iv)

This will automatically reduce the day-to-day interference of

judiciary, which is not the healthy
trend for any democratic country.
Apex bodies, the local Chambers and Associations should come forward to bring
the facts before the Ministers in place
of praising every policy wrong or right.

Special Feature

A Look Through The Saga Of Essar Steel

F

Genesis & Evolution

or the young Essar Group that was

born with a vision to match the
step of developing nation that was in
the making, it was a giant leap to venture into the steel production sphere.
The journey started in 1989 by setting up two DRI modules at Hazira in
the state of Gujrat with capacity of 0.9
million tonnes (MT). Then, the company advanced to build a pellet plant
in Visakhapatanam, and eventually a
fully integrated steel plant in Hazira.
Today with a production capacity 14
MTPA and footprint in India, Canada,
USA, Indonesia and the Middle East
and significant presence in the key
markets of Asia, Europe, Africa and
North America, Essar Steel is a world
class flat steel producer to reckon with.

Current Operations

ira

Essar Steel India Limited, Hazwith capacity of 10 MTPA

Essar Steel Algoma, Canada with

production capacity with 4 MTPA

PT Essar, Indonesia with a downstream production capacity of 0.4 MTPA

Essar Taconite Plant, USA under construction with a production

figure
of
7MTPA
Essar Steel India is an integrated steel
producer with an annual production capacity of 10 million tonnes which comprises ore beneficiation, pellet-making,

Aerial view of the Essar Steel complex at Hazira, Gujarat, India

iron-making, steel-making, and downstream facilities including cold rolling

mill, galvanising, pre-coated facility,
steel processing facility, extra wide plate
mill and a pipe mill. The Hazira Steel
Complex has modern infrastructure
like a power plant and a port that can
handle 30 million tonne cargo annually.
Essar Steel, Canada is an integrated steel producer with a flexible
manufacturing process and specialises in the production of hot and
cold rolled sheet steels in carbon
and high strength low-alloy grades.
Essar Steel Minnesota LLC, with an access to over 1.4 billion tonnes of iron ore
reserves, is Essars ambitious project.
PT Essar Indonesia is the largest producer of cold rolled steel in Indonesias private sector with a current
rolling capacity of 0.4 MTPA along
with a galvanising line of 0.2 MTPA.

STEEL & METALLURGY

14

FEBRUARY 2014

Apart from this it operates an

8 MTPA Pellet Plant at Bailadila
and is setting up a 12 MTPA Pellet Plant at Dabuna in Odisha.

Product Basket
The company has specified plants for
value added steel products such pipes
and plates. It has leadership position
in the cold rolling, galvanising and precoated segments. Apart from that Essar Steel has the ability to provide all
kinds of steel with versatile production lines cut to length, slitting, shot
blasting, burnt to shape, trapezoidal,
and factory-welded beams through
Essar Processing and Distribution.

Milestones
In its 25 years of existence Essar has
many encouraging accomplishments
to its credit. In 2011 Essar Steel completed expansion and modernisation
of its Hazira Steel complex with a cost
of around Rs. 37,500 crores which

doubled the capcity to 10MTPA making

Hazira the single largest location flat
steel producer in India and the fourth
largest in the world. Essar Steel incurred
a cost of just $750 per tonne of steel as
compared to industry standard of US
$1 billion for a million tonnes of steel.
In 2007 Essar Steel achieved another
milestone by laying 267km slurry pipeline
which is the second largest in the world.
Essar has commissioned a 6MTPA capacity pellet plant at Paradip, Odisha
in the first phase of 12 MTPA plant.
This pellet plant Paradip along with Visakhapatanam pellet plant will provide
20 MTPA pellet capacity to Essar Steel.

Technological
Devolopment
Essar Steel has adopted three ironmaking technologies: HBI/DRI, COREX and BF. These technologies offer flexibility in raw material inputs:

The complex uses varying

grades of iron ore including lump
ore, fines, slimes, sinter and pellet

The complex uses different

energy sources, including natural gas, coking coal, COREX export
gas, BF gas and non-coking coal.
Also in its expansion and modernisation efforts, Essar Steel installed
worlds first 3-stand CSP plant by
SMS Siemag with an annual capacity
of 3.5 MTPA of hot rolled strips and a
range of products that cover carbon
steel as well as pipe grades silicon
and duel phase steels. The CSP Mill is
capable of producing HR strips down
to 0.8mm thickness, lowest in India.

Sustainable
Run
Sustainability is of
utmost importance
to Essar Steel that
has been ensured
with safety and
environmental
aspects that are
given due importance in the design,
construction and
operation of the
plant. The steel
complex reiterated
this effort with
adoption of COREX
process which has
better
environmental compatibility. This effort has
resulted in making Essar Steel the
lowest emitter of
greenhouse gases
and zero waste
among the Indian
steel
producers.

Processing
&
Distribution
Network
Essar Steel Processing and Distribution is Indias
largest steel solutions chain with a
capacity of 5MTPA,
located in seven
key industrial hubs
in India Hazira,
Pune, Chennai, Indore, Bhuj, the NCR
region, Kolkata and
three international

Special Feature

locations- Dubai, UK and Indonesia.

Essar Steel has laid countrys first and
largest supply chain in the country
with its retail distribution brand Essar Hypermart with 520 outlets which
provide customised services to original equipment manufacturers (OEMs)
and retailers, along with meeting the
requirements of small and medium
enterprises (SMEs) with transparency
on pricing, availability and quality.

The Journey Ahead

Essar
look

Steel has ambitious outfor

its
future
growth.

Essar Steel is focusing on the completion of its remaining capacity expansion by 2014, a plan that is expected
to boost earnings three-fold and stave
off liquidity crisis. The immediate challenges before the company are raw
material crisis, particularly drop in gas
availability and delay in constructing
the slurry pipeline from Dabuna Beneficiation Plant to Paradip Pellet Plant.
However, the company is taking various measures including completing the slurry pipeline and connectivity to the national grid to reduce
power costs, besides completion of
its coke oven plant. It also expects

STEEL & METALLURGY

18

FEBRUARY 2014

Odisha Government to allocate iron

ore mines as promised in the MoU.
The steel firm has also seen rise
in demand for exports in recent
months and expects the momentum to continue in the future.
Essar Steel is taking all measures to
shrug off the dilly-dallying in its financial and operational front to ensure
that all production capability come
on stream. Once the economy picks
up enough pace, Essar Steel will be
a major contender in Indias coveted
run up to touch steel production target of 300 million tonnes by 2025.

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Technology

Most Modern SBQ Production Technology

Guenther Schnell,
General Manager Proposal and Sales,
Wire Rod and Bar Mills, SMS MEER GmbH

Introduction

n 2006 the world wide first 3-roll

block for SBQ production with adjustment under load feature went into
operation at Deutsche Edelstahlwerke
(DEW) Siegen-Geisweid/Germany. The
great opportunities of the advanced
3-roll technology with the hydraulic
adjustment under load feature were
obvious. The adjustment under load
feature opened up possibilities in most
modern SBQ production which were
so far not available on the market.
The achievements and results after implementing the PSM set a new technology standard. After years of successful
operating experience with the advanced 3-roll technology a precise online measuring system in combination
with the closed loop size control was
added in order to achieve an even higher process transparency. The fully automatic control system is interacting with
the hydraulic gap adjustment system of
the PSM and thus able to directly react online under load on real time measured deviations from the target size.
In combination with the advanced
3-roll technology for most modern SBQ
production the 51st pouring reel line of
SMS MEER will go in operation in 2013.
This pouring reel line is based on 62

years operational experience and represents the most modern pouring reel
line technology.
Demands such as improved coil
formation and scratch free production of sensitive SBQ products is part of the advanced state
of the art pouring reel technology.
The advanced rolling technologies
for most modern SBQ production
are introduced in the technical paper and operational results shall underline the great potential of this
most modern rolling technologies.

PSM - The Advanced 3-Roll

Technology

duction technology.
The first advanced 3-roll block for wire
rod and special bar quality production went into operation at Deutsche
Edelstahlwerke Siegen/Germany (DEW
Siegen). DEW Siegen is part of the
SCHMOLZ + BICKENBACH Group, which
with around 11,000 employees are
the worlds largest manufacturer, processor and distributor of special steel
long products. They are rolling at their
Siegen works up to 460.000t quality
steels, ball bearing steel, spring steel,
cold heading steels, high alloyed stainless steels and tools steels per year.
DEW Siegen has a long experience in
3-roll technology since they were the
pioneer in 3-roll technology when they
started up in 1979 the first industrial
used 3-roll blocks for SBQ production.

A new innovative rolling technology

has been introduced in 2006 for special bar quality (SBQ) production and
is represented by
the Precision Sizing
Mill (PSM). This
advanced
3-roll
technology is already appreciated
at several leading
SBQ producers in
Germany, USA and
China and set with
its features a new
benchmark in the
field of SBQ pro- Figure 1. PSM 3-roll sizing technology at DEW Siegen/ Germany

Keywords: advanced 3-roll technology, hydraulic adjustment under load, PSM, closed loop size control, MEERgauge,
special bar quality (SBQ), sizing technology, free-size rolling, pouring reel technology, bar in coil production

STEEL & METALLURGY

20

FEBRUARY 2014

Technology
From their start-up experience followed by 25 years operating experience
of three 3-roll blocks of the first generation, DEW Siegen immediately identified one of the great key features of
the advanced 3-roll PSM which was so
far not available in the market: the hydraulic adjustment under load feature.
Well aware that, at that time, a pilot
installation has some risk and is also
challenging, however, due to the outstanding advantages of the PSM and
the great potential for further improvements of size tolerance they decided for
the advanced 3- roll sizing technology
supplied by SMS Meer. The first 3-roll
PSM went into operation at Deutsche
Edelstahlwerke Siegen/Germany 1) in
2006 replacing two of the three existing 3-roll blocks of the first 3-roll generation (Fig. 1). Today all sizes (22mm
85mm) are finished successfully
with the 6-stand 3-roll PSM fulfilling all market requirements with tolerances much better than required.
The PSM is offering all typical features
of the 3-roll sizing technology such as:

Single pass family rolling (Fig. 2)

- for all diameters
- for all steel grades,
- at any time

Free size rolling (9% of dia. / max.

