SMS Newsletter 01 2015 en

THE MAGAZIN E OF T HE S M S GROUP
ISS UE 01/20 1 5
Systems provider
Solutions from the SMS group
increase quality, boost production
and reduce emissions.
sms group newsletter 01/2015
CONtents
Contents
14 Big River Steel: Steelmaking plant and rolling mill from a single source
All from a single source:

from mechanical equipment, E & A to service.
Being a systems provider, the SMS group is the
right partner for mill
operators. Read more
starting on page 12.
In focus Electrics &

Automation
04 Deutscher
Zukunftspreis
08 in brief
138 Events
141 Imprint
The SMS group newsletter app is

now available in the App Store and at
Google Play.
THE MAGAZ INE OF THE SMS GROUP

ISS U E 01 / 2015
SySTEMS PROvIdER
Solutions from the SMS group
increase quality, boost production
and reduce emissions.
Cover photo: Control pulpit at MMK, Russia. The steelmaker

operates, among others, a heavy plate mill from SMS Siemag.
22 Remote access
In an interview, Detlef Ehlert
29 Precise measurements
and Bernward Reif describe
The MEERgauge measuring
plant automation solutions of
system from SMS Meer impress-
the future.
es at Deutsche Edelstahlwerke.
25 Plug & Work in 3D
30 Mobile control
With visualizations in 3D, SMS
The Product Inspector, devel-
Siemag achieves an even more
oped by SMS Siemag, is an ap-
realistic view of the plants.
plication for slab quality control.
28 Process supervision
at its best
34 Aluminum strip from

Saudi Arabia
The BFXpert automation
An aluminum rolling mill was
package from Paul Wurth in-
put on stream in Saudi Arabia.
creases process stability and
Systems supplier SMS Siemag
reduces costs.
automated the equipment.
contents
44 Kardemir relies on SMS.
84 Galvanizing line for Wuppermann.
126 Industry 4.0 at SMS.
Markets
Projects
40 Remarkable
growth
The Turkish aluminum pro-
52 SMS Siemag
Service
Innovations
Ecoplants
56
Paul Wurth
58
Metallurgical technology
ducer ASAS goes for steady
67
Steel refining
growth using high-tech
68 Continuous casting plants

(flat products)
equipment.
48 Made in Turkey
Habas has started producing
flat steel on a hot strip mill
supplied by SMS Siemag.
50 Close to the
customer
72
Hot rolling mills
74
Cold rolling mills
82
Aluminum plants
84 Strip processing lines and

furnace technology
90 SMS Meer
With its Gebze service work-
90 Steelmaking/CC technology
(long product mills)
shop in Turkey, SMS Siemag
94
Tube & pipe plants
is right on its customers
96
Long products plants
doorstep.
104 Forging plants
112 Experience counts

Efficient maintenance helps
plant operators achieve higher
quality.
130 Heat-treated
New concepts for heat treating
heavy plates.
134 Forged
The SMX 800 from SMS Meer
now also forges tubes and pipes.
109 N
F-Metals
Deutscher Zukunftspreis
Award for joint project

On November 19, 2014, German Federal President Joachim Gauck
presented the Deutscher Zukunftspreis. The German Presidents Award
for Innovation in Science and Technology was conferred on the joint
Horizontal Belt Casting of Steel project. Partners to the project are
Salzgitter Flachstahl, SMS Siemag and the Clausthal University of
Technology. The project was one of three put forward for the
prize following a selection procedure.
4
From right to
left: Professor Dr.
Karl-Heinz Spitzer,
Clausthal University
of Technology, Ulrich
Grethe, Chairman
of the Managing
Board of Salzgitter
Flachstahl GmbH,
Burkhard Dahmen,
Spokesman of the
Managing Board of
the SMS group.
It is an old dream of the steel industry: making steel products with as few intermediate steps as possible directly
from the liquid steel. This saves energy and resources, protects the environment and facilitates a more flexible and
efficient manufacturing process. The solution: the Belt
Casting Technology (BCT), a horizontal strip casting process. In this process, the steel is no longer cast into up to
30-centimeter-thick slabs, which have to be reduced in
various time-consuming and energy-intensive downstream
processes. Instead, the new technology casts strips of one
to two centimeter thickness. This already comes close to
the product thickness suitable for numerous applications.
SMS Siemag built the first industrial scale pilot plant for
Salzgitter Flachstahl in Peine near Hanover to demonstrate
the viability of horizontal strip casting in the steel industry.
The project was sponsored by the German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety. Commissioning of the
plant took place in December 2012.
The pilot plant can process approximately 40,000 tons of steel per year.
Meanwhile, several dozens of casting
trials have proved the stability and reliability of horizontal strip casting.
What makes this innovation so important is the fact that the number of processing steps from the casting of the
liquid steel down to the final steel
product has been markedly reduced,
says Ulrich Grethe, Chairman of the
Managing Board of Salzgitter Flach
stahl GmbH.
i
Deutscher
Zukunftspreis
Deutscher Zukunftspreis, the
German Presidents
Award for Innovation in Science and
Technology, is one of
the most important
science awards
in Germany. Prize
money amounts to
250,000 euros. The
FASTER, BETTER, LESS COSTS
prize is awarded
In the BCT process, the liquid steel

flows into a tundish and from there
into another container which feeds the
steel onto a cooled circulating transport belt. The steel solidifies on the
horizontally running section of the
belt to form a thin strip. This does not
involve any bending of the strip or addition of casting fluxes. The metallurgical length of the Peine pilot plant
amounts to eleven meters, with casting speeds of up to 30 meters per
minute. The cast strip is about one
meter wide. The high cooling rates of
the material have a positive effect on
the casting quality. The casting thickness is sufficient to ensure that the
rolled product will feature the required
properties. Only through these process characteristics will a wide range
of new, high-grade steels become
producible in the future. The new
by the German
President, currently
Joachim Gauck. It
honors outstanding
research activities
and developments
with a clear relevance to practical
application.
From right to left:

Burkhardt Dahmen,
Spokesman of the
Managing Board
of the SMS group,
Ulrich Grethe,
Chairman of the
Managing Board of
Salzgitter Flach
stahl GmbH, Federal
President Joachim
Gauck, Professor Dr.
Karl-Heinz Spitzer,
Clausthal University
of Technology.
The steel is poured

from the ladle into
the tundish.
Part of the visualization system in the

control room for
the horizontal strip
casting process.
technology opens up numerous possibilities of application

in various steel using industries. For example in automotive engineering: To reduce fuel consumption, vehicles become lighter every time. This is only achievable through the
use of innovative special steel grades, such as HSD steel.
HSD steel is a high-manganese steel. This gives the material excellent forming properties and high strength at the
same time. Consequently, also the weight of safety-critical
components, such as seats, side impact beams and shock
absorbers, can be reduced. Conventional continuous casting processes failed to produce this class of special steels.
With BCT, steel producers will be able to overcome this
obstacle.
At the same time, BCT protects the environment. Fluxes, as used in other casting processes, are not needed. As
the cooling water is not in direct contact with the cast strip,
it can be reused without prior treatment. BCT requires
much less energy than the conventional continuous casting
route, with the effect of lower emissions of harmful CO2.
Photo above: bildschn/deutscher zukunftspreis
LONG TIME TO MARKET
The fact that the joint project of Salzgitter Flachstahl, SMS

Siemag and the Clausthal University of Technology was put
forward by the Federation of German Industry for one of the
most important German science awards shows how much
innovative vigor and engineering expertise have been put
into the development of the BCT process, and what enormous efforts in terms of time and money the partners to the
project have undertaken since the mid-1990s. Four or five
years ago, we, who would be building the plant, had come to
the conclusion together with SMS and the Clausthal University that the innovative process had worked out on the laboratory scale, explains Salzgitter Chairman Grethe. We had
reached a point at which we couldnt see how we could further improve the tests conducted in the lab.
Therefore, a fundamental decision had to be taken: On
the one hand, the demand of the customers for increasingly lighter-weight and better-performing materials had
to be considered. On the other hand, there was the challenge to take the process to industrial maturity. In order to
accommodate both aspects, we decided to take the
plunge, meaning we were ready to take the risk of invest-
ment and invest generously to build

this innovative plant as the first of its
kind worldwide, says Grethe.
In spring 2012, the strip casting
plant was shipped to Peine in pre-assembled portions suitable for the
transport. Prior to that, SMS Siemag
had assembled and tested the complete plant in Hilchenbach. Scientifically, the project was accompanied by
the Chair of Metallurgical Process
Technology of the Institute for Metallurgy of the Clausthal University of
Technology. Thus, all three, Salzgitter
Flachstahl as steel producer, SMS
Siemag as plant and mechanical engineering company, and the University of Clausthal, worked together hand
in hand. Either one of us alone would
never have been able to take this project to its current level of maturity,
neither in terms of efficiency nor in
its technological sophistication, emphasizes Burkhard Dahmen, CEO of
SMS Siemag AG. In that sense, it is a
joint product of all three partners. For
Germany as an industrial location
with a high salary level, it is important
that we join forces to adopt a strong
position in the global export landscape and stay ahead of the low-price
competitors through innovative technology.
www.deutscher-zukunftspreis.de
in brief
SMS group
Two awards
Paul Wurth
Change at the company head

Marc Solvi, Chief Executive Officer of
Paul Wurth S.A. since January 1, 1998,
will resign from his function as of December 31, 2014, but remain a member
of the companys Board of Directors.
Georges Rassel, since 1988 active at
Paul Wurth and since 2011 a member
of the management as Chief Operations Officer, has been appointed by the
Board of Directors as his successor.
Marc Solvi
Georges Rassel
www.paulwurth.com
SMS Meer
New record in ring rolling

TPCO Bohai from Tianjin, China, has rolled the first ten-meter ring on its new radial-axial ring rolling machine from SMS Meer, breaking the previous valid record
of 9.65 meters. In hot-rolled condition the rings at Bohai achieve a diameter of
10.15 meters and 10.0 meters after cooling. They are seamless rolled rings, which
can be used in tank construction, in the chemical and petrochemical industry, in
cement mills or tunnel boring machines and, in future, also in towers of big wind
power systems.
8
The SMS group received

two awards from AIST for
papers presented at AIS
Tech 2013: the Charles H.
Herty Award for the best
submitted paper for the
presentation titled Advanced blowing and stirring
conditions in the BOF process. The second award
was presented by the Computer Application Committee for the paper on Numerical EAF oscillation
model and operational validation. Both papers were
delivered by Hans-Jrgen
Odenthal, General Manager Fundamentals & Models Melting and Reduction
at SMS Siemag. The award
was handed over to coauthor Jochen Schlter,
VP Special Technologies,
SMS Siemag.
IN BRIEF
SMS Siemag
SMS group
Visit by the Russian Consul

General
Award-winning
On July 14, 2014, Yevgeny Alexeyevich Shmagin, Consul General of the Russian
Federation, visited SMS Siemag in Hilchenbach. Burkhard Dahmen, Spokesman of the Managing Board of the SMS group, and Jens Barth, a member of
the Managing Board of SMS Meer, showed Shmagin around the revamped
manufacturing facilities.
www.sms-siemag.com
The
corporate
magazine of the
SMS group, the
SMS Newsletter,
has received the
2014 Golden Fox
Award for the best
Corporate magazine/mobile application. With the renowned Fox Awards,
the German communication and media
sector honors achievements in different
media and communication categories.
SMS Meer
Prize
award for
HybrEx
SMS group
Sustainability credential
The SMS groups office building in Gurgaon, India, has been awarded a golden LEED certificate (Leadership in Energy and Environmental Design) by the
U.S. Green Building Council (USGBC),
a nonprofit organization promoting

sustainable building. The USGBC
based its rating on the provable high
resource efficiency of the building in
energy, water and material use.
The Design Council, an independent

and internationally oriented institution, has honored the product design
of the new SMS Meer extrusion press
HybrEx in the category Industry, Materials and Health Care with the
Special Mention award. The German Design Award honors cuttingedge products from the product and
communication design that are pathbreaking in German and international
designing. For this competition 2,250
entries were received.
www.sms-meer.com
SMS Meer
Double-ended boring machine in the SMS Meer workshop in Mnchengladbach.
NEARING COMPLETION
By 2015, SMS Meer will have invested about EUR 60 million in the
manufacturing site at the Mnchengladbach location. Customers will benefit
from shorter throughput times and greater flexibility.
Whoever wants to survive in the international competition

of machinery and plant engineering has to invest at regular
and timely intervals. SMS Meer has thus given the goahead for the modernization of manufacturing and assembly in 2010. Within five years, approx. 75 percent of all machine tools are to be replaced. Investments amount to EUR
60 million. The focus is on increasing productivity, achieving
shorter processing times and better quality, and on the
possibility of machining even larger plant and machine
parts in future. Already in 2012, the new heavy-load production shop 1a with a floor space of 4,000 m was opened,
which is attached directly to the old production shop 1, re10
sulting in an open workshop complex

with a total floor space of approx. 9,000
m. The clearance height is around 20
meters enabling the ability to maneuver even large components with three
overhead crane areas providing a lifting capacity from five to 180 tons. Assembly can therefore take place in
every point of the shop.
At the same time, foundation work
began for the new facilities and the old
facilities were disassembled. In spring
i
SMS Meer
Better quality,
shorter throughput times: This
is achieved by
SMSMeer with
the investments in
manufacturing.
SMS Meer
2012, the first turning/milling center

was set up and put into service. One
year later, the new paint-spray cabin
featuring an efficient exhaust air system has come on stream. Since the
summer of 2013, a master computercontrolled machining line with four
machining centers has been available.
Tooling of the machining centers takes
place fully automatically. Simulta
neously, the pallet racking system was
installed feeding the four machining
centers automatically. Disassembly of
the old facilities was launched in the
fall of 2013 and has already been
completed.
Lower production costs
Only a few weeks ago, the newly installed furnace plant for PQSC (Premium Quality Surface Coating) mandrels was taken into operation. At
present, a vertical turret lathe is in the
ramp-up phase. Provided with an additional milling cutter the turret lathe
allows for full machining of work
pieces. Besides the demanding logistical aspects to work on different machines it also reduces production
costs.
Towards the end of the work the
long lathe (turning length 21 meters,
weights up to 28 tons) and the heavyduty lathe (turning length 9 meters,
weights up to 60 tons) are to be placed
onto their new foundations just in time
in spring 2015 and put into service.
On completion of the project more
efficient and productive machining
facilities will be available to SMS
Meer a benefit to the customers.
With the new machines even complex
Steven Glomb (left) and Oskars Sprizdans from SMS Meer loading the process furnace for the
production of PQSC piercing mandrels.
components with unit weights of up

to 200 tons can be manufactured
economically. Moreover, we also make
important parts for spare parts
services, states Heinz Joachim
Gietmann, Head of Production at
SMS Meer.
www.sms-meer.com
75
percent of the machine tools will have been
replaced by SMS Meer at the production site
in Mnchengladbach by 2015.
11
In Focus
Into the future

Lower operating costs, higher productivity: This is what operators of
metallurgical plants and rolling mills expect from plant technology. Being a
systems provider, the SMS group offers suitable solutions for the mechanical
design, for E & A systems and for life-cycle services from a single source.
12
In FOcus Electrics and Automation
OVERVIEW
A steelworks where all systems fit together
The SMS group will build a steel and rolling mill
complex for Big River Steel.
Automation systems
Experts describe solutions of the future.
Systems for planning
3D visualization provides a realistic view of the plants.
Systems for plant modernization
Innovative solutions make plants fit for the future.
Monitoring system
Higher process stability with BFXpert for blast furnaces
Measuring system
MEERgauge impresses in bar rolling mill
Control system
Mobile quality control of slabs
Systems for data control
Integrated E & A solution masters data floods.
AluControl system convinces
Maaden-Alcoa banks on automation system from SMS.
14
22
25
26
28
29
30
32
34
IN Focus
Hernando Desoto Bridge

crossing the Mississippi
River between Tennessee
and Arkansas.
14
In Focus Electrics and automation
BIG RIVER STEEL:

ALL SYSTEMS FIT TOGETHER
Big River Steel LLC, U.S.A., has awarded the SMS group the order to build
a steel complex in Mississippi County, Arkansas. As a provider of integrated
systems, SMS will supply the plants and systems for the entire project.
he ground was broken on September 22, 2014, during a ceremony marking the start of this ambitious
greenfield steel project on the Mississippi River.
Big River Steel LLC. and the SMS group had signed
the contract in July 2014. The first touchdown has been
scored, says John Correnti, Chairman and CEO of Big River Steel. Now, we will need some good passes and a highspeed 25-yard sprint once in a while to make sure that this
project becomes a success. With the SMS group, an experienced partner, being at our side, we are certain that we will
accomplish this goal. The steelworks is planned to start
producing in 2016.
Photo: gettyimages/Thinkstock
PRODUCTS OF EXACTING QUALITY
The new mills product range will be focused on demanding

steels, such as tube grades for pipeline construction, silicon steels for electrical applications and Advanced HighStrength Steels (AHSS) grades. There is a growing market
for these products in the U.S.A. Especially the automotive
industry needs AHSS grades, explains Correnti. The carmakers are looking for higher-strength and lighter-weight
steels. High strength is needed to be able to fulfill the exacting safety requirements, and lower weight to reduce fuel
consumption. With major carmakers having their facilities
in the southern part of the U.S., Big River Steel is moving
very close to where their future customers are located. The
fact that the U.S.A. is still required to cover a considerable
portion of its steel demand by imports indicates that there
is definitely a market for steel products.
In future, we will be the most modern steelmaking facility in North America, adds Correnti. The SMS group is
responsible for implementing technology of the latest state
of the art. We at SMS can look back on more than 30 years
of successful and trustful cooperation

with John Correnti, says Dieter
Rosenthal, Member of the Managing
Board of SMS Siemag. We are extremely pleased to continue this cooperation with such a large-scale
project. John Correnti had been instrumental in initiating the SeverCorr
complex commissioned in 2007 and
constructed by SMS Siemag, also in
the southeast of the U.S.A. We can
contribute our experience from comparable large-scale projects to Big
River Steel, where we will also employ new-generation systems in addition to our proven technology, explains Project Manager Axel Sprenger
of SMSSiemag.
i
Big River Steel
Big River Steel is
the biggest private
single investment
in the history of the
U.S. state of Arkansas. The new steel
complex, located in
Osceola, will give
work to about 500
people and primarily produce steel
grades of which
there is a shortage
HIGHLY EXPERIENCED PARTNERS
in the U.S. market.
Big River Steel will receive all plants

and equipment, including the mechanical, electrical and automation
systems and the coil logistics, from
systems supplier SMS. In its first construction stage, the plant will produce
1.5 million tons of hot strip. It is
planned to, step-wise, double the production in several expansion stages.
The Big River Steel project is one
of the biggest orders in the history of
SMS Siemags Electrics and Automation Division. In numerous large-
Construction will
take approximately
20 months.
15
IN Focus
567
hectares is the area covered by the new steel
complex of Big River Steel.
The planned steel

mill complex of Big
River Steel.
16
scale projects, we have demonstrated that the X-Pact

electrical and automation technology from SMS Siemag is
a good choice. The customer banks on our solutions implemented in numerous reference plants. We will supply
the entire electrical and automation systems in cooperation with our SMS colleagues in the U.S., says Detlef
Ehlert, Executive Vice President of the E & A Division at
SMS Siemag.
The key units of the steelmaking shop will be the electric
arc furnace, a ladle furnace and an RH-TOP X-eed plant.
The RH plant will facilitate the production of sophisticated
grades, including high-quality silicon steels. The carbon
rates required for these steels can only be achieved with an
RH unit. It will be designed as a high-productivity, fast vessel-exchange unit. In cooperation with their U.S. colleagues,
SMS Siemag will supply not only the automation systems,
but also all components required in the works to guarantee
a reliable power supply. We will provide high-current systems including the transformers and rectifiers for the furnaces. Our level-2 models will optimize the production process. The fully automatic logistics system will provide high
process security and ensure an optimal material output,
says Ehlert. Big River Steel places great emphasis not only
on automation, but also on environmental technology. The
gas recovery system installed in the steel plant will ensure
compliance with the applicable, high environmental standards. The dust will be collected and filtered in a baghouse
facility. This steel mill will certainly be the cleanest one in
the U.S.A., says Project Manager Sprenger.
From a single source
The CSP plant consists of the CSP caster, a tunnel furnace and the CSP rolling mill with six mill stands and a
down coiler. With a maximum strip width of 1,930 millimeters, it will be the widest of all CSP plants. The annual
capacity will amount to 1.5 million tons of hot strip. It is
planned to add a second casting strand at a later stage.
Also here, SMS will supply the level-2 systems complete
with all process models and level-1 automation, including
the technological controls for all production units from the
casting machine down to the coil transfer system. The Mold
Monitoring System MMS clearly displays the casting be17
IN Focus
The CSP plant will produce 1.5 million tons of hot strip
per year.
Jens Haupt, Vice President Financial Services Division, Dieter Rosenthal, Member
of the Board of SMS Siemag, John Correnti, CEO of Big River Steel, and Joe Dzierzawski, SMS Siemag Pittsburg, at the signing of the agreement.
havior in the mold and effectively prevents breakouts.

The Hydraulic Segment Adjustment system, which achieves
stepless thickness changes of the slabs, optimizes the
throughput. The DSC model (Dynamic Solidification Control) ensures optimal strand cooling and improves the internal slab quality by soft reduction. The employed moldlevel control and resonance oscillator systems will ensure
a stable production process and high product quality. Some
900,000 tons of the hot strip produced in the CSP plant will
be processed into high-grade cold strip in the downstream
coupled pickling line/tandem cold mill. Another 120,000
tons will be sold as pickled and oiled strip. The remainder
of the production, i.e., about one third, will be supplied in
the as-rolled condition.
COLD ROLLING FACILITIES
In connection with the two downstream strip processing

lines, the tandem mill will produce a broad portfolio of
products. Along the discontinuous process route (batch annealing and offline skin-passing mill), strip made of carbon
steels and non-grain-oriented (NGO) silicon steel will be
produced. Non-grain-oriented Si steel is used in electrical
engineering applications, for example, for making rotating
parts used in motors. The continuous process route, which
includes the continuous annealing and galvanizing line
(CAL/CGL) and an inline skin-passing mill, will be used to
make hot-dip galvanized cold strip, including strip made of
multiphase steels for automotive applications, especially
structural parts. The continuous and the discontinuous
routes will each process about half of the produced cold
strip. The offline skin-passing mill (discontinuous route),
arranged downstream of the batch annealing furnace, will
be designed to operate with a rolling force as high as 18
18
Service
Scope of supply:
150-ton-electric arc furnace
50-ton-ladle furnace with two
1
treatment stations
50-ton-RH-TOP plant / ladle treat1
ment stands
Gas recovery system
Single-strand CSP plant with a
maximum strip width of 1,930 mm,
expandable to two strands
oupled pickling line/tandem mill,
C
emulsion system and innovative
fume extraction system
ffline skin-passing mill (SPM) with
O
18 MN rolling force
Inline skin-passing mill (ISPM)
niversal continuous annealing and
U
hot-dip galvanizing line (CAL/CGL)
Batch-annealing furnace (BAF)
MN, facilitating elongation rates of up

to 8.5 percent; 914 to 1,880 mm wide
and 1.4 to 0.28 mm thick strips will be
skin-pass rolled at speeds of up to
1,000 m/min.
In the coupled pickling line/tandem mill, our process models and
technological controls will opti-
Interview
I appreciate the
professionalism of SMS
Michael Hore, Chief Automation Officer at Big River Steel, Had you heard about our Plug & Work
explains why the entire plant will be equipped with E & A integration tests before this recent
systems from the SMS group.
project?
Yes, I had heard about the Plug & Work
Why did you choose to order all plant and equipment from concept before and seen how well it
works. It reduces the time required for
SMS Siemag?
Hore: Because of the companys professional demeanor commissioning the plants and accelabout a perfectly functioning product. It is their own me- erates ramping up.
chanical equipment and their own design. Therefore, SMS
knows better than anyone else how the product is sup- What do you expect from the integraposed to work. Communication between the SMS depart- tion tests?
ments is good, making for a smooth flow of information. I expect that I will be able to watch how
No finger-pointing when there is a problem, but solutions. the key operational functions work,
In the past, when we worked with several suppliers on a that I can test them and that I can verproject, the interfaces between them were always prob- ify before the systems are installed at
lematic. Dealing with just one supplier lessens this prob- our site that all data are transferred
lem. John Correnti and I believe that SMS is the worlds via the interfaces as required. For me,
leading supplier of CSP casting and rolling plants for flat it will be important to see that all functional units are complete and ready for
products. Why should we shop somewhere else?
use and that all systems from the field
In your opinion, how important is it to order everything devices up to level 3 are fully functional before the plants are started up.
from a single source?
It is very important because it makes the flow of informa- This guarantees fast ramp-up to full
tion between the various trades smoother and speeds up production.
problem solving. During commissioning, cooperation between the people in charge of the various tasks is more What do you appreciate about the coefficient because they have usually worked together on operation with SMS Siemag?
previous projects and are familiar with the operation of the I appreciate SMS Siemags professionalism in all matters concerning
overall plant.
the project. The employees are readily
and
always
helpful.
What is your impression about our X-Pact automation available
SMS Siemag is always on the spot to
systems?
Ive come to like the X-Pact automation solution. It has tackle any problem that may arise and
been constantly improved, and it is very reliable and user- to make sure that everything works
friendly now. The integrated diagnostic features and the perfectly. SMS Siemag certainly idenremote access make the support very convenient and effi- tifies with their products.
cient, for example, through the iba integration into the
X-Pact automation system and through the reflective
memory.
Michael M. Hore
Chief Automation
Officer, Big River
Steel
19
IN Focus
900,000
tons of pickled hot strip will be rolled on the
five-stand tandem mill. About one half of the
hot strip will be processed in the downstream CAL/CGL, the other half in the batchannealing furnace.
Right: Groundbreaking: (f.l.) John Correnti,

CEO of Big River Steel,
Dr. Heinrich Weiss,
Chairman of the Advisory Board of the SMS
group, Mike Beebe,
Governor of Arkansas.
Below left: Big River
Steel has its future
customers the automotive industry in
focus.
Below right: BRS will
predominantly produce
steel grades that currently still have to be
imported into the U.S.A
20
All plants will be tested in our proven plug & work

procedure. This will markedly reduce the commissioning
time and ensure a fast ramp-up of the equipment.
Detlef Ehlert, Executive Vice President E & A Division, SMS Siemag
mize the settings for a smooth process, says Detlef

Ehlert. The pickling model optimizes pickling performance
and energy consumption. This is achieved by resetting the
strip speed, acid concentration and liquor temperature as
required from one strip to the next. By taking into account
the technological limits of the plant as well as the current
plant situation, the material properties and the product dimensions, the technological rolling models ensure proper
setting of the mill stands and a stable rolling process. The
coupled pickling line/tandem rolling mill will be equipped
with an SMS laser welding machine, a descaler, a turbulence pickling section and five four-high rolling stands with
CVC plus technology. The laser welding machine will also
be able to reliably join the high Si steels planned to be produced in the future. Additionally, provision will be made in
the pickling section for a second circulation system where
the Si sludge resulting from pickling high Si steels will be
settled. The CAL/CGL will be equipped with a cleaning section, a Drever furnace, a FOEN air-knife system, a skinpassing mill, a leveler and a spray passivation section. A
special design feature will be the ultrafast cooling system
in the Drever furnace, which will facilitate the production of
high-strength dual-phase grades. It will also be possible to
bypass the zinc tank by guiding the strip over a cold deflector roller and use the line as an annealing line. This concept
provides a high degree of flexibility. Also the other strip processing lines will be equipped with X-Pact electrical and
automation systems. All plants will be tested in our proven
Plug & Work procedure, markedly reducing the commissioning time and ensuring a fast ramp-up of the equipment, adds Ehlert. In addition to the supply of the mechanical and electrical equipment, Big River Steel and SMS have
also signed a service contract: a 10-year agreement cover-
Service
Innovative E & A solutions from

SMS for CSP casting plants
Mold Monitoring System
Dynamic Solidification Control
Hydraulic Segment Adjustment
Mold Level Control
ing maintenance activities for the caster, the repair of core components and
operation of the roll shop.
Ground was recently broken on the
premises on the Mississippi River. The
first steel is scheduled to be produced
in early 2016. With an experienced
partner like the SMS group at our side,
we are certain that the project will turn
out as a success, says Big River CEO
Correnti.
www.bigriversteel.com
21
IN FOCUS
Interview
Remote access
virtually from any
place in the world
i
SMS Siemag
The high-capacity
In this interview, Detlef Ehlert and Bernward Reif, Executive Vice Presidents, Electrics and Automation at
SMS Siemag, describe automation solutions of the future. Already today, it is possible to control production
plants from the office. Data Mining and Industry 4.0 have
been finding their way into steelmaking plants and rolling
mills.
X-Pact automation
systems from SMS
Siemag make metallurgical plants and
rolling mills fit for
the future. They are
optimally tailored to
the specific process
requirements.
Is it still possible today to produce steel without automation systems?

