Search Documents

By Renata Cristina Teixeira

The lubricant oil is a complex mixture of different basestocks and additives. Engine oils evolved from the use of pure mineral basestocks back in the early years of automotive industry to the advent of synthetic, fully formulated, low ash lubricants. This evolution was driven by a number of factors, such as new engine designs, extended durability needs, increased fuel economy needs, environmental concerns, feedstock prices and availability and legal issues. This paper uses technology prospecting on literature and patents databases to allow an investigation on the historical evolution of engine oils. Main basestocks (mineral, hydrotreated, polyalphaolefins, esters) and additives (antioxidants, antiwear, friction modifiers, detergents and dispersants) are characterized according to their research effort. Technology prospecting data is crosschecked against the evolution of engine oil classes, allowing an analysis of how the main drivers push the development of lubricant oil quality. A research effort was identified in late 1990’s until mid-2000’s and related to the adoption of chemical limits for lubricants. Different patterns for the articles and patents publication account for the high value technological knowledge has in this industry. Technology prospecting is seen as a useful methodology for the understanding and forecast of lubricant technology movements.

Jul 31, 2018

By Valeria Collini, Antonello Mestroni, Enrico Plazzogna

The Danieli Group is deeply involved in the technological improvements stimulated by Industry 4.0 concepts widely applied to the metals industry and process automation. The so-called "Intelligent Mill" is the natural evolution of the company’s consolidated know-how and undisputed leadership in the fields of mini-mill and turnkey plants. Complete and structured data collection is the basis for real-time analysis and process optimization in terms of quality, efficiency and easy maintenance. A centralized repository of information is possible thanks to the strong interconnection between process control system architecture and intelligent sensors, together with dedicated software tools leading to an intuitive approach to data analytics.

Oct 1, 2019

By François DUMORTIER

Due to the increasingly stringent requirements and the needs of the automotive industry, galvanizing lines for automotive products have to be modernized and improved. Beginning of 2017, SEGAL, a Tata Steel CGL located in BELGIUM and fully dedicated to automotive market, placed an order to increase the line capacity from 550kt/year to 600kt/year to process a wider range of steel grades and improve the product quality according to automotive requirements. To improve quality, a major revamping of the skin pass was necessary. The objectives were first to increase the work roll diameter from Φ560mm to Φ650mm to be able to transfer the required roughness with low elongation on soft material and second to increase the rolling force and tension to reach higher elongation on high strength steels. The result was the adaptation of the whole skin pass mechanics. Old mechanical elongation system has been replaced by a completely new single AC motor with helical gearbox at each bridle roll. John Cockerill achieved such complicated revamping in a very short time since the shutdown started only 6 month after the contract signature. The shutdown down schedule has been optimized with pre-erection works and the teams working 24/7 to implement all the changes. The complete project (skin pass, furnace, loopers) have been adapted during the three weeks shutdown. Today the customer can use both 560mm and 650mm work roll diameters. Thanks to the use of the new 650mm work roll diameter, the customer is able to make the same elongation using a bigger roll force (average 20% more), which has strongly improved the roughness transfer to the strip and the removal of the defects. SEGAL is really satisfied able to produce and supply higher quality automotive products to his customers.

Oct 1, 2019

By Juliano Braz Possatti, José Fagundes Júnior

This project involved a teamwork including process control, maintenance and operation specialists, R&D and CTO experts to identify and actuate on each opportunity to increase charging temperature, furnace efficiency, decrease discharging temperature when possible, decrease FM and RM cycle time (mainly speed increase and interpass time decrease), tracking zones optimization, safe use of equipment power limits, safety interlocks revision and tune models for Mill Pacing Control and Slab Design.As result of these efforts, ArcelorMittal Tubarão HSM today occupies a prominent position among the best HSM of similar layout and produced mix of the group and worldwide. This paper will show the path which was followed by the AMT HSM team to achieve more than a 20% productivity increase resulting in a hot coils production per year more than 700 million tons higher.

Oct 1, 2019

By Robert Horwood, Richard Harvey

The copper stave was a development of the Blast Furnace cooling system intended to utilise the high heat transfer properties of copper within a fully covered shell cooling solution. They were originally conceived as being able to provide a permanent cooling lining for use primarily in the higher heat zones of the Blast Furnace. Despite a large number of campaign successes around the world the everlasting concept has not proven universal, with some plants having suffered issues in two particular areas: stave bending (leading to water leaks at back of the stave) and stave wear (erosion on the hot face). Primetals Technologies have in the past been approached to provide assistance to a number of Blast Furnace operators who were experiencing operational issues with the copper stave furnace cooling systems of others. Through knowledge gained resolving these issues, and with the positive experiences of their own copper stave designs, Primetals Technologies have worked towards developing a new concept in copper stave design capable of providing a more robust solution to cope with the greater productivities of modern ironmaking. This paper will provide an outline to the concepts that have driven the design of this new technology.

Oct 1, 2019

By Bimal Nathwani

This paper presents an overview of bearings failures with focus on steel mill applications such as continuous casting, rolling mills, multi-roll cluster mills and wire and rod mills. This paper will also provide countermeasures for prevention of these modes of failures.

Jul 30, 2018

By Johan PEERS, François DUMORTIER

Today, solutions to optimize Capital Expenditure (CAPEX) & Operational Expenditure (OPEX) for small capacity Cold Rolling Mills (CRM) as well as for high capacity CRM are available, as extensively described by various Original Equipment