3mm)
- for infinite sizes

(NOT ONLY discrete

sizes)
- requires less cassette/roll changes
- leads to less inventory (e.g. rolls,
guides)

Quick cassette
changing
- 5 min for individual or all cassettes

Figure 3. CARTA PSM - network structure

And beside all the typical features of

a 3-roll system, one of the outstanding key features in addition to the
before mentioned is the real time hydraulic gap adjustment capability under load which makes this machine
inimitable. Thanks to the advanced
closed loop Technological Control System (TCS) which is also used in other
applications such as section mills.
Instead of having a black box where
only the entry and exit size of the bar
can be measured, the TCS offers full
process transparency since each individual roll position and in addition, the
individual roll force can be detected.
Furthermore the system is able to compensate individual mill spring, feeder
variations and bar entering impacts
but also is able to balance temperature
variations along the bar.
Based on the TCS closed
loop control system, the
system can adapt to different rolling conditions
in order to immediately
optimise the system for
achieving maximum yield
on highest availability.

Figure 2. PSM - Single Pass Family Rolling Principle

The setup for achieving

the required quality of

STEEL & METALLURGY

22

FEBRUARY 2014

the final product will be planned by

the SMS Meer Computer Aided Rolling Technology Application System
(CARTA) for the PSM. Set point selections for the rolling mill setting
can be easily determined and transmitted to the rolling mill automation
system via the data network (Fig. 3).
The core element of the CARTA PSM
is a central high-performance server
with databases for mill parameters and
result values. The server is interconnected with the basic automation system and can be linked to an unlimited
number of workplaces, for example
the rolling mill managers, technologists
or the roll shop and operator staff2.
To quickly determine the rolling data
the CARTA PSM system already includes the concepts of rolling technology experience from SMS Meer as presetting. For a wide range of special steel
grades and individual requirements,
the operator is even able to flexibly
adapt the setting values by means of a
groove editor or create them completely new from the diameter of the initial
pass via the design of the actual groove
form up to the calculation of
the
relevant
rolling
speeds.
Simulations and visualisations of
the systems support the operator
at the set-up planning stage (Fig 4).

SUCCESSFUL IMPLEMENTATION OF
FIFTH SUBLANCE SYSTEM IN INDIA
Recently, the fourth and fifth of a total of
seven Sublance Systems were successfully
commissioned at the SMS II operated by JSW
Steel at Toranagallu, India. Operation of the
three earlier systems commissioned at SMS I is
stable and the remaining two will be installed at
SMS II to become fully operational before the
end of this financial year.
This is the first successful implementation of
SublanceBased BOF Process Control in India.
This market has been very reluctant towards
installing sublances, but operations at JSW Steel
are now proving the value for the Indian market.
The reduction in taptotap time, that may vary
between 7 and 10 minutes, will allow for up to
20% of additional heats from the same steel
plant. Additionally, the client will experience
benefits from using the SublanceBased
System in terms of increased hit rates, reduced
consumption of fluxes, optimized utilization of
scrap and hot metal and improved health, safety
and environmental performance. Typically,
benefits of SublanceBased Process Control for
the SMS operator translate into value as follows:
Your benefits:
Taptotap time
Hot metal consumption
Scrap consumption
Oxygen consumption

Reduced by 710 min.

Reduced by 10 kg/ton
Increased by 10 kg/ton
Reduced by 1.0 Nm/ton

Aluminium consumption

Reduced by 24 kg/heat

Ferromanganese consumption

Reduced by 60 kg/heat

Energy savings

Equivalent to 20C

Refractory wear

Reduced by 20%

Ergonomics

Improved working conditions

For these sublances, the newest generation of measurement

computer, DIRC VI, is implemented. This new version allows
for future additions to the measurement system. Phosphorous
measurement will be implemented as well.

120 BLAST FURNACE PROJECTS 209 HOT BLAST STOVES 63 PULVERIZED COAL INJECTION
SYSTEMS 28 GAS CLEANING SYSTEMS 27 CASTHOUSE PROJECTS 35 CHILLED FURNACE
RECOVERIES 20 SALAMANDER TAPS 22 BLAST FURNACE BLOWINS 23 OPERATIONAL
IMPROVEMENT PROJECTS 41 PLANT AUDITS 114 SUBLANCE SYSTEMS
58 HOT METAL DESULPHURIZATION SYSTEMS
Danieli Corus
P.O. Box 10000
1970 CA IJmuiden
The Netherlands
T
+31 (0)251 500 500
E
info@danielicorus.com
W
www.danielicorus.com

Danieli Corus India Pvt. Ltd.

S3 Level, E Block
Intl. Trade Tower, Nehru Place
New Delhi 110 019
T +91 11 4950 1000
F +91 11 4950 1099
www.twitter.com/danielicorus

Technology
3-roll cassettes and 3-roll The MEERgauge at the exit side of the
guides in the roll shop. All PSM operates on the basis of the light
cassettes and guides can cut technology(Fig. 7). Based on laser/
be transferred directly into image technology four sensors meathe PSM roll shop by the sure synchronous and contact free the
cassettes changing device entire cross section of the bar. With a
and will be prepared off- scanning rate of 500 scans per second
line shop during rolling (Fig. a true-shape cross-section is estab5). In case of very tight tol- lished of up to 400 measuring points
erance requirements the and displayed with highest precision.
rolls and rollers have to
be aligned in the roll shop The essential characteristic values of
Figure 4. CARTA PSM - groove manipulation possible
by means of an optical roll the individual measurements are sent
For each bar the CARTA PSM system positioning/aligning device. The rolls to the Technological Control Centre
stores the setup/calibration data of and rollers can be axial and radial po- (TCS) of the PSM via a direct prothe rolling mill and the most important sitioned with a measuring accuracy of cess field bus connection in real time.
rolling results. The data can be evalu- 0.002mm by means of a CCD-camera. The TCS logic analyses the values
ated by tables and graphics. In addition,
they can be deposited in an empirical In order to further
database which ensures possible reuse. expand the capabilities of the advanced
Another feature is the tool manage- 3- roll technology,
ment function which is of tremendous SMS Meer and DEW
support to the operators and mill man- Siegen
successfully
agement in order to optimise the tool/ implemented in joint
roll ring costs. The roll ring sets and cooperation a high3-roll cassettes can be tracked with the ly dynamic closed
CARTA PSM system and information loop size control sysabout e.g. wear is available. With the tem for the PSM:
Fig. 6: MEERgauge at the exit side of the 3-roll PSM
aid of the CARTA PSM system, cus- the
MEERgauge.
tomers are able to fine tune many de- This is another milestone with regard and assigns relevant adjustment set
tails in case it is required. These excel- to the advanced 3-roll technology. points for gap corrections if required.
lent features make the difference to any
other system available in the market. The MEERgauge (Fig. 6) is installed Due to a combination of a highly dydown stream the 3-roll PSM directly namic control system and a true-shape
Furthermore the CARTA PSM system behind the last 3-roll stand position and measuring system a fully automatic rollsupplies all data for the setup of the is replacing a conventional laser mea- ing operation of the PSM could be sucsuring gauge which cessfully realised with the MEERgauge
was working on the - independent from the operator.
shadow
measuring
method. The short- It is a fully automatic size control syscoming of the conven- tem which is able to directly react ontional laser gauge is line under load on real time measured
the number of mea- deviations from the target size. It insuring points around teracts in closed loop mode with the
the cross section as hydraulic gap adjustment system of
well as the measur- the PSM. The basis for the closed
ing method due to loop operation of the rolling gap is
Figure 5. PSM - cassette quick change equipment
swiveling laser heads. the adjustment under load capability.

STEEL & METALLURGY

24

FEBRUARY 2014

Technology
the whole size range can be reached in
fully automatic mode independent of
the skill/experience of the operators.
Recent achievements are shown in the
following screen shots (Fig. 9).
Figure 7. Light-cut sensor arrangement and
true-shape cross section display

Figure 8. Advanced PSM 3-roll cassette

This is realised by the advanced design

of the 3-roll cassette (Fig. 8) in combination with the three hydraulic cylinders. The hydraulic cylinders can adjust
all three rolls concentrically but in case
it is required the system is also able
to adjust individually only one or two
rolls. Thus symmetrical as well as unsymmetrical positioning adjustments
of individual rolls under load offer possibilities for fine optimisation of the net
shape tolerances.
Another advantage of the design is,
that during rolling operation occurring rolling loads are transferred via
hydraulic cylinders into the stiff housing of the PSM. Due to the inimitable design concept of the PSM wear
and maintenance of the cassettes are
reduced to an absolute minimum.

Operational Results3)
Since the beginning of 2012 the closed
loop size control system has been in
successful operation - interacting with
the new precise true-shape measuring system. The commissioning was
uneventful and shortly after start up
expectations about the system have
already been exceeded. Thanks to the
advanced automation level and reliability of the PSM excellent results across

Required product tolerances are easily fulfilled and even exceeded even
for the most demanding applications
tolerances up to 1/8 DIN EN 10060 are
achieved reliably and regularly. It goes
without saying, that the MEERgauge
does not necessarily help to produce
even better tolerances with the PSM,
but does support the operator to react
on varying parameters such as feeder
size tolerance, temperature variations
along the feeder, size and steel grade
changes, wear of rolls or even operates
the PSM in a fully automatic mode.
The advanced 3-roll technology of SMS
Meer pays off for their customers. Not
only DEW Siegen/Germany benefits
since 2006 from the great features
of the PSM, since 2009 also Timken/
USA established several production
and quality records after the installation of the advanced 3-roll technology.
Following the successful installations
at DEW Siegen/Germany and Timken/
USA three more 3-roll PSMs will
be installed in 2013. One complete
new state of the art SBQ rolling mill
will be installed in China with process and key equipment for the specialty steel production of SMS Meer.
Beside a new 3-roll PSM including
the CARTA PSM, Controlled Cool-

ing Technology systems (CCT) with

online thermo-mechanical rolling process control packages will be supplied.
The complete new SBQ rolling mill at
Xining Special Steel Co. Ltd., will be
equipped in addition with an advanced
quick cooling bed transport of straight
bars which is considered for temperature sensitive steel grades in order to
avoid cracks during cooling procedure.
Another 3-roll PSM will be installed at
Steel Dynamics. In summer 2012 Steel
Dynamics (SDI), Indiana, USA awarded
to SMS Meer the contract to supply a
new roughing mill and a new 3-roll Precision Sizing Mill (PSM) to their Pittsboro works. The new rouging mill will
be operated in semicontinuous mode
consisting of a two-high reversing mill
followed by eight rigid housing
less stands in H/V configuration
which will feed the existing mill.
The advanced 3-roll PSM will be installed at the place where a former
3-roll block of the first generation was
installed (Fig. 10) and will finish all special quality bars in the range from diameter 19-76,2 mm. Those high-quality
products are used in a variety of transportation, industrial, energy and automotive applications. The PSM package
consists of looper, two shear groups
and in addition the automatic 3-roll
cassette change system, a roll shop for
assembly of the 3-roll cassettes and the
3-roller guides as well as the technology package CARTA PSM.