Ehlert: Definitely not! The degree of automation varies
very much depending on the process stage. However,
without an automation system that keeps track of the
specifications of the process it is not possible to make
products in a constant, reproducible quality and optimally exploit the capacities of the production plants. Another
important aspect is the reporting, which is needed to
document the quality of the products as well as the productivity and availability of the plants in a transparent
manner.
In which way have automation solutions changed over
the past 20 years?
Ehlert: Thanks to the fact that the processors of our automation systems have become increasingly powerful,
we can map and control the metallurgical processes
more and more accurately with our process models and
controls. This has lead to significant quality improvements.
Reif: What is more, the diagnostic features are becoming
more efficient every time. Modern automation systems
are increasingly closely interlinked with the IT world in
the offices. This makes it possible to monitor the plants
22
and respond to unusual situations

from the office, or even by remote access from virtually any place in the
world.
What are todays requirements on
automation systems?
Reif: The customers expect maximum
availability of the systems, intuitive
operation, process analysis and optimization support, easy troubleshooting and guidance during fault correction. The SMS group is renowned for
its extensive portfolio of automation
solutions for metallurgical plants and
rolling mills.
What distinguishes SMS Siemags XPact electrical and automation systems from other systems?
Ehlert: The close interlinking between our mechanical design departments and our process technologists
ensures that our X-Pact automation
systems optimally use the potentials
of the plants and that the corresponding electrical and drive technology is perfectly tailored to the process requirements. For example, for
the design of our plants, we use the
same process models that will be
implemented in the customers
plants later on for the online control
of the process.
IN Focus Electrical AND Automation
Heads of the E & A Division, Bernward Reif (left) and Detlef Ehlert.
Reif: In addition to the automation system, we supply the

complete electrical engineering components including power supply and power distribution as well as the medium and
low-voltage drives. We supply in-house-built low-voltage
drives, but also closely cooperate with leading drive manufacturers to ensure that the drives we install fully meet our
customers requirements.
What is so special about the Big River project?
Ehlert: The Big River Steel project is special in the way that
we supply the electrics and the automation systems for all
process stages, from the steelmaking plant and the CSP
plant down to the cold rolling mill including the coupled
pickling line/tandem mill and the processing lines. For our
customer this means a uniform operating philosophy, consistent reporting structures and largely the same components for the same tasks.
What are the benefits of the Plug & Work concept?
Reif: Also for the Big River Steel contract, we will use our
Plug & Work procedure, as we have done for all orders
handled during the last few years. This means that we will
simulate and visualize the mechanical equipment, the process and the associated drive equipment for all plants in
real time. The original automation systems and all operating stations will be connected with the simulation system
and intensively tested. At the end of the test phase, our
customers operating and maintenance staff can test the
new plants under realistic conditions. It is possible to run
virtual production scenarios, which are also suitable to
train the operating staff prior to the on-site installation of
the plants. This teaches the operators how to handle critical operating situations without putting the equipment at
risk. They will also learn how to manage malfunctions.
SMS also adapts automation solutions to existing

mechanical equipment environments.
During the last few years, we have

provably achieved a significant decrease in the commissioning times of
our plants and faster ramp-ups of
production through the Plug & Work
procedure.
What are the latest developments in
this field?
Ehlert: In collaboration with the other
divisions, we are committed to the
constant further development of our
products. In this context, Id like to
mention as an example the latest generation of our CSP plants. The USP
plant we will supply to an Indian customer will come with many new features. We see the interrelation of mechanical, process and automation
equipment as a virtually inseparable
unit.
Reif: Additionally, during the last few
years, we have developed new HMI,
visualization and control concepts,
which take special account of the ergonomic needs of our customers
personnel. We have also further improved our Plug & Work activities to
be able to map the dynamic behavior
of the mechanical components and of
the process even more realistically,
for example, by visualizing the plants
in 3D. As we produce drive sys23
IN FOCUS
Our specialists are also familiar with now obsolete electrical engineering
solutions for power distribution, drive equipment and controls and can
offer modernization concepts for these plants.
Bernward Reif, Executive Vice President, Electrics and Automation at SMS Siemag.
tems in-house, we can optimize the design and procurement processes and provide our customers with
cost-optimized solutions. This is ideally complemented by
our commissioning service, which we offer for our own
drive equipment as well as for drives built by other manufacturers.
Where will the journey go next? What do you expect for
the future?
Ehlert: We must be prepared for an increasingly closer
interlinking of plant automation and drive technology with
office IT. The gigantic flows of process data used to optimize our plants and processes must be managed intelligently. To this end, we have already developed first Data
Mining solutions. The term Industry 4.0, which stands
for an imminent revolution in this area, may be new. However, we have already been dedicated to the issues associated with this term for a very long time.
Would it be possible to order just the automation systems
from SMS Siemag, independent of the mechanical equipment?
Reif: The life cycle of automation systems is much shorter
than that of the mechanical equipment. As a result, it may
be necessary to replace the automation systems completely or in parts, while the mechanical equipment can
be retained more or less unchanged. In the past, we have
very successfully implemented numerous modernization
projects, which included the adjustment of our X-Pact
automation solutions to existing mechanical equipment,
independent of the original equipment supplier. Our specialists are also familiar with now obsolete electrical engineering solutions for power distribution, drive equipment
and controls. Therefore, they are in a position to offer be24
spoke modernization concepts for

these plants. We also boast all required competences for planning and
performing the installation and for
the commissioning activities.
What are the advantages for plant
operators relying on systems supplied by the SMS group?
Ehlert: Our E & A systems exploit the
full potential of our mechanical equipment. We place utmost emphasis on
energy-saving modes of operation
and high availability. The products
made with our plants and equipment
are usually seminal in terms of product properties and dimensional tolerances. Also after the official acceptance of a plant, we are there to
support our customers with our service teams.
If you have any questions, please contact our
experts Detlef Ehlert and Bernward Reif.
detlef.ehlert@sms-siemag.com
bernward.reif@sms-siemag.com
IN Focus Electrical AND Automation
During virtual test

operation, the operating staff can familiarize themselves
with the features of
new plants.
Plug & work in 3D

With integration tests visualized in 3D, SMS Siemag
achieves an even more realistic view of the plants.
izing complex scenes and processes

as well as fundamental physical relations. Such tools can be directly integrated into our systems for real-time
simulation of production plants.
Synergies increase efficiency
ith the proven Plug &

Work concept developed
by SMS Siemag, automation systems are tested
and optimized in the test field in a
near-reality environment before being
shipped and commissioned at a customers site. The process and production simulations provide images showing the specific mechanical equipment,
the drive systems and the technology
of the corresponding customer plant.
The Plug & Work concept guarantees shorter commissioning times and
faster ramping up of the plant. During
the virtual production process simulated in the Plug & Work tests, the operating staff learn how to use the functions of the plant before the systems
are installed on-site and how to handle
them under realistic operating condi-
tions. In the tests, the original control

pulpits of the new plant are used and,
up until now, a dynamic 2D visualization
has been used to simulate the plant.
Now, the latest step in the futureoriented development of process and
production simulations, allows us to
enter the 3D world. This is achieved by
simplifying 3D design data available at
the customer plant and required for
the production process in an automated procedure and feeding these simplified data directly into the simulation
models. We make use of well-known,
established techniques from an entirely different IT branch, namely computer games, says Marc Kalkuhl,
Head of Product and Process Simulation at SMS Siemag. This economically quite relevant segment has
brought about tools capable of visual-
This new approach simplifies and shortens the simulation process by taking
advantage of the synergies existing in
the company. Moreover, it provides the
process and production simulation systems with the necessary information to
generate models that can go further into
detail and have a broader functional
scope, resulting in a markedly enhanced
quality of the tests. Another advantage
of 3D visualization in integration tests is
that complex individual functions can
now be illustrated in a clearer and easier-to-comprehend way. 3D is not a gimmick, but a solution that helps plant operators in steel and aluminum
production alike understand the full
range of functions and possibilities of
their plants in less time.
Marc Kalkuhl
marc.kalkuhl@sms-siemag.com
25
In Focus
The four-stand tandem cold mill of OAO Severstal will

be completely renewed.
Modern control station from SMS Siemag.
Higher performance,
less operating cost
With the objective of enlarging the product range, improving quality and increasing
annual production, the Russian company OAO Severstal placed an order with
SMS Siemag for the modernization of its existing four-stand tandem cold mill 1700.
n February 2014, the Russian steel producer OAO Severstal placed an order with SMS Siemag for upgrading its
four-stand tandem cold mill 1700 at its Cherepovets
works in northwest Russia. The renewal of the four-high
tandem cold mill, operating since 1963, will increase annual production by 200,000 tons up to 1.3 million tons. The
modernization provides for the opportunity of later coupling the tandem cold mill with a new pickling line. Thereby, OAO Severstal will be prepared to meet increasing material requirements of the customers, especially in the
automotive industry.
SMS Siemag has supported numerous customers in
adapting the technology of their tandem cold mills to current
and future market demands. This experience combined with
the expertise as systems supplier of mechanical, electrical
and automation equipment has essentially contributed to
26
OAO Severstals decision to choose

SMS Siemag as supplier.
FOUR NEW MILL STANDS
SMS Siemag is to replace the four tandem mill stands and the complete entry section. A double expansion-head
pay-off reel with strip centering device
and equipment for strip head preparation as well as a roller press will be
installed on the entry side. The roller
press helps increase strip tension upstream of the first mill stand, especially when rolling thicker strips, which
proves beneficial for the processing of
higher-strength grades. Additionally,
i
Spare parts
SMS Siemag offers
individual EA spare
parts services from
level 0 to 2. They
include consultancy
in line with the customers needs and
reliable supply of
spare parts.
In Focus Electrics and Automation
FACTS + FIGURES
OF THE MODERNIZED TANDEM COLD MILL

Commissioning
Annual capacity
Strip width
Strip thickness

Rolling speed
Material grades

2016
1,300,000
7801,850 mm
5.51.5 mm (ingoing)
3.20.4 mm (outgoing)
max. 1,500 m/min.
Carbon steel and high-strength and
micro-alloyed silicon steel
the entry-side coil car will be equipped with new hydraulic

controls. The heart of the tandem cold mill is the four new
mill stands in four-high design. The technical configuration
includes hydraulic gap and wedge adjustments, CVC plus
as well as positive and negative work roll bending. In the
last mill stand, strip quality is optimized by multi-zone
cooling and the Dry Strip (DS) system. SMS Siemag has advanced roll and inter-stand cooling equipment according to
the latest findings, thus enabling high reductions.
Thanks to automatic devices, work roll changes are accomplished quickly and idle times reduced. This is especially important with a view to the intended later coupling
of the TCM with a pickling line and to realizing continuous
operation. Back-up roll changes are assisted by a new
semiautomatic change device.
RENEWED DRIVING EQUIPMENT
The drive of the first mill stand, i.e., gear unit, motor and
feeding by a medium-voltage frequency converter, will be
completely modernized. The remaining mill stands are
equipped with new drive spindles. The existing Leonard converters driving of mill stands 2 to 4 as well as the tension reel
are provided with a new field control.
The tandem cold mill will be equipped with the latestgeneration X-Pact automation system, level 1 and level 2.
In addition, the technological measuring systems for strip
thickness, strip tension and rolling speed are changed.
To satisfy the challenging demands on strip flatness, one
X-Shape flatness measuring system each is installed downstream mill stands 1 and 4. A threading assistant together
with associated models and controls ensures reduced
thickness tolerances and shorter off-gage lengths at the
strip head and tail ends. Modern mill stand enclosures fitted with an extremely effective fume exhaust system keep
1.3
million tons is the envisaged annual production of the modernized mill.
the environment of the mill operators

free from emissions, and the mill stand
platform with hydraulic valve stands
ensures good accessibility for maintenance. Furthermore, SMS Siemag is to
install new high- and low-pressure hydraulic systems and to revamp the existing emulsion plant. New feed line
filters and chain-type magnetic separators clean the emulsion in an efficient way from the contamination of
the rolling process. Thus, emulsion
consumption and operational costs are
reduced. For this challenging modernization, the shutdown period is scheduled to take no more than two and a
half months.
Bernd Tiepelmann
bernd.tiepelmann@sms-siemag.com
27
In Focus
Automation solutions can improve blast furnace operations.
The modular BFXpert automation system enhances

the process control in blast furnace plants.
Process supervision at its best

With BFXpert from Paul Wurth, blast furnace operators
increase process stability and reduce costs.
The automation package supervises all processes.
rocess models and expert systems are critical to

reducing the running costs of blast furnace operations. Consistent support of the operating processes is provided by the model-based control of
the process data in conjunction with the evaluation of
these data by an expert system.
Modular automation package
The modular BFXpert automation package integrates

models from different areas of blast furnace operations
with an expert system and a rule-based automation interface. The benefits for the operator include improved process control because of the extra information available on
the blast furnace process, and cost savings resulting from
the optimized blast furnace operation. By automating routine functions, e.g., in connection with the charging of the
blast furnace or with the operation of the hot blast stoves,
time can be saved and procedures standardized. Models
for the thermal control of the blast furnace have been
specifically developed with the objective to reducing fuel
28
consumption. BFXpert includes a

customizable platform that provides
wide-ranging possibilities of interaction and can network the single models. When developing the system,
special emphasis was placed on the
scalability of the system in order to
make it possible for the customer to
modify existing functions and add new
functions at a later point in time.
i
BFXpert
BFXpert may
significantly reduce
hot-metal production costs, resulting
in payback periods
www.paulwurth.com
of approximately
six months.
Precise measurement technology

Deutsche Edelstahlwerke (DEW) is operating the first
3-roll PSM (Precision Sizing Mill) of SMS Meer worldwide with
hydraulic roll adjustment under load. The plant impresses
with MEERgauge measuring technology.
or its location in Siegen, Germany, DEW has now ordered a

new rake-type cooling bed. With
the cooling bed the steel manufacturer is upgrading its bar mill. The
new cooling bed allows controlled bar
cooling, conveyance gentle to surfaces
and very straight end products. Consequently, all requirements on quality
steel are fulfilled. Apart from bars in the
round size range from 21.5 up to 90
millimeters hexagonal profiles can also
be deposited on the cooling bed in future. The goal of this modernization is
to achieve a homogeneous temperature
distribution of the bar layer, says rolling mill manager Jens Eisbach. This
enables us to prevent inaccuracies
when cutting the bars and to improve
our productivity and quality in the finishing line. Commissioning of the new
cooling bed is scheduled for the third
quarter of 2015.
FIRST 3-ROLL PSM
DEW is operating the first 3-roll PSM

(Precision Sizing Mill) of SMS Meer in
the world with hydraulic roll adjustment
under load. The plant was put into service in 2008. Four years later, the plant
was expanded by DEW by the precision
measurement technology MEERgauge
and a dynamic monitor control. The
MEERgauge laser measuring device
displays the complete product crosssection on the basis of the light section
Cooling bed of a bar mill.
process. It simultaneously senses up to 500 measuring points

per second at the cross-section, which are directly shown in a
coordinate system. This high-precision measuring device
provides the data for monitor control, controlling the rolls by
means of a hydraulic adjustment system. Fluctuations in
cross-section, temperature or steel grade of the feedstock
are automatically corrected allowing close rolling tolerances,
independently of the operating staff.
Meanwhile, an automatic surface inspection is per
formed to detect surface defects in the rolling line during
rolling. In connection with hydraulic adjustment and control
systems the PSM together with this measurement technology is a milestone in the production of quality and stainless steel.
www.sms-meer.com
29
In FOcUS
ADVANTAGES
of the Product Inspector

he operator is no longer confined
T
to stationary data entry points
ny previously used paper-based
A
forms become obsolete
he direct storage in a database
T
avoids any intermediate processing
steps; no information is lost
he software can be used as a
T
stand-alone solution or to support
the IPQS
ost-effective and easy-to-use
C
solution
calable to include the inspection
S
of additional products (sheets,
coils) or areas (maintenance)
sing local network environments
U
avoids the risk of security gaps as
may arise from Internet-based data
transmission
Documentation of
the slab quality.
30
Mobile quality
control of slabs
New development: Documenting the slab quality
with the Product Inspector. A mobile, cost-effective
and easy-to-use solution.
he Product Inspector is a
software application newly developed by SMS Siemag for
documenting the slab quality.
The operating personnel can now perform a mobile check at any suitable
location in the works via a touch-optimized tablet and document the obtained results. SMS Siemag offers the
Product Inspector as a cost-effective
stand-alone solution or as a solution
networked into the Integrated Product
Quality System (IPQS).
Stand-alone solution
The Product Inspector works with an

own database installed in a suitable
server system. After having set up a
new slab file, the operator enters the
detected defects. Provided that the appropriate infrastructure exists, a slab
list will pop up to select from. The system will then display a list of possible
defects, from which the relevant defect will be selected and specified (position, length, depth, comment, etc.).
The entered data will then be stored in
the database of the Product Inspector and can be retrieved system-wide.
Therefore, it does not need a database

of its own. The operator selects the respective slab from a list showing the
produced slabs and documents the
quality of the slab. The IPQS database
is updated with the new data so that
they can be used as input parameters
by the IPQS. This enhances the evaluation efficiency of the IPQS.
i
SMS Siemag
The Integrated
Product Quality System (IPQS)
developed by
Online/offline mode
SMSSiemag pro-
The
application
developed
by
SMSSiemag operates in the online/off
line mode. If WLAN connectivity is
available at the location of use, the new
data will be directly transmitted to the
database (online mode). Otherwise,
they will be temporarily stored in a buffer on the tablet (offline mode). The
data will be synchronized as soon as a
WLAN connection is available again.
Cases of conflict, if any, will be solved
by the operator by manual entries.
vides uninterrupted
and consistent acquisition and storage
of all quality-relevant
values from the
connected process
stages as well as
planning, laboratory
and inspection data
of a plant.
Ferdinand Springmann
ferdinand.springmann@sms-siemag.com
Support of the IPQS
In the latter configuration, the Product Inspector is part of the IPQS.

31
In FOcUS
PLANT OPERATION MADE EASY

Gigantic floods of data and information arise in steel and rolling mills today.
With the right concept in place, plant operators are on the safe side.
SMS Siemag has the right solution. Wuppermann will use it in the future.
n production plants, the number of employed sensors

and actuators is constantly growing. So is the degree of
automation. However, the sophistication of the technology does not make the human operator redundant. All
information converges in the control room. SMS Siemag offers an ideal integrated solution taking into account the
control room and the HMI. A first characteristic of this solution is the clear separation between an operating area and
a social/analysis area. During production, people in the
operating area must be highly concentrated and may by no
means be distracted, says Stefan Luxenburger, Operation
and Process Control Technology Specialist at SMS Siemag.
By contrast, the social or analysis area serves as a meeting place for colleagues, customers and visitors. Here, pro-
The analysis desk

is the central
team workplace.
32
duction results can be analyzed and presented without having to actively interfere with the actual production process.
The selected devices and function panels supplement and
complete the operating concept. Several options can be
chosen to achieve a clear visual separation between both
these areas. These may be a step, a handrail or different
color variants for the floor. These structural measures provide a clear barrier, which protects the operating personnel
against disturbances and distractions when they have to
concentrate on controlling the plant, adds Luxenburger.
The operating area
The core of the control pulpit is the operating area, where

SMS Siemag offers several advantages compared to conventional solutions. The control desk is the heart of the
workplace. Here, the operator receives detailed information
on the production process. The HMI screens are located directly in the operators line of vision. Additional overview
screens are mounted on the ceiling. The desk can be moved
by a motor to standing level. The HMI screens move along
with it.
Operating elements that are not allowed to be implemented via touch panels or the HMI for reasons of safety
are arranged in a clearly structured, accessible manner in
the area in front of the screens. In this way, it is ensured
that the right measures are taken intuitively even in emergency situations.
Based on new, innovative IT devices, SMS Siemag has
developed the Technical Operation Management TOM for
short. This enables the operator to record notes and peculiarities on the production process without paper. The
touchpad provided for this purpose is operated intuitively
and facilitates quick entries by means of prepared texts and
icons. The recorded events are stored in a database and can
be further processed later. Large overview screens continuously display the relevant information from the production
process. Plant areas that are not easily visible are repre-
The operating area is separated from the social and analysis area by visual means.
sented as live images and can be displayed in a correspondingly large format whenever required. The operating area is
completed by ergonomically optimized control-room chairs
designed for 24/7 use, reducing physical strain on the operators and supporting their power of concentration.
The social or analysis area
With its large number of cabinets and lockers, the newly designed social area provides sufficient storage space. This
increases the attractiveness of the entire control pulpit. Located at the center of the control pulpits social/analysis area
is the Data Analysis and VIsion Desk DAVID for short. It has
been consciously designed to stand out from the other functional furniture, as a stand-alone item intended especially for
teamwork. Equipped with the latest communication technologies, the discussion desk DAVID is the information
center of the plant. Here, all information for production analyses, performance evaluations and shift meetings is compiled. To effectively support the teamwork, a large multitouch display is horizontally installed into the desktop and
can be operated intuitively. DAVID and TOM have most recently been purchased by Wuppermann and will, for the first
time, be used in a pickling and hot-dip galvanizing line (see
article on page 86). Also our employees will benefit from the
new production plant due to its high degree of automation
and the ergonomically designed work places, says Dr. Carl
Ludwig Theodor Wuppermann, Spokesman of the Board of
Management of Wuppermann.
Also for customer visits, the discussion desk with its
wide variety of possibilities will become the focal point and
thus be predestined to serve as a central meeting place in
the plant. Thanks to the concept developed by SMS
Siemag, operators always have a clear view of the production process.
At the new control pulpit, operators have a clear view of

the production process.
SERVICE
In the analysis area, the users can choose between

four application areas.
In the documentation area, the entire plant documentation
can be accessed electronically. Via search and filter functions, the user quickly finds the required information, and
can add comments where necessary and forward them
correspondingly.
he shift meeting area supports the paper-free control
T
pulpit. Here, the special features of the scheduled production list are described and recorded. Also, unusual events
during the last few shifts are communicated to the operating team, for example, when another shift takes over.
In the analysis area, all archived information can be accessed to perform a quick and targeted production analysis.
This may comprise, for example, short videos, measureddata evaluations and production data.
In the performance data area, quality and production
information can be compared and evaluated with reference
to time.
Stefan Luxenburger
stefan.luxenburger@sms-siemag.com
33
In Focus
Aluminum is also
used to produce
beverage cans.
Maaden-Alcoa
recently rolled its
first strip.
34
ALUMINUM STRIP FROM

SAUDI ARABIA
In a place where, five years ago, there was nothing but desert sand, there is now
a production site for aluminum hot and cold strip: Ras Al Khair, Saudi Arabia.
The equipment for the joint venture Maaden-Alcoa was supplied by SMS Siemag.
A keystone is the electrical and automation systems.
he first aluminum strips produced were given top marks

by beverage bottlers. For
Maaden-Alcoa this was a
successful start. The joint venture
supplies its products mainly to customers in countries of the Gulf Region
and the Middle East, and is thus establishing a complete supply chain
for aluminum including all process
stages from bauxite mining to the finished strip. To safeguard productivity
and quality in the long run, the joint
venture partners decided in favor of
equipment from a single source.
For the new works, SMS Siemag
supplied the hot and cold rolling mill
and the strip processing lines. Being a
systems supplier, the manufacturer
provided all equipment items with the
X-Pact electrical and automation
systems.
Photo left: gettyimages/luismmolina
EXPERIENCE COUNTS
SMS Siemag is a specialist for automation solutions not only in the field of
steelmaking plants. The success for
aluminum hot and cold rolling mills
came in the early 2000s along with
modernization projects. The focus
then was on level-1 technological controls and level-2 process models. As a
rule, operating and sequence control

systems remained in the packages of
the driving equipment suppliers, which
resulted in additional interfaces between the systems. Moreover, responsibilities were not defined clearly.
For new plants, success was not
long in coming, too. In 2006, the first
single-stand cold rolling mill of Hydro
Aluminium Slim S.p.A. in the Italian
town of Cisterna di Latina was completely equipped and put on stream
with SMS Siemags own X-Pact electrical and automation systems. Just
one year later, this was followed by the
big 160" aluminum hot mill at Aleris
Aluminium GmbH in Koblenz, Germany, which is one of the most powerful
plate rolling mills around the globe.
AluControl in hot and

cold rolling mills
30
20
10
0
Level 0
Level 1
Level 2
Orders for AluControl in aluminum hot (left)

and cold (right) rolling mills since 2000
SAFE ROLLING WITH ALUCONTROL
Since then, system solutions have

consistently been advanced. Especially
with a view to meeting the requirements on hot and cold rolling of aluminum, the product AluControl was
born as part of the SMS Siemag XPact electrical and automation systems. AluControl considers the experience gained in the specific process
sequence and product-oriented operation of aluminum hot and cold
35
In FOcUS
i
Maaden-Alcoa
Together with the
globally leading U.S.
aluminum producer
Alcoa, the SaudiArabian company
Maaden is joint venture partner of the
production complex
in Ras Al Khair. The
integrated facility is
the heart of a new
Industrial City
for the production
and processing of
aluminum in the Gulf
Region.
From top to bottom:

All plant components are tested
by SMS Siemag to
the Plug & Work
principle.
The material rolled
on Maaden-Alcoas
finishing mill meets
all requirements.
36
Aluminum rolling mills with AluControl

20
15
10
5
0
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
Aluminum rolling mills with AluControl commissioned since 2004 (new and modernized
plants)
rolling mills. It cares for the implementation thereof to permit safe and
efficient commissioning and transfer to
future plants.
ON THE ROAD TO SUCCESS WITH ALUCONTROL
AluControl is used by Maaden-Alcoa.