Figure 9. Screen shots of PSM rolling in closed loop mode

STEEL & METALLURGY

26

FEBRUARY 2014

Technology
nance requirements. each coiler drum on a lift able
After the water cool- platform. Attached to the lift
ing box an automatic able platform is also the guidswitch guides the bar ing trough which makes the
towards the pouring connection to the spiral pipe layreel guide trough. For ing system which guides the
an optimum coiling bar to be coiled to the bottom
temperature a water of the water cooled coiler drum.
cooling box is installed
considering an ap- The pinch roll arrangement, an adpropriate equalisation vanced wobbling function as well as
length before entering a stiff guiding steel structure assures
Figure 10. SBQ mill upgrade for Steel Dynamics / USA
the pouring reel for the a stable operation procedure which
wide range of different steel grades. forms very dense coils up to 4000 kg/m.
State Of The Art Pouring Reel The water cooling box is integrated and
Technology
controlled by the Controlled Cooling In general special attention has been
The ideal combination for most mod- Technology (CCT) system which can be paid for a scratch free transport and
ern SBQ production is represented by either operated in off-line or in on-line guiding of the rolled bar in order to asthe advanced PSM 3-roll technology closed loop control.
and the state of the art pouring reel
technology of SMS Meer. Based on 62 The bar feed line
years experience in bar and coil tech- is of highly wear
nology the 51st pouring reel line of SMS resistant
mateMeer will be installed at Fujian WuHang rial. The U-shaped
Stainless Steel Co., Ltd./China (FWSS). bar feed line with
covers allows quick
The 51st pouring reel line (Fig. 12) of elimination of rollSMS Meer is arranged downstream the ing
material
in
advanced 3-roll PSM. It is designed case of a cobble.
to fulfill not only todays market deFigure 12. Pouring reel line arrangement at Fujian WuHang
mands with regard to improved coil For head and tail
formation and scratch free production cropping as well as for sampling a shear sure a smooth rolled material surface.
of sensitive SBQ products but is also is installed downstream the water Therefore the whole curved guiding
considered to offer highest flexibility cooling box. After the shear a further system of the pouring reel line includand availability with minimum mainte- switch is installed in order to guide the ing the spiral pipe laying system is
bar than into the indi- equipped with air/oil lubricated rollers.
vidual pouring reel for The pouring reels are equipped
the coiling process. with wear strips on the inner pins
Special attention has and outer rotating drum to prebeen paid for the loca- vent mechanical damage during
tion of the pinch roll. the formation of the coil (Fig. 13).

Figure 11. SBQ rolling mill at Fujian WuHang Stainless Steel

STEEL & METALLURGY

In order to have an
optimal
supported
coiling process, one
individual pinch roll
is installed as close
as possible upfront

28

FEBRUARY 2014

An elevating coil plate assembly incorporated in the pouring reel removes the coil from the tub. The coil
plate height is adjustable to provide
optimum drum depths for each product size or range of sizes to ensure

Technology
lifted without harm out of the coiling
drum by a hydraulic cylinder which
is installed below each coil drum.
As soon as the coil is lifted out of the
coiling drum the discharging system
(Fig. 14), a so called sugar tong, hands
the coil over to a pallet transport system for further processing in one of the
most complex coil handling systems.

Figure 13. Water cooled pouring reel

the coil is formed at the highest possible level to minimize the tail end
length at the top of the formed coil.
After the coiling process has been started the spiral pipe laying system is lifted
according to the increasing coil height.
In order to avoid scratches after completion of the coiling process further
measurements have been taken. Before the coil is lifted out of the water
cooled coiling drum, the inner supporting and forming pins are collapsing and thus the compact coil can be

Figure 14. Coil discharging device

Various inline post treatment routes

are possible at Fujian WuHang Stainless
Steel Co., Ltd. as can be seen from the
layout such as heat holding, quenching,
online annealing and others. However,
those are not further considered in this
paper.

Conclusion
With pioneering spirit, courage and
persistence revolutionary technological milestones have been introduced
by SMS Meer into the market. More
than 450 successfully installed wire
rod and bar mills represent trust and
great partnership of our customers.
The experience of the above mentioned installations in combination with
the advanced 3-roll PSM with hydraulic adjustment under load capability already stimulated the SBQ market. The
indisputable process transparency of
the 3-roll PSM offers a wide field for
further improving qualities of our customers products. The great potential
of the PSM/MEERgauge combination still need to be further discovered.
The SMS Meer state of the art pouring reel line is the perfect completion of the advanced 3-roll technology for most modern SBQ production
and an ideal combination. The improved coil formation and scratch

STEEL & METALLURGY

30

FEBRUARY 2014

free production of sensitive SBQ

products is considered to offer highest flexibility and availability with
minimum maintenance requirements.
The installation of the afore described
key technologies for special bar quality and advanced wire rod production in demanding countries such
as USA, Germany, China are indications for the huge potential of these
new technologies. They are installed
at highly reputable steel producers
which are in fierce competition in their
individual market but also abroad.
Those superior technologies are inventive solutions to follow the todays
and future demands of the individual
markets. They are developed, designed, engineered and manufactured
exclusively by SMS Meer based on a
long experience in special quality steel
production. This in combination with
the vast process know how offers to
our customers inimitable possibilities.

References
1) Jens Eisbach, Dr. Thomas Helsper,
DEW Siegen, Practical experience
with the worlds first hydraulic adjustable 3-roll block for bars, International
Steel Conference 2011, Duesseldorf/
Germany, November 2011

2) Dr. Axel Koermer, Dr. Peter Thieven,

SMS Meer, Publication in Stahl und
Eisen 131 (2011), Nr.5, p .51-58
3) Dr. Thomas Helsper, Jens Eisbach,
DEW Siegen; Guenther Schnell, SMS
Meer, The closed loop size control system in combination with the advanced
3-roll PSM at DEW Siegen-Geisweid,
30th international Steel Industry Conference, Paris/France, December 2012

Rolling Mills

odernisation Solutions For Long Product Rolling

MMills
To Increase Productivity, Utilisation And
Product Quality

B. V. Kiefer and S. M. Shore

Siemens Industry, Inc.

Introduction

ith the current economic pressures faced by the global steel

industry, producers need to continually
modernize their operations to remain
competitive. These modernisations
must be done selectively in order to
maximize the benefits. Developments in
equipment and process designs for rod
and bar rolling mills have made possible
significant improvements in size control
and mill productivity, mill utilisation,
operating cost and product quality.
Through the intelligent combination
of robust rolling stands and finishing
blocks, high speed shears, pinch rolls,
laying heads, ring distributors, coil handling systems and compactors, along
with controlled temperature rolling and
controlled cooling, many process improvements in rod and bar mills can be
realised. Mill upgrades can be done with
a phased approach to minimise downtime, which minimises the effect on
yearly capital expenditures and thereby
maximises the return on investment.
Long product rolling mills continue to
provide an essential segment of the
industry with the capability for coiled
and straight products in a wide range
of sizes and steel grades for literally
thousands of end-use applications.
With the consolidation across the industry in the last two decades, the long
product mills that have survived have

been forced to streamline operations

and cut costs to remain competitive.
This trend is expected to continue as
the world economy experiences very
slow growth or additional contraction
occurs in well-developed countries.
The recent evolution in the industry has
also led to a severe lack of skilled/experienced workers. The previous generation of workers, because of their experience, may have been able to make
best use of aging equipment and process practices. Now, the key to success
in sustaining/improving operations is to
selectively replace the outdated equipment with new technology and increase
the level of automation. Modernisations can provide consistent operations
with higher speeds, less maintenance
and downtime, longer wear part life for
more up time between changes, and as
little operator intervention as possible.

The Long Rolling

Process Line
From starting billet to finished coil
or bar bundle, the conventional
long rolling mill has many possibilities for improvement through equipment and process modernization.

Roughing And Intermediate

Mills
In the roughing and intermediate
mill area, modernisations could be as
straightforward as stand and guide
replacement to reduce maintenance

STEEL & METALLURGY

32

FEBRUARY 2014

and give better section control. In

multi-strand mills, options for stand
replacement are limited. In singlestrand mills, product quality can be improved by replacing horizontal stands
and twist guides with a horizontal/
vertical stand arrangement. Several
options are available for upgrades
with fixed or convertible stands, using technology such as that available
with the Red Ring family of stands.
Often of interest for modernisation of
older rod and bar mills is an increase
in billet size. This change requires additional reductions that can only be
achieved with more stands. One workable upgrade solution is the addition of
a breakdown mill ahead of the roughing mill, typically a three- to six-stand
arrangement, depending on the new
billet size. Of course, the addition
of stands ahead of the roughing mill
means changes to the furnace area, although the new billet size may not be
possible in the exiting furnace, so a new
furnace may be needed. This could help
with the logistics of the project, since it
may be possible to construct a new
furnace and the breakdown mill upstream of the existing furnace, so that
much work can be done while the mill
is still running. Processing a larger billet with breakdown mill stands will require a roller table between the breakdown mill and the existing roughing
mill, so that the rolled billet from the
breakdown stands can be a free bar,

Rolling Mills
allows the mill to be configured with
four, six, eight or ten roll stands, with
any combination of 250mm, 230mm
and 160mm housings. A relatively new
development on No-Twist Mill technology is that of the Modular No-Twist
Mill, which utilizes many of the design
features of the patented Reducing /
Sizing Mill technology. This provides
added improvements through commonality of rolling units, reduction
in operating cost, and improvements
in mill efficiency, as well as significant
reductions in maintenance downtime
through extended component life.
Figure 1. Pre-finishing mill Vee Mini-Block

which can be decelerated to an acceptable taking speed for the existing mill.
Other common upgrades in the roughing and intermediate mill areas are with
shears, to improve reliability, speed
and cutting capacity. From up and
down cut shears for billets and blooms
to rotary and crank shears between
sets of stands, several shear solutions
are available for modernisation projects. New laser speed measurement
technology provides for improved cut
accuracy and repeatability especially
for bar mill divide shear applications
for improved cut length optimization.