Its modules are suited to fully cover
the fields from driving equipment (level 0) to open-loop and closed-loop process control functions (level 1), pass
schedule and setup calculations (level
2) through to process planning and
control (level 3).
The fact that the joint venture partner Alcoa, a leading global aluminum
producer, decided in favor of the
SMSSiemag automation technology in
2011, had a signal effect on the whole
industrial sector. Further orders were
placed, including a major one comprising several hot and cold rolling
lines for Tianjin Zhongwang, in China,
where all facilities are being automated with AluControl. In the aluminum
sector, SMS Siemag has succeeded in
advancing from a component supplier
to a systems supplier within a mere
ten years. Frank Mehlich, General
Manager Sales Electrical and Automation Systems Cold Rolling Mills and
Aluminum, at SMS Siemag, says: The

increasing market penetration of our
X-Pact electrical and automation systems with its AluControl products being tailored to the rolling of aluminum
is a story of success and the result of
hard work. At the same time, it is motivation to keep on improving our products in order to satisfy the demands of
our customers and the market requirements to an even greater extent
in the future.
ADVANTAGES
AluControl offers aluminum

producers numerous benefits
Slim system structure
Clear arrangement
Modular design
Easy adjustment
SECOND CONSTRUCTION STAGE 2015
The first marketable strip for can production was rolled in Ras Al Khair on
June 24, 2014. After completion of the
second stage in 2015, the portfolio will
be extended with products for automotive and architectural applications and
by foil starting stock. The opening ceremony was attended by Klaus Kleinfeld, Chairman and CEO of Alcoa, and
Abdulaziz Al Harbi, President of
Maaden Aluminium. Leading representatives from SMS Siemag had also
been invited.
www.sms-siemag.com/aluminium
37
MARKETS
INCREASING DEMAND
The Turkish economy is growing by about three to four percent
annually. This economic growth is mainly due to domestic demand
and public investment in developing the infrastructure as well
as the construction sector. Thus, the steel and aluminum
industries are strengthened, too, which is reflected by projects
of the SMS group at its customers ASAS and Habas.
38
MARKETS TURKEY
Photo: iStock/scpist
OVERVIEW
Remarkable growth
ASAS on the road to success with high-tech equipment.
Made in Turkey
Fadil Demirel relies on technology from the SMS group.
Expanded capacities
Habas starts producing flat steel on a
new, compact hot strip mill.
Close to the customer
With its Gebze service workshop,
SMS Siemag is right on its customers doorstep.
40
44
48
50
Markets
Strip entering the cold rolling mill.
Control desk for electrical and automation systems.
40
Markets Turkey
REMARKABLE GROWTH
ASAS Alminyum attributes its remarkable growth over the past years to the
conviction that the only way to success is offering high-quality products. An
important contribution to reaching this aim is the production facilities the Turkish
company exclusively purchased from renowned equipment suppliers.
The ASAS Group specializes in light

metals today and has been going
strong for 22 years, during which it has
expanded its turnover by an average 26
percent each year. The key to this has
been continuous investment in new
technologies and the expertise of its
employees, now numbering over 1,800,
who have made it possible to cultivate
the market on a successful and wideranging basis.
One of the reasons for the growth of
ASAS is the full utilization of sales-related synergies through the manufacture of related or alternative products.
One example is the strong growth in
the market for window profiles, initiated both by the building boom in the
country and by the achievements of
Turkish construction contractors in
large-scale projects abroad. ASAS has
not only contented itself with the production of standard profiles for renowned system suppliers but, parallel
thereto, has established its own production of window profiles.
The booming building industry continues to determine the progress of
business in the dynamically developing
Turkish aluminum industry. ASAS
counts on high-quality products manufactured on technologically excellent,
largely automated plants that are operated by well-trained personnel. Our
recipe for success is primarily the
application of high-grade technology
with the greatest possible depth of

added value, emphasizes Safa Yavuz,
General Executive at ASAS.
NEW WORKS FOR FLAT ALUMINUM PRODUCTS
The move into the production of aluminum flats represented a logical advancement for ASAS. In AdapazanAkyazi, about 150 km to the east of
Istanbul, a new works was built to
achieve an annual production of
125,000 tons of coils (coated and uncoated), strip, plates and sheet, and
foil. The plants and machinery installed
during the first construction stage with
a capacity of 70,000 tons per year were
provided by renowned European equipment suppliers.
The central part in the new works,
the complete cold rolling mill, was supplied by SMS Siemag. It comprises a
six-high mill stand, three shear lines
and a strip coating line designed for
50,000 tons a year. The cold mill stand
reduces the up to 2,200-millimeterwide cast strips to gages of down to 0.1
millimeters at rolling speeds of 1,500
m/min. Depending on the desired final
condition, these products are manufactured as strips and sheet for differing
intended uses, such as architectural
strip for subsequent painting or as
starting strip for the foil rolling mill.
As far as the cold rolling process is
concerned, ASAS relied on the expertise of SMS Siemag and ordered a
137
ASAS Alminyum is among the 500 largest
companies in Turkey. At present, it holds
number 137 in the ranking. Through further
growth the family-owned company wants to
proceed to be among the 50 biggest Turkish
enterprises.
41
Markets
six-high mill stand, which is the

first of its kind in Turkey and, regarding
its design, the actuators installed and
the degree of automation, it belongs to
the most modern ones. With a view to
the range of dimensions to be rolled,
the mill stand is equipped with CVC
plus with intermediate and work roll
bending. This allows ASAS to produce
also hard alloys of the 5xxx, 6xxx and
7xxx series.
LATEST TECHNOLOGY FOR TOP RESULTS
To ensure top flatness results, the mill

stand is equipped with, among other
things, a hot-edge spray system. For
environmental protection, it has been
equipped with the patented Dry Strip
(DS) system, a multiplate filter developed by SMS Siemag and an Airwash
exhaust-air purification system.
Regarding the decision to invest in a
renowned equipment supplier, Safa
Yavuz says: We dont want to have to
deal with problems that arise from the
operation of inferior plant and equipment. From the experience gained
with extrusion presses from SMS
Meer, we know that the new cold rolling mill will ensure trouble-free operation and thus contribute to acquiring
the confidence of our customers. For
us, SMS Siemag is not just a supplier,
but rather a partner.
SMS Siemag honors this high level
of expectation not only by supplying
carefully planned and manufactured
mechanical equipment. In its function
as a systems supplier, the company
also integrated the entire electrical
and automation systems and supplied
such ancillary equipment as hydrau42
lics and exhaust air systems. An important aspect not only for the integration of the complete line, but also for
the training of the ASAS rolling mill
operators was the application of the
Plug & Work concept. In the Digital
Workshop in Hilchenbach, all functions of the rolling mill were simulated
in real time and could be optimized already before the delivery of the plant
and equipment. This gave ASAS the
benefit of fast and trouble-free commissioning. Safa Yavuz comments:
There is no time to lose. We want to
concentrate on what is essential and
that is our production.
For the manufacture of the entire
product range of aluminum strips and
plates/sheets, SMS Siemag supplied
two slitting and one dividing shear
line for the cold rolling mill. These allow the cutting and finishing of coils
with widths varying from 25 to 2,300
millimeters and sheets/plates with
edge dimensions from 400 to 12,000
millimeters in the gage range of 0.2 to
4.5 millimeters. As a result, ASAS has
become the supplier of the widest dimensional portfolio in Turkey. Part of
the companys future cold strip production is color-coated or coated with
functional layers on the new coilcoating line, also supplied by SMS
Siemag. Since ASAS mainly supplies
the rapidly developing construction
industry market, care was taken to
ensure the greatest-possible plant
flexibility when rating the line. It is designed primarily for strips being 900
to 2,100 millimeters wide and having
thicknesses between 0.2 and 2.0 millimeters. These strips can be provid-
130
Turkey has more than 130 extrusion press
plants with about 230 extrusion presses.
ASAS Alminyum is considered to be the
number one. Today, its seven press lines
produce 75,000 tons of aluminum profiles
per year, mainly for the construction industry. Five of these presses were supplied by
companies of the SMS group.
Markets Turkey
ed with up to four paint coats in one

strip pass.
MODERN COATING SYSTEM
Fast color change is one of the characteristics of a modern coating system.

Entry and exit groups are arranged in
direct vicinity to one another, and this
proves advantageous as regards future
coil logistics for the planned high-bay
store.
Since ASAS places great value on
the quality of its products, specifically
with respect to coating thickness and
perfect surface, the lines exit section
includes a vertical strip inspection facility for monitoring the layer thickness and strip surface.
ASAS Group is optimistic about the
future, particularly with a view to the
further development of the Turkish
aluminum market. Beyond this, the
Group is increasingly looking towards
Europe. To be successful there, the
companys high quality of equipment
combined with the cost-effectiveness
of its production site provide favorable
conditions. Further growth opportunities are offered by the strategically
good location of the country in relation
to markets such as Russia and the Gulf
Region and, viewed in the longer term,
to the future up-coming energy producers of Central Asia. In ten years
time, the ASAS Group sees itself among
the 50 largest companies in Turkey. In
the extrusion press field, the company
then wants to belong to Europes ten
largest producers.
From top to bottom:

The new cold rolling
mill at ASAS was
supplied by
SMSSiemag.
The works of ASAS
in Adapan-Akyaz
produce 125,000 tons
per year of coils,
strips, plates and
sheets as well as
foils.
The owners of ASAS ,
Gkhan and Safa
Yavuz, in front of the
cold rolling mill.
www.asasalu.com
43
MArkets
Sections in the
Kardemir plant, Turkey.
44
MArkets Turkey
Interview
FRUITFUL
COOPERATION
The second-largest steel producer after Germany in Europe
is Turkey, and Kardemir A.S. from Karabk is one of the most
important Turkish steel manufacturers. In the following interview, Fadil Demirel, CEO at Kardemir, explains his passion
for steel and why he relies on the plants of the SMS group.
Mr. Demirel, in your professional career you have always
worked for the steel industry. What makes steel so fascinating for you?
Steel is the starting material for a large number of industries, which makes it so interesting. When I graduated from
Fadil Demirel
university, it was my aim to choose the best industrial field.
CEO of Kardemir, studied mechanical
For that reason, I decided in favor of the steel sector.
engineering at Istanbul Technical University,
The Turkish steel industry has a 100-year-old history. started his professional career in the steel
sector as an engineer in 1977 and today he
What is the market situation in Turkey today?
Today, we have the highest growth in steel production after is Kardemirs CEO.
China and India. Nowadays, Turkey is the eighth-biggest
steel producer in the world. Steel is predominantly applied
in the automotive industry, in mechanical engineering and
in the home appliance industry. These industries are the
driving force for the future demand of the products made by
the Turkish iron and steel industry. In Turkey, the expenditures on the infrastructure, the construction sector and
transportation will increase further due to major projects
such as the third Istanbul airport, the North-Marmara
highway and new high-speed train projects.
How has Kardemir developed since the privatization 20
years ago?
Established in 1937, Kardemir was the first integrated steel
plant in Turkey. It was here in Karabk where Turkish steel
was born. The history of industrialization of the young Republic of Turkey started with Kardemir. After privatization,
we have changed the steelmaking process with a new steel
shop including converter system and increased our capacity, productivity and profitability with state-of-the-art technology. In 1999, we abandoned the Siemens-Martin furnace
technology in the steel shop and established basic oxygen
furnaces. With the rail and section mill from SMS Meer
commissioned in 2007, Kardemir has expanded its
45
Markets
1937
is the year that Kardemir was initially established. The company was the first integrated
steel plant in Turkey, and it was in Karabk
where Turkish steel industry was born.
A new wire rod and

bar mill is now being
built by SMS Meer
for Kardemir.
The steel plant of
Kardemir is located
in Karabk, around a
four-hour drive east
of Istanbul.
46
MArkets Turkey
i
SMS Meer
SMS Meer is currently supplying a
combined rolling
mill for high-grade
steel to Kardemir,
enabling the company to produce bar
steel and wire rod.
The core element is
a three-roll precision
sizing block (PSM)
and the wire rod line
is equipped with
product portfolio and has become the only manufacturer of rails and heavy sections in Turkey and the surrounding countries of the region, as well. Our vision is to
produce steel products that have not yet been manufactured in Turkey and also to produce at least three million
tons of steel per year to be globally competitive. To reach
these goals we will continue to invest.
What could still be improved?

Generally, we are satisfied with SMS.
With the plants, we are able to achieve
the desired profit and the product
quality we are looking for. For us the
What products do you primarily produce?
Our main products are railroad rails, medium and heavy SMS group is of prime importance
sections, structural steel, rounds, sectional steel, mine when it comes to new investments. We
props, shipbuilding sections, heavy steel plates, billets and require facilities at the lowest possible
blooms. Kardemir is the only manufacturer of railroad rails cost, with minimal energy consumpnot only in Turkey but also in the neighboring countries and tion and for high-quality products. The
the entire Middle East. Our company fully covers the de- Turkish steel sector is growing rapidly.
mand for rails by the Turkish State Railways and has there- SMS supplies a wide range of equipfore eliminated the dependence of Turkey on foreign coun- ment and is therefore of great benefit
tries. In our rail and section mill we manufacture heavy to Turkish companies.
sections up to 750 millimeters.
MEERdrive technology. Commissioning

is scheduled for
2015.
cialists has developed in a very positive way, while everyone of course has
their own habits and preferences.
What plans are you pursuing with SMS Meer?

I have known SMS Meer for about 35 years and believe that
the company has good technologies at fair prices. With regard to upcoming investments of our company, SMS Meer
will always be taken into account as an appropriate business partner. For our rail and section mill we have opted for
SMS Meer; for our continuous caster we chose SMS Concast and our new bar mill will also be built by SMS Meer.
Over the last five years, we have realized a total of four major
projects with the SMS group.
Fadil Demirel
fadil.demirel@kardemir.com
How has the cooperation developed so far? What are the

differences between Turkish and German engineers?
A difficult question. Of course, your engineers are well
trained, have gathered many years of experience and have
profound knowledge of our equipment. As regards the
technology and its application, Turkish engineers have
drawn even in many ways in recent years. Compared with
other countries, it is a fruitful cooperation it can be said
that friendly business relations have developed over time.
And the cooperation between Turkish and German spe47
Markets
MODERN STEEL GRADE

TECHNOLOGY
Habas starts production of flat steel on a compact hot
strip mill completely supplied by SMS Siemag.
The Turkish steelmaker Habas has

successfully commissioned a hot strip
mill supplied by SMS Siemag, Germany, in Aliag
a, Turkey. Production of the
first coil in July 2014 marked Habas
entry into the market of flat products.
The compact hot strip mill is designed for an annual production of 2.5
million tons of hot strip. The strip
widths vary between 700 and 2,100 millimeters and the strip gages between
1.2 and 25.4 millimeters. The hot strip
mill is designed for the production of a
wide range of premium steel grades
according to international standards
as, for instance, carbon steels and
multiphase steels as well as pipe
grades up to strength class X80.
48
The main components of the hot strip

mill in the first construction stage are a
four-high reversing roughing stand
with edger, a mandrelless coilbox, a
drum-type crop shear, seven finishing
stands with CVC plus, the laminar
cooling section, two downcoilers and a
pallet transport system including an inspection line. Mill capacity may be increased at a later stage to 4.5 million
tons per year by the installation of a
second reheating furnace, an additional two-high reversing roughing stand
and a third downcoiler.
Strip cooling with reinforced cooling
groups allows Habas to benefit from
high cooling rates and differentiated
cooling strategies for the manufacture
of special grades. The two downcoilers
are designed as UNI plus coilers for the
winding of high-strength pipe grades
up to a strip gage of 25.4 millimeters.
The UNI plus coilers are characterized

by reinforced mechanical components
and an optimized coiling strategy for
high-strength, heavy-gage strips.
PRODUCTION PLANNING WITH LEVEL 3
The supply scope of the X-Pact automation package included the level-1
and level-2 systems with the process
models, level-3 production planning
system, technological measuring systems, instrumentation, sensors, industrial camera system and a common HMI for both automation levels.
The drive systems with their converters and all motors, main and mill pinion gear units, as well as the drive
spindles for the compact hot strip mill
at Habas were also included in
SMSSiemags supply.
Jrgen Armenat
juergen.armenat@sms-siemag.com
Markets TURKEY
From top:
The mandrelless
coilbox homogenizes
the strip temperature
between roughing and
finishing rolls.
Prior to commissioning
at Habas, the X-Pact
automation system was
subjected to the Plug &
Work test.
FACTS + FIGURES
Commissioning
July 2014
Annual capacity 2.5 million t (initial stage)

Strip width
7002,100 mm
Strip thickness
1.225.4 mm
Steel grades Carbon steels, HSLA

grades, tube/pipe grades,
DP steels, stainless steel
grades
49
MARKETS
The service workshop impresses with state-of-the-art

equipment such as the CNC lathe.
The team of the SMS Siemag service workshop.
SERVICE
ON THE
BOSPORUS
Focus on maintenance: For almost three
years now, the SMS Siemag service
workshop on the Sea of Marmara
has been offering mold plating services
and maintenance services for rolling
mill components.
vices has been continuously extended. The portfolio now includes the repair of core components such as spindles and
coiler mandrels for rolling mills and the powder coating of
mold frames in continuous casters. The workshop is
equipped with a five-axis CNC milling machine, two box-plating stations, a dip tank, testing and inspection devices, special tools and a roller build-up welder.
CENTRAL LOCATION
The workshop is situated close to Istanbul, which has

many advantages. We can reach our customers within a
short period, says Uluayli. The seaport is just 20 minutes away, the airport 15 minutes, and one of the largest
steelworks in Turkey is domiciled virtually on our doorsteps. Being connected to the worldwide service network
of SMS Siemag, customers are offered every technical
support they need and thus benefit from the companys
expertise to the effect of further improving the efficiency
of their plants. At present, the worldwide service network
of the SMS group comprises more than 60 locations.
FACTS + FIGURES
In Gebze, close to Istanbul, SMS Siemag was a trailblazer on

Turkish soil. In 2012, the company opened a service workshop there and since then has been offering the Ni/NiCoplating of molds, among other things. SMS Siemag was the
first to provide this service in Turkey. The main service we
offer to our customers is the nickel-plating of copper molds
from their continuous casters and the reconditioning of segment and table rollers, says Kerem Uluayli, General Manager of the SMS Siemag service workshop in Gebze. In addition, we manufacture new copper plates. We are able to
machine up to ten sets per month of wide and narrow copper
plates. Since the opening of the workshop, its range of ser50
Location
Gebze Cayirova Kocaeli (near Istanbul)
Workshop area
3,000 m
Maximum loads Crane 20 t, machinery 15 t

Capacity, copper plates 240 wide and 300 narrow sides
Services
econditioning of molds, nickel plating of

R
mold plates, repair of spindles and coiler
mandrels, manufacture of new mold copper plates, reconditioning of segment and
table rollers
Installations
-axis CNC milling machine, 2 box-plating

5
stations, 1 dip tank, test and inspection
equipment, laboratory, special tools, roller
build-up welders, CNC lathe
MArkets TURKEY
Interview
An eye on hot strip

processing lines
What are the benefits customers have using the knowhow of the workshop?
Today, steelwork operators are in an extremely competitive
market. There is no mercy in case of unplanned shutdowns
or quality problems, which are generally accompanied by
high costs. So, we provide our customers with state-of-theart repair and maintenance services and thus minimize the
risks leading to equipment failure. In cooperation with our
customers we increase their productivity and quality.
Can you give us some facts about the workshop?
Our workshop has been in operation for two and a half years.
Compared to the 150-year-old history of SMS Siemag we
are a young company, but benefit from the strong network of
the SMS group. Our business is mainly on the Turkish
market, which produces 34 million tons of crude steel per
year. This makes the Turkish steel industry Number 8 in
the world.
Kerem Uluayli
General Manager SMS Siemag Metalurji
Servis Sanayi ve Ticaret Ltd. Sti.
What projects is SMS Siemag working on?

Currently, we are working a lot on the repair and maintenance of core components in Turkish hot strip mills. This
field is a niche market. There is no other company in Turkey
offering such a service, so this is our main target. We also
repair and clad the rollers of two major Turkish steel makers. This method offers great advantages, especially with a
view to quality.
Where do you see the differences between Turkey and
Europe?
I would say the Germans are excellent planners and show
proactive behaviors. Turkish people are much more reactive and very experienced in the management of emergencies. So what is important is that the synergy of the two
cultures can bring big advantages if communication is done
the right way. At SMS Siemag we have been successful in
accomplishing this aim.
Kerem Ulucayli
kerem.ulucayli@sms-siemag.com
51
Projects
Active worldwide
The SMS group is currently implementing a great number
of projects worldwide, for example, a new steelmaking and
rolling mill plant for Siderrgica Nacional in Venezuela,
a pickling and hot-dip galvanizing line for Wuppermann and
a new HybrEx press for ASTAS in Turkey.
52
OVERVIEW
SMS Siemag
Paul Wurth
Metallurgical technology
Steel refining
Continuous casting plants (flat products)
Hot rolling mills
Cold rolling mills
Aluminum plants
Strip processing lines and furnace technology

SMS Meer
Steelmaking/CC technology (long product mills)
Tube & pipe plants
Long products plants
Forging plants
NF-Metals
56
58
67
69
72
74
82
84
90
94
96
104
109
in brief
Bhushan Steel, India
Mycron Steel, Malaysia
Low-emission coke oven plant Roll load system upgrade
On June 26, 2014, the first coke was

successfully pushed at Bhushan
Steels newly built coke oven plant at
the Meramandali works, Orissa, India.
Paul Wurth designed and supplied

key components for this coke oven
plant, which also includes a gas
cleaning facility. With 74 ovens, an
oven height of 7.6 meters and a useful volume of 78.92 cubic meters, the
coke oven battery is designed for theannual production of 1.3 million tons.
This large-volume battery, which is
of the top-charging type, represents
the latest state of the art in coke
making, above all, because it minimizes pushing per day and reduces
the emissions released by the plant.
Additional emission prevention is
provided by the Sopreco Single Oven
Pressure Control system developed
by Paul Wurth.
www.paulwurth.com
TATA Steel, UK
Roll separation system

automated
Parkegate, a subsidiary of SMS group,
was selected by TATA Steel, UK, to incorporate and adapt automatic work
roll separation systems in its DR mill.
Covering the full range of work roll
diameters, the new separation cylinders were integrated into the existing
work roll chocks with minimal modi
fication.
www.parkegate.co.uk
54
At the six-high cold

rolling mill of Mycron
Steel, Malaysia, a new
servo valve solution
helped improve the issues with the existing
roll load hydraulics. To
reduce the expenses for
spare parts and simplify maintenance, a servo
valve solution was developed by Parkegate
utilizing the existing
seals, filtration, oper
ating pressures and accumulator pre-charge.
Parkegate engineered
the new valves into
the existing cylindermounted manifold
arrangement.
www.parkegate.co.uk
IN BRIEF
Shandong Weiqiao Aluminium, China
DMKD, Ukraine
Milestone reached
PCI on stream
On August 15, 2014, the Chinese aluminum producer Shandong Weiqiao Aluminium & Electricity Co., Ltd. granted to
SMS Siemag the acceptance certificate
for two aluminum cold rolling mills.
Both are part of a major order that
Ukrainian PAO DMKD, Dniprodzerzhynsk, a company of the ISD Group,

has started injecting pulverized coal
into its blast furnaces. Paul Wurth designed the coal grinding, drying and
injection plants, and supplied key
components such as grinding mills,
filters, valves, instruments and automation systems.
Shandong Weiqiao had awarded to

SMS Siemag in 2011. It comprised
two fully equipped cutting-edge single stands of six-high design, with
CVC plus, work roll and intermediate roll bending systems, hot edge
spray system, multi-zone cooling
section and dry strip system. This
rolling technology enables Shandong
Weiqiao to satisfy all customer requirements in terms of strip thickness and quality.
SMS Siemag supplied a total of three
cold rolling mills to Shandong Weiqiao.
In August 2014, acceptance was granted
for the two single-stand rolling mills. The
three-stand tandem mill (left side in the
background) has started operation, too.
U.S. Steel Koice, Slovakia
50% more in ten days

SMS Innse was awarded an order to revamp the
continuous pickling line of U.S. Steel Koice, in
Slovakia. The main goal of the modernization is
a capacity increase from 1 million to 1.5 million
tons per year. For that purpose, entry and exit
sections including coil transport equipment
will be renewed and the looper capacities increased. Furthermore, a new side trimmer with
integrated scrap chopper, a side notcher and a
strip centering device will be installed. The revamp will be done within just ten days.
ROGESA, Germany
Blast furnace to be revamped
VSB, Brazil
In operation
At the end of July 2014, the JV company
Vallourec Sumitomo do Brasil (VSB)
blew in its No. 2 mini blast furnace at
the Jeceaba plant in Mini Gerais. The
new blast furnace has a working volume of 350 m3. It is the first of two mini
blast furnaces VSB has ordered from
the Paul Wurth Group. The orders include the design and supply of the
blast furnaces complete with ancillary
plants. A team of experts assisted the
customer in starting
up the process and
the plant safely.
Paul Wurth has booked two orders for the modernization project planned by
ROGESA for blast furnace No. 4 at Dillingen. Paul Wurth will design and supply
copper and cast-iron cooling staves, new pool runners and pressure equal
izing valves. ROGESA will also replace the dust catcher with an axial cyclone.
Paul Wurth will provide the engineering and supply the core components for
this new equipment.
51
PROJEcTs
The upper part of one of the

condensation towers is being unloaded at the docks.
56
Projects Paul Wurth
Blast furnace modernization according to schedule

Europes biggest blast furnace, ThyssenKrupp Steel Europes (TKSE)
blast furnace 2 in Duisburg-Schwelgern, underwent a comprehensive
reline, after a first campaign of 21 years.
Within the framework of the modernization project for blast

furnace 2 of TKSE in Duisburg, Paul Wurth Umwelttechnik,
based in Essen, Germany, was awarded the contracts to reline the complete Bell-Less Top charging system and revamp the condensation towers, including a granulation
tank extension for the slag granulation plant. Paul Wurth
was also responsible for the modernization of the furnace
cooling system in cooperation with a TKSE subsidiary. Particularly challenging about this project was that the order
involves not only the replacement of existing components,
but also the implementation of solutions that will optimize
the overall blast furnace operation. One of the measures
implemented to achieve this objective was a 25 percent enlargement of the volume of the material hoppers of the
bell-less top. As a consequence of this enlargement, a
stronger valve actuating unit controlling the feeding rate of
raw material into the blast furnace was installed and the
existing top structure was rebuilt. To upgrade the slag
granulation equipment of blast furnace 2 to the latest state
of the art, Paul Wurth will supply two INBA slag granulation systems. These systems are of a similar design to
those installed by Paul Wurth when building TKSEs blast
furnace 8 in Duisburg.
Short disassembly and assembly times
For disassembling the old and assembling the new components, Paul Wurth had available a time frame of 60 calendar days within the 90-day period scheduled by TKSE for
the complete relining. Such a tight time frame could only be
met if a major part of the equipment is preassembled before being shipped and if the logistics have been perfectly
planned. Some of the plant components shipped by Paul
Wurth have diameters of up to eight meters. Each of the
two material hoppers weighs 120 tons. Some of the parts
for the condensation tower weigh as

much as 45 tons. We have not had a
heavy transport of such dimensions in
almost ten years, says Peter Caron,
Project Manager at Paul Wurth. The
logistical effort is enormous. Almost
50 people were involved in taking the
freight to Duisburg safely. Due to their
large size, some of the parts had to be
transported on waterways. The large
components were loaded on freight
ships and transported over various
waterways to the Walsum docks in
Duisburg. The old components of the
blast furnace top were disassembled
and the new ones installed. This takes
place at a height between 46 and 73
meters above ground with the aid of a
500 ton mobile crane, a 1,350 ton
track-type crane, and a wire rope lifting and shifting system, specially
mounted in the blast furnace tower for
this purpose. The construction of the
condensation towers took place in
parallel. The project was being handled in close cooperation between
TKSE, Paul Wurth and specialist companies subcontracted by Paul Wurth,
so that Europes biggest blast furnace
could be restarted on October 18,
2014, after an overall relining time of
90 days.
i
Paul Wurth
Starting from a
works in Dinklage
in the German federal state of Lower
Saxony, the large
components were
transported by road
over a distance of
80 kilometers to the
Coast Canal. From
the Walsum docks in
Duisburg, they were
transported to blast
furnace 2 on TKSEowned roads. At
the same time, four
trucks were transporting further plant
components weighing several tons from
Luxembourg.
www.paulwurth.com
57
Projects
The converter vesselchanging car from

SMSSiemag has a
payload of 1,200 tons.
58
Projects Metallurgical technology
Environmental
protection through
dry-type dedusting
PT Krakatau-Posco Company, Indonesia, has successfully
commissioned the efficient converter-vessel-changing concept supplied
by SMS Siemag. The dry-type electrostatic precipitators achieve
a separation efficiency well over 99.8 percent.
PT Krakatau-Posco Company (PTKP), Indonesia, and

SMS Siemag, Germany, have successfully put into operation the efficient converter-vessel-changing concept comprising a 300 ton change-vessel converter, a changing car
as well as highly effective environmental technology for the
converter shop. SMS Siemag developed the concept for the
converter-vessel-changing technology for PTKP and supplied the tilting gear unit for the converter, the changing
car, which has a payload of 1,200 tons, and the complete
X-Pact electrical and automation package.
In the new PTKP plant, the latest generation of
SMSSiemags dry-type converter-gas dedusting technology has been deployed for the first time. This technology includes a gas conditioning tower and a dry-type electrostatic precipitator. Lee Jung-Bae, Project Manager of the
steelmaking plant at PTKP, is very pleased with the new
plant: Using SMSSiemags vessel changing concept was
the right choice. It is the most economical solution.
PT Krakatau-Posco Company and SMS Siemag have successfully

started up the efficient converter-vessel changing equipment.
New-generation converter-vessel-changing
technology
The converter-vessel-changing concept provides for two

blowing stands with permanently installed trunnion rings,
three exchangeable converter vessels, a vessel-changing
car, a wrecking and relining stand, a standby depositing station and a connecting trackway. The converter-vesselchanging car picks the worn converter up at the blowing
stand and takes it to the wrecking and relining stand. From
there, the changing car moves to the depositing stand
59
Projects
Latest-generation
dry-type dedusting of the converter
gas, using a gas
conditioning tower
and a high-capacity
dry-type electrostatic
precipitator.
i
SMS Siemag
The dry-type electrostatic precipitator developed by
SMS Siemag excels
through low pres-
and collects the second converter

vessel, which has already been relined,
and takes it to the blowing stand. Converter changing takes ten hours, i. e., it
is accomplished within a regular maintenance shift at the steelworks. In its
lower part, the changing car is equipped
with a special lifting and turning manipulator, which enables the car to be
turned through 90 degrees in order to
reach the respective locations.
sure loss, maintenance-friendly
Effective environmental
design, low operat-
technology
ing costs and high
The dust-laden flammable gas arising

during the process is collected by the
primary dust-collecting system above
the opening of the converter and fed
into the cleaning and recovery facilities.
The gas is cooled in the conditioning
tower before cleaning is performed in
the dry-type electrostatic precipitator.
Here, efficient separation of the dust
particles takes place. The electrostatic
precipitators achieve a degree of separation of well over 99.8 percent. In the
downstream spray-cooling tower, the
cleaned gas is cooled in order to reduce its volume. Depending on the operating phase of the converter, the gas
is either conducted to the flare or sent
to the gas holder for intermediate
storage. The gas-flow switch ensures
safe changeover. From the gas holder,
the converter gas is fed to other consumption points in the works via a
pressure-boosting station. The dry-
separation efficiency.
60
type electrostatic precipitator, with its

low pressure loss, its maintenancefriendly design and long service life,
stands for low operating costs. Thanks
to the high dust-extraction capacity,
low residual dust contents can be attained and demanding environmental
standards complied with. Both energy
costs and CO2 emissions are significantly reduced, as the energy obtained
from the flammable converter gas
serves as a replacement for other energy sources.
PTKP, a joint venture between Pohang Iron & Steel Company (Posco),
South Korea, and PT Krakatau Steel,
Indonesia, has been investing in a new
integrated steel plant in Cilegon, West
Java. The plants annual production
amounts to three million tons of steel.
A second phase is planned to increase
the production to six million tons.
www.sms-siemag.com/steelmaking
99.8
percent separation efficiency is achieved by
the electrostatic precipitators used in the
latest generation of converter-vessel-changing equipment.
Short shutdown
The second 400-ton converter at
ThyssenKrupp Steel Europe AG has
restarted production, after the
successful revamp by SMS Siemag.
We would like to thank all parties involved for their performance and commitment demonstrated during the project,
which is a very good example of the fact that precise agreements, an open attitude towards one another, good communication and close cooperation between the sub-suppliers, our specialist departments and the Oxygen Steelworks
I have paid off, said Tim Moscheik, Project Manager in
charge of the converter revamps at ThyssenKrupp Steel
Europe in Duisburg-Bruckhausen.
NEW CONVERTER VESSEL
The new converter vessel is one of the largest of its kind

worldwide. Thanks to the design developed by SMS Siemag
the new vessel is much larger. While leaving the charge
weight of up to 400 tons unchanged, the internal volume of
the converter could be increased by 24 percent. The lamella suspension system developed by SMS Siemag provides
for a more efficient use of the installation space. The lamella system is a maintenance-free solution, which allows
the converter vessel to be suspended in the trunnion ring in
an unrestricted manner. The additional vessel volume provides the preconditions for a more environmentally friendly
process control and more efficient energy recovery.
Converter I, which has been on stream again for almost
one year, provides good results and fulfills our exacting requirements. For Converter II, we awarded acceptance after
a period of only 14 days. We are very satisfied with the per-
The project teams of TKSE and SMS Siemag after the successful
revamp of the 400-ton converter at ThyssenKrupp Steel Europe
formance, added Wolfgang Schulte,