Pre-Finishing Mills
For rod mills in particular, the prefinishing mill area can benefit significantly from an upgrade to the rolling
equipment. It is common to have limited rolling load capacity in the prefinishing stands, which means that
the stock temperature needs to stay
relatively high and thus low temperature rolling and quality improvements
become more difficult. Replacement
of older stands with a heavier-duty
stand is a straightforward solution,
but another successful approach has
been upgrading the pre-finishing mill

area with one or more Morgan Vee

No-Twist Mini-Blocks. These blocks
are well-suited to many upgrade situations, offering a small footprint, good
section control and ease of maintenance. The compact size allows the
addition of water cooling boxes ahead
of the finishing mill or an increased
equalization distance for further improvements in processing capabilities.

Finishing And Post-Finishing

Blocks
The Morgan No-Twist Mill (NTM) still
remains an essential piece of equipment for many new and revamp mill
projects. With continued refinement
over more than 35 years to the present
Vee configuration, the NTM has proven
to be capable of sustained, reliable
operation at speeds up to 120 m/s. In
addition to high speeds, the mills are
rated for higher loads, providing the capability to roll a wide range of grades
from carbon steels through difficult
heat-resistant alloys. These blocks can
typically be supplied with pass reduction of anywhere from 12% to 23% per
stand. Subsequent changes in pass reductions are easily accommodated by
a flexible design that facilitates bevel
gear changes. The flexible design also

STEEL & METALLURGY

34

FEBRUARY 2014

Increases in production speed and

operational reliability have also been
aided by ancillary equipment and systems for the NTM. High-speed roller
entry guides accurately direct oval sections into round passes while limiting
scratching of the rod surface. The reliability and versatility of these guides
have evolved to allow for sustained operation for 5.5mm product up to 3,000
tons at speeds in excess of 100 m/s, for
example. In addition, special cooling
entry and delivery guides help control
temperature in the process section.
One of the most significant advancements in high speed rod mills was the
development of the patented Reducing/
Sizing Mill (RSM) in the early 1990s. This
specialized piece of equipment serves
as a post-finishing mill block. More than
60 strands of RSMs have been installed
worldwide, mostly as part of major mill
modernization projects. The justifications for the installation of the RSM
in these mills are as varied as the benefits provided by this technology(1, 2).
For most mills, especially pre-1980 vintage multi-strand mills, the RSM has
provided significant increases in productivity, especially on small diameter
product where the maximum finishing
speeds were previously limited to less

Rolling Mills
erance and ovality typically 0.1mm
tolerance and 0.1mm ovality. On special steel products such as stainless
steels, the ability to produce a closetolerance product has reduced the
amount of peeling required, resulting
in large savings from improved yield.
In addition, experience with the ovalround-round-round pass sequence in
many mills has shown that the overall pass life is double that of conventional rolling, thereby reducing the
downtime for pass changes. This pass
sequence is also beneficial to wire
drawers and other subsequent users,
since it minimizes circumferential surface variations at the parting areas.

Figure 2. Morgan Reducing/Sizing Mill

than 70m/s. Installing the RSM after

an existing 10-stand NTM and rolling
7.0mm in the last stand to feed the RSM
can increase the finishing speed for
5.5mm from 65m/s to nearly 100m/s,
as was the case, for example, at Global
Steel Wire in Spain. For mills producing
a large percentage of 5.5mm products,
the addition of the RSM can result in a
significant increase in annual output.
In the case of one Asian steel producer, with 85% of the product mix being
5.5mm, production was increased from
540,000 tpy to over 740,000 tpy, with an
increase in mill efficiency from 72% to
76.5% in conjunction with an increase in
finishing speed from 70 m/s to 94 m/s.
Multi-strand mills already operating at,
or close to, the maximum rolling rate
on small diameter product have had
little to gain from this benefit; however, the installation of the RSM has still
provided productivity improvements
with added rolling flexibility. These
improvements have been realized following the introduction of the single
family rolling method inherent with
the application of the RSM technology.
The single family rolling method al-

lows a single roll groove to be used in

each stand from the first stand in the
roughing mill to the last stand in the
NTM to produce the complete product
size range through the RSM. The same
concept is also extended to the Bar Reducing/Sizing Mill providing a true integrated rolling solution for combination
mills. This not only simplifies the mill
setup, but also improves yield through
reduced number of cobbles and elimination of trial bars. It also significantly
reduces the roll and guide inventory. With the multireduction external gear drive, the RSM can produce
multiple finished sizes from a single
feed section. This, coupled with offline roll units and the quick-change
transfer car, allows size changes to be
made within five minutes. As a result,
even though the rolling rate or finishing speed has not been significantly
increased, the mill is still capable of
improving their productivity through
increased operating efficiency with the
reduction in downtime for roll changes.
Other benefits provided by the RSM
include minimisation of roll and guide
changes, ability to increase rolling cycle
frequency, and improved product tol-

STEEL & METALLURGY

36

FEBRUARY 2014

An additional option for a post-finishing

block is a Vee Mini-Block, which is usually configured as a 2-stand block to roll
small sizes in a rod mill. In many cases,
this block has been used to increase
productivity on small sizes by as much
as 50 percent, while also improving
control of product dimensions when
compared with older upstream equipment. When used as a pre-finishing mill
block, the Vee Mini-Blocks small footprint simplified retrofit projects. The
latest design of these blocks is modular, with two-stand units that allow for
fast changes and help minimise maintenance and spare parts inventory by offering compatibility with Vee No-Twist
Mill and Reducing/Sizing Mill units.

Water Boxes and Equalization

Troughs
A common limitation in rod and bar
mills is the control of product temperature through the process line. In many
cases, there is lack of cooling capacity,
making control of mechanical and metallurgical properties, as well as amount
and type of scale, difficult. Product
quality requirements have therefore
prompted many mills to upgrade their
water box systems, usually replacing

Rolling Mills

Figure 3. Traversing Water Boxes

older systems with new technology

with more efficient cooling that is easier to maintain. Depending on available
space, more cooling can be provided to
allow for an expanded range of product qualities. A necessary component
of a new water box line is that of a
temperature control system, such as
the SIROLL LR Enhanced Temperature
Control System, which provides the
mill operator with the ability to closely
control and monitor process temperatures on the finishing end of the mill.
To maintain a high level of mill utilisation with minimum personnel, while
supporting a multiple cycle rolling
schedule, mill owners need fast changes of rolls and other parts throughout
the mill, as well as quick changing of
auxiliary equipment. The Siemens split
bore cooling nozzle design allows operators to quickly and easily open a
nozzle for inspection or cleaning and
to remove cobbles. To avoid the necessity of manually changing the nozzles in
the cooling line for a new product size,
multiple lines of different bore nozzles
can be arranged in a traversing box
that can shift positions for the different nozzle bores, requiring less manpower an minimising mill downtime.

High Speed Trimming Shears

A challenge for every rod mill is trimming the head and tail ends of every

coil produced, to eliminate hot and outoftolerance product on the ends of the
coil. In most mills, the trimming is performed manually at a combination of
locations on the cooling conveyor and
at a trimming station in the coil handling system. To increase worker safety
and improve trimming consistency and
efficiency, high speed trimming shears
are available for the process line. These
shears have the ability to cut front and
tail ends at extremely high speeds,
while controlling the amount of material trimmed in order to maximise yield.

The ability to roll small size product

at high speeds, i.e., above 100m/s, is
meaningless if the ring pattern on the
Stelmor cooling conveyor is not consistent and the laying head pipe needs
frequent changes. A bad ring pattern
can result in failure to achieve the specified tensile uniformities and additional
personnel required at the laying head
or reform station to prevent cobbles in
each coil. The Morgan High Speed Laying Head was developed to operate at
those speeds and has achieved a good
reputation for reliable high-speed operation. Numerous mills have upgraded
their laying head and pinch roll systems
in recent years to increase production,
reduce manpower, improve yield and
ensure consistent product quality. Recent developments on the high speed
laying head system have resulted in a
new upgrade package. Design changes
in the laying head and pipe support
have led to even better performance
at high speeds, with extremely low
vibration levels. Also, a significant advancement in the technology of the
laying head pipe now enables many,
many more tonnes of small diameter

For example, the shear shown in Figure 4 is a continuously rotating arrangement using two separate shears
for trimming and cobble cutting with
a high speed servo drive switch system, for improved cut length accuracy
and repeatability. The system works
in conjunction with front-end orientation at the laying head to insure that
the new trimmed head end is placed
at the desired location on the conveyor. The shear design can be used
for a right or left hand mill, with a size
range capability from 5mm through
20mm for speeds up to 120 m/s.

High Speed Laying Heads And

Pinch Rolls

Figure 4. High Speed Trimming Shear

An area of the process line that commonly limits the success of a rod mill is
that of the laying head and pinch roll.

products to pass through each pipe at

high speeds resulting in a dramatic reduction in downtime for pipe changes.

STEEL & METALLURGY

38

FEBRUARY 2014

Rolling Mills
The success of the laying head and
pinch roll system is also dependent on
the mechatronics package that is integral to an equipment upgrade. This
system provides for consistent coordination of speeds between the units,
for repeatable front end positioning
of each coil, fine control of ring diameter and wobble adjustment for large
sizes. The Morgan Intelligent Pinch
Roll incorporates servo control of
pinch force and position, closed loop
control of pinch force and speed, plus
rapid and repeatable roll close times.

Stelmor Controlled Cooling

Conveyors
Conveyor processing is critical for mills
producing high quality products, since
it directly affects as rolled properties
and indirectly affects properties of
products that are heat treated after
rolling. The latest roller conveyor configuration improves cooling uniformity
and surface quality and gives a mill the
capability to run continuously in a slow
cooling, or retarded cooling mode. Improved cooling air distribution through
the patented OptiMesh system and
nozzle deck design between the fan
plenum and rod surface increases
product cooling and uniformity. In addition, many conveyor upgrades in-

clude increased fan capacities. Higher

air velocities improve cooling rates and
thereby reduce the total fast cooling
length requirement. This is particularly
advantageous for mills producing
large diameter, fast-cooled products. The addition of a roller conveyor
in combination with, larger fan capacity increases both average tensile levels and tensile uniformity(6).