Senior Engineer of the Plant Development Department at ThyssenKrupp
Steel Europe.
SMS Siemag supplied the vessel,
the trunnion ring, the lamella-type
vessel suspension system of the latest
generation, the vessel supporting
bearings and the bearing pedestals.
The solution developed by SMS Siemag
makes it possible to retain and continue to use the existing converter tilt
drive. SMS Siemag was also responsible for the dismantling of the existing
converter plant, the installation of the
plant components as well as the erection of a new converter platform. The
revamp was carried out in cooperation
with ThyssenKrupp MillServices &
Systems GmbH, Duisburg, Germany.
The SMS Siemag team succeeded
in falling below the scheduled shutdown time of 44 days by more than 36
hours.
61
Projects
Long-standing
partnership
For more than 20 years, SMS Siemag has supplied
submerged arc furnaces (SAF) to CBMM in Brazil.
Most recently, the company ordered a further SAF unit.
CBMM (Companhia Brasileira de

Metalurgia e Minerao), a leading
niobium producer in Brazil, placed an
order with SMS Siemag for the supply
of a submerged arc furnace (SAF).
With the new furnace, the customer
intends to increase its production capacity.
Commissioning is planned to take
place at the end of 2016/beginning of
2017. The scope of supply includes the
engineering and the delivery of the
SAF, the 15-MVA transformer, a gas
cleaning plant, a water cooling plant
and equipment for reactive power
compensation. The new SAF will be
used to produce refined niobium concentrate, which is a basic material for
the production of ferro-niobium (FeNb)
and niobium oxides.
Niobium-containing steels are used in the

automotive industry.
First furnace supplied in 1993
Niobium is mainly used as a microalloying element in steels, where it gives

the material higher strength and
toughness. The most important fields
of use of microalloyed steels include
the automotive industry, pipeline construction for oil and gas transport and
the construction industry.
Previously, SMS Siemag supplied
SAFs to CBMM in 1993, 1998 and 2004.
62
CBMM is a privately owned company,

founded in Araxa, Minas Gerais, Brazil, in 1955.
Projects MEtallurgical Technology
The most recently commissioned 165 ton converter.
Proven cooperation between the teams of Tata Steel and SMS. Fourth person from left:
Tata Project Manager, Binod Kumar. Third person from right: Nikolay Ryabkov, Construction Site Manager SMS.
Tapping after 37 days

SMS Siemag has successfully completed
the revamp of the Converter Shop I at Tata Steel,
India. A highlight of the project was the short
shutdown period required.
The first heat was tapped from the

second converter in Jamshedpur after
a shutdown period of only 37 days. The
first of the two converters had already
been put into operation in 2013. The
trustful cooperation between Tata
Steel and SMS has turned out successfully once again. It helped us keep
the shutdown periods very short. We
are very satisfied, says Binod Kumar,
Manager Modernization Project Converter Shop I, Tata Steel Jamshedpur.
Convincing tilt drives
SMS Siemag supplied the engineering

for the two 165 ton converter vessels,
the lamella suspension system, the
converter tilt drives and one watercooled top cone for each converter.
The converters can cope with the
thermal stresses due to the use of the
lamella suspension system, the de-
sign of a large clearance and the use

of high-temperature-resistant finegrained structural steels. No additional cooling media is required because sufficient cooling is guaranteed
by natural cooling alone. We have
known the advantages of the lamella
suspension system and the reliable
tilt drives from SMS Siemag for a long
time. Now, we too can benefit from
them, says Gurmit Singh, Manager
Converter Shop I, Tata Steel.
A successfully completed revamp: the

converter platform in Tata Steels Converter
Shop I.
Click on the QR code

to watch a video
about a recently supplied production line.
www.sms-group.
com/qr/tata
63

03/2014
Rubrik
Projects
Scrap being charged into the converter.
Ecoplants solution
for SSAB Lule
SSAB Lule, Sweden, has awarded
SMS Siemag the contract for the revamp of the converter shop and the
supply of environmental technology.
gained facilitates environmentally friendly process control and efficient energy recovery. I am looking forward to
benefitting from this new technology and to breathing new
life into our steelmaking plant, says Kurt Lindqvist, Project Manager at the SSAB Lule Converter Shop. By using
the lamella converter suspension system, along with the
design of an enlarged clearance and the use of high-grade
heat-resistant fine-grained structural steels, the converters will be well prepared to cope with the thermal loads.
This will be achieved without any additional cooling fluids
because sufficient cooling is ensured merely by the natural thermal conditions.
Reduced dust emission
SMS Siemag will supply lamella suspension systems and

the converter tilt drive systems for both converters. The
two-motor tilt drive systems will be easily accessible and
make maintenance more convenient. The scope of supply also includes the converter trunnion bearings, measures to increase the height of the existing trunnion pedestals as well as the installation of the vessels and the
trunnion rings.
Thanks to the design concept developed by SMSSiemag,
the new converter vessels will have a clearly greater volume. With an unchanged quantity of material charged (up
to 130 tons), it is possible to increase the internal volume
of the converter by 10 percent. The additional capacity
64
The SMS Siemag Ecoplants solution also comprises the

revamp of the primary-gas cooling system of the BOF
steelmaking plant. To this end, the cooling stacks of both
converters will be modified and provided with easy-tomaintain SMS Siemag Baumco adjustable skirts, which
will be lowered hydraulically onto the converter mouth
during the blowing phase, allowing the primary gases to
be efficiently extracted under suppressed combustion. In
addition, diffuse dust emissions will be substantially reduced. The gas recovery system will be used in the best
possible way, as CO gas will be generated under suppressed combustion.
Increased
productivity
SMS Siemag revamped the AOD converter No.1 at Acerinox stainless steel
plant in Los Barrios, Cadiz. The objectives of this project
were to increase the converter vessel and optimize the process.
As a result of the increased free volume of the vessel from

50 to 54 cubic meters, which corresponds to 0.46 to 0.5 cubic meters specific volume per ton, and of the optimized
vessel geometry, metal splashing has markedly decreased.
The vibrations of the old AOD converter had been measured during three campaigns. The vessel geometry and
the arrangement of the purging plugs were simulated using a CFD (Computational Fluid Dynamics) model in order
to ensure proper bath movement. Measurements on the
new AOD converter demonstrated that, after the revamp,
the vibrations and the dynamic tilting torques of the vessel
were distinctly lower. The process is much smoother now,
with the positive effect of markedly longer lining lives.
Longer tuyeres life
The revamp led to higher productivity. The number of heats

per lining increased from 55 to 70 on average. Also under
metallurgical aspects, the revamp was a success. The chromium yield has increased, while ferro-silicon and lime consumption decreased. The valve station supplied by
SMS Siemag controls the cooling media supply separately
for each tuyere, leading to longer tuyere lives.
65
Projects
The new active torque support leads to a

marked reduction in vibrations.
Two converters at ArcelorMittal Bremen will be

revamped with new drive equipment.
Graphical illustration of the deslagging stand

to be supplied by SMS Mevac UK.
Improved
converter
Modern drive New deslagtechnology

ging stand
New active torque

support for Fuxin.
SMS to supply equipment

for converter.
SMS Mevak UK receives

order from Tulachermet.
A new active torque support for AOD

converters reduces vibrations by 75
percent. This means less wear. The
newly developed, active torque support
installed on the 180 ton AOD converter
of Fuxin Special Steel, China, has been
proven to perform as successfully as
in the pilot tests. Measurements during more than 1,100 heats have shown
that the hydraulic torque support reduces vibrations in the drive train to a
fraction of the previously common values. By installing the active torque
support, Fuxin Special Steel has decided in favor of an innovative solution
developed by SMS Siemag that provides a dramatic reduction in vibration-induced wear, Jan Bader, Head
of Technical Sales Steelworks, summarizes the performance. This results in a longer service life and higher availability of the tilt drive and,
eventually, also in an increased availability of the converter.
ArcelorMittal Bremen has awarded

SMS Siemag the order to revamp
the electrical drive equipment of two
steel converters. The converters
each have a tapping weight of 290
tons. SMS Siemag will supply new
drive equipment for the converters,
including the variable-frequencycontrolled AC motors and the controls for an automatic converter
tapping and deslagging system. As a
service part, the order also covers
the inspection of the two tilt drives.
The drives were supplied in 1968 by
SMS Siemag (then DEMAG) and
have been in operation ever since.
With this future-oriented modernization by SMS Siemag, ArcelorMittal Bremen will harmonize and stabilize its productivity independent of
the personnel. The revamped converters are scheduled to be commissioned in spring and fall 2015
respectively.
SMS Mevac UK Ltd. will supply a

deslagging stand to Tulachermet
Steel as part of the major order that
the SMS group had received in April
2014. The SMS group will supply a
complete converter steel plant including secondary metallurgy facilities, a continuous billet caster and
two light-section mills. Within the
consortium, SMS Mevac UK Ltd. is
responsible for the engineering and
supply of the deslagging stand,
which will be equipped with two
deslagging machines, two ladle tilting devices, a movable suction hood
and temperature measuring and
sampling probes installed on the
suction hood. As an option, an upgrade to a hot metal desulphurization (HMD) plant has been negotiated. Additionally, the plant will feature
a truck unloading station, silos and
injection dispensers, as well as an
injection lance with valve racks.
Jan Bader
jan.bader@sms-siemag.com
66
www.sms-siemag.com
www.sms-mevac.com
Projects STEEL REFINING
Follow-up order
completes steelworks
SMS Siemag is supplying more equipment for the new
steelworks complex built by Siderrgica Nacional (SN) in Venezuela:
a ladle degassing plant and a twin-stand Steckel mill.
The new 200 ton VD X-eed vacuum

degassing plant to be supplied by
SMSMevac will complete the X-Melt
electric steelmaking plant and allow
the production of high-quality tube
steel and ULC grades with low carbon
content. In the final construction
stage, the ladle degassing plant will
have two treatment stands. The twinstand Steckel mill will be designed for
the production of 844,000 tons of hot
strip per year with a maximum strip
width of 1,880 millimeters. The core

equipment of the Steckel mill will
consist of two identical four-high
stands in tandem arrangement, which
will roll out the transfer bars arriving
from the heavy-plate mill to final
thicknesses between 1.5 and 18 millimeters. Also for the plants of the second construction stage, SMS Siemag
will supply the complete electrical
and automation package, including
the process automation (level 1) and
the technological process models

(level 2). Before being installed onsite, the automation system will be
tested in the Plug & Work procedure.
The first stage of the works complex,
which is currently under construction,
comprises an electric steelmaking
plant, a continuous caster and a
heavy-plate mill.
Bernhard Espendiller
bernhard.espendiller@sms-siemag.com
Twin-stand Steckel
mills are characterized by low investment and conversion
costs.
67
Projects
2.15
meters per minute is the casting speed for
which the caster has been designed.
Top: The RH-TOP

plant from SMS Mevac
is the first of its kind
in Argentina.
Left: The caster is
designed for a casting
speed of 2.15 meters
per minute. The photo
shows the exit side.
68
Projects continuous casting PLANTS AND steel refining
PRODUCTION START
AT SIDERAR
The Argentine steelmaker Siderar in San Nicols has started production
on a high-capacity slab caster supplied by SMS Siemag. An RH-TOP plant
supplied by SMS Mevac went already into operation at the end of 2013.
At San Nicols in Argentina, Ternium Siderar and SMSSiemag

have successfully commissioned the two-strand X-Cast
continuous slab caster. This high-capacity caster allows Siderar to fully exploit the capacity of the upstream steelmaking
plants and increase its production of low- to medium-carbon
steels and of peritectic grades. An wRH-TOP plant, the first
of its kind in Argentina, was already commissioned at the end
of 2013. It was supplied by SMSMevac.
The casting plant started operating according to schedule. Commissioning took place without problems. We were
able to cast an entire ladle right from the beginning and we
are very satisfied with the performance of the plant, says
Sebastin Capote Lpez, Department Head Continuous
Casting and Secondary Metallurgy, Ternium Siderar. Designed for a casting speed of up to 2.15 meters per minute,
the plant achieves a production capacity of approximately
2.5 million tons of slabs per year. The currently twelve-segment containment zone is able to be expanded by two further segments in the future. This would make an even higher casting speed possible and give the plant an additional
boost in productivity. Designed to produce slabs between
200 and 250 millimeters thick and between 750 and 1,900
millimeters wide, the plant is equipped with various technological Intelligent Slab Casting (ISC) modules, which
determine quality and production. These modules include
the hydraulically actuated resonance oscillation system,
remotely adjustable narrow mold faces for changing the
slab width during casting and position-controlled CYBERLINK segments for Dynamic Soft Reduction.
production of slabs of high internal

quality. The plant is equipped with
SMS Siemags X-Pact electrical and
automation systems, covering the process automation (level 1), the technological process models (level 2) and the
commissioning. Personnel training was
also part of the SMS scope of supply.
i
SMS Siemag
Ternium Siderar is
an Argentine company headquartered
INTELLIGENT LADLE LIFTING CONCEPT
in Buenos Aires.
The RH-TOP plant is the first of its kind

operated by a company of the Ternium
Group. It enables Siderar to enter higher-grade quality segments, especially
ULC grades for the automotive industry. The RH unit also expands the product range. The equipment is designed
to treat heats with a nominal weight of
200 tons. SMS Mevac equipped the RH
plant with a newly developed RH-Rocker-Type as a ladle lifting device. This
makes for optimal integration of the
plant into the material flow. The vacuum is generated by a four-stage
steam-ejector vacuum pump, which is
characterized by low steam and water
consumption required for cooling the
condensing unit. The suction capacity
of the pump is controlled to serve the
needs of the heat.
It employs approximately 18,000

people. San Nicols
de los Arroyos is
situated about 230
kilometers to the
northwest of Buenos
Aires.
COMLETE WITH X-PACT ELECTRICS
Combined with the width-dependent air-mist secondary

cooling system and the technological process model Dynamic Solidification Control (DSC), these features guarantee the
Thomas Scheiblich
thomas.scheiblich@sms-siemag.com
69
Projects
Within the SMS

group, SMS Mevac has specialized in secondary
metallurgy plants.
Revamped RH plant
in operation
Taigang Group International Trade Co., Ltd., and the plant
operator Shanxi Taigang Stainless Steel Co., Ltd. (TISCO), both
located in Taiyuan, China, have successfully commissioned the
existing 80-ton Duplex RH-TOP plant revamped by SMS Mevac.
April 2014 had already seen the commissioning of the

new RH-TOP plant No. 2 supplied by SMS Mevac. Both the
supply of the new and the modernization of the existing
RH plant (Ruhrstahl-Heraeus process) were handled by
SMS Mevac, Germany, in cooperation with the consortium
partner SMS Siemag Technology (Beijing) Co., Ltd. Shanxi
Taigang Stainless Steel can now use both 80-ton Duplex
RH-TOP plants for the refining of various high-quality
steel grades with low levels of hydrogen. The plants will
primarily be used for the treatment of steel for electric
sheet production.
SUPPLY OF KEY COMPONENTS
In both plants, the vacuum is generated by a four-stage

steam-ejector vacuum pump with variable pressure reduction (RH-SC) for optimized process control. SMS
Mevacs scope of supply for this project included almost
the complete basic engineering, the main part of the de70
tail engineering, the delivery of key

components for the mechanical,
electrical and instrumentation equipment, the complete level-1 and level-2 automation systems as well as
supervision of installation and commissioning.
www.sms-mevac.com
Projects Continuous casting plants
Nucor celebrates 25 years

of CSP production
More than 600 guests attended the ceremonies at
Nucor Steel in Crawfordsville, Indiana, U.S.A. Here,
25 years ago, Nucor Steel and SMS Siemag had started
to write anew chapter in the history of the steel industry.
The CSP plant in Crawfordsville

commissioned in 1989 was the first of
its kind in the world. It revolutionized
the production of flat steel products.
The plant was made up of a singlestrand caster, which produced thin
slabs of 50 millimeter thickness, followed by a 158-meter-long tunnel
furnace, four rolling stands for a minimal hot-rolled thickness of 2.5 millimeters as well as a laminar cooling
section and a down coiler. The plant
paid for itself very soon, John Ferriola, CEO and President of Nucor Steel,
proudly stated during the celebrations. The original investment had
amounted to 300 million U.S. dollars.
Since commissioning, the plant has
produced 38 million tons of steel and
has, to date, achieved a sales volume
of 19.3 billion euros. Ferriola is convinced that the plant will produce
successfully for another 25 years.
27 plants installed worldwide
During the anniversary celebrations,

Wolfgang Spies, General Manager Order Handling Flat Rolling Plants at
SMS Siemag and a member of the
commissioning team 25 years ago,
explained why the CSP technology is
so successful: Meanwhile, we have
installed 27 plants worldwide. The
steel grades processed by these
plants also include high-strength

multiphase steel of type DP 800, tube
steels to API standards and highstrength HSLA steels. We have been
working with Nucor for several decades on a highly trustful basis. In
summarizing his experience with
CSP technology, Ron Dickerson, Nucor Steel Crawfordsville General
Manager, said: Although the CSP
concept was not yet a proven technology in the mid-1980s, it was exactly
what we needed to set foot on the
market for flat steel products. I was
lucky to be one of those involved in
starting up the first CSP plant. We
had to cope with many challenges and
obstacles. It was not always an easy
job. But with a partner like SMS
Siemag at our side we succeeded. Today, we operate four CSP plants.
This illustrates the success. Some
38 million tons of hot strip produced
in Crawfordsville alone is ample proof
of how well the technology works.
John Ferriola, CEO and President of
Nucor Steel, and Ron Dickerson, Nucor Steel Crawfordsville General
Manager, accepted a present from
SMS Siemag on the occasion of the
anniversary. The present was a miniature statue of the Ironworker Frieder, who symbolizes iron mining in
the Siegerland region. Since 1904, the
John Ferriola, CEO and President of Nucor

Steel, and Ron Dickerson, Nucor Steel
Crawfordsville General Manager, accepted a
present from SMS Siemag on the occasion of
the anniversary.
original statue has been a monument

on the bridge crossing the River Sieg
in Siegen, Germany, together with the
Mineworker Henner.
Wolfgang Spies
wolfgang.spies@sms-siemag.com
71
Projects
From top:
Positioning of the
first mill housing for
the reversing roughing mill.
The first plate rolled
on the new mill
stand.
Layouts of Hyundai
Steels two heavyplate mills.
72
Projects Hot rolling mills
SYSTEMATIC EXPANSION
AT HYUNDAI STEEL
In summer 2014, SMS Siemag finished the expansion of Hyundai Steels
5.0-m heavy-plate mill. To keep impairment of production as low as possible,
the revamp was implemented in several steps.
Initially, the 5.0-m heavy-plate mill of Hyundai Steel was

started as single-stand mill at the end of 2009. In 2011,
Hyundai Steel entrusted SMS Siemag with the second construction stage including the installation of a reversing
roughing stand with edger, extension of the plate cooling
system and supply of an additional cooling bed, a second
shear line with dividing shear as well as additional piling
equipment and roller tables in the plate stockyard. The order furthermore covered the complete X-Pact automation
system. The purpose underlying the expansion of the 5.0-m
rolling mill was to increase annual capacity from 1.5 to two
million tons and to enhance the product portfolio.
EXPANSION IN FOUR STEPS
The first unit to be expanded within the second stage was

the plate cooling section, which was enlarged by a new
spray cooling system and a pre-leveler during the annual
plant shutdown in autumn 2012. The experts of SMS Siemag
installed the spray cooling system upstream of the existing
laminar cooling system. This combination provides Hyundai
Steel with great flexibility in selecting the adequate cooling
strategy for the respective material. Thanks to its very high
cooling rates it is also an ideal tool to produce high-strength
plates, for instance direct hardening from rolling heat. Expansion of the cooling bed area by a third walking-beam
cooling bed and installation of a second shear line were accomplished in 2013 during ongoing production.
The final step of the revamp, i.e., installation of a new reversing roughing stand with edger, was implemented at the
beginning of 2014, when the neighboring 4.3-m roughing
mill had reached full capacity. Upon the customers request,
the new roughing stand was installed in two stages. In the
course of a 25-day shutdown in February and March 2014,
the mill housings were positioned and

the mill stand, including edger, mounted. Following this work, piping was carried out within just one month while
production was going on. During this
period, Hyundai Steel could operate its
5.0-m mill at full capacity. Completion
of the mill stand and commissioning
were accomplished in April 2014.
The new reversing roughing mill has
a rolling force of 100 MN and is equipped
with hydraulic and mechanical adjustment systems. The backup rolls are
supported in Morgoil bearings of KLX
design, which offer optimum running
accuracy at high operational safety and
are suited for extremely high loads.
Same as the mill supplied in 2009, all
expansion equipment operates with
SMSSiemags X-Pact level-1 and level-2 automation systems, which were
subjected to an integration test according to the Plug & Work principle before
commissioning.
i
Hyundai Steel
With the 5.0-m mill
put on stream in
2009 and expanded
until recently and
the 4.3-m mill,
which has been in
production since
June 2013, Hyundai
Steel now has two
heavy-plate mills
with an annual capacity of 3.5 million
tons, which were
completely supplied
by SMS Siemag.
FACTS + FIGURES
Commissioning
December 2009
2nd construction stage
20122014
Annual production
2.0 million t
Plate thickness
6200 mm
Plate width
1,0004,800 mm
73
Projects
JSW Steel inaugurated Cold

Rolling Mill Complex II
In a special ceremony, JSW Steel Ltd., India, inaugurated Cold Rolling Mill
Complex II in Vijayanagar, Karnataka, and granted its acceptance in September.
In addition to a large number of customers, SMS Siemag participated
in the event as supplier of the pickling line/tandem cold mill.
Under the motto Leading change together, JSW Steel Ltd. had invited numerous guests to come to its Toranagallu works in the Indian federal state
of Karnataka on April 25, 2014. The
new production facilities are an important milestone to the company. Innovative and superior cold strip products
require adequate sophisticated plant
technology. Being the main supplier of
JSWs new pickling line/tandem cold
mill, SMS Siemag was represented by
Burkhard Dahmen, Spokesman of the
SMS group Managing Board. In his address he underlined the importance of
the almost 20 years of cooperative

partnership between JSW and the
companies of the SMS group as a basis
for supplies and modernization of essential production equipment at JSW.
SUCCESSFUL COMMISSIONING
The heart of Cold Rolling Mill Complex

II is the five-stand high-tech pickling
line/tandem cold mill, which commenced operation on October 19, 2013.
After successful hot commissioning, a
plant with an annual capacity of 2.3
million tons and meeting all quality requirements is now available to JSW.
The tandem cold mill processes a
broad material range primarily used in
the automotive industry. For
fast, reliable and ergonomic quality inspection, the continuous
exit section of the
tandem mill was
equipped with the
JSW Steel Ltd. supplies customers with
high-quality cold
strip that has been
produced on the
pickling line/tandem cold mill from
SMSSiemag.
74
Six-high mill stand of the tandem cold mill.
inline strip inspection station Rotary

Inspect. SMS Siemag implemented
this inline strip inspection solution in
combination with a carousel reel for
the first time worldwide. On September 27, 2014, JSW granted the final
acceptance of the pickling line/tandem cold mill.
Henner Schultz
henner.schultz@sms-siemag.com
FACTS + FIGURES of the pickling line/

tandem cold mill
Strip width
8001,890 mm
Strip thickness (ingoing)
1.56.5 mm
Strip thickness (outgoing) 0.32.6 mm
Projects Cold rolling mills
In a ceremonial act JSW Steel Ltd. inaugurated its new Cold Rolling Mill Complex II on the Toranagallu site.
Let us work towards our goals by consistently

supplying innovative and superior products and services that
will even exceed our customers expectations.
Sajjan Jindal, Chairman and Managing Director of JSW Steel
75
Projects
Modernization
at Outokumpu Nirosta
SMS Siemag is to modernize the 20-roll cold mill of
Outokumpu Nirosta in Krefeld, Germany, to make the 45-year-old
cold mill stand fit for new rolling tasks.
Outokumpu Group ranks among the

leading producers worldwide of sophisticated stainless steel grades. The
cold rolling mill SG3, stand type
mono-block MB 21BB-61", had been
supplied in 1969 by SMS Siemag (previously Demag) and was modernized
in 1991. Following the closure of the
Outokumpu works at the DsseldorfBenrath location, the production previously carried out there, for example
thin mirror-finish material, will be
transferred to the Krefeld works.
REVAMP OF THE COLD ROLLING MILL
The SG3 cold mill will continue to be

used for the production of high-grade
stainless steel strips made of austenitic, ferritic and martensitic materials.
The mills future rolling tasks will include, in particular, thin-gage ferritic
strips in high-gloss quality (2R bright
annealed). The supply package of
SMS Siemag comprises modifications
at the entry and exit sides and at the mill
stand itself. To achieve the desired strip
surface quality, the existing squeezer
system will be changed to a dual-cassette wiper system, including changing
device, which can be operated with differently coated wiper rolls. One of the
aims of the revamp is to enable the entire thickness range to be rolled at maximum speed.
76
The SG3 20-roll cold mill at Outokumpu Nirosta in Krefeld will be modernized.
The existing strip cooling system will be

equipped with a volume control to permit different rolling oil quantities to be
preset, depending on the pass schedule. In the mill stand, the axial shifting
system of the inner intermediate rolls
will be renewed. The plant will also be
provided with a new mill stand door and
exhaust hoods.
Uwe Kaden
uwe.kaden@sms-siemag.com
Facts + Figures
Mill stand type
MB 21BB-61"
Material
artensites, austenites,
M
ferrites
Strip width
1,570 mm
Strip thickness Max. 10.00 mm (ingoing)

Min. 0.50 mm (outgoing)
Coil weight
Max. 26 t
Rolling speed
Max. 500 m/min.
Projects cold rolling mills
The TCM 400 helps TISCO produce stainless steel very economically.
A GREAT LEAP FORWARD

At the Chinese Shanxi Taigang Stainless Steel Company, a subsidiary of
TISCO, two new integrated plants supplied by SMS Siemag for the production
of stainless steel cold strip started operation.
In August 2014, the Chinese company Taiyuan Iron and