Coil Reforming
The patented Ring Distributor system
has for many years defined rod mill
coil reforming technology by, offering
a consistent approach to the reforming of coils. With the Ring Distributor,
coil rings from a Stelmor Controlled
Cooling system are collected high in
the reforming tub and are distributed
for optimal placement by a rotating
blade. The resulting coil package is
dense and well-shaped. When compared with systems without the Ring
Distributor, coil heights can be reduced
between 15 and 20% on 5.5mm rod,
for example. Reduction in coil height
and enhancements in coil shape translate directly into improvements in
shipping by allowing more coils to be
placed on the truck or rail car bed, as
well as a decreased risk of loosened
coil ties or strapping during shipment.

Figure 5. Morgan High Speed Laying Head and Pinch Roll

STEEL & METALLURGY

40

FEBRUARY 2014

A major benefit for the wire drawer is

that coils have a better payoff with reduced number of tangles. The system
can be retrofitted into existing mills and
has proven very beneficial in accommodating larger coil weights and reducing
damage to coils in transit and in storage.
Ring Distributors have been installed
in more than 100 strands worldwide.

Coil Handling And Compacting Systems

The coil handling and compacting system completes the process of making
the best possible coil package, starting at the laying head and continuing on to the Stelmor conveyor and
reform area. In most rod mills built
before the 1980s, coil handling and
compacting are in need of an upgrade.
Many existing systems use horizontal
hooks for transporting cooling coils
from the reform, through the compactor to the unloading station. Some older mills and many new installations use
vertical stem pallets. The latest designs
of horizontal hook carriers and vertical
stem pallets systems are of modular
design with standardised components
for ease of maintenance. They are usually custom-configured to fit into the
available space and to meet the specific
needs for production and coil processing, while enabling future expansion.
For compacting of coils, both horizontal and vertical compactor systems are
available for seamless interfacing with
the upstream coil handling system and
with the downstream unloaders to coil
storage and shipment. Some of the key
features of these compactors include
the capability of handling coils with a
maximum 1450mm outer diameter and
750mm inner diameter, the possibility
of using binding wire in diameters from
6mm to 8mm as-rolled, with cycle times
for compacting and tying in the range
of 30 to 35 seconds, depending on coil

Rolling Mills
Case Study 1 Wire Rod Mill
Laying Head And Reform
Modernisation
NUCOR Nebraska wanted to improve their coil package in order
to reduce delays in the mill and to
provide a better product for their
wire drawing customers. Their modernisation project focused on the
laying head and the reform areas.

Figure 6. Vertical Coil Handling System

weight. The compactors are versatile

and can be offered with wire binding
or strapping using hydraulic, pneumatic
or electric systems. The wire binding
heads are designed to make a consistent, high-strength knot for safe transport through storage and shipping.

Automation And Mill

Management Systems
Mechanical equipment upgrades can by
themselves result in improvements to
the long product rolling mill process and
products. However, their contribution
can be maximised when used in conjunction with upgrades to mill control,
automation and management systems.
As mentioned above, water box temperature control is a necessary ingredient in a cooling system upgrade and the
mechatronics package is key to the
success of the laying head and Stelmor
conveyor performance. Other typical
areas of upgrades include mill setup
and speed control, tension and loop
control, sequencing and tracking, plus
other mechatronics packages for mill
equipment components. Modernisation of these elements in the rolling mill
can together help optimise the process
and make the best possible product.

For the overall management of the mill,

Siemens offers the XpertManager
system, which provides seamless integration of process data in real time,
from the Manufacturing Resource
Planning stage through to entire production process, including billet yard
and coil or bar bundle yard management. This system has been implemented in numerous mills, providing
operators and mill managers with upto-date information on the mill process and performance. Management
of rolls and guides within this system
can further improve its effectiveness.

Rod Mill
Modernisations
With the above advances in rod mill
equipment and system technology,
Siemens VAI has been able to successfully upgrade numerous mills around
the world in recent years. Usually,
the mill modifications have included
an RSM as the main component to
improve productivity, mill utilization and product quality. However, it
is the combination of the RSM with
the other equipment and controls
that has enabled the full realization
of the production and operational improvements of these modernisations.

STEEL & METALLURGY

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The new laying head equipment consisted of a Morgan High Speed Laying
Head, which was to be the basis for consistently good ring formation onto the
controlled cooling conveyor. The laying
head was supplied with the patented tail
end control deflector plate to help with
the consistency of head and tail ends.
To ensure proper delivery of the rings
to the conveyor, a new adjustable entry
section was added to span from the laying head to the existing conveyor. The
mean pipe diameter of the new laying
head was chosen to match the coil dimensions previously made on the mill.
On the reform end of the conveyor, a
completely new reform station was installed, with a Morgan Ring Distributor
to further ensure formation of a good
coil package. The reform tub was custom designed to maintain the previous coil dimensions. A new sliding exit
section of the conveyor, designed to
receive the rings from a drop off the existing conveyor, enabled speed changes
ahead of reform. A new section of the
coil handling system vertical stem pallets was also provided, designed to interface with the existing pallet system.

Case Study 2 Wire Rod Mill

Reform And Coil Handling
Modernisation
The single strand rod mill at CELSA
Atlantic in Spain was built in 2006,
primarily to produce ribbed reinforcing products and industrial grade rod
in coil. The finishing end of the initial

0091 80 4512 7800 / 7801

0091 80 4512 7802

Rolling Mills
Controls for the coil handling area were expanded to accommodate
changes in the existing
equipment and manage
the new pallet system, interfaces and compactor.

Case Study 3
Wire Rod Mill
Stelmor, Reform
And Coil Handling
Modernisation
The single strand rod
mill at Sterling Steel in
the USA was originally
installed in 1983 and
underwent various upgrades over the years.
Those included laying
Figure 7. Vertical compactor
head modifications in the
mill consisted of a Morgan Vee No- late 1990s, a new Stelmor conveyor in
Twist Mill, water boxes with interme- the early 2000s, changes in the finishing
diate pinch rolls for HYQST produc- block area, and new water boxes with a
tion, Morgan High Speed Laying Head, temperature control system in 2008.
Morgan Stelmor conveyor, reform
with a two-arm mandrel and transfer The latest modernisation, which was
car for interfacing with a horizontal recently completed, included extension
hook coil handling system with a single of the Stelmor conveyor, a new reform
horizontal compactor. After several station with a Ring Distributor, a new
years of operation, shifts in the prod- vertical stem pallet system and a newuct market and change of mill owner- generation vertical compactor with
ship resulted in the need for increased wire binding. This upgrade has enabled
capacity in the coil handling system. Sterling to increase mill utilisation to
The solution included changes to the more than 90% and to set several new
reform tub including a new nose cone production records. The totally vertical
to improve coil formation with the system, from reform through to comexisting Ring Distributor, plus modi- pacting, has resulted in less distortion
fications to the lower reform area to of the coil during cooling, so that the
replace the two-arm mandrel with final coil package offers better coil storan interface to a new section of verti- age, shipment and customer use. Fewer
cal stem pallet coil handling. In addi- coils have to be re-worked due to loose
tion, the horizontal hook system was or broken bindings. Also, coils have exextended with a new section to pro- perienced significantly less scratching,
vide more coil positions and to inter- attributed to their less frequent manipface with the new vertical stem pallet ulation. All components of the systems
system, incorporating a transfer car are easily accessible, improving worker
and trimming stations. A second hori- safety, and the mechanical design has
zontal compactor was also installed. resulted in reduced maintenance costs.

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Conclusions
Rolling mill equipment and process improvements by Siemens VAI during the
last decade have enabled many mills to
undergo successful modernisations.
Significant increases in rolling speed,
production rate, mill efficiency and
product quality have been realised with
these modernizations. The combination
of highly flexible and reliable equipment, superior process design and
automation systems offer many possibilities for improving mill operations.

References
1. Shore, S. M., Developments
for High-Speed Rod Mills, Iron &
Steel Institute of Japan, Nov. 2001.
2. Shore, S. M., Dyck, J. and Shore,
T. M., New rod rolling technology for
improved mill utilisation and product
quality, MPT International, Aug. 1995.
3. Kiefer, B. V., Vincent, J. C. and
Varo, R. A., Thermomechanical Process Improvements in High Speed Rod
and Bar Rolling with Reducing Sizing
Mills, Proceedings, International Conference on Thermomechanical Processing: Mechanics, Microstructure &
Control, Sheffield, England, June 2002.
4. Vincent, J. C. and Kiefer, B. V., Modernisation of Stelmor Conveyor Systems
for Expanded Process Capability and Improved Product Quality, Proceedings,
Wire and Cable Technical Symposium
Interwire 2003, Atlanta, GA, May 2003.
5. Ichida, Y. et al, Overview of the
New Finishing Block Mill and Coil
Handling Line at the No. 7 Wire Rod
Mill, R&D Kobe Steel Engineering
Reports, Vol. 50, No. 1, Apr. 2000.
No-Twist and Stelmor are registered trademarks of Siemens Industry, Inc. XpertManager and HYQST are
trademarks of Siemens Industry, Inc.

Product Profile

Risk More Weight With igus Drylin W System

between shaft centres. Compared to
the other drylin W sizes, these new
dimensions give a higher load capacity, up to two tonnes, as well as resisting higher moments. Statically each
of the four bearing housings made
of zinc die-casting can take up to 480
kg. A gliding foil made of iglidur J200
is responsible for the lubrication-free
travel of high loads at low friction values and most minimal wear, especially
developed for the use with hard-anodised aluminium as friction partner.

igus now introduces the fourth size in the Drylin W linear guide family: the size 25 (below). With a load of up to 2 tonnes possible, it can easily move the load of a properly
equipped middle class estate car linearly - maintenance-free and without lubrication.

inear technology that is lubricationfree and dirt resistant now withstands the weight of a well-equipped
middle-class estate car (up to 2 t). The
new Drylin W linear guide size 25 from
igus connects these characteristics.
Previously, a lubrication-free and
cheap alternative to linear guide systems that run on ball bearings was developed with the Drylin W system.
As early as the construction stage,
the flexible and modular design with
its most different accessories allows
more freedom of design. New fields
of application for the manifold linear
guide systems such as in agricultural
machines, automobile construction,
but also in the field of medicine technology or packing industry, offers now
the high-load version in the size 25.
Like all members of the Drylin W
family, the new version consist of

three simple basic elements: a guide

rail made of hard-anodised aluminium,
the housing bearings made of zinc die
casting and the gliding foil made of the
tribo-optimised plastic iglidur J200.
The W25 double guide rail has a 25mm
shaft diameter and 120mm distance

All four sizes of the Drylin W system are easy to mount because the
double rail makes the costly alignment
of two parallel shafts or guides unnecessary. The rails are available up
to a length of four meters. For longer
travels, the rails can be easily placed
in sequence. The factory-made attached bevel allows gliding of the glide
elements from one rail to the other.
The system is available from stock.