Steel (Group) Co., Ltd. (TISCO) celebrated the 80th anniversary of its foundation. TISCO ranks among the biggest
steel producers in China, and, with an annual production
of four million tons, also occupies a leading position in the
global stainless steel sector. Right from the start, the
group has attached great importance to cutting-edge technology and relies on SMS Siemags rolling expertise. Over
the past ten years, the German machine and plant manufacturer supplied a total of five 20-roll cold mills to TISCOs
subsidiary Shanxi Taigang Stainless Steel Company. At
present, SMS Siemag participates in establishing two fully
continuous production lines for stainless steel cold strip,
so-called White Rolling, Annealing and Pickling Lines
(WRAPLs).
TWO NEW PRODUCTION LINES ON STREAM
Almost coinciding with the anniversary of the parent company, the two new production lines, each equipped with a
high-tech tandem mill (TCM 400 and TCM 300) and a strip
cleaning section from SMS Siemag, were put on stream at
the stainless steel producers site. The TCM 300 is the first
five-stand tandem mill of 18-HS design worldwide. Its
slim, horizontally stabilized work rolls permit high reductions to be achieved.
In addition to the tandem mills, SMS Siemag supplied two

strip cleaning sections as well as bridle roll sets for the
two continuous production lines. On its website, Shanxi
Taigang Stainless Steel appreciates the importance of the
two new production lines to the company analogously: By
commissioning of the most modern production lines for
stainless steel around the globe, TISCO made a great leap
forward in cold rolling and process technology.
www.sms-siemag.com/cold-rolling-mills
FACTS + FIGURES
TCM 400
TCM 300
Stand type
5x six-high
5x 18-HS
CVC plus Sexto
Annual capacity
500,000 t
600,000 t
Material
AISI 400
AISI 300
Strip width
1,0401,650 mm
Strip thickness, ingoing
2.06.0 mm
Strip thickness, outgoing
0.62.0 mm
77
Projects
SERVICES
Parkegates portfolio comprises

a wide spectrum.
Design and supply of new plant
Plant modernizations and upgrades
Sale and relocation of existing plant
Design consultancy
Process studies
Design studies
From top to bottom:

For Hindalco, India,
Parkegate modernized a hot rolling
mill.
Parkegates head
office located in the
Winchester Palace,
Poole, UK.
The Managing
Directors of
Parkegate: Neil
Winkley (left)
and John Meaden.
78
Projects Cold rolling Mills
Parkegate: The specialist

for modernizations
Parkegate, UK, impressed because of its know-how and flexibility. Projects like
those carried out at Hindalco, India, or Hulamin, South Africa, illustrate the fast and
efficient solutions of this modernizing specialist who is part of the SMS group.
The expert for modernizing rolling mills

and strip processing lines can look
back on almost 20 years of experience.
Since its foundation, it has completed
more than 250 projects worldwide. Our
focus is not on large new plants, says
Neil Winkley, Managing Director of
Parkegate. We are strong in expanding
and modifying existing plants and providing services for improving existing
equipment. Our customers benefit in
terms of time and cost from solutions
that provide a good and favorable alternative to a new mill or line. The type of
material processed is of secondary importance as Parkegates engineers
have the knowledge to deal with both
steel and nonferrous metal equipment.
On behalf of the Indian company
Hindalco, for instance, the UK enterprise modernized a 1+3 stand aluminum hot line plus two foil mills, which
up to that time were located at Novelis
facilities in the UK. We were responsible for the engineering, supply of new
plant components and supervision of
the relocation project, says Winkley
who has 50 years of experience in the
metals industry. Parkegates package
included a new ingot handling system,
roller tables, centering guides, interstand equipment, uprated drives, media systems plus engineering integra-
tion of a future fourth mill stand, along

with the engineering of extensive modifications to existing equipment items.
The mill started rolling in 2013 and is
the first plant to produce beverage can
stock in India. Plant operators are constantly in search of new ways and
means to make their equipment even
more productive, with improved product quality and simultaneously reduced
operating costs. This is precisely where
the experts of Parkegate start their
mission. They provide consultancy to
their customers, conducting feasibility
studies and offering solutions for even
very small equipment modifications.
INDEPENDENT ASSESSMENT
An aluminum producer, to give an example, wants to upgrade his two mills

(aluminum hot rolling mill and tandem
cold rolling mill) in order to increase
productivity by 25 percent while, at the
same time, raising product quality to
market-leading levels by improving
thickness and flatness accordingly. By
selecting Parkegate to prepare an analysis he gets an independent assessment of the existing mechanical equipment, fluid systems and electrical and
automation systems of both mills. The
analysis evaluates the effects of the
proposed productivity increase on the
performance and service life of the

components. Critical components are
then identified to permit procurement
of strategic spare parts. Parkegate prepares recommendations for all equipment items it considers being in need
of replacement or modernization.
Generally, the cost of a study will be
quickly recovered from the payback
generated from the implementation of
our recommendations, adds Paul Osborne, Sales and Business Development Manager at Parkegate.
Parkegates products and services
offer fast and efficient solutions. That is
appreciated by its customers. We have
handled many projects together with
Parkegate, says Ricky Venkasami from
Hulamin, South Africa. Recently, we
enhanced the coil width from 1,600 to
2,100 millimeters in one of our rolling
mills. Thanks to the Parkegate experts,
this could be done within a very short
period. In 2012, Parkegate was acquired by SMS Siemag.
79
Projects
Better quality with

SMS experts
On August 8, 2014, the first aluminum strip was rolled on the new cold rolling mill
of Jilin Midas Light Alloy Co., Ltd. in Liaoyuan City in China.
With the cold commissioning, the Chinese company Jilin Midas Light Alloy
Co., Ltd., which was founded in 2011,
has reached its goal of establishing its
own production site for aluminum
flats. Ma Guilin, Technical Project
Manager at Jilin Midas, describes her
experience:
We are very pleased that Reiner
Busenius and Dong Bang, two experienced specialists from SMS Siemag,
were by our side to supervise and ac-
company erection. That helped us improve the quality of installation, and

our own, mainly young operating and
maintenance staff had the opportunity
to learn a lot.
With strip widths of up to 2,200 millimeters and final thicknesses of minimum 0.1 millimeters, the mill meets a
wide range of market demands. The
annual production is 100,000 tons.
www.sms-siemag.com/en/aluminium
Cold rolling mill with entry and exit sections at Jilin Midas Light Alloy.
80
Technical data of the first coil

Material
luminum alloy,
A
class 3xxx
Strip width
1,630 mm
Strip thickness 1.80 mm (ingoing)

1.38 mm (outgoing)
Coil diameter
1,700 mm
Projects COLD ROLLING MILLS
Convincing
2,400 millimeters
On June 26, 2014, Henan Yulian
Energy Group Co., Ltd. put on stream
its cold rolling mill supplied by
SMSSiemag and opened the new
rolling mill complex in Gongyi, China.
After the acceptance of the hot rolling line in July 2014,

Henan now has an own annual cold rolling capacity of more
than 135,000 tons. The six-high, single-stand cold rolling
mill has been equipped by SMS Siemag with the latest rolling mill technology including CVC plus, work and intermediate roll bending systems, multi-zone cooling, hot edge
spray and dry strip systems.
Wang Yuanming, General Manager, Henan Yulian Energy Group Co., Ltd.
Technical Data of the first coil

Material Aluminum alloy
1xxx
Strip width
1,580 mm
Ingoing strip thickness
3.0 mm
Outgoing strip thickness
2.0 mm
Coil diameter
2,200 mm
MEETING EXPECTATIONS
The mill is designed to roll up to 2,400-millimeter-wide strips

down to final thicknesses of 0.15 millimeters. The first strip
completely fulfilled our expectations about the plant. We
trust that the good cooperation with our supplier can be continued over the complete ramp-up period and that we will be
able to take this cold rolling mill to full capacity, says Wang
Yuanming, General Manager of Henan Yulian. The first coil
produced in aluminum alloy grade 1xxx had a strip width of
1,580 millimeters, an ingoing thickness of 3 millimeters and
an outgoing gage of 2 millimeters. Coil diameter was 2,200
millimeters. Henan Yulian Energy Group took advantage of
the intense and comprehensive training in the digital workshop of SMS Siemag. The latest technology of virtual engi-
neering serves as communication and

working platform. Among others,
SMSSiemag uses the digital workshop
to provide its customers a virtual and
interactive insight into the equipment
and operating technologies of cold rolling mills. Shortly before cold commissioning in spring 2014, 15 employees
from Henan Yulian participated in such
a particularly vivid training course at
SMS Siemag.
www.sms-siemag.com/en/aluminium
81
Projekte
All process-relevant
information converges in the control
station of the cold
rolling mill.
FIRST STRIP ROLLED

AT GUANGXI ALNAN
On July 15, 2014, the single-stand aluminum cold rolling mill at
Guangxi Alnan Aluminium Fabrication Co., Ltd. in the Chinese town
of Nanning successfully commenced operation.
This six-high cold rolling mill with CVC plus including

X-Pact automation system was completely supplied by
SMSSiemag and is rated for high rolling forces up to 32 MN.
The electrical equipment was planned and supplied by
SMS Siemag Germany in cooperation with its Chinese subsidiary SDT. It comprises driving equipment, automation
hardware, measuring devices, sensors and the complete
plant automation system aa latest thickness and flatness
control as well as the setup processor for level 2.
PROCESSING HARD ALUMINUM STRIP
The plant is equipped for the processing of thick and hard

aluminum strip up to a width of 2,650 millimeters and a
maximum ingoing thickness of 10.00 millimeters. The minimum achievable final thickness is 0.20 millimeters. The
X-Shape flatness measuring roll safeguards the high quality of the extraordinary strip spectrum. Thomas Dring,
Project Manager of SMS Siemag, says: Right from the
82
beginning, Guangxi Alnan Aluminium

has placed great importance on the
fact that SMS Siemag is a manufacturer supplying the quality-determining
core components of the mill from its
own workshops in Germany, since the
large material range and, in particular,
the hard aluminum grades put high
demands on the precision and robustness of the mill. Even hard strips with a
large starting thickness do not impose
any problems on this plant.
Thomas Dring
thomas.doering@sms-siemag.com
Projects rolling mills
DUMA-BANDZINK will supply a micro oiling

machine to Tianjin Zhongwang Aluminium.
EPS cells in a pickling line.
Surabaya is the second-largest city in Indonesia and is situated on the main island of Java.
Oiling machine Eco-friendly

for Tianjin
descaling
250,000 tons
of cold strip
Order from China for

DUMA-BANDZINK.
Strip processing lines will

be equipped with EPS cells.
Cold strip mill for

Surabaya Steel.
DUMA-BANDZINK GmbH is to supply to Tianjin Zhongwang Aluminium

Co., Ltd. in Liaoning, China, an electrostatic micro oiling machine of vertical design for its Tianjin Color Coating Line 1. The strip speed is variable
between 30 and 300 meters per minute for a strip thickness from 0.15 up
to a maximum of 0.5 millimeters.
The quantity applied to each strip
side ranges from 0.005 to 0.020
grams per square meter. The maximum spraying width is 2,200 millimeters. The liquid to be applied is
DOS (dioctyl sebacate). A 500-liter
working tank and an electrical filter
to collect and separate excess DOS
are also included in the supply package. The separated DOS is returned
to the working tank for reuse. The
cleaned air is discharged through a
piping system connected to the filter.
The filter has a flow rate of 3,400 cubic meters per hour.
The Material Works, Ltd. (TMW) and

SMS Siemag have entered into an
agreement
that
will
enable
SMS Siemag to offer, design, build
and install processing lines incorporating EPS cells (Eco Pickled Surface)
for descaling carbon and stainless
steel strips. On announcing the conclusion of the agreement, TMW President Kevin Voges stated: Among
steel producers, SMS Siemag is one
of the most renowned suppliers. We
are very pleased that SMS Siemag
has chosen to include EPS in its portfolio of advanced technologies. EPS
is an environment-friendly process
for removing scale from the surface
of hot-rolled steel. It uses just ordinary water and a blast-cleaning abrasive, which are then returned to the
process for further use.
The Indonesian steel producer P.T.

Surabaya Steel Investama awarded
Esmech Equipment Pvt. Ltd. an order to supply a cold strip mill.
The new cold strip mill is designed for an annual capacity of
250,000 tons and scheduled to start
operation as from mid-2015. Esmech Equipment will supply a pickling line with tension leveler and acid
regeneration system, an electrolytic
strip cleaning section, one slitting
shear each for hot and cold strip, a
dividing shear, a skin-pass mill as
well as a recoiling and trimming
line. Surabaya is situated at the
northern tip of the main island of
Java and, following the capital Jakarta, is the second-largest city in
Indonesia. P.T. Surabaya Steel Investama is part of a family-owned
and dynamically developing Indonesian group of enterprises.
www.duma-bandzink.com
Michael Haentjes
michael.haentjes@sms-siemag.com
www.esmech.com
83
Projects
84
Projects Strip processing lines and furnace technology
SYSTEMS EXPERTISE IN STRIP

PROCESSING LINES
Wuppermann Group selects SMS Siemag to supply a pickling
and hot-dip galvanizing line including electrical and automation systems.
The equipment will be installed in a new plant in Hungary.
At the end of June, Wuppermann Group, Germany, a family

business with 140 years of experience in steel processing,
awarded SMS Siemag, Germany, the contract to deliver a
hot-wide-strip pickling and hot-dip galvanizing line for its
new plant in the Hungarian town of Gyor-Gnyu
.
SMSSiemag is delivering the entire line, including the mechanical equipment, process engineering and X-Pact
electrical and automation systems. We have been working
together with SMS Siemag for decades and are delighted
to continue this cooperation, said Dr. Carl Ludwig Theodor
Wuppermann, Chief Financial Officer and Spokesman of
the Board of Management at Wuppermann, at the signing
of the contract in Leverkusen, Germany. We have already
successfully developed and commissioned Wuppermanns
first hot-wide-strip pickling and hot-dip galvanizing line,
which is in Moerdijk, the Netherlands. We are delighted
with this continued cooperation and the opportunity to establish a plant of the highest technical level, added Michael Cottin, Executive Vice President of the Strip Processing Lines Division at SMSSiemag.
The new strip processing line will go into operation in
2016 and process some 500,000 tons of steel annually. The
strip widths will vary between 400 and 1,650 millimeters,
and the strip gages between 1.0 and 6.0 millimeters. Process speeds of up to 150 meters per minute can be reached
when galvanizing strips, with speeds of up to 220 meters
per minute possible at the entry and exit sections.
The fact that this line, which comprises numerous
high-performance plant components, is being supplied by
a single source, and that Wuppermann was able to pour its
long-standing technological know-how as an internationally experienced plant operator into project planning,
speaks volumes for SMS Siemag. The production plant will
be state of the art, both technologically and environ-
Signing the contract: Michael Cottin (Executive Vice President of the

Strip Processing Lines and Furnace Technology Division, SMS Siemag
AG) and Mario Dorfer (Board of Management, Wuppermann Hungary
Kft.) (seated, from left to right) together with Frank Reinschmidt (Management of the Commercial Sales Division, SMS Siemag AG), Markus
Jaenecke (Project Director in the Strip Processing Lines and Furnace
Technology Division, SMS Siemag AG), Dr. Carl Ludwig Theodor Wuppermann (Chief Financial Officer and Spokesman of the Board of Management, Wuppermann AG) and Omar Tissoudali (Assistant to the Board of
Management, Wuppermann AG) (standing, from left to right).
SERVICE
SMS Siemag as a full-range

supplier
esign and manufacture of the
D
production line
Erection
Commissioning support
-Pact electrical and automation
X
systems
85
Projects
the USA. The purchasers of the galvanized hot strip include companies active in the automotive and construction
industries, as well as in the fields of
metal-fitting technology, pipe production and component construction.
i
Wuppermann
The Wuppermann
ALL COMPONENTS FROM ONESOURCE
The line is equipped with numerous

high-performance plant components,
which win people over with their environmental compatibility, economic efficiency, operational reliability, flexibility and product quality, and that are
being delivered in full by the SMS
Wuppermann supplies wide and slit strip to customers all over the world. group. Among other things, an X-Pro
laser welding machine is being integrated, which automatically adapts the
mentally, explains Wuppermann. Thus, no interface welding parameters for new steel
problems arise and the plant can reach full capacity after a grades. The turbulence pickling techshort commissioning phase. We were also won over by nology is characterized by its efficient
their vast experience as an integrated supplier of pickling descaling and optimal acid utilization.
and hot-dip galvanizing lines, continued Wuppermann. In Use of the induction furnace from
addition to the design and manufacturing of the plant SMSElotherm is economical, even at
equipment, both installation and commissioning support partial loads. With its two zinc pots
from IAS, which are equipped with a
are included in SMS Siemags scope of supply.
Scaled hot strip will be pickled, heated to galvanizing special refractory lining for zinc-magtemperature, galvanized, skin-passed and post-treated in nesium coatings, the line offers a high
the new line, giving it long-life anti-corrosion protection degree of flexibility when it comes to
and with an appealing visual appearance as well as with coatings. The zinc layer thickness is
enhanced mechanical robustness. The so-called heat-to- precisely adjusted by a FOEN air-knife
coat process is characterized by its high profitability, as all system. The aerodynamically optiprocesses take place in a single facility. Wuppermann sup- mized nozzle-module design mini
plies hot-dip-galvanized wide and slit strip by ship, rail or mizes strip vibration while maintaintruck to customers all over Europe, and even as far as in ing high cooling capacity in the Drever
cooling section. An outstanding thickness reduction is achieved with the
four-high skin-pass mill. An electrostatic oiler from DUMA-BANDZINK
precisely coats the surface. EMG is
supplying the high-grade strip flow
control system.
www.sms-siemag.com/strip-process
ing-lines
86
Group is a small to
medium-sized fam
ily business, which
has been operating
successfully in the
steel processing
industry for over 140
years. Their product
portfolio includes
surface-finished
flat-rolled products,
piping, pipe components and sheet
parts made from
steel, stainless steel
and aluminum.
Projects Strip processing lines and furnance technology
ASC trimming shear units are easy to integrate and primarily enhance availability and product mix at low maintenance costs.
More quality, less cost

Special Processing Machines increase the efficiency of existing strip processing
lines with low amounts of time and cost to be spent for their integration.
An efficiency check identifies and evaluates possible revamping measures
according to the cost-benefit effect.
The demands on the economical and ecological efficiency of

strip processing lines have grown. At high productivity, these
lines must come with efficient processes and simultaneously cover a wide product range. Existing plants are in
competition with new ones. Standardized Special Processing Machines from SMSSiemag are designed to permit easy
installation into existing strip processing lines within a short
downtime. All machines are supplied in a ready-to-operate
condition and with integrated automation system. This immediately strengthens the competitiveness of existing lines.
To identify the machines to be replaced or newly installed, SMS Siemag offers an efficiency check to be made.
This special procedure evaluates the effect of new machines on production in relation to the expenditure. Thus,
possible measures can be quickly identified and evaluated
to the cost-benefit effect. Some examples of Special Processing Machines are trimming shears, dividing shears,
pre-levelers, welders, strip stabilizing systems or air
knives. Depending on the individual equipment, the main
effects of improvement are decreasing operating costs,
enhanced capacity, higher quality and a broader product
portfolio.
SEVERAL ORDERS
Last year, for instance, Panzhihua, China, ordered two side

trimmers, one thereof with a slitting unit. Baosteel ordered
two trimming shears to be installed in a new cold mill
complex in southern China. Another trimming shear will
be supplied to Wuppermann Staal in the Netherlands. The
machines come with a proven automation system with preset and preinstalled cutting parameters. The delivery period for all orders is short, generally less than one year.
The main advantage of our Special Processing Machines
is their high efficiency and easy integration of the standardized and tested machines. Hence, the customer will
immediately benefit from the measures taken, says
Markus Jaenecke, Project Director Sales Strip Processing
Lines at SMS Siemag.
Markus Jaenecke
markus.jaenecke@sms-siemag.com
87
Projects
Expansion of stainless
steel production capacity
65,000 tons of stainless steel per month
already a short time after production of
the first coil. The Chinese stainless steel
maker TISCO and SMS Siemag will
soon finalize the performance
tests at the new annealing
and pickling line.
The line will be the most productive

annealing and pickling line for hot
strip in the world and be capable of
producing one million tons of ferritic,
martensitic and austenitic stainless
steel strips per year. The line comes
with modern processing and environmental technology to meet all standards in respect of exhaust air and
waste water in a very efficient and
flexible production process. The high
degree of automation as well as the
low number of maintenance activities
will reduce operating costs.
HIGH PERFORMANCE, Low
CONSUMPTION
First, the strip is annealed in a horizontal furnace in the line. Then, part
88
of the scale is mechanically removed

by a scale breaker and six shot-blasting cabins. Furthermore, the surface
is cleaned by newly developed and efficient, oscillating abrasive brushes.
The pickling section stands out due to
its high performance and its extremely high flexibility as well as minimized
energy consumption and operating
costs. The section consists of two
tanks with sulfuric acid and five tanks
with mixed acid, while some tanks
may also be operated with water, if required. An integrated pickling and
dosing model ensures a consistent
pickling quality and minimizes media
consumption. A DeNOx system with
selective catalytic converters prevents
nitrogen oxide from escaping. Be-
TISCOs new annealing and pickling line.
tween the tanks, the surface is

cleaned by several combined rinsing
and brushing facilities.
stainless.strip.processing@
sms-siemag.com
FACTS + FIGURES
Annual production
1,000,000 t
Strip width
1,0401,650 mm
Strip thickness
2.06.0 mm
Entry speed
350 m/min.
Process speed
100 m/min.
Exit speed
300 m/min.
Steel grades
ISI 300 series (ausA

tenitic) and AISI 400
series (ferritic)
Projects Strip processing lines and furnace technology
TINPLATE PRODUCTION
AT SHAGANG
The annealing line and the electrolytic tinning line in the new cold rolling
mill of the Shagang Group in Zhangjiagang City are on stream.
On March 26, 2014, the first strips were

processed on the Shagang Groups new
tinplate annealing line. The electrolytic
tinning line, which serves to coat the
annealed and skin-passed strips with a
thin layer of tin, followed on April 21,
2014. Since that time, Shagangs new
cold rolling mill in the eastern Chinese
province of Jiangsu has been producing
tinplate as starting stock for packaging
material. The mechanical, processing
and furnace equipment as well as electrical and automation systems for both
lines were supplied by SMSSiemag.
Due to the use of soluble tin anodes,

which are produced in an anode caster
also included in the supply package,
the operating company benefits from
considerable economic advantages including reduced expenses for tin. A
special process component is the
preparation cell, which activates the
strip immediately before tinning and
removes iron hydroxide particles. Tinplating takes place in eight vertical
cells. The position of the vertically
movable reflow unit in relation to the
running strip is adjusted flexibly to
achieve the desired alloy layer.
HIGH-PERFORMANCE EQUIPMENT
The annealing line provides the strip

with the required material and surface
properties by annealing and subsequent reduction plus surface treatment. In a powerful Drever radiant tube
furnace, the strip is processed according to an exactly defined annealing
curve. Two four-high skin-pass mill
stands are integrated for post-treatment. The first skin-pass mill stand
serves to set the mechanical-technological strip properties by thickness
reduction, whereas the second one
creates a defined strip surface texture.
In the electrolytic tinning line the strip
is plated with a thin layer of tin whose
thickness can be precisely controlled
also in the case of very thin tin layers.
The first tin-plated strip produced at Shagang Group.
www.sms-siemag.com/stripprocessing-lines
FACTS + FIGURES
TINPLATE ANNEALING
LINE
ELECTROLYTIC
TINNING LINE
Annual capacity
418,100 t
202,500 t
Strip thickness
0.180.55 mm
0.120.55 mm
Strip width
7001,250 mm
7001,250 mm
Entry speed
1,000 m/min.
650 m/min.
Process speed
720 m/min.
520 m/min.
Exit speed
1,100 m/min.
650 m/min.
Steel grades
T2,5, T3, T4, T5 T2,5, T3, T4, T5; DR7M,

DR8, DR9, DR10
89
Projects
Steel beams and sections

for the Middle East
United Steel Company (SULB), based in Hidd in the Kingdom of Bahrain,
has successfully commissioned its minimill for beams and sections. The plant
was supplied by companies of the SMS group.
In Hidd, SULB operates an integrated

steel complex covering the complete
production chain from pelletizing down
to the finish-rolled product. The local
concentration of these facilities forms
the basis for highly efficient production
at low operating costs. In Bahrain,
SULB produces about 15 percent of all
steel beams and sections currently
imported into the Middle East region.
SMS had supplied the complete mechanical and electrical equipment for
this steel complex including the
workshops and laboratories. The
steelmaking plant was supplied by
SMS Concast, the complete section
mill including the walking-beam furnace by SMS Meer.
The plant was built on a turnkey basis in cooperation with South Korean
Samsung Engineering (SECL). SECL
was responsible for the foundations,
halls and buildings, ancillary facilities
as well as the assembling activities.
The foundations were laid on reclaimed land to the southeast of Muharraq Island. SMS supplied a total of
16,000 tons of machinery including
parts weighing as much as 300 tons
and screws of just a few grams. The
steelworks, supplied by SMS Concast,
is of the latest state of the art. It consists of an electric arc furnace with a
90
tapping weight of 120 tons and a 96

MVA transformer an 18 MVA ladle furnace, a four-strand continuous caster,
associated ancillary equipment, including a conveyor system and a dedusting plant to ensure compliance
with the demanding environmental
standards. The electric arc furnace is
charged with direct reduced iron (DRI)
produced in a newly built direct reduction plant. DRI is directly hot-charged
into the EAF via a material transport
system.
The continuous caster can produce
a wide range of formats from billets
to heavy beam blanks. The steelworks
annual capacity amounts to 800,000
tons, enough to also supply a SULB
medium-section mill in Saudi Arabia.
draulic roll screwdown. The CRS

straightener is designed as a 9-roller
machine with double-supported rollers and hydraulic roller adjustment.
Thanks to the hydraulic adjustment
systems, the products can be rolled
with tight tolerances. The entire plant
is so designed as to allow quick format
changes in no more than 20 minutes.
The rolling mill produces beams in the
size range from 100 x 100 millimeters
to 900 x 300 millimeters, channels,
angles and sheet piles.
This complex built by SULB is the
first fully integrated iron- and steelworks in the Gulf region producing the
complete range of light, medium and
heavy sections.
www.sms-group.com
Compact design
The section mill supplied by SMS Meer

has an annual capacity of 600,000 tons.
Designed for a wide range of product
dimensions, it comprises a walkingbeam furnace with a capacity of 180
tons per hour, a reversing breakdown
mill, a compact rolling group, a cooling
bed, a straightener and finishing facilities. The plant is of a compact design
in order to make best use of the available space. The compact rolling group
consists of three CCS stands with hy-
Projects
From above:
Look into the steelworks supplied by
SMS Concast.
The tandem group in
the rolling mill produces the full range
of sections.
180
tons is the hourly capacity of a walking-beam

furnace. SULB accounts for 15 percent of the
products in the Gulf market.
91
Projects
Two-strand caster
for SLR Metalliks
SLR Metalliks, based in Hospet, India, has placed an
order with SMS Concast for the supply of a two-strand billet
caster with a 9 meter radius.
The plant will be designed to cast structural steel, tool

steel, ball-bearing steel and micro-alloyed steel. The annual capacity of the caster will amount to approximately
300,000 tons. The employed CONVEX Technology mold
achieves higher productivity rates than conventional molds.
Provision will be made for the possibility of adding a third
strand in the future. The scope of supply also includes a
35 ton ladle furnace. The CONVEX Technology cartridge
molds supplied by SMS Concast guarantee high product
quality. Thanks to the use of cartridge molds, plant shutdown periods for maintenance work or section changes will
be reduced. As a result, productivity will increase. An electromechanical monitoring system developed by SMS Con-
cast will be used to ensure fast and

precise positioning of the stopper. The
employed electromagnetic mold stirring system (M-EMS) will refine the
internal microstructure of the cast
steel, leading to higher billet quality.
SMS Concast will also supply watercooled housings, which will extend the
service life of the equipment. The plant
is scheduled to be commissioned in
the third quarter of 2015.
www.sms-concast.com
A similar plant, with

a radius of 9 meters,
will be supplied to
SLR Metalliks, India.
92
Projects TUBE & PIPE PLANTS
Continuous round caster built by SMS

Concast.
Interior view of a spiral-welded pipe.
Straightening roller change for a CRS

straightener.
High product
cleanness
Superior pipe Turnkey

quality
order
SMS Concast to supply

caster.
Order for PWS from

Algeria.
Belval receives new

CRS straightener.
Vizag Steel Plant (VSP), based in Visakhapatnam, India, has placed an order with SMS Concast for a five-strand
round and bloom caster. VIZAG plans
to use the caster to produce highquality primary material for wheels
and axles in various steel grades. The
plant will have a capacity of one million tons per year. The state-of-theart continuous casting plant will operate with a 12 meter radius and feature
cartridge molds with CONVEX Technology. It will come with an electromagnetic stirring system for the production of blooms of high product
purity and with a flawless internal
quality. The blooms will be used as
starting material for end products to
be subjected to high loads and of very
large dimensions, such as axles and
steel wheels. The use of the cartridge
molds with CONVEX Technology will
provide higher productivity than is
achievable with conventional casters.
Altumet S.p.A. from Algiers, Algeria,

receives a pipe end finishing machine
from PWS. The plant will be integrated into the existing line at the Algiers
location and is to machine up to 20
pipe ends per hour in three-shift operation. The diameters of the machined pipes are between 8 and 42
inches with wall thicknesses from 5
to 20 millimeters and pipe length between 5 and 13 meters. Grades up to
X80 can be processed and the finished pipes correspond to the API 5L
certification. We expect the new
plant to achieve improved quality of
the machined pipes, says Farid Amrouche, CEO of Altumet in Algiers.
The fact that we are able to attain
considerably higher throughput requiring less maintenance makes us
take a very positive outlook for other
investment programs. Commissioning is scheduled for the third quarter
of 2015.
ArcelorMittal Belval, Luxembourg,

has awarded SMS Meer an order to
supply a CRS straightening machine
(Compact Roller Straightener) for
sheet pilings. The machine allows
straightening of the worlds largest
sheet piles at a width of 1,100 millimeters. SMS Meer delivers a turnkey
CRS straightening machine for
sheet pilings supported on both sides
with all the required changing de
vices. It is the first fully hydraulically
adjustable straightener exclusively
used for sheet piles and it is tailormade for straightening sheet piles of
U- and Z-shape. Thanks to the double-supported design, the straightener achieves better and more homogenous straightening results than
conventional machines with flying
support. All straightening rollers can
be changed at the same time, reducing the changing times and increasing plant availability.
www.sms-concast.com
www.sms-pws.com
www.sms-meer.com/long-productsplants
93
Projects
New concept convincing

For the production in its seamless tube mill in Rath, Germany,
Vallourec Deutschland receives sizing mill stands of
new design from SMS Meer. The stands have adjustable rolls for
improved tube quality and higher plant availability.
Vallourec Deutschland has commissioned SMS Meer to upgrade its sizing mill in Rath, Dsseldorf, Germany. SMS Meer will be supplying three
adjustable sizing mill stands in new
design for the plug mill at the Dsseldorf location. Owing to the novel
roll changing system, larger rolls can
be applied than in conventionally adjustable mill stands. As a result, the

stands can also be used in the upper
size range. Other advantages of the
adjustable stands improved tube
quality and increased plant availability
additionally remain unchanged.
The capacity of the modernized sizing
mill from Vallourec is approx. 350,000

tons per year. The adjustable stands
will be commissioned in the fourth
quarter of 2014.
www.sms-meer.com/tube-pipe-plants
Pre-testing of the
mill stands in the
Mnchengladbach
workshop.
20
percent larger outside diamenters can
be rolled with the adjustable stands of
new design.
94
Projects TUBE & PIPE PLANTS
SMS Meer supplied a tube welding machine to California Steel Industries. The line has now started operation.
Product range
extended
CSI Tubular Products, Inc. (CSITP)
from Fontana, USA, commissions
24-inch HF tube welding line from
SMSMeer.
The lines production speed is up to 35 m/min enabling TP,

a company holding a majority share in California Steel Industries, Inc., to produce up to 400,000 tons of tubes per
year. SMS Elotherm supplied the necessary HF induction
welding and seam-annealing technology and SMS Meer has
further developed the process and plant technology for the
company. Coil pay-off can now be performed from above
and below, meaning better strip alignment within the plants
forming process, depending on the direction of rolling of the
inserted strip.
Database-assisted plant setting
The inline and offline quick-change systems for the URD

stands are more productive than changing systems for con-
ventional stand designs. The quickchange system is supported by the CSS

Quicksetting system sustainably improving product quality with databasesupported plant configuration. The
stand drives can be controlled individually, distributing power in a highly effective manner. SMS Elotherms EloWeld
1800 tube welding plant is integrated
into the central section of the pipe mill
and ensures reliable welding of the
longitudinal seams. The downstream
EloSeam 3000 pipe seam annealing
plant allows for post-annealing, where
necessary, thanks to its ability to be traversed longitudinally. This is required,
for example, if a portion of the non-annealed pipe does not meet quality requirements after the plant is brought to
a standstill. Output is therefore higher
than with conventional, stationary seam
annealing plants.
95
Projects
Automatic Roll
Adjustment
For its new rail and section mill Panzhihua
Steel & Vanadium Co. Ltd. in Panzhihua, China, has awarded a contract
to SMS Meer for the supply of a three-stand CCS tandem group.
With this order, a successful cooperation between the two companies will be
continued. In 2005, a rail and section
mill from SMS Meer had already been
taken into operation successfully. The
effective operation of our rail and section mill purchased from SMS Meer
has impressed us so much that we
have again ordered the core components known to us for our new rolling
mill from SMS Meer, says Wang
Renfu, Assistant to the Factory Director of Panzhihua Steel & Vanadium Co.
The section mill is designed for an annual capacity of 700,000 tons of rails
(up to 100 m), beams, channels, angles
and special sections. The three-stand
CCS tandem group with hydraulic adjustment systems and automatic
quick-change system ensures minimum program changing times and
close rolling tolerances. The Technological Control System (TCS) developed
by SMS Meer provides for automatic
roll adjustment after roll change, measurement and compensation of mill
spring, roll gap control and is utilized

as active roll protection in the case of
rolling force overloads.
With the new section mill Panzhihua
is able to react flexibly to different
degrees of demand from its customers
for rails, beams and special sections,
and strengthen its position as a renowned rail manufacturer in China.
Commissioning is scheduled for spring
2015.
www.sms-meer.com/long-products-plants
Rails are in demand

in China. Panzhihua
therefore ordered,
among other things a
new rail and section
mill.
96
Projects
Photo midle: wrangel/iStock
Peeling machine from SMS Meer.
The machine upgraded by SMS Meer produces

bicolored coins.
Multi-zone induction furnace

(TEM-PRO Heater) with billet transport.
New peeling
machine
Coin production secured
Convincing
performance
Order from BGH Edelstahl, Siegen
Shutdown terminated
after only six weeks.
Heating plant for Ilsim

Almax.
BGH Edelstahl from Siegen, Germany, has ordered a rotary peeling machine of the PMH 600 type for machining forged bars. The scope of
supply comprises the rotary peeling
machine including finishing line, accessories, erection and commissioning. The plant will have to meet
high requirements on performance,
quality and flexibility, and also allow
for the production of round material
with flawless surfaces even with
close tolerances. The working range
of the finished diameter ranges from
160 to 600 millimeters, at a maximum bar length of up to 18 meters.
By using peeling tools such as tandem or trio systems, chip reductions
of up to 15 millimeters are possible.
The feed speed is up to 2 m/min, depending on the material quality. The
plant will come on stream in the
third quarter of 2015.
The State Bank of Colombia (Banco

de la Republica), headquartered in
Bogota (Colombia), has successfully
taken into operation a casting machine upgraded by SMS Meer. The
modernized machine produces bicolored coins. It dates back to 1982
and supplies two strip processing
lines for coin production. For the hydraulic system as well as for the
control system spare parts supply
was no longer secured. To realize the
modernization, SMS Meer applied a
control technology, type Siemens S7,
as well as an advances control system. In addition to that, the mechanical and the hydraulic systems were
replaced by new parts. The complete
mondernization took only six weeks.
Ilsim Almax from Hwasung-City,

South Korea, has ordered a TEMPRO Heater system from IAS enabling the company to heat aluminum extrusion billets for the
production of thin-walled aluminum
heat exchanger tubes. In contrast to
comparable plants, the TEM-PRO
Heater attains higher productivity
of up to 15percent. IAS, a subsidiary
company of SMS Meer, delivers a
TEM-PRO Heater, type NIB 800,
5/229 x 1300 AL/ITN. The temperature profile heating system allows
for precise temperature control and
a perfect manufacturing process
during isothermal extrusion. Thanks
to a precise process control and
high flexibility, the TEM-PRO Heater outclasses the gas furnace or
conventional induction furnaces. A
multilayer coil version and infinitely
variable output control ensure low
energy consumption.
www.sms-meer.com/service
www.ias-induction.com
97
PROJEcTs
From top to bottom:

LLC (loop laying
heads with cooling
conveyor) at ArcelorMittal in Ruhrort.
The steel location of
ArcelorMittal Ruhrort
at Duisburg viewed
from the air.
98
Projects Long Product plants
Steel location
Duisburg, Germany,
with new wire rod mill
Since the beginning of this year, ArcelorMittal has been operating
a wire rod mill in Duisburg-Ruhrort with state-of-the-art
technology. Almost coinciding with the closure of
the old plant in Duisburg-Hochfeld, the wire rod mill at
the Ruhrort location is ready to take up production.
Duisburg as steel location has a more than 150-year tradition. The very first blast furnaces along the Rhine were located in Duisburg-Hochfeld. Here, wire rod was rolled in
1913 for the first time. In 2010, ArcelorMittal and SMS Meer
signed a contract for the supply of a wire rod mill at the new
Duisburg-Ruhrort location. At that time, the plant in Hochfeld was 40 years old and could no longer satisfy the demands of continuing to offer a competetive production service. Ruhrort became attractive as new location; a steel
plant from ArcelorMittal with direct accessibility to billet
production was already in operation.
450,000
tons of high-grade steels can be rolled to
wire rod in the dimensional range from 5.5
up to 25 mm by ArcelorMittal every year on
the Duisburg-Ruhrort plant in a temperature-controlled manner. The maximal rolling
speed is 120 m/s, corresponding to 432 km/h.
NEW CONFIGURATION
In the boom phase up to 570 staff members were working on

the construction site. It was a challenge for the team to
retrofit the closed-down building complex of an earlier
blooming and continuous mill for the new wire rod mill, says
Stefan Etges, Project Manager at ArcelorMittal. Following a
two-year construction period and an intensive alignment and
initial period of about one year, the plant has been operating
at almost full capacity since the beginning of 2014.
The supplied wire rod mill of the MEERdrive type provides a configuration used in Europe for the first time: the
finishing block is divided into two parts, a 6- and 4-stand finishing block allowing exact process control and best thermomechanical characteristics of the end product. The surfaces
of the rolled wire rod are of high quality and always keep the
dimensions given. The product range

of the plant extends from spring steels
in Superclean quality, case-hardening
steels, cold-heading grades, free-cutting steels as well as tool and anti-friction bearing steels up to carbon and
alloyed steels, welding wire and pure
iron steel. The products from altogether 200 steel grades are applied in the
automotive industry as valve springs
and screws of the highest quality.
99
Projects
The Kingdom
Tower in Saudi
Arabia will be the
highest building in
the world. (photo:
Jeddah Economic
Company/Adrian
Smith + Gordon
Gill Architecture)
100
Projects Long product plants
Steel at an altitude of
1,007 meters
South Steel is producing steel on SMS Meer plants for the highest
building in the world: The Kingdom Tower in Saudi Arabia. The minimill went
on stream in 2013. The skyscraper is scheduled to be completed in 2018.
It will be a truly exceptional building:

never before in history has a building
surpassed the magic altitude of 1,000
meters. With exactly 1,007 meters the
Kingdom Tower in Jeddah, Saudi Arabia, will reach up to the sky. For the
foundation and the construction of the
tower, SOLB Steel from Jizan, Saudi
Arabia, will supply steel from a mini
mill of the SMS group.
Photo: Jeddah Economic Company/Adrian Smith + Gordon Gill Architecture
MAJOR PROJECT KINGDOM CITY
The Burj Khalifa, with an altitude of

828 meters the highest building worldwide since 2010, is located in Dubai
and will be outreached by another 179
meters already in 2018 by the Kingdom Tower in Jeddah, Saudi Arabia,
with an altitude of 1,007 meters, the
construction of which is already underway. The project developer and future owner is the Jeddah Economic
Company and the responsible building
company is the Saudi Bin Laden Group.
The design for the skyscraper comes
from the architect offices Adrian Smith
and Gordon Gill (AS+GG) from Chicago,
U.S.A. who were also responsible for
the Burj Khalifa. The building costs of
this mammoth project are approx. 1.2
billion US dollars.
The slim, streamlined shape of the
building is a symbol in the emerging
Red Sea Region. On its 530,000 square

meters, the Kingdom Tower provides
space for offices, apartments and a
luxury hotel. A round observation deck
with a diameter of 30 meters located
on the 157th floor, at 502 meters high,
is the highest in the world offering a
breathtaking view over Jeddah. The
skyscraper is also the heart of the
planned Kingdom City. The construction project next to the Red Sea totaling approx. 20 billion US dollars, which
accommodates houses, hotels and offices on an area of 5.2 square kilometers aims to up the value of the region
from an economic perspective and to
attract financially strong high-tech enterprises. The statics of such building
heights are faced by exceptional technical challenges. Wind and even small
earth tremors tremendously pull at
the construction. In wind tunnel tests
80,000
tons of rebars alone for the foundations have been supplied by SOLB.
the architects Adrian Smith and Gordon Gill developed a shape offering a
point of attack as small as possible to
the airstream. The footprint of the
building is constructed as a Y-Shape
with flanks spreading at 120 degrees.
Apart from good wind compatibility
this shape allows large window areas.
An important aspect for future users is
that anyone residing in the highest
building in the world wants to have at
least one window in their room and enjoy the view.
GERMAN KNOW-HOW
Whether it is the civil engineering

company Bauer for the foundations,
the concrete pump specialist Putzmeister or the elevator expert Krone
without the know-how of German
companies the Kingdom Tower could
not be realized. For example, Krone
delivers 57 elevators, of which seven
are of the two-storied type, and eight
escalators. With the development of
lightweight carbon fiber strands, being
lighter by around 80 percent compared
to a conventional steel cable, Krone
was able to more than double the maximum travel height of the super skyscraper elevators from 500 to approx.
1,000 meters. Until now, this would
have failed due to the dead weight
101
Projects
A special footprint
allows for an aerodynamically favorable overall
construction of the building against wind forces.
furnace for secondary metallurgy as

well as a five-strand continuous caster. The production capacity of the plant
is approx. one million tons of square
billets per year in the 130 millimeter
or, respectively, 150 millimeter format.
Half of the billets are sold on the regional market and the other half,
which is still in a warm condition, is
further processed in the rebar rolling
FACTS + Figures
SELECTION OF HIGHEST BUILDINGS THROUGHOUT HISTORY

BUILDING
COMPLETED
ALTITUDE COUNTRY
Pyramid of Cheops
2,500 BC
146.59 m
Egypt
Cologne Cathedral
1,880 AD
157.38 m
Germany
Empire State Building
1931
381 m
U.S.A.
Taipei 101
2004
508 m
Taiwan
One World Trade Center
2014
541 m
USA
Burj Khalifa
2010
828 m
United Arab Emirates
Sky City
Planned for 2014
838 m
China
Kingdom Tower
Planned for 2018
1,007 m
Saudi Arabia
102
mill of the plant. Besides structural

steel SOLB supplied roughly 80,000
tons of rebars alone for the foundations. SOLB enjoys a long working relationship with the Saudi Bin Laden
Group and has already delivered steel
for expansions of the mosques in Mecca and Medina.
www.sms-meer.com
Photo top: Jeddah Economic Company/Adrian Smith + Gordon Gill Architecture
of the steel cables. The elevators in

the Kingdom Tower travel at a speed of
ten meters per second.
The steel for the heavy-loaded foundations and the structure of the building is produced by South Steel (SOLB)
from Jizan on a modern minimill of the
SMS group. The minimill was taken
into operation in July 2013 and it comprises an electric arc furnace, a ladle
Projects Long product plants
Expansion at Tung Ho
in Taiwan
Tung Ho Steel Enterprise Corporation from Taipei
(Taiwan) has ordered a second rolling mill and
another induction heating system from the
SMSgroup for its CMTTM minimill at Taoyuan site.
The rolling mill No. 2 to be supplied by

SMS Meer can handle billets with dimensions up to 160 mm x 16 meter
length, coming from the upstream
continuous caster supplied by SMS
Concast. The Multi-Zone Induction
Heating Technology (MZT) will come
from SMS Elotherm.
The new mill will be equipped with
14 rolling stands, an eight-stand finishing block, a high-speed delivery
system (HSD), a cooling bed fitted

with lifting aprons, a cold shear with
850 ton shear force and two finishing
sections of 18 and 24 meters, each
with four wire rod tying machines.
Rebars with diameters from 8 to 57
mm can be produced on the mill. The
production of a special screw shape
with a diameter of 19 mm will now also be possible for the first time.
Due to its special design and flexible
technical features the multi-zone

heating will be able to roll billets in
hot, warm or cold charging mode. It
allows for a uniform temperature of
the billets lengthwise, which are
therefore able to flow directly into the
rebar mill. A holding chamber is installed upstream of the multi-zone
heating system in order to increase
the flexibility if the billets cannot be
rolled immediately. The chamber can
store the billets in a warm condition
for the following warm charging mode.
It functions with the first-in/first-out
principle so that temperature losses
are minimized to the greatest-possible extent.
ECOPLANTS
The second rolling mill and the second induction heating system will render it possible to roll 100 percent of
the billets produced by the upstream
continuous caster at very low operating costs.
The second mill is nearly identical to
the first a reference for SMSgroups
ecoplants. This benefits Tung Ho in that
the operating personnel can be quickly
familiarized with the mill operation.
www.sms-group.com
Cooling bed with HSD System.
103
Projects
First HybrEx press

for Turkey
SMS Meer has been commissioned by
Astas Alminyum San. Ve Tic. A.S. (Astas) from Istanbul,
Turkey, to supply a 14 MN HybrEx extrusion press.
It is the first machine of this type for the Turkish aluminum

market. Compared to a conventional extrusion press, the
new technology reduces energy consumption by up to 55
percent and increases productivity by up to 20 percent. On
the new machine, Astas will be able to produce 5,000 to
10,000 tons of profiles for automobiles, solar modules and
the construction industry, depending on the respective
product. The HybrEx operates with only very short non-productive times. A reduction of downtime by only one second
means that production is increasing by up to 100 tons of
profiles per year. Shorter non-productive times result from
the idea to replace conventional hydraulic drives by fast
electrical servo drives as regards the movements where
speed is the primary issue. The electric servomotors are
more energy-efficient and can be positioned more quickly
and precisely. In addition to that, they

can be put into service with less effort.
We are proud to accomplish a high
quality standard with this new technology, says Trker Kkhan, owner and
Chief Executive Officer of Astas. We
are additionally pleased that even lower maintenance costs are arising for
us. The new machine will go on
stream in September 2015.
www.sms-meer.com/extrusion-presses
SMS Meer supplies a

14 MN HybrEx extrusion press to Turkey.
104
ProjECTS Forging PLants
Extrusion presses from SMS Meer impress

with efficient drives.
Extruded sections manufactured on the plants

of SMS Meer.
The new front-loading extrusion press manufactured by SMEC in Shanghai.
20 percent
Top quality
energy saving worldwide
Less wear
Order for extrusion

presses from Saudi Arabia
Extrusion presses from

Indian workshop.
Asen Metal orders frontloading press.
Altaiseer from Riyadh, Saudi Arabia,

has placed an order with SMS Meer
for two 25/27 MN extrusion presses
for the Riyadh site. Altaiseer will use
the presses to manufacture highquality aluminum sections for facades. Through the use of energy-efficient drives and ancillary equipment,
the extrusion presses enable energy
savings of 20 percent to be achieved
compared with conventional presses.
They therefore satisfy the preconditions for the distinctive ecoplants
mark. The extrusion presses will operate as front-loaders allowing high
productivity and quality to be achieved.
In addition, the plants will be equipped
with induction furnaces supplied by
IAS from the SMS Meer Business
Area. The induction furnaces heat the
8-inch billets before extrusion following a given temperature profile, the
so-called taper. The capacity of the
plant lies between 12,000 and 14,000
tons per year.
SMS Meer India has produced the

first 18 MN extrusion press in its
Thane plant in Mumbai. Know-how
and engineering have been delivered
by the head office in Mnchengladbach, the components came from local suppliers. They are certified and
selected in accordance with the same
quality management system prac
tices as in Germany to meet the high
quality demands of SMS Meer. The
Indian customer was so impressed
with the first plant that he decided to
order a second extrusion press immediately after signing the contract,
says Jens Magenheimer, Sales Representative, Hydraulic Presses. SMS
Meer sees future potential for lightmetal extrusion presses in the Indian
Market. The planned expansion of the
local transportation infrastructure
implementing an eco-friendly railway
system will increase the demand on
passenger cars with light aluminum
components.
Asen Metal Endstri rnleri Sanayi

Ticaret Ltd. S ti., Turkey, has placed
an order with SMS Meer for the supply of an 18 MN short-stroke frontloading extrusion press. It is the first
machine of its kind, which will be
built by SMS Meer Engineering China
(SMEC). Modern equipment available
at the enlarged Shanghai production
facility makes it possible to build and
maintain machines and plants. On
the new machine Asen Metal is able
to produce up to 8,000 tons of structural aluminum sections per year.
Owing to an improved hydraulic system the press is operating more energy-efficiently compared to other
technologies and stands out compared to its predecessor model due
to lower maintenance expenses. The
new linear guides for the container
and the stem cross-beam perform,
for example, with significantly less
mechanical wear.
105
Projects
EXTRUSION PRESSES
MADE BY SMS
A success story: With its extrusion presses of the Schloemann product series, SMS Meer is the only company worldwide providing
all extrusion processes for all materials and alloys. In the course of
this, the plants are constantly further developed.
Nowadays, extrusion presses allow the production of sophisticated high-tech products from complex profile
structures made of aluminum in the lightweight construction of transport, up to the high-pressure seamless tube
made of stainless steel for energy production. In the case of
extrusion presses, SMS Meer looks back on more than 100
years of experience. In 1908, Eduard Schloemann in Dsseldorf begins with the development and manufacture of
quick-acting press controls. And soon after that, the construction of complete hydraulic extrusion plants was
launched. Up to 1918, about 100 of these plants were supplied to SMS customers mainly for the production of wire
rod, profiles and rods made from copper.
From the 1940s, aluminum as a material is increasingly
used in the automotive and aircraft industry and processed
into lightweight and high-strength profiles. During this
time, Schloemann builds the first rod and tube extrusion
presses with a press force of more than 100 MN. In the
1970s, the first press frame from Schloemann in lamellar
design is introduced. The prestressed lamellae are still the
unique selling proposition featuring practically unrestricted
service life compared to the classical tension rod.
Impressive FRONT-LOADER TECHNOLOGY
With the merger of Schloemann and Siemag to form the

Schloemann-Siemag AG (SMS), the Schloemann extrusion
presses were integrated into the portfolio of SMS in 1973. In
1998, SMS designs and manufactures the first machines
featuring the front-loader technology. The shorter frontloader design increases the stiffness of the press particularly relevant in the case of large plants with respective billet
106
1,000
extrusion presses have been built by SMS so far.
lengths. Short strokes allow dynamic

motion sequences with short non-productive times increasing productivity
and achieving excellent profile quality.
SMS consequently relies on this concept and it became the industrial standard for light-metal presses. Light
metal applied in aircrafts and automobiles often requires aluminum alloys
with high strength values. These materials, which are difficult to shape, have
to be partly extruded in the indirect process. After Schloemann had already
delivered the first presses using this
extrusion method in the 1970s, the
company quickly became the leader in
this niche market with a newly developed indirect press type. Owing to the
almost frictionless indirect process, billet lengths can be enlarged thus significantly increasing productivity.
Projects forging plants
150 MN frontloader rod and tube

extrusion presses,
Yankuang Light
Alloy, Shandong,
China.
POWERFUL EXTRUSION PRESSES
Apart from aluminum presses,

SMS Meer also builds heavy-metal
extrusion presses. These plants extrude copper and brass, but also zirconium, sliver and gold alloys, as well
as high-strength light-metal titanium.
SMS technicians continuously optimize these plants making them more
productive and energy-efficient. The
outset of the new millennium gave
rise to an increased demand worldwide for seamless tubes made from
special steel, which are for example
applied in the highly corrosive offshore sector. The corrosion-resistant
steel grades Duplex and Super-Duplex required for this purpose can only
be formed to seamless tubes in the
extrusion process. The same applies
to high-temperature-resistant steel
tubes made from nickel-based alloys
for working temperatures of more
than 550C.
Since the turn of the millennium
particularly the expansion of the highspeed railway network leads to a renaissance of very powerful presses.
SMS is able to also satisfy this demand
for energy-efficient presses with a
pressing force of up to 160 MN.
With the HybrEx presented in 2014

SMS now revolutionizes the extrusion
press technology: a hybrid drive concept combines the power of hydraulics with the dynamics of electrical
servo drives with the result of less energy consumption and higher productivity. HybrEx will continue the success story of Schloemann extrusion
presses.
i
SMS Meer
In the period from
1926, to date approx.
1,000 Schloemann
extrusion presses
haven been built. On
www.sms-meer.com
top of that there are

numerous machines
from SMS Sutton,
SMS Innse and
Mannesmann Meer
(Hydraulic Presses,
Duisburg and Sack),
merged into the
present-day SMS
group.
107
Projects
Comparable press type MP 4000 S in

operation.
Representatives from HELVEX and SMS Meer

shaking hands after awarding the contract.
High-quality copper wire rod produced on

plants from SMS Meer.
Top-quality
forgings
Order from
Mexico
Tons of copper wire rod
Installations producing
for automotive industry.
Casting plant and extrusion press for HELVEX
Ningbo Shimao Copper

puts plant into operation.
Bharat Forge Aluminiumtechnik

from Brand-Erbisdorf, Germany, has
put into operation a forging roll
ARWS 2 and a closed-die forging
press type MP 4000 S from SMS
Meer. With the two installations the
company ehas expanded its product
portfolio and is able to supply highquality forgings for the automotive
industry.The automatic forging roll
forms aluminum parts for further
processing in the forging line. In this
way, masses are distributed better
for the subsequent closed-die forging process. For stabilizing the process heat the forging roll is equipped
with four heatable rolling segments.
After preforming, the eccentric
press forges highly stressable chassis components made from aluminum. The closed-die forging plant of
the MP4000 S type reaches a pressing force of 40 MN and a ram stroke
of 450 millimeters.
HELVEX, a leading Mexican manufacturer of sanitary accessories, has

ordered a horizontal casting machine for brass billets and an extrusion press from SMS Meer. The two
machines complement the plant in
Apaseo El Grande, Mexico. The new
horizontal casting machine produces
extrusion brass billets from which
profiles are then extruded. The casting plant achieves an annual capacity of up to 20,000 tons with a diameter from 150 to 250 millimeters.
The new extrusion press processes
cast brass billets into profiles and
hollow bars. With a pressing force of
12.5 MN billets up to a diameter of
170 millimeters and a length of
600 millimeters can be extruded.
Commissioning of the two machines
will take place in mid-2015.
For the production of copper wire rod

Ningbo Shimao Copper from Yuyao
City, Zhejiang Province, China, has
commissioned a CONTIROD plant
from SMS Meer. The line allows for an
annual production capacity of up to
225,000 tons of high-quality copper
wire rod from cathodes, the output
per hour being around 35 tons. The
plant also includes a Hazelett twinbelt caster in modular design with a
casting cross-section of 90 x 70 millimeters. The casting machine operates together with a flexible twelvestand SMS rolling mill. The shaft
furnace for melting the copper cathodes is equipped with an automatic
gas control system. With the newly
designed Lambda gas control system
and the variable-frequency drives for
blower and stands, the plant is one of
the most economic and eco-friendly
facilities of its kind. It therefore meets
the criteria of ecoplants the quality
seal of the SMS group.
www.sms-meer.com/nf-metals-plants
www.sms-meer.com/nf-metals-plants
www.sms-meer.com/forging-plants
108
Projects NF MEtalS
Three orders for

Hertwich
Hulamin, South Africa, and AMAG, Austria, have each placed an order with
Hertwich Engineering for an aluminum melting furnace of the PS-250 type and
a homogenizing and sawing plant is being supplied to Hindalco in India.
The Ecomelt melting furnace and the casting furnace for

AMAG will be installed in the Ranshofen plant. The Ecomelt
PS-250 is the largest aluminum melting furnace with preheat shaft ever built by Hertwich. The annual capacity of the
plant is about 76,000 tons. Because of their proven technology, the Ecomelt furnaces from Hertwich achieve particularly low energy consumption and low metal loss. The
specific energy consumption of the PS-250 is roughly
550 kWh/t, the melting capacity being up to 230 tons per day.
The casting furnace has a maximum capacity of 120 tons.
With its preheat shaft the plant is also suited to melting
scrap with organic adherences using energy from these adherences for preheating solid metal and for heating. The annual capacity of the furnace at Hulamin is approx. 80,000
tons. As a result, Hulamin expands its capacities and enhances competitiveness. Each day, the Ecomelt PS-250 is
able to melt down 250 tons of aluminum scrap. The furnace
is also operates highly energy-efficiently. In addition, it produces low emissions and very low metal loss. Commissioning of the furnaces will take place in 2015.
The multi-chamber melting furnace Ecomelt

PS from Hertwich Engineering.
delivered and subsequently mounted.