Also the new size has been designed according to the successful principle of the Drylin W
system: double guide rail made of hard-anodised aluminium. Its counterpart is the guide
slide that consists of four zinc die casting bearings, equipped with a sliding foil made of the
tribo-optimized plastic iglidur J200.

STEEL & METALLURGY

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Product Profile

ECOFLUX * Corrugated Tube Heat Exchangers

thermal efficiency and
eliminates
product
channeling. Thermal efficiency is so improved,
that for typical thin film
applications heat transfer area can be reduced
to less than half of that
required in a plain tubular heat exchanger.

Salient Features / USP

Compact tubular
heat exchanger;

K- Series

orrugated Tube Heat Exchangers

are shell and tube heat exchangers
which use corrugated tubes instead of
plain tubes. This kind of tube combines
the best features of both the plain
tube and the plate heat exchanger. The
tubes are corrugated to induce turbulence in both flows (product & service) at lower velocities. This increases

Long running times

due to turbulent flow

Very low maintenance costs, minimum spares requirement.

Lower heat transfer areas.

Minimal fouling and hence high

response to CIP

Wide choice of
MOC. Heat exchangers can be made in SS
304 / L, 316 / L, Cu Ni,
Hastelloy,
Alloy 20,
Duplex, Titanium, etc.

Uniform thermal
processing.

More flexibility in
annular space sizing.

MI - Series

STEEL & METALLURGY

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FEBRUARY 2014

DT - Series

Product Application
ECOFLUX* Corrugated Tube Heat Exchangers are used in varies industries
for processing of pharmaceutical,
chemical, petrochemical, fertilizers, edible oil, paper & pulp, cosmetics, steel,
cement, power, rubber, paints, breweries & distilleries, waste & waste water
management, sugar, automotive, fruit
pulp, beverage, particulate ready-to-eat
foods, milk & milk based products, nutraceuticals and probiotic supplements.
ECOFLUX* is used for an extensive
range of applications like heater, cooler,
condenser, reboiler, regenerator, hot
water generation, chiller, pasteurizer,
sterilizer, aseptic filler and evaporator.

AS- Series

Company Profile

Speed and Length Measurement (down to Zero)

Precision
Laser Surface Velocimeters LSV 1000 / 2000

umbach
Electronics
presents new, high-tech length
and
speed
measuring
gauges.
Precision speed and length measurements are critical for optimisation of
continuous or quasi-continuous production processes. Proper utilization
of these measurements can lead to
lower production costs and higher
product quality. The ideal sensor must
exceed traditional contact encoder
performance, increasing reliability and
accuracy while minimising maintenance requirements and material yield.
The LSV Laser Surface Velocimeters
have been designed as the ideal next
generation sensors for non-contact
length and speed measurement. They
provide precise length and velocity data
quickly and reliably for both process
control and cut-to-length applications.
The LSV 1000/2000 measure reliably on
almost any solid surface, whether controlling processes utilising carbon steel,
shiny aluminium or oily sheets, or producing round wire and cable, or manufacturing paper, cardboard or tissue.

Benefits / Advantages /
Main Features

LSV 2000 Velocimeter

Attractive ROI, fast payback

All-in-one system, easy integration into production processes and

control environments

Easy to operate and no re-calibration required

Reduced operating and maintenance costs

Includes two trigger inputs for additional light barriers or optical switches for high precision edge detection
and offset length compensation

Visible laser for easy alignment in

the field

Zero speed, direction detection

(model LSV 2000 only)

Fast, state-of-the-art signal processor with powerful command set for

efficient system communication via serial or Ethernet interface

Robust sensor technology for

reliable operation even under harsh
conditions, protection classes IP 66 and
IP 67

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FEBRUARY 2014

Hardware status signals for remote diagnostic functions available

User-selectable full quadrature

pulse output and interfacing as LAN &
RS 422/232

Company Profile

Zumbach At Tube 2014

PROFILEMASTER SPS 300-S4

UMBACH Swiss Prime Measuring since 1957 - will join the international trade fair for tube products
TUBE 2014 in Dusseldorf, Germany,
7-11 April. Novel and intelligent solutions as well as cost efficient solutions
for in-line measurement and control of tubes, pipes and profiles are
going to be the focus of Zumbachs
exhibition booth at Stall No. 5E17.

Excerpt Of The
Novelties

nificant advantages over other gauges,

when it comes to fast and accurate
capture of dimensions in longitudinal and radial direction. The maintenance for SMR gauges is close-to-zero.
The mechanical concept is extremely
simple and robust; no wear parts,
no collector rings, no brakes,etc.

Depending
the
application and the customer needs,
static STEELMASTER SMS or oscillating SMO are also available

STEELMASTER SMR Gauges

- New Rotating Gauges For PROFILEMASTER - New InHigh Speed Dimension Mea- Line Profile Gauge For Hot
surement In Hot Rolling Mills Rolling Mills
These new gauges feature, among
others, a revolutionary new system
for fully contactless power and signal
transmission from the laser heads.
Additionally they offer novel and sig-

In addition to the existing line of profile

gauges for cold steel and metal profiles,
Zumbach exhibits this new version for
hot applications. The gaugesare based
on triangulation by camera vision, often

STEEL & METALLURGY

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FEBRUARY 2014

STEELMASTER Rotating SMR Gauge

also called light cut principle. Models

are available for any hot rolled profile
up to 500 mm (edge length). All models
are also available for cold applications.

ECOGAUGE Systems-
New Compact And Low Cost
Diameter/Width Gauges For
Hot And Cold Processes
On show will be one of the new upgraded ECOGAUGE systems of single axis gauges. With new models,
ECOGAUGE 160 and 550, the range
of applications have been extended to a diameter of 500mm (20in.).
Typical solutions are between rolling stands for bar or for strips or in
conveyors, after hot extrusions, after radial forges or in peeling and
grinding operations. Mounting is
very flexible and possible in horizontal, in vertical or any orientation.

News Desk

Installs Three
Siemens
Continuous Slab
Casters At Tisco

iemens Metals Technologies installed three continuous slab

casters at Chinese steel producer Taiyuan Iron and Steel Group
(Tisco) in the last quarter of 2013.
Two casters were installed in Tiscos
carbon and special-steel works and the
third in the companys stainless steel
works in Taiyuan. Each of the continuous casters is designed to produce one
million tonne of slabs per year. The
new casters increase Tiscos capacity for manufacturing high-quality carbon, silicon and stainless steels with
a high interior and surface quality.
Tisco, Chinas leading producer of stainless steel, have already put two singlestrand continuous slab casters, CCM
1 and CCM 2, from Siemens in operation in Steel Making Plant 2 North since
2007. Now with the third caster, CCM
0, having gone on stream, Tisco can
now produce an additional one million
tonne of stainless-steel slabs every year.
The casting plant has a machine radius of nine meters and a metallurgical
length of 27.4 meters. The thickness
of the slabs can be varied between
180 and 250 millimeters and their
width from 1,000 to 2,150 millimeters.

The other two continuous

casters,
CCM 01 and CCM
04, were erected in
Steel Making Plant
2 South, which is
Tiscos carbon and
special-steel works.
CCM 01 replaces
one of the two Siemens continuous
casters which have
been in operation
there for many
years. The two
new casting plants are almost identical in order to optimize maintenance,
operation and spare parts stocks.
They have a machine radius of eight
meters and a metallurgical length of
27.6 meters. The thickness of the slabs
ranges from 200 to 230 millimeters and
the width from 830 to 1,630 millimeters. The two plants cast a wide range
of carbon steels and special steels with
high silicon content, and each has an
annual production capacity of one mil
lion
metric
tons
of
slabs.
All three Siemens casters feature a cassette-type Smart Mold with a hydraulic
DynaFlex mold oscillator. The plants are
equipped with DynaWidth for automat-

STEEL & METALLURGY

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ic setting of the slab width, and Smart

Segments are installed in the strandguiding system. DynaGap Soft Reduction enables the position of the final
solidification of the strand to be determined with high precision, which means
the roll gap can be controlled precisely
to ensure high internal slab quality. Dynacs dynamic secondary cooling and
DynaJet nozzles, combined with internally cooled I-Star Rollers, produce a
slab surface of consistently high quality.
Siemens also supplied the complete basic (level 1) and process
automation (level 2) for the three
casters and assisted Tisco with
construction and commissioning.

News Desk

Process Engineering Industry Calls For Greater

Thermal
Coordination To Enhance Energy Efficiency
conserve energy through optimised, application-oriented and well-coordinated heat exchanger designs by bringing all
the major players on a single platform.
HTRI is a Texas based industrial research and development consortium which serves the thermal process engineering needs of more
than 1,400 corporate member
sites world-wide for over 50 years.

Mr. Haresh K. Sippy, Chairman and MD,

TEMA India Ltd.

hermal process engineering industry took a pledge for greater

energy efficiency efforts as designers, engineering consultants, manufacturers, buyers, processors and EPC
companies gathered at the HTRI-CC
India meetings held at Delhi and Mumbai recently to explore newer and
innovative solutions to make Heat
Exchangers more energy efficient.

Speaking on the current challenges

faced by the industry, Chairman and
Managing Director, TEMA India Ltd. and
the oldest HTRI Member, Mr. Haresh K.
Sippy said, The coming years and decades will see reduced availability of
crude oil and hence Indian companies
need to upgrade ideas and standards
to meet global requirements and resultantly help conserve environment.

89 companies of India representing

all key stakeholders were brought together by Heat Transfer Research Inc.
(HTRI) at the HTRI-CC India meetings.

Heat Exchangers are to be tailormade as per the end-users requirements and not merely as specifications
and datasheets. After all, the wealth
of information comes only from the
end-users. Though heat exchanger is

The meetings highlighted the need to

a mystery, it can be solved with the

better coordination with the end-user
since conceptualisation. If that data is
shared with manufacturers - through
EPC Companies - it would be easy to
nail this obscurity, he concluded.
TEMA India Ltd. is among the global
leaders in manufacturing of Heat Exchangers and one of the major users of HTRI technology in India.
HTRI CC-India (Communication Committee) is a formal Users Forum and
it provides a non-business platform to
collect feedback on various aspects
related to HTRI technology and its usage. This forum regularly discusses
the current relevant matters and
sends feedback to HTRI which gets
documented and suggestions implemented for the future development.
On the technical side of the discussions, 19 presentations, covering varied aspects on thermal, process and
mechanical engineering, showcased
the recent trends and future requirements. Also there were conducted two
panel discussions with the discussions.

Wins Order Worth Rs. 246.78

Elecon EPC Projects
Crores From NTPC

lecon EPC Projects Limited, one of

the Indias largest Material Handling
Equipments and Transmission Products
manufacturers and a subsidiary of Ele-

con Engineering Company Limited,

has bagged an order from NTPC LIMITED of Rs. 246.78 crores for Ex-works

STEEL & METALLURGY

52

FEBRUARY 2014

(India) supply for coal handling plant

package of Gadarwara Super Thermal
Power Projects, Stage I (2x800MW).

News Desk

World Steel Association To Launch Steel Safety Day

T

he World Steel Association (worldsteel) plans to launch Steel Safety

Day, reiterating its commitment to
the safety and health of the people who work in the steel industry.
This safety awareness day is aligned
with the World Safety Day held by
the International Labour Organisation on 28 April every year. In support
of this global event, World Steel Association and its members will carry
out an industry-wide safety audit.
worldsteel has carried out an analysis

on safety and health practices in the

steel industry over the last five years
and has identified the main causes
of serious safety incidents. The Steel
Safety Day is expected to reinforce
awareness of the five most common
causes of safety incidents and to create a safer working environment across
the entire steel industry worldwide.
worldsteel is requesting all its members as well as all related organisations within the steel industry to carry
out a special audit on the five main
causes of safety incidents in all plants

around the world. This should engage

both employees and service providers involving as many as four million people in total. Edwin Basson,
Director General of worldsteel said.
Andrew Page, Chairman of worldsteel Safety and Health Committee
said: The steel industry has seen a
steady and notable reduction in the
rate of injuries since 2006 and the average lost time injury frequency rate
has gone down by 50% in the last five
years. But our goal remains to create an injury-free, illness-free and
healthy workplace with zero incidents.

SAIL Posts 7% Sales Growth In Feb 14

C

ontinuing its encouraging Q3 results, Steel Authority of India Limited (SAIL) maintained its upward trend
in its sales and production in February 2014. The company registered 7%
growth in sales in Feb 14 compared
to the same month last year (SMLY).
For the cumulative 11-month period
Apr 13 Feb 14, SAILs concerted effort in increasing domestic sales
as well as exports paid off as these
grew by 8% and 33% respectively.
SAIL plants kept pace with the
rise in sales, as the company produced 1 million tonnes (MT) of saleable steel in Feb 14, marking a 7%
growth over SMLY. The month also
witnessed 4% production growth
each in hot metal and crude steel, at
1.12 MT and 1.04 MT respectively.

SAIL Chairman Mr. C.S. Verma ascribed

SAILs growth trend to consistently
good performance throughout the financial calendar. Consistent growth
in sales over the last few months

STEEL & METALLURGY

54

FEBRUARY 2014

has given us the confidence of reporting a better outcome in the

coming months, which will further
pick-up with the expected strengthening of the market, he averred.

News Desk

Producers To Set Up Rural

Steel Minister Asks Steel
Stockyards

Steel Minister
Prasad Verma

overnment
has asked
major steel companies in the
country to set
up stockyards
in rural areas
so that consumers save on
time and cost of
Beni transportation.

We have asked
leading steel players, including SAIL and
RINL, to establish stockyards in rural areas for providing products required in
construction and other applications.
Steel Minister Beni Prasad Verma said.
Steel consumption in India is barely
60 Kg per capita against the global average of 210 kg per capita.

A Parliamentary panel on Steel and

Coal in December had expressed disappointment over low steel consumption.
A high-level panel had asked the government to issue necessary direction to all major steel producers to
set up processing units and stockyards, particularly in rural areas, to
boost the per capita consumption.
The Steel Minister said a few players have already begun setting
up such stockyards in rural areas.
Latest in this series of initiatives is the
establishment of stockyards by Steel
Authority of India Ltd (SAIL) and Rashtriya Ispat Nigam Ltd (RINL) in rural areas of Gorakhpur and Gonda, he said.

Taking this concept a step forward,

it has been decided that the stockyards would also have service centers
in their premises, where small fabrication jobs could be carried out, he said.
The service centres would facilitate small fabricators to manufacture steel products according to the
needs of customers and at the same
time provide better infrastructure
to small entrepreneurs, he added.
Indias steel consumption grew 3.3
per cent, the lowest in three years,
to 73.3 million tonne in 2012-13
on subdued demand due to slackening economy and high interest rates. It grew by 5.5 per cent in
2011-12 and 9.9 per cent in 2010-11.

Dolvi Steel Plant Capacity to 5

JSW Steel To RaiseMillion
Tonnes

SW Steel Limited plans to shift its focus

to its Dolvi Steel Plant in Maharashtra, which is better placed to support its
expansion plans, compared with its flagship plant in Karnataka, where difficulty
in raw material sourcing has curtailed
growth, according to the company.
As per report, the 3.3 million tonne Dolvi
Steel Plant in the Raigad district of Maharashtra that came to JSW Steel from
its acquisition of Ispat Industries Limited in 2010 is seeing new investments.

A senior executive in JSW Steel was

quoted as saying: There is a lot of
activity taking place there. A capacity addition of 1.7 million tonne has
been planned for Dolvi which will push
up the total capacity at the plant to 5
million tonne. The plan is likely to be
implemented in the next few months.
Mr. Prashant Jain, Head of Corporate Strategy and Development at
JSW Steel, said, We will be expand-

STEEL & METALLURGY

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ing capacity of Dolvi plant in future as it a very good location for

brownfield expansion. However, we
have not yet decided the timelines.
The official said that JSW had made
new investments for a pellet and a coke
oven plant, which are in trial phase and
almost ready for production. The company has also invested in using flare gas
a byproduct to generate 25% to 30%
of the power required by the plant.

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News Desk

Steel Production At 135 Million

SAIL Sees IndiasTonnes
By 2015-16

AIL Chairman Mr. C.S. Verma

said that with around 50% capacity increase in the offing, Indias steel industry is likely to face
a temporary over supply situation.
Mr. Verma said that Substantial capacity additions are lined up in the
next 1 to 2 years in the country taking the capacity from the current

level of around 90 million tonnes

per annum to around 135 million
tonnes per annum by 2015 to 2016.
He added The rise in production may
lead to a temporary phase of oversupply, this is because typically the increase in capacities is in spikes, whereas the increase in consumption follows
a relatively smoother trajectory.

During the April-February period of

the current fiscal, Indias steel consumption expanded by just 0.7 per
cent to 67.253 million tonnes (MT)
over the same period last fiscal,
mainly due to slow economic growth.
Mr. Verma added that this increased
capacity and subdued consumption might lead to more exports.

Steel Consumption Inches Up 0.7% In Apr-Feb

S

low economic growth weighed

down on Indias steel consumption
which expanded by just 0.7% during
April-February period of current fiscal at 67.253 million tonnes (MT) over
the same period last fiscal. The country consumed 66.78 MT steel during corresponding period last fiscal,

Joint Plant Committee, a Steel Ministry Unit, said in its monthly report.

the domestic economy and a sharp

decline in imports, the report said.

Indias real consumption of total

finished steel was up by 0.7% yearon-year in April-February FY14, impacted primarily by the slowdown in

The low growth rate in domestic steel

consumption indicated that base level
demand conditions continued to be weak
during the current fiscal so far, it said.

RINL Puts In All Round Performance In Feb14

C

ontinuing the good performance in

Production as well as in Sales, RINL
recorded a growth of 11% and 20%, in
Liquid Steel, Saleable Steel production
respectively compared to February13.
The month of February also witnessed a
growth of 5% in Power Generation thus
reducing dependency on state grid.

A turnover of Rs 1382 crores was

achieved in February with a sequential growth of 7% over previous month.
The cumulative of Rs 11,766 crores
achieved in current FY, representing a
growth of 2% over CPLY. The exports recorded a growth of 72% at Rs 725 crores
compared to CPLY of Rs 421 crores.
The cumulative sales volume of Sale-

able Steel, Special

Steel and Wire
Rods registered
a growth of 12%,
9% and 39% respectively compared to CPLY.
Sri P Madhusudan, CMD, RINL
attributed
the
good show to the
dedicated
and
committed employees steered
by able leadership and asked to continue the efforts during last month of this FY

STEEL & METALLURGY

58

FEBRUARY 2014

with more zeal and to make every

effort in surpassing the set targets.

News Desk

Minds From Tata

Young
Steel Clinch Industry
World Champions Title
At 8th Steelchallenge

ausik Tamuli and Animesh Kumar Singh from Tata Steel India
bagged the Industry World Champions
at the World Steel 8th steelChallenge,
held on 19 February 2014 in Brussels .
The two young minds from Tata
Steel in India won in the category
for young steel industry employees.
A team Ezio Agustin Casalini and
Francisco Branas from Universidad Nacional del Sur in Argentina won in the student category.
The regional champions from the first
round vied for the World Champions title of the 8th steelChallenge where the
task was to produce high strength steel

billets at the lowest

total cost using secondary steelmaking simulation tools
at steeluniversity.
org. An application
of this steel is the
cables of suspension bridges which
can span greater
distances
than
any other type of
28-02-2014
bridge and typically
use less material,
leading to lower construction costs. nouncing the winners said: This global
competition, simulating the manufacDr. Karl-Ulrich Khler, Chairman of turing of steel, provides a unique opworldsteel Education and Training Com- portunity to young professionals
mittee and CEO Tata Steel Europe, an- from steel companies and universities to test their skills.

Two Winners Kausik Tamuli and Animesh Kumar with Dr. Karl-Ulrich Khler in the middle

STEEL & METALLURGY

60

FEBRUARY 2014

Mr. Joon-Yang Chung,

Chairman of worldsteel
and CEO and Chairman,
POSCO,
commented
upon presenting the
trophies and certificates to the champions: The steel industry
requires
continuous
innovation and creativity and, in exchange,
offers a rewarding and
challenging career. This
industry boasts continuous technological
innovations making a
vital contribution towards the sustainable
growth of society.