Production startup is scheduled for
spring 2015.
Order from Hindalco
Hindalco Industries, India, has commissioned Hertwich Engineering with the supply of a continuous homogenizing
plant and a sawing facility for billets. Owing to the continuous homogenizing plant, the progression of the temperature can be uniformly controlled for all billets and Hindalco
achieves the best-possible metallurgical microstructural
properties. The continuous homogenizing furnace is part of
a production expansion of Hindalco at its Mahan location.
The continuous homogenizing line reaches an annual aluminum capacity of 64,000 tons. The billet diameters are between 178 and 229 millimeters. In July 2014, the plant was
www.hertwich.com
80,000
tons is the annual furnace capacity at Hulamin.
109
Service Innovations Ecoplants
FUTURE-ORIENTED
SOLUTIONS
The SMS group offers its customers cutting-edge solutions irrespective
of whether the development of a new plant or the right concept
for repair is concerned. Research projects in cooperation with the
customers promote innovations and create added value.
110
Overview
Experience counts
112
Planning maintenance strategies with SMS Siemag.
The perfect cut
116
Reliable shear repair.
Industry 4.0 for steelworks
126
Pilot project achieves costs savings in the BOF process.
Heavy-plate heat treatment
130
New concepts increase flexibility and precision.
Now also for tubes and pipes
134
The SMX 800 from SMS Meer can now also
weld large-diameter, thick-walled tubes and pipes.
Service
Qualified experts
from SMS Siemag
support the customers in their maintenance work.
In ongoing production it is important
that defective parts
are replaced quickly.
112
Service MAINTENANCE STRATEGY
EXPERIENCE COUNTS
Lower prices, higher quality. The competitive pressure
keeps on growing and calls for efficient maintenance concepts.
SMS Siemag is an experienced partner.
Successful maintenance is based on

two factors: An intelligent maintenance strategy and a reasonable mix
of in-house and outsourced services
depending on the general conditions
in each individual case.
THREE MAINTENANCE STRATEGIES
As a rule, distinction is made between

three maintenance strategies: Due to
failure, preventive and conditionoriented. The due-to-failure strategy
remedies the causes as they arise and
accepts a possible shutdown of the
plant. In the case of preventive maintenance, inspections are made at regular intervals to be able to recognize
and remedy defects at an early stage.
To catch the right moment for replacement of particularly critical components, condition-oriented maintenance is needed. For this purpose,
sensors measure the symptomatic
characteristics. If the system exceeds
a preset limit value, an alarm will be
released.
Condition-oriented maintenance is
very useful, a fact that ArcelorMittal
Tubaro came to learn after failure of
the mill pinion gear unit in its hot rolling mill (established in 2002). The
company then retrofitted critical components with condition-monitoring
systems. The failure of our first mill
stand which lasted for two and a half
months was a shock that shook us up.
Since that time, we have been using
sensors to monitor gear unit vibrations and bearing temperatures, explains Evandro de Figueiredo Neto,
Maintenance Manager AM Tubaro.
SMS Siemag supported us right from
the beginning with its experts, spare
parts and a monitoring test unit.
olakoglu Metalurji, Turkey, preferred the condition-oriented maintenance version already in the planning
phase of its hot rolling mill in 2008.
Recently, increased values at the spur
gear unit of the first mill stand required an inspection during the next
downtime, which confirmed the assumption of significant wear in the
gearing. While SMS Siemag cared for
fast procurement of a spare gear
wheel, the plant continued to produce

under controlled load. The advantages
are obvious according to Bilal Akgl,
Hot Strip Mill Mechanical Maintenance
Chief Engineer at olakoglu Metalurji: Offline measuring and evaluating
of such values is almost impossible.
Therefore, an online monitoring system is inevitable. Even more important, however, is a company like SMS
to implement such system because
it has excellent knowledge of the
process.
Jointly with SMS, the company is
extending its monitoring system to
include descaling pumps as well as
edger, coil box, and coiler gear units.
The measured values help us
FACTS + FIGURES
ESSENTIAL FEATURES OF PLANT MONITORING

ArcelorMittal TubarO,

Brazil

Hot rolling mill
lu
olakoG
Metalurji, Turkey
Hot rolling mill
Commissioning
2002
2010
Annual production
3.8 million t (goal 4 million t)
3 million t
Dimensions /
equipment

7001,880 mm
8001,650 mm
Test system for vibration
Torque measurement at
monitoring in the finishing mill roughing stand and F1/,
vibration and temperature
monitoring of all finishing
mill gear units
113
Service
The drives in the

finishing mill are
permanently exposed to high loads.
adapt the alarm limit values to our

rolling processes, supplements Akgl.
Reliable experts are needed to assess the existing system conditions
and minimize failures. Same applies to
the decision in favor of in-house or
outsourced service. Maintenance by
own staff offers the advantage of growing know-how within the company. In
this case, however, full responsibility
is with the operator. SMS relieves the
plant users from their workload. As a
service partner, the SMS group is to
plan, procure and supervise budgets,
tools and machines. It is responsible
for employment of the staff and its

training according to the latest state of
the art. The plant user thus gains a
high degree of planning security both
from the technological and the commercial point of view.
The Russian company MMK has
trusted on SMS Siemag as maintenance service provider since 2009 already. More than 90 service employees are coordinating, planning and
managing, within the frame of online
maintenance, all maintenance and repair tasks concerned with continuous
caster No. 6. In addition, these experts
from SMS take care for productionrelated reconditioning of molds and
segments in a specific workshop located close to the plant (offline maintenance).
MUCH EXPERIENCE AND KNOW-HOW
The condition of individual components is

inspected on the test station.
114
While SMS is performing the maintenance work, MMK may completely

concentrate on its core competence,
i.e. the production. The plant has
been operating without any failure
whatsoever over a period of two years
and four months which is unprecedented with a view to the worldwide
operating conditions. The output of
marketable slabs amounts to 99.78
percent, says Andrey Kulzhov, Chief
Metallurgists Service, OJSC MMK.
None of our contract partners has
the experience SMS is employing

here.
In September 2014, another Russian customer and SMS Siemag
signed a comprehensive maintenance
contract covering online/offline maintenance of an RH plant and two ladle
furnaces as well as offline maintenance of the molds and segments of
nine continuous casters.
Christoph Husler
christoph.haeusler@sms-siemag.com
SERVICE
Maintenance objectives
Prevent system failure
Maximum usage of plant life cycle
Improve operational safety
Enhance plant availability
Optimize operational processes
Reduce malfunctioning
Prospective cost planning
Service MAINTENANCE STRATEGY
Training dates
Well prepared for the daily routine

The practice-oriented training courses of the TECademy
help companies in the field of metallurgical and rolling mill
technology operate more effectively and cost efficiently. In
the seminar and training academy of the SMS group, experts
communicate process know-how and information on plant
components. In addition to basics and theoretical skills, the
participants may deepen their newly

acquired knowledge by process modeling and practical application to be able,
for instance, to manage the systems
and equipment in their plants without
any restriction in case of emergencies.
TRAINING DATES 2015
TECHNOLOGY
Jan 20-21
Paul Wurth - Basic Seminar on Crude Steel Production | Seminar No. 1001
Jan 22-23
Basic Seminar on Steelmaking | Seminar No. 1011
Jan 26 Basic Seminar on Secondary/Tertiary Metallurgy | Seminar No. 1019

Jan 29-31
Basics Trends in Materials Technology | Seminar No. 1061
Feb 03-05
Expert Training for Aluminum Hot Strip | Seminar No. 1033
Feb 24
The Digital Workshop Cold Rolling, Strip Processing Lines | Seminar No. 1131
Feb 25 The Digital Workshop Hot and Cold Rolling of Aluminum | Seminar No. 1141
Feb 24-25
Expert Training for Hot Strip and Heavy Plate | Seminar No. 1031
Feb 24-26
Expert Training for Aluminum Cold Strip | Seminar No. 1043
MAINTENANCE AND SERVICING
Feb 06-07,
March 13
Basic Course on the Roll Shop | Seminar No. 2521
March 02-06 Media Systems SMS Siemag Hydraulic Systems | Seminar No. 2041
March.0325 Basic Course on The Roll as a Tool | Seminar No. 2511
Oct 15-17
MORGOIL Roll-Neck Bearings Basics of Oil Film Bearings | Seminar No. 2051
The 2015 program

is available at:
http://tecademy.
sms-siemag.com
PLANT TECHNOLOGY
Jan 27-28
Energy Efficiency in Metallurgical Technology | Seminar No. 3111
March 26 Basics of Flatness Measuring in Flat Rolling Mill | Seminar No. 3041
115
Service
THE PERFECT CUT

Whether cropping, trimming or dividing what truly matters
is the precise cut. In all process stages of steelmaking, flawlessly operating
shears ensure a smooth workflow and a perfect final product.
With a powerful strike, the 20-yearold drum shear in Chtelet, France,

separates the irregular head from the
50 millimeter strong transfer bars.
The material runs to the first roll gap,
through the rolling mill without any
trouble and finishes as reeled strip on
the coiler. In the long run, the forces
generated by cutting do not leave the
shear unaffected, even if it is very robust. High loads and wear are part of
the daily routine. As a systems supplier, SMSSiemag is aware of the demands on a perfect cut and knows
how to revamp and modify old shears.
Being a manufacturer of shears,
every shear is close to our heart. In
fact, it tells us the story of its life
and we are listening carefully. We
arrange for suitable measures to
meet our customers priorities, explains Rolf Franz, General Manager
Special Machinery/Documentation at
SMS Siemag. Clean processes and
high final product quality are in the
fore here.
In
the
service
workshop,
SMSSiemag checks all the important
functional dimensions of the shear
unit. Together with gear specialists
and bearing manufacturers, the
maintenance experts inspect the condition of the components for being reused. They trace the irregularities observed. Material abrasion in the area
of the knife holder and clamping device, for instance, may require restor116
ing work from the procurement of

new parts up to design adjustments.
In order to consider and implement
improvements during the repair, the
design experts analyze the causes for
the existence of wear, potential malfunction and damage.
scheduled shutdown, the experts of

SMS Siemag assisted the customer in
the installation of the parts and put the
shear on stream again.
Frank Benfer
frank.benfer@sms-siemag.com
HIGH ECONOMIC EFFICIENCY
Tolerance limits and the preservation

of big core components play an important role in the valuation of the individual parts. The team of experts determines the parts to be exchanged,
machined or modified by measures
like a wear-resistant coating. In the
repair workshop, the experts explained
their detailed damage report directly
at the drum shear. The economic aspects of the necessary repairs gave us
a safe feeling, which made it easy to
determine the repair scope for our
drum shear, confirms Barthelemy
Lemaire, Mechanical Improvements
Engineer, Aperam Chtelet. Short distances, structured processes as well
as blanks and finished parts from
stock ensure smooth working and
hence a reliable and fast repair.
Outside its service workshop, too,
SMS Siemag renders consultancy and
support directly at the equipment. After fact finding, the systems provider
supplied to ArcelorMittal Saldanha
Works, in South Africa, new knife holders, a drive shaft and further key spare
parts for a pendulum shear. During a
ADVANTAGES
Shear repair
Individual condition assessment of
the parts installed
Checking irregularities
Analysis of functional errors
Implementation of all required
design adaptations
High economic efficiency
Service repair of shears
i
SMS Siemag
For the repair of shears,
SMSSiemag offers
its customers
economic, fast and
reliable reconditioning from the fault
analysis to design
adaptations through
to a complete shear
revamp.
From top to bottom:

Drum shears are
just one of numerous shear types repaired in the service
workshops.
Sandra Seibel working in the manufacturing SMS-workshop in Hilchenbach,
Germany, is one of
many employees engaged in the repair
of shears.
117
Service
The aluminum strip producer Hulamin relies

on technical consultancy by the SMS group.
Paul Wurth performs the maintenance of the

blast furnaces at ThyssenKrupp CSA.
SMS Meer upgraded a pair of robotic arms,

which are part of an induction heater at ThyssenKrupp Crankshaft, USA.
Videoconferencing
Service during Robot

shutdowns
upgrade
SMS Siemag supports

Hulamin.
Paul Wurth receives

maintenance contract.
SMS Meer updated

robotic arms.
Hulamin, a leading Southern African

fabricator of semifinished and aluminum products is the first customer to
sign up for technological consultancy
through videoconferencing. This system allows for detection of functional
errors or product quality deteriorations even when production is interrupted. The result is that Hulamin
engineers will be given personal
direct notification and assistance by
SMS Siemag. The videoconferencing
provides the platform for discussing
sudden problems in a dialog with experts at short notice. Further advantages offered to Hulamin are training
via video. The customer and equipment supplier can exchange relevant
information in a direct conversation.
Potential causes of failure or nonconformance can be identified and
delved into in more detail, thus saving
the customer valuable time and
avoiding unnecessary downtime.
In 2013, Paul Wurth performed a

complete servicing package for
ThyssenKrupp CSA, in Brazil, encompassing the preventive maintenance for blast furnaces No. 1 and 2.
After this first service order, the
Paul Wurth service experts have
now been contracted to also perform the maintenance activities during the coming four yearly shutdowns. Since the start-up of the
blast furnaces built by Paul Wurth in
2010, Paul Wurth service specialists
have regularly been present on-site
in order to support the customer.
The servicing activities led by Paul
Wurth do Brasil at the blast furnaces
and auxiliary plants include the inspection of the Bell Less Top gearbox, the replacement of different
components like valve seals and
bleeder seats, various welding activities as well as other cleaning and
inspection activities.
The SMS Meer Strongsville team has

successfully upgraded a pair of robotic arms, which are part of an induction heater at ThyssenKrupp
Crankshaft in Veedersburg, USA. The
robots, which are part of an automation system used for loading and unloading the SMS Elotherm induction
heater for the KPS 6300 forging line,
arrived at the SMS workshop in
Strongsville in January 2014. The robotic system consists of an automated bowl feeder and two ABB robots
that will unload the induction heater
and load the roll former.
Since their arrival in Strongsville,
the grippers on the robotic arms
have been assembled and mounted
to the unit and a pneumatic system
has been installed. The robots were
also wired and programmed. The robots have been back in operation at
ThyssenKrupp since September.
www.sms-siemag.com/service
118
www.paulwurth.com
Service
LATEST GENERATION
In March 2014, Anshan Iron & Steel Group, China, contracted
Paul Wurth for the engineering and supply of two chute
transmission gearboxes of the latest generation for the Bell Less
Top charging systems of their blast furnaces.
Compared to the standard gearbox, this newly designed

unit with closed-loop pressurized cooling has the advantage of being maintenance-free, as the cooling circuit is
completely isolated from the blast furnace atmosphere,
thus avoiding contaminations by blast furnace gas, dust or
grease. Other features are reduced water consumption
(25 l/day vs. 1,000 l/day), longer lifetime of the chute tilting
gear, a compact and simplified cooling circuit as well as a
significant reduction in nitrogen consumption.
The gearbox was manufactured by the Paul Wurth workshop in Shanghai, which has been active since 2008 in the
fabrication and refurbishment of Paul Wurth key components for the local Chinese market. In the meantime, the
Shanghai workshop has also been servicing customers
from other Asian countries. To mark

the occasion of this first new gearbox
being handed over to a Chinese customer a Customer Open Day was organized at Paul Wurth Shanghai on July
25, 2014. About 120 guests, among
which were representatives of the
most renowned steel producers of the
region, were given the opportunity to
discover the latest Paul Wurth technologies.
www.paulwurth.com
Official handover
of the BLT chute
transmission gearbox to the customer.
119
Service
The manufacturing and service workshop covers a total area of 21,000 square meters.
Inauguration of the new workshop

by lighting a lamp.
Tour of the newly erected workshop.
Traditional Indian dance performance round off the

opening ceremony.
120
Dr. Heinrich Weiss welcomes the guests.
Service
First Sms Group

Workshop In India Starts
Producing
On November 27, 2014, the SMS group inaugurated its new
manufacturing and service workshop in Bhubaneswar, in the Indian state
of Odisha, for an investment of approximately 31 million euros.
In the presence of more than 300 guests from politics and

industry, Chief Minister Naveen Patnaik, who attended the
event as a guest of honor, cut the red ribbon in a festive
ceremony. Then a lamp was lit by Naveen Patnaik,
Dr. Heinrich Weiss (Chairman of the Advisory Board of the
SMS group), Burkhard Dahmen (Spokesman of the Managing Board of the SMS group), Sam Schreiner (Ambassador
of Luxembourg to India), Rainer Schmiedchen (German
Consul General in Kolkata), Christian Klein (CEO & Managing Director SMS India) as is tradition in India. The new
workshop, which covers an area of about 21,000 square
meters, will focus on the supply of steelworks equipment
and services tailored to the growth market India. The manufacturing facilites, equipped with machinery of the latest
state of the art, is strategically located centrally to our customers. Most of them are within a range of some 300 kilometers. Moreover, it will also be possible to supply customers outside India with components made at the
Bhubaneswar workshop via a marine port, which is just 130
kilometers away.
STRENGTHENED MANUFACTURING NETWORK
The investment strengthens our manufacturing network

for steelworks equipment in India. It is an important step
for the SMS group in tapping this growth market and being
set to participate in the upswing taking place in this country. Annual steel production in India is expected to grow in
the future from its current level of 80 million tons. India
alone aims at increasing its annual steel output to almost
300 million tons over the next 15 years.

It is part of the SMS strategy to serve
their customers locally, says Burkhard Dahmen. The SMS groups
clear commitment to India opens up
excellent prospects for development.
We manufacture product tailored to
the requirements of our customers
and to customized specifications. The
portfolio includes steelworks components such as electric arc furnaces,
secondary-metallurgy plants like ladle
furnaces and RH plants (RuhrstahlHeraeus), and BOF plants, including
cooling stacks for gas cleaning systems. For continuous casting plants,
ladle turrets, tundishes, tundish cars
and roller tables will be supplied. All
the plants will be manufactured, assembled and tested in Bhubaneswar.
This ensures high quality of the equipment. As a systems supplier, SMS also
offers a broad range of services, including spare parts services, the manufacture and repair of plant components in OEM quality, the manufacture
of value-added components (segment
rollers, spindles, mandrels), copper
plating of casting molds as well as
i
SMS India
SMS is present in
India with sites in
Gurgaon, Pune,
Kolkata and Bhubaneswar. From the
blast furnace down
to strip processing
lines the employees are familiar with
the complete product
range of the SMS
group.
121
Service
technical assistance in on-site installation and maintenance activities.

The service workshop of SMS India is
equipped with various high-tech machines. These machines are critical to
meeting OEM standards in the rendered repair and maintenance services. With enough space for 120 people,
the new location also has plenty of capacity for customer training courses.
In future, the TECademy will offer
seminars on metallurgical and rolling
mill technology subjects.
In his address, Naveen Patnaik emphasized the outstanding importance
of the new manufacturing and service
workshop for consolidating the relationship between the SMS group and
its Indian customers. With this commitment to India, SMS supports the
countrys new Make in India campaign. In this context, the new manufacturing site of the SMS group meets
with great acceptance in the country.
Currently, SMS has more than 1,000
employees in India. In future, at Bhubaneswar, some 200 SMS employees
plus approximately the same number
of contractor staff will form a further
pillar of the SMS groups worldwide
network of quality-manufacturing sites.
It is planned to expand the workshop in
the future and continue to invest in
modern machinery and additional
qualified personnel.
At the workshop
in Bhubaneswar
in the Indian state
of Odisha, steelworks equipment is
manufactured with
modern machinery.
With this new SMS
group workshop, we
guarantee the quality SMS customers
expect.
communications@sms-group.com
A short video shows
the new workshop
in Bhubaneswar,
Odisha.
www.sms-group.
com/qr/india
122
Service
Close to the customer in Southeast Asia

In a traditional ceremony on August 28, 2014, SMS Siemag opened
the doors of its new service workshop in Cilegon, Indonesia.
Hence, the worldwide service network of SMS Siemag comprises 40 locations.
I am delighted that our company is now represented in

Indonesia by a new service workshop, said Dr. Guido
Kleinschmidt, Member of the Managing Board of SMS
Siemag, in the opening ceremony. The area for repairs of
PT SMS Siemag Metallurgical Services in Cilegon has a
size of 2,200 square meters. In cooperation with the
worldwide service network, the modern machine park offers the full range of repairs in all fields from steel production to strip coating. The services cover, for example,
the repair of core components such as mandrels, spindles, AGC cylinders, refurbishment of rolls (caster rolls)
and mold plating. State-of-the-art machinery, be it a CNC
machining center or an HGC cylinder test station, ensure
a high quality standard.
The scope of services offered by the 30 employees further includes the manufacture and stock-keeping of spare
parts. All our services are available to customers in Indonesia and the ASEAN region, emphasizes Dwi Murdijanto,
Managing Director of the new workshop. We will support
our customers in maintaining their equipment, to give an
example, and in the case of operational disturbances or
machine failure our experts will be on-site at short notice. On occasion of the opening event, SMS Siemag invited
its guests to participate in a first tour through the workshop
where the visitors were shown the coating of copper plates
using to the box-plating method.
Indonesia is an important growth market for the SMS
group. Recently, the company supplied to PT KrakatauPosco Company a dry-type converter-gas cleaning system
with gas-conditioning tower and dry-type electrostatic precipitator, and to PT Gunung a single-strand slab caster as
well as an electric steel plant.
Dwi Murdijanto
murdijanto.dwi@sms-siemag.com
Top: Christoph Roth, Dr. Guido Kleinschmidt, Pino Tes, Doug Dunworth and Dwi Murdijanto (all SMS Siemag) ceremoniously cut the
ribbon and opened the workshop in Cilegon, Indonesia.
Bottom: The new workshop in Indonesia repairs core components
such as spindles.
123
Service
Modernization of an SMS Meer twister press at the new repair shop in Cranberry, USA.
Successful start
SMS Meer offers modernization measures of MEERcare
products at the new repair shop in Cranberry, USA. Recently,
a twister press has been rebuilt on-site.
SMS Meer successfully completed a challenging rebuild on

a crankshaft twisting device for a North American forging
company at the beginning of this year. The so-called twister
press a machine used throughout the entire closed-die
forging industry for the production of crankshafts required
a new electrical control system, as well as modernizations
to the hydraulic and lubrication systems. This rebuild was
one of the first ones carried out in the newly opened repair
shop in Cranberry Township, USA. With the repair shop
just opened, along with a demanding one-month rebuild
schedule required by the customer, it took the dedication
and unique talents of employees pooled from every department to complete this project in time, says Stephen Robash, SMS Meer Field Service and Repair Shop Manager.
Construction of the repair shop began in August 2013, and
was completed in early January 2014. The new shop, which
handles MEERcare repair and modernization services, offers about 2,000 square meter of workspace.
HIGH LOAD CAPACITY
The bay floor has a maximum load capacity of up to

27 tons. The Cranberry Township repair shop offers a
range of services from rebuilding press carriages,
straighteners, gearboxes, axial cones, loaders, pull back
124
cylinders and roll stands right through

to machine assemblies and testing,
machine overhauls and engineering
capabilities. The twister project was
completed and handed over to the
customer at the end of February. The
unit was successfully commissioned
for production at the plant only three
days later.
info@sms-meer.us
With the following
brochure you find
out more about our
new repair shop:
www.sms-group.
com/qr/cranberry
Service
Repaired
anticipatorily
SMS Meer has successfully repaired the
4,000 ton eccentric press at Gesenkschmiede Schneider
in Aalen (GSA), Germany.
Such a complex repair measure requires a detailed analysis of the actual state and perfect preparation to
keep downtime as short as possible.
At the same time, not only a quick repair on-site is what counts but also
the immediate procurement of spare
parts is decisive.
At GSA the SMS experts recognized the bearing damage to the
press in good time through regular
inspections. Spare parts for the
Eumuco SP400 c could be ordered
accordingly in time. After GSA had
produced in a forward-looking manner, the modernization team started
with the disassembly of the press.
Since the defective bearing shells
were located inside the machine body
it had to be disassembled completely.
Disassembly work ended on schedule, however, a much larger extent of
damage was revealed than was
expected before, which could not be
detected in mounted condition. Inside
the machine base an approx. 300-millimeter-long and up to 60-millimeter-deep crack had formed due to
continuous loading for many years in
the area of the bearing bore, which
was milled out and polished by the
SMS fitters. In the machine ram several deep cracks appeared, which
A crack in the eccentric shaft made further production impossible.
were repaired by extensive welding

and machining. However, then came
the actual challenge: repairing the
broken eccentric shaft. A circumferential crack at a depth of 130 millimeters had been detected within the
radius of the eccentric. The bad news:
reuse was impossible.
The good news: within only ten
weeks SMS has procured a new,
ready-to-assemble eccentric shaft.
Four months after starting disassem-
bly work the press was again assembled. Already another two months
later GSA resumed production.
125
Innovations
126
Innovations industry 4.0
Industry 4.0 for

steelworks
With the introduction of a pilot project, the Technical University of Dortmund, AG
der Dillinger Httenwerke and SMS Siemag are breaking new ground.
For the first time, large amounts of data from the converter shop are being
collected for a prediction model for the benefit of the steelworks owner.
A pizza deliverer and converters what do they have in

common? Not much. But if, for instance, all the routes of a
pizza delivery fleet are laid on top of one another, you will
recognize the city in which the pizzas have been delivered.
They form a city map. The individual routes would be almost
meaningless, says Professor Katharina Morik, who holds
the Chair of Artificial Intelligence at the Technical University of Dortmund. This is where our development project
ties in. If you want to determine the point in time when the
converter blowing time ends, you must have seen many
converter processes. The example is an illustration of the
complex project for the application of data mining in the
converter process, drawn up between the Technical University of Dortmund, AG Dillinger Httenwerke and SMS
Siemag. A data-driven prediction model for the 190 t BOF
has been developed for Dillinger Htte. The basic aim is to
improve the prediction accuracy of the four target parameters of tapping temperature, carbon content of the melt,
phosphorus content of the melt and iron content of the slag
at the end of blow. Our final aim is to produce at lower cost
and environment-friendlier, says Jochen Schlter, Vice
President Special Technologies at SMS Siemag.
Photo background: iStock/nadla
Steelmaking using the BOF converter
In the BOF, crude iron and steel scrap are charged and
slag-forming material such as lime is added. The blowing
lance blows oxygen into the bath of molten metal at supersonic speed. During this process, the accompanying elements such as carbon, phosphorus or silicon burn and are
absorbed by the slag and the off-gas. The aim of the BOF
process is to obtain a metal bath with defined properties at
the end of the oxygen blowing. The influencing variables of
the BOF process, such as the quantity

of scrap and crude iron, the amount of
oxygen blown, the quantity of coolant
and heating media or the age of the
converter, correlate with the target parameters.
In order to be capable of predicting
the target parameters at the end of
blow, conventional so-called metallurgical models are used that compute
the charge materials and propose corrections to the plant owner during the
process. The amount of oxygen needed
is also computed. The prediction accuracy of conventional models depends
on how well the producer knows the
influencing variables (crude iron and
scrap quantity, crude iron and scrap
analysis, etc.). The less accurately he
hits the end of blow, the more the resulting corrective actions cost time
and money (re-blowing, addition of
heating medium and coolant). As a result, the yield decreases and the wear
on the refractory bricks in the BOF increases.
Data-driven models predict target
parameters on the basis of the measured influencing variables. Extremely
large data stocks can be scanned systematically using data mining techniques and characteristic patterns
i
Industry 4.0
Industry 4.0 stands
for the complex
interlinking of
manufacturing
processes. Objects
of everyday use are
becoming more and
more intelligent and
meanwhile some of
them have selflearning capabilities.
127
Innovations
Burkhard Dahmen, Spokesman of the Managing Board of the SMS group, inaugurated
the Press Day on the subject of Industry 4.0
at SMS Siemag in Hilchenbach, Germany.
discovered. The relationships between target and influencing variables

are calculated using modern regression algorithms. The reliability of the
prediction increases, the more useful
the data for modeling are. A prerequisite for highly dimensional calculations is that training or learning data
are taken from the total data volume.
erometer on the lance, a microphone

on the converter mouth and a radiation pyrometer to monitor the off-gas
flame. A total of 126 process variables
are available.
When applying the data-driven prediction model, it became obvious that
the data and model handling (collecting and preparing the raw data, learning phase of the model, prediction by
the model, statistics) was very timeconsuming because many data sets
had to be edited manually. Therefore,
we have developed an object-based
storage using an SQL*-based index
for the efficient storage of large data
volumes that can be retrieved via the
SQL index, says Katharina Morik.
The database administers data ob-
The 190 t LD converter at Dillinger Htte

Lance
Vibration measurement for lance
Data-based prediction model
128
Preamplifier
Lance power loss
Offgas analysis
Control room
Cooling stack
Signal
converter
Level 1
Hub
Sound measurement
Preamplifier
Pyrometer
Converter
At Dillinger Htte, a PC has been integrated into the process automation to

collect the process data. Ninety static
process parameters, such as hot metal weight, scrap weight, hot metal
analysis, the age of the converter and
the age of the lance are thereby detected. In order to obtain a higher prediction accuracy, also 36 dynamic process variables such as the off-gas
composition (CO, CO2, O2), the cooling
water quantity and the cooling water
temperature are taken into account. In
addition to this conventional measuring technology, further sensors from
the domains of vibration, sound and
optics have been installed: a 3D accel-
jects such as raw data, prepared process data, process features, process
metadata, learned submodels and
their results.
The software environment, which
has been implemented with the Chair
of Artificial Intelligence, is of modular
structure and is extendable. The initial results of the new model show
that the work was worth it. The prediction accuracy of the temperature at
the end of blow is considerably higher.
Instead of 23C, it is 16.2C (see
graphics). Furthermore, the datadriven model is capable of also predicting the target parameters of [%P],
[%C] and (%Fe), unlike with conventional models. A better temperature
accuracy due to less overblowing of
Signal
converter
At Dillinger Htte, a PC records all process data. Installed sensors detect the values of
(dynamic) process variables and of vibration, sound and optics.
Innovations industry 4.0
Interview
One step further
126
Are we now experiencing a fourth

industrial revolution?
The interlinking of production engineering and IT has initiated an new
era. The keyword is Industry 4.0.
Web interfaces make it possible to access large data volumes that have
been made available on a cloud platform, for instance.
process variables are available for the

data-driven prediction model.
the melt and less re-blowing has a

positive influence on productivity and
reduces the amount of thermal losses, says Dominik Schne, Project
Manager in the Research and Development/Steelmaking department of
Dillinger Httenwerke. For the time
being, the model is being fed with
actual process data so as to obtain
a broad basis. If it were really possible to achieve a greater degree of
precision in the hit rate for the target
temperature, this would represent
considerable technical progress, comments Schlter. If, in the case of the
190 t converter, an improved hit rate
accuracy of 1C for the tapping temperature were to be assumed, the
heating media and re-blowing ratio
could be reduced correspondingly,
thus achieving cost savings of up to
100,000 euros per year. This shows
that data mining is profitable. And the
money saved could set quite a number of pizza deliverers in motion in
Dillingen.
Jochen Schlter
jochen.schlueter@sms-siemag.com
Jochen Schlter
Vice President
How is SMS Siemag prepared for

this?
Prior to the commissioning of our
plants, our software is subjected to
extensive testing in order to comply
with the highest quality standards and
to guarantee short commissioning
times. For this, we basically even go
one step further compared to the
world of models represented in Industry 4.0: The real physical world is
replaced by a virtual physical world in
our plant tests. We test our software
engineering by using real-time simulation of the customer-specific plant
technology.
* SQL is a specialpurpose programming language

designed for
defining data structures in relational
databases. It is also
used for processing
(inserting, altering
and deleting) and
making queries
regarding the data
stocks present in
the databases.
Special Technologies, SMS Siemag.
Which development will follow this?