News Desk

To Expand By 2-3% In Fy14:

Indian Steel Consumption
INSDAG
2013-14, according to Mr. Sushim Banerjee, Director General, Institute for
Steel Development & Growth (INSDAG).
The steel industry is facing sluggish consumption growth. We expect
some improvement in Q4 period and
the sector may see a growth of 2-3%
in 2013-14, Sushim Banerjee said.
The steel demand in the 10 month
period (April 2013- January 2014)
increased
by
only
0.5-0.6%.
Sushim Banerjee

teel consumption in the country

might register a growth of 2-3% in

Mr. Banerjee mentioned traditionally in the Q4 period (April-March) demand and price remained bouyant, but
this year long products were witness-

ing price pressure after slump in steel

scrap price in the international market.
He said crude steel production in
April 2013-January 2014 period was
4.6% and for the full fiscal FY14 it was
projected to remain at around 5%.
On the final report on the steel policy that aimed to increase Indian
steel production capacity to 300 million tonnes by 2026 from 96 million
tonnes now, Mr. Banerjee said he was
not sure and it might come sooner as
elections were knocking on the doors.
Despite sluggish demand and production outlook in FY14, the scenario
was likely to improve in 2014-15.

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News Desk

Plants To Clean Sinter Offgases For

Siemens Meros
Italian Steel Producer Ilva S.p.a

Cuts fine dust emissions to below ten milligrams per standard cubic meter
Reduces dioxins and furans to less than 0.1 nanograms per standard cubic meter
Substantially reduces acidic gases and volatile organic compounds
Plant design allows for major reduction of sulfur dioxide emission

talian steel producer Ilva S.p.A. has

placed an order with Siemens Metals Technologies to supply four turnkey
Meros plants for the two sinter plants in
its Taranto steel mill, which is the single
largest production unit in Europe with
a capacity of 11 million tonnes per year.

come down from the actual emission

load of 12 grams per year at the actual limit of 0.4 nanograms I-TEQ per
standard cubic meter to a level less
than 3 grams per year. The design of
the plant is also featuring installations
for major sulfur dioxide reduction.

Siemens Meros process will clean all

the offgas from the sinter process
totaling more than 2.6
million cubic meters per
sinter plant per hour.
This will reduce emissions of sulfur dioxide,
fine dust, organic compounds, heavy metals
and acidic gases to levels
significantly below the
usual limits in Europe.
The first two Meros
plants are scheduled to
go on stream in April
2015 and the other two
will follow in September 2016. The value of
the order lies in the mid
double-digit million euro range.

Siemens recently won an order in summer 2013 to equip the sinter plants with

Meros plant from Siemens

In the future, the fine dust emission via

the smoke stack of Ilvas sinter plants in
Taranto will be reduced by more than
1,000 tonnes compared to the legal
emission level, which is actually set at 40
micrograms per standard cubic meter.

two new secondary dedusting systems.

The Meros plants will replace the existing outdated MEEP electrostatic precipitators, which can only remove dust. The
new units will be installed and integrated into the offgas system of the sinter
plants during ongoing operation, which
will only require brief shutdown times.

Furthermore, the dioxin emission will

The Meros process involves injecting

STEEL & METALLURGY

62

FEBRUARY 2014

and finely distributing adsorption and

desulfurizing agents, such as activated
carbon and sodium bicarbonate, into
the flow of offgas. This efficiently binds
and removes heavy metals, harmful
and hazardous organic components, as
well as sulfur dioxide and other acidic
gases. The use of sodium bicarbonate
to reduce the amount of sulfur dioxide
also eliminates the need for a conditioning reactor. The process is water-free, which
avoids steam plumes
coming from the smoke
stack. The dust particles
are deposited in a specially developed, energy-efficient bag filter, which is
suitable for temperatures
of up to 250C and very
low cleaning pressures.
The greater part of the
dust removed by the precipitator is recycled back
into the flow of offgas to
further optimise the efficiency and cost-effectiveness of the gas purification process.
Any remaining unutilised additives
are then once more in contact with
the offgas, so that they are finally almost completely utilised. The process automation system ensures
stable operation, even during fluctuations in the volume and composition of the offgas. Emission limits can
therefore be observed at all times.

2-DAY INTERNATIONAL CONFERENCE

STEEL CONCLAVE 2014

Raw Materials, Technology, Energy Management

& Logistics in Steel Industry

28 - 29 October 2014

Bombay Convention & Exhibition Centre

Goregaon (East), Mumbai, India
Organised by:

Concurrent to:

Technical Focus:

Coke making
Future supply of coal & iron ore
New coke making technologies
Iron ore production and handling
Iron ore beneficiation technologies
Sinter plant operation and automation
Pelletisation
Blast furnace iron making
New blast furnaces
Direct reduction: production and use of DRI
Environmental control in iron making
CO2 reduction and energy saving in
steelmaking
Alternate Fuel
Waste Heat Management
Water Treatment

Primary and secondary steelmaking

Continuous Casting technology
Refractories developments in casting
additives
Special technologies for high performance
steels
Automation, maintenance, on-line machine
control
New plants and updating of conventional
plants
Safety and environmental aspects
Downstream processing of CC products
and of ingots (interactions with successive
working processes, i.e. rolling, forging,
wire drawing, extrusion, etc.)
New casting processes, novel casting
technologies, new products

Product quality (surface defects, internal

quality)
Near-net-shape casting / thin and medium
slabs
Strip casting, beam blank casting
Finishing
Testing technology (cleanliness, gas
content, surface quality)
Casting, solidification and phase formation
Metal forming processes and thermomechanical treatment
Coating and finishing
Integrated modelling of process chain and
production
Materials transportation and handling
logistics

Registration Form:
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Statistics

World Steel Association

Monthly crude steel production in the 65 countries included in the report, in thousands of tonnes.
January 2014
January

January

% change

2014

2013

Jan-14/13

Austria

681

672

Belgium

580 e

627

Bulgaria

45 e

43

3.7

Croatia

20 e

1 month
2014

2013

% change

1.5

681

672

1.5

-7.5

580

627

-7.5

45

43

3.7

546.6

20

546.6

Czech Republic

458

443

3.5

458

443

3.5

Finland

330

300

9.7

330

300

9.7

France

1 350 e

1 351

0.0

1 350

1 351

0.0

Germany

3 663

3 585

2.2

3 663

3 585

2.2

Greece

110 e

87

26.4

110

87

26.4

Hungary

80

78

2.6

80

78

2.6

2 245

1 756

27.8

2 245

1 756

27.8

Italy
Luxembourg

200 e

186

7.6

200

186

7.6

Netherlands

620 e

612

1.4

620

612

1.4

Poland

640 e

649

-1.4

640

649

-1.4

Slovakia

393

388

1.3

393

388

1.3

Slovenia

54

42

28.2

54

42

28.2

1 111

1 000

11.1

1 111

1 000

11.1

387

371

4.4

387

371

4.4

1 083

824

31.5

1 083

824

31.5

Spain
Sweden
United Kingdom
Other E.U. (27) (e)
European Union (28)
Bosnia-Herzegovina

417

-13.6

360

417

-13.6

14 409

13 433

7.3

14 409

13 433

7.3

75

61

22.1

75

61

22.1

360 e

10.3

10.3

Norway

49

52

-5.9

49

52

-5.9

Serbia

54

..

54

..

Turkey

2 829

2 854

-0.9

2 829

2 854

-0.9

Other Europe

3 013

2 972

1.4

3 013

2 972

1.4

Macedonia

5e

Byelorussia

175 e

226

-22.6

175

226

-22.6

Kazakhstan

300 e

198

51.3

300

198

51.3

45 e

..

45

..

Moldova
Russia

5 935

5 704

4.1

5 935

5 704

4.1

Ukraine

2 490

2 878

-13.5

2 490

2 878

-13.5

58

2.6

60

58

2.6

9 065

-0.7

9 005

9 065

-0.7

Uzbekistan
C.I.S. (6)

60 e
9 005

STEEL & METALLURGY

66

FEBRUARY 2014

Statistics
Monthly crude steel production in the 65 countries included in the report, in thousands of tonnes.
January 2014
January

January

% change

2014

2013

Jan-14/13

2014

2013

% change

1 050 e

1 096

-4.2

1 050

1 096

-4.2

Cuba

35 e

20

72.6

35

20

72.6

El Salvador

10 e

25.0

10

25.0

40 e

26

53.8

40

26

53.8

1 550 e

1 552

-0.1

1 550

1 552

-0.1

59

-22.8

45

59

-22.8

7 328

7 362

-0.5

7 328

7 362

-0.5

10 058

10 122

-0.6

10 058

10 122

-0.6

397

320

24.1

397

320

24.1

2 738

2 776

-1.4

2 738

2 776

-1.4

Canada

Guatemala
Mexico
Trinidad and Tobago
United States
North America
Argentina
Brazil

45

1 month

Chile

110 e

141

-21.8

110

141

-21.8

Colombia

125 e

89

40.0

125

89

40.0

60 e

46

30.6

60

46

30.6

Ecuador
Paraguay
Peru
Uruguay
Venezuela
South America
Algeria
Egypt
Libya
Morocco
South Africa

5e

354.1

354.1

110 e

87

27.1

110

87

27.1

10 e

..

10

..

175

-37.0

110

175

-37.0

3 634

0.9

3 665

3 634

0.9

110 e
3 665

19

80.8

35

19

80.8

677

-27.8

489

677

-27.8

41

72.8

70

41

72.8

58

53

9.3

58

53

9.3

615 e

615

0.0

615

615

0.0

35 e
489
70 e

Africa

1 267

1 405

-9.8

1 267

1 405

-9.8

Iran

1 350 e

1 111

21.5

1 350

1 111

21.5

165 e

197

-16.2

165

197

-16.2

Qatar
Saudi Arabia

469

463

1.4

469

463

1.4

United Arab Emirates

157

216

-27.5

157

216

-27.5

2 141

1 987

7.7

2 141

1 987

7.7

China

61 573

63 622

-3.2

61 573

63 622

-3.2

India

6 954

6 955

0.0

6 954

6 955

0.0

Japan

9 401

8 863

6.1

9 401

8 863

6.1

South Korea

6 040

5 928

1.9

6 040

5 928

1.9

Middle East

Taiwan, China
Asia
Australia
New Zealand
Oceania
Total 65 countries*

1 776

3.6

1 840

1 776

3.6

85 809

87 144

-1.5

85 809

87 144

-1.5

339

408

-17.1

339

408

-17.1

1 840 e

77

83

-7.1

77

83

-7.1

416

491

-15.4

416

491

-15.4

129 783

130 253

-0.4

129 783

130 253

-0.4

* - the 65 countries included in this table accounted for approximately 98% of total world crude steel production in 2013e - estimated

STEEL & METALLURGY

67

FEBRUARY 2014