Our entry into the world of 3D will be
the next decisive step in the development of our process and production
simulations. Upstream 3D designs
necessary for production will be integrated directly into the simulation
models after they have been simplified automatically. Here, we are using
already well-known and established
solutions from a completely different
area of information technology: the
games industry.
129
Innovations
HEAVY PLATE HEAT

TREATMENT
New plant concepts and technologies make the heat treatment
of heavy plate more efficient, precise and flexible.
High-strength and wear-resistant steel

grades are among the most demanded
heavy-plate products today. Therefore,
plant technology must undergo continuous advancement to permit operators to produce ever higher plate
strengths and toughness and also reduce, for example, the volumes of alloying agents. New rolling and cooling
technologies often allow the mechani130
cal properties to be set inline, i.e., inside the rolling line. Extremely challenging materials, however, require a
final heat treatment.
As a systems supplier, SMS Siemag
has been focusing on the heat treatment of heavy plates for some years
now, to make it more efficient and flexible. The development of new materials and the decline in margins for
standard grades caused a demand for

multipurpose plant solutions concentrating on flexibility and material
quality. SMS Siemag is dedicated to
this trend. The solutions found in the
course of the development programs
permit a wide range of heating and
cooling strategies to be set on one
plant for the efficient production of a
great variety of materials.
Innovations HEAVY PLATE
EFFICIENT FURNACE TECHNOLOGY
The type of furnace normally used in a

continuous heat treatment process is
the roller-hearth furnace. Its strengths
are, on the one hand, different speeds
for the individual heat treatment of
plates and, on the other, a high maximum speed, which is important, in the
first place, to transport plates to the
quench. Heating is accomplished either by open or indirect firing through
radiant tube burners with the furnace
chamber being rendered inert by
flushing with nitrogen.
The indirect heating method results
in less scale on the plates, but requires
considerably higher investment and
operating costs. The radiant tubes of
indirectly
heated
furnaces
are
equipped with recuperator burners.
For open-fired furnaces, however, it is
recommended to use high-speed
burners with a central recuperator for
preheating the air since essential gas
savings when using recuperator burners can only be achieved with preheated plates.
Double walking-beam and chamber
furnaces are also frequently used for
the heat treatment of stainless steels.
In 2013, SMS Siemag supplemented
the existing heat treatment line of
Outokumpu Stainless in its Degerfors
works by two chamber furnaces and
one quenching unit. Outokumpu uses
its existing roller-hearth furnace for
plate dimensions and temperatures
having a limited burden on the said
furnace, whereas the chamber furnaces are operated for combinations of
high plate loads and temperatures,
i.e., mainly small batches and niche
products. At temperatures of more
than 1,200C, the furnaces at
Outokumpu Stainless can also produce demanding steels such as highalloy grades for special applications.
Chamber furnaces are operated in
i
Heat treatment
The heat treatment
of carbon steels
includes heating to
above austenitizing
temperature (normalizing, approx. 900
to 950C), quenching
(hardening) and reheating (tempering,
up to approx. 680C).
The MultiFlexQuench has an

extremely wide
cooling range.
131
Innovations
sets and have a stationary hearth.

Due to their flexibility they are used for
small volumes and frequently changing batches. The two units at Outokumpu are particularly flexible as
each furnace can be subdivided by a
separating inner door, permitting
Outokumpu to heat even short plates
at different temperatures in an energy-efficient manner. This measure
substantially increases the material
throughput and improves specific gas
consumption. In the face of increasing
energy prices and rising environmental requirements, SMS Siemag attaches great importance to high energy
efficiency in the rating and design of
the furnaces. For each project SMS
Siemag develops a tailor-made opti-
Heat treatment line at Outokumpu Stainless with the two chamber furnaces and the
quench.
mum solution in cooperation with the

customer, taking into consideration
upstream plant areas. The result of a
quenching process, i.e., the application of large water volumes within very
short periods of time, is a significant
Facts + Figures
Main references in recent years

customer commissioning heat treatment plants
Acroni, Slovenia
2016 Complete heat treatment line with two

roller-hearth furnaces and MultiFlexQuench, including electrical and automation systems as well as water treatment
plant
Acroni, Slovenia
2015
Modernization of furnace and quench
Outokumpu
2013
Complete heat treatment line with
Degerfors,
chamber furnaces, one discontinuous
Sweden roller-type quench including electrical and
automation systems as well as water
treatment plant
Acroni, Slovenia
2015 Discontinuous roller-type quench, including electrical and automation systems
Xingcheng Special 2011

Steel, China

Two rollerhearth furnaces and continuous

quench, including electrical and
automation systems
Yingkou
2009
Minmetals, China
Continuous quench,including electrical

and automation systems
MMK, Russia
132
2008 Continuous quench, including electrical

and automation systems
increase in hardness due to the formation of martensite. Plate fixing during the quenching process ensures
good flatness even at high cooling
rates. Whereas a continuous quench
cools the plates on their way through
the line, a platen quench or a discontinuous roller-type quench cools in
sets plate by plate. Because of their
low throughput, these solutions are
economic especially for low production volumes. In 2013, SMS Siemag
supplied to Outokumpu Stainless a
discontinuous roller-type quench capable of treating two plates simultaneously.
MODERN MULTIFLEX-QUENCH
A new type of quench, the MultiFlexQuench, developed by SMS Siemag,

will be put on stream at the Slovenian
steelmaker Acroni in 2016. Contrary to
conventional continuous quenches,
this type is no longer rigidly subdivided
into an HP and an LP section. Instead,
the entire range of cooling rates is
available over the full length. All cooling patterns from gentle cooling to
abrupt quenching can thus be realized
to achieve an even wider product portfolio. By installing different nozzle systems and control valves the MultiFlexQuench can be individually designed
to suit the customers product mix.
Prior to commissioning of the MultiFlex-Quench, SMS Siemag will assist Acroni in determining the optimum heat treatment parameters for
new high-quality plate products. This
will be done, for instance, by tests in
the laboratory. Material properties
such as time-temperature transformation characteristics or mechanical
core values after different heat treatment steps will be integrated into the
Innovationen Grobblech
All processes are clearly visualized by the X-Pact electrical and automation systems.
1,200
degrees Celsius and more is the maximum
temperature in the heat treatment furnaces
of Outokumpu Stainless to produce demanding steel grades.
automation systems and to optimize

the process parameters. Based on this
know-how, it will be possible to set the
mechanical properties achievable by
the heat treatment more precisely,
minimize the use of alloying elements,
shorten process times, increase the
output and hence contribute to environment protection.
ELECTRICAL AND AUTOMATION SYSTEMS
Purposeful heating and cooling of

plates requires holistic process control, and this is the reason why SMS
Siemag integrates its X-Pact electrical and automation systems also in

heat treatment plants. To describe the
complex and, in part, highly dynamic
processes, mathematical models are
used and combined in a holistic approach. The essential target values for
plant control are set mechanical properties and respectively the microstructure, energy efficiency and plate flatness. Calculation of the cooling rates
that determine the material properties
is made on the basis of SMS Siemags
material database which is the foundation of all SMS Siemag process
models. For all steel grades it provides
the most important physical and mechanical properties depending on their
chemical composition and temperature. The X-Pact cooling model then
calculates the right cooling strategy
for each individual plate.
For further information please contact the
experts Gerhard Horn and Christian Sprung.
gerhard.horn@sms-siemag.com
christian.sprung@sms-siemag.com
133
Innovations
SMX forges tubes

The SMX a radial forging machine with hydraulic cylinders and
tools arranged in X-shape has now started forging tubes as well.
Its hydraulic drive is of higher performance compared to the
mechanical drive of conventional machines.
The SMX forging machine is also capable of forging big thick-walled

tubes. In 2011, the largest hydraulic
radial forging machine in the world at
that time was put into operation at Vitkovice Hammering, a Czech group for
plant construction and mechanical
engineering. The product range of the
SMX 800 / 18 MN comprises not only
long and flat products made from cast
billets of up to eight tons in weight, but
also special products such as train axles. Starting very recently, the machine additionally forges tubes. The
SMX radial forging machine is an adequate machine tool for manufacturing large high-alloy tubes. From temperature and pressure-resistant tubes
for power stations to corrosion-resistant oil field pipes and wear-resistant
mechanical pipes, the SMX 800 is an
all-rounder in tube production. In addition to steel bars and semifinished
products of different sizes, the SMX
also manufactures multi-stepped
shafts and axles and drive spindles.
Due to the radial arrangement of the
tools, the forged piece is almost completely enclosed, and the material flow
takes place exclusively in an axial
direction. The degree of forming is
therefore three- to four-times higher
than that of a comparable conventional open-die forging press. In the case
of special steel grades with low scale
formation, inside descaling is not re134
quired at all. The hydraulic radial forging machine is especially suitable for the shaping of material that is difficult to
form, such as stainless and acid-resisting steel grades or
nickel-base alloys.
NEW PROGRAM: ComForge Tube
When using the hydraulic drive concept, the maximum

forging force can be applied over the entire forging stroke
as far as the core of the workpiece. The SMX performs accurate forming work. Thanks to the homogeneous and finegrained microstructure, the tube has very good mechanical
properties. Just one heat is necessary to forge the entire
tube on an energy-efficient and thus cost-favorable basis.
The hydraulic radial forging machine has been tailor-made
A second manipulator takes over the tube for the final forging strokes.
Innovations forging plants
The SMX radial forging machine at work.
to meet the customers increased requirements as to quality and size of the forgings, and since its introduction is being continuously developed further. The computer-controlled system makes it possible to manufacture high-level
forgings with small tolerances. The control system integrated by SMS Meer synchronizes all movements of the
forging manipulators and the mandrel manipulator. The
whole forging process is performed in fully automated
mode and is controlled and monitored by the ComForge
Tube Program. ComForge Tube is a recently developed
module of SMS Meers ComForge technology package.
Originally Vitkovice Hammering started with the SMX800
to manufacture forging products from conventional steel
grades. Nowadays, the machines whole range of production is used in the Czech Republic and was the basis for a
successful start in the manufacturing of high-quality tubes
for profitable niche markets. This machine has a maximum
tool opening of 800 mm and a forging force of 18 MN or
1,800 tons on each of its four cylinders. These features
make it possible to manufacture forgings with a maximal
block weight of 8,000 kg. The forging machine was de-
signed for diameters from 150 to 500

mm for round forgings. The maximum
length of the finished products is 18
meters. Before the forging process
starts on the machine, the manipulator tongs center the mandrel, which
has innovative internal cooling. For
this reason it does not need any coating. Using a mandrel bar, the tapered
mandrel is positioned in the hollow ingot. The mandrel bar is moved by a
separate manipulator.
www.sms-meer.com
135
INNOVATIONS
Paul Wurth has

taken over the
coke oven machine segment of
Bochum-based
Schalker Eisenhtte
Maschinenfabrik.
Paul Wurth expands

portfolio by coke oven
machines
Acquisition of the coke oven machine
segment of Bochum-based Schalker
Eisenhtte Maschinenfabrik
With the acquisition of the coke oven

machine segment of Bochum-based
Schalker Eisenhtte Maschinen
fabrik, Paul Wurth has strategically
expanded its portfolio of coke making
technology. The two companies
signed the agreement on July 2, 2014.
It includes the takeover of patents,
references, drawings, licenses, brand
name and know-how by the Paul
Wurth Group. Being a subsidiary of
the Eickhoff Group, Schalke has established itself as a worldwide market leader for coke oven machines,
relying on more than 130 years of experience.
136
Significant new asset in coke oven
technology, the most modern and

largest coke oven batteries in the
world can be equipped with man-less
coke oven machines that meet the
highest standards in terms of productivity, emission control, user-friendliness and plant safety. Today, more
than 200 Schalke-branded machines
are in operation worldwide.
technology
This acquisition will strengthen Paul

Wurths position as a global player in
the design and construction of complete coke oven plants, coke oven batteries, coke oven gas treatment and
by-products plants as well as coke
dry-quenching facilities. The newly acquired technology includes a wide
range of coke oven machines: charging cars, pusher machines, coke
transfer cars, quenching cars, crane
systems, maintenance and service
cars as well as automation and emission control systems. Thanks to this
www.paulwurth.com
200
Schalke-branded machines are in operation
worldwide. With the takeover, Paul Wurth will
strengthen its position as an expert in coke
oven technology.
Innovations ECOPLANTs
Air cleaning
Per ton of steel, 10 to 20 kilograms of dust arise in the converter.
This dust is discharged with the exhaust gas. In order to protect man and
the environment, it is necessary to clean the exhaust gas. Here, the
SMS group provides a solution that saves costs.
The SMS group offers a solution that

combines a wet-type scrubber with
a wet-type electrostatic precipitator
(hydro-hybrid filtration). The filters
clean the CO-containing process gases
arising in the converter process effectively and economically, while complying with stringent safety and environmental standards. This innovative
process makes it possible to achieve
dust contents in the cleaned gas, which
are below ten milligrams per cubic
meter of converter gas at standard
temperature and pressure.
Modern retrofit option
Vertical hydro-hybrid plant.
As a retrofit option for an existing BOF

wet-dust-collection facility an option
exclusively offered by the SMS group
the hydro-hybrid filter is a technological first. The wet-type electrostatic
precipitator will be integrated into the
existing gas cleaning system. The principle is similar to that of Diesel particulate filters in cars. For cleaning the
electrostatic precipitator, the existing
water system can be used. The unit
may be arranged horizontally or vertically, depending on the space conditions, the gas flow rate and the gas volume. The hydro-hybrid filter is an
optimal solution not only for environmental reasons, but also under economic aspects. Compared to a complete new construction of a gas
cleaning system based on dry-type

precipitator technology, the retrofit is a
much less expensive option. Another
advantage is the fast and easy installation as a standby unit for example, to
bridge a longer downtime due to maintenance measures being performed on
the main system. This avoids high costs
due to lost production. Consequently,
the operator can react in less time to
newly imposed regulations. The overall
system can be operated with a less
powerful blower and with energy consumption reduced by up to 30 percent.
In times of rising electricity prices, this
is an important aspect.
www.sms-ecoplants.com
ADVANTAGES
Ecological
ower emissions:
L
Dust: < 10 mg/Nm (stp)
Economical
OPEX: 510 euro/ton of steel
CAPEX: 7580% savings**
** vs. an upgrade to dry-type
dedusting
137
Events
From top to bottom:

Liu Jianwei from
Zhejiang Kingland &
Pipeline Technologies Co., Ltd., during
the discussion.
The panel during the
tube welding symposium in Qingdao.
Participants of the
first SMS Meer tube
welding symposium
in China.
138
Events
Expert forum in China

The tube and pipe industry is faced with constantly new quality
requirements for welded tubes that were intensely discussed during
the SMS Meer symposium in Qingdao.
Roughly 100 tube welding experts from 45 companies came

to the first tube welding symposium in Qingdao, China,
which was organized by SMS Meer together with the Chinese tube welding association. Frank Lth, Head of Commercial Division Tube and Pipe Plants at SMS Meer, opened
the series of presentations. We at SMS Meer regard it as
our duty to offer equipment and services to the tube and
pipe producers enabling economic success in todays and
future markets, he said.
SMS Meer has revolutionized the production of largediameter pipes by introducing the JCO forming process.
Welspun, in India, was the first customer in 1996 to take
such a plant into operation, followed by the Chinese Julong
Steel Pipe, Sashi Steel Pipe and Zhongyou BSS Petropipe.
For HF welded tubes in the large diameter range up to 26
inches SMS Meer has gained Chinese pipe manufacturers,
such as Baoshan Iron & Steel, Wuhan Iron & Steel and
Tianjin Pipe. Spiral pipes, which are also included in the
product portfolio of SMS Meer since PWS has been integrated into the SMS Meer Business Area, were supplied to
Dragon Pipe Industries, Shandong Shengli Steel and Zhejiang Kingland & Pipeline Technologies Co., Ltd., in China.
TOP QUALITY ALSO IN CHINA
It is now apparent that the existing boundaries between the

individual tube and pipe production processes are vanishing
more and more. Nowadays seamless tubes can be manufactured in sizes that were previously only reserved for
large-diameter pipes. The same applies to large-diameter
pipes with smaller diameter and larger wall thickness,
which are now able to replace seamless pipes. Submergedarc welding is in turn applied for specific applications in the
traditional HF tube welding area.
The speakers described current developments and explained SMS solutions for constantly high standards of quality in all these areas. With SMEC SMS Meer Engineering
(China) Ltd. the company has significant manufacturing
and assembly capacities in Shanghai

where quality requirements are the
same as in Germany. The local presence offers benefits such as reduced
costs, simplifications for import regulations, easier communication, and
improves services during the entire
lifetime of the tube and pipe plants.
The event in Qingdao was organized
as a result of cooperation between SMS
Meer and the tube welding committee
of the Steel Rolling Institute under the
leadership of the Chinese Society for
Metals. The association represents the
Chinese tube welding producers with a
clear focus on research and development of Chinese tube production.
i
SMS Meer
At the event,
representatives
from Beisteel Pipe
(Yinkou) Co. Ltd.
and SMS Meer held
project discussions
and conducted
preliminary contract
negotiations on the
supply of a JCO
forming press. The
contract was signed
in August.
The SMS Meer topics at a glance

J CO pipe making technology: highly
efficient technology and environmental
protection
Successful ERW welding lines for
premium quality products
Large diameter spiral pipe production:
process automation and production
quality management system; PERFECT
arc welding technology.
German quality made near by the
customers: manufacturing, modernization
and after sales and services by SMEC
If you are interested in the above-mentioned
topics, please contact Ms Hannah Jansen:
hannah.jansen@sms-meer.com
139
Versanstaltungen
Presentation of HybrEx
Also in 2014, the SMS group was present at the Aluminium Trade Fair in Dsseldorf. A special focus was on solutions for the automotive industry, which has
been increasingly demanding electro-discharge textured (EDT) surfaces. The
plants supplied by the SMS group fulfill these requirements. SMS Meer introduced its newly developed HybrEx press. The special feature of the HybrEx press
is its hybrid drive solution. We have replaced hydraulic drives with electric servodrives wherever it is important to have high-speed movements, explains Axel
Bauer, Manager Sales Extrusion Presses at SMS Meer. This improves both productivity and energy efficiency. Our customers took a great interest in this technology. A short video gives an impression about the SMS groups presence at
Aluminium 2014 and its technology for the aluminum production chain.
A short film gives

an impression about
the appearance
at the Aluminium
Trade Fair 2014 and
the solutions in the
aluminum sector
www.sms-group.
com/qr/trade fairaluminum
ECCC
At the end of June, the 8th European
Continuous Casting Conference took
place in Graz, Austria. In his keynote
titled Market demands drive continuous casting to exceptional solutions, Dr. Jens Kempken, Executive
Vice President, SMS Siemag, presented four market trends that provide incentives to the SMS group to
develop new products and be as close
as possible to our customers. Other
papers presented dealt with the use
of the HD mold at ArcelorMittal in
Duisburg-Ruhrort and near-netshape casting with the Belt Casting
Technology (BCT).
140
Hands-on presentations
On September 1, 2014, SMS Siemag staged a conference of the European Plant
Engineering Committee EPEC at its office in Dsseldorf. SMS used this hometurf advantage to offer the conference participants hands-on presentations of
two of its products. The experts present had the opportunity to try out the laser
tracker by measuring a segment and processing the measured data. The second
item presented was the broad face of an HD mold. The features of the HD mold
were explained and extensively discussed. How long does it take for the system
developed by SMS Siemag to display the heat in this case, induced in the coated copper plate by a hot-air fan on the screen? The experiment demonstrated
how much faster and more accurately the information is available thanks to the
fiber-optic-based technology of the HD mold.
Events
SMS Elotherm
Developing new markets in Mexico

For the first time ever, SMS Elotherm participated in the
Heat Treatment Congress held in Mexico. The Congress
was a very good opportunity for our company to convince
more potential customers in a promising market like Mexico of the process accuracy and quality of our technology,
Prathepan Gnanes (Project Manager Sales, in the photo on
the left) and Javier Ramirez (General Manager, Mexico)
summarize the event. For several decades, SMS Elotherm
has been setting benchmarks in the field of induction technology with its developments and systems solutions.
Imprint
SMS group Newsletter
Issue 02|2014
ISSN 00000000
Publisher
SMS group Corporate
Communications, Eduard-
Schloemann-Strae 4
40237 Dsseldorf, Germany
Phone +49 211 881-0
E-mail: communications@
sms-group.com
www.sms-group.com
Responsible according to
German press law
Dr. Thomas Isajiw
Printing and prepress
processes
Druckhaus Kay GmbH
Hagener Strae 121
57223 Kreuztal, Germany
Published on
December 12, 2014/
SMS group/Circulation in
German 6,200, in English
11,500/Printed in Germany
Events 2015
Jan 1013, 2015 TEKNO / Tube Arabia - 12th int. Trade Fair |
Dubai, United Arab Emirates
Jan 1013, 2015
METAL Middle East 2015 | Dubai, United Arab Emirates
Feb 0912, 2015
MINING INDABA 2015 | Cape Town, South Africa
Mar 2326, 2015
Arab Lab 2015 | Dubai, United Arab Emirates
Mar 31 Apr 03, 2015 Metal + Metallurgy China 2015 | Shanghai, China
Apr 1317, 2015
Hannover Messe 2015 | Hannover, Germany
Apr 1416, 2015
Forge Fair 2015 | Cleveland, U.S.A.
Apr 1416, 2015
Aluminium Middle East 2015 | Dubai, United Arab Emirates
Apr 2224, 2015
Rolls Conference 2015 | Birmingham, United Kingdom
Apr 2830, 2015
8th European Stainless Steel Conference | Graz, Austria
May 0407, 2015
7th AISTech 2015 | Cleveland, U.S.A.
The information provided in

this magazine contains a
general description of the
performance characteristics of the products concerned. The actual products
may not always have the
characteristics described
and, in particular, these
may change as a result of
further developments of the
products. The provision of
this information is not intended to have and will not
have legal effect. An obligation to deliver products
having particular characteristics shall only exist if expressly agreed in the terms
of the contract.
More information
May 12-14, 2015 The 6th International Congress on the Science and Technology of
Steelmaking (ICS2015) | Beijing, China
about upcoming
June 08-11, 2015 Metallurgy-Litmash / Tube Russia / Aluminium / Non-Ferrous

2015 | Moscow, Russia
com/conferences.php
June 1620, 2015
11th International THERMPROCESS | Dsseldorf, Germany
June 1620, 2015
9th International METEC | Dsseldorf, Germany
July 0610, 2015
Aluminium China 2015 | Shanghai, China
events is available
at: www.sms-group.
141
SMS group at
METEC, GIFA and THERMPROCESS 2015
/
GIFA
/
C
E
MET PROCESS
M
THER 015
2
, 2015
6 20
1
e
n
Ju
10
5 and
Halls
many
f, Ger
r
o
d
l
e
Dss
Save the date

You may book
a hotel room
from the quota
reserved by
the SMS group
using the
following link::
www.smsgroup.com/
metec
From June 16 to 20, 2015, Dsseldorf will

once again be the meeting point of our industry. Under the trade fair motto Growth Engine Metallurgy, we will present our solutions for future challenges in the steel and
non-ferrous metals industries. Come and
Eduard-Schloemann-Strae 4 Phone: +49 211 881-0

40237 Dsseldorf
Fax:
+49 211 881-4902
E-mail: metec@sms-group.com
Internet: www.sms-group.com
visit us at our trade fair stands (Metec, Hall 5,

5E22/5E32 and Gifa/Thermprocess, Hall 10,
10H41) and learn about our innovative concepts and new developments for efficient and
eco-friendly plants in personal conversation,
through exhibits and presentations.

SMS Newsletter 01 2015 en

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THE MAGAZIN E OF T HE S M S GROUP

sms group newsletter 01/2015

All from a single source:

In focus Electrics & 

The SMS group newsletter app is

THE MAGAZ INE OF THE SMS GROUP

Cover photo: Control pulpit at MMK, Russia. The steelmaker

and Bernward Reif describe

The MEERgauge measuring

plant automation solutions of

system from SMS Meer impress-

25 Plug & Work in 3D

With visualizations in 3D, SMS

The Product Inspector, devel-

Siemag achieves an even more

oped by SMS Siemag, is an ap-

realistic view of the plants.

plication for slab quality control.

34 Aluminum strip from

The BFXpert automation

An aluminum rolling mill was

package from Paul Wurth in-

put on stream in Saudi Arabia.

creases process stability and

Systems supplier SMS Siemag

automated the equipment.

44 Kardemir relies on SMS.

84 Galvanizing line for Wuppermann.

126 Industry 4.0 at SMS.

ducer ASAS goes for steady

growth using high-tech

68 Continuous casting plants

Hot rolling mills 

Cold rolling mills

84 Strip processing lines and

With its Gebze service work-

shop in Turkey, SMS Siemag

Tube & pipe plants

is right on its customers

Long products plants

104 Forging plants

112 Experience counts

sms group newsletter 01/2015

Award for joint project

FASTER, BETTER, LESS COSTS

In the BCT process, the liquid steel

sms group newsletter 01/2015

From right to left:

The steel is poured

Part of the visualization system in the

technology opens up numerous possibilities of application

Photo above: bildschn/deutscher zukunftspreis

LONG TIME TO MARKET

The fact that the joint project of Salzgitter Flachstahl, SMS

ment and invest generously to build

sms group newsletter 01/2015

Change at the company head

New record in ring rolling

The SMS group received

Visit by the Russian Consul

a nonprofit organization promoting

The Design Council, an independent

sms group newsletter 01/2015

In focus Electrics &

25 Plug & Work in 3D

34 Aluminum strip from

68 Continuous casting plants

Hot rolling mills

84 Strip processing lines and

112 Experience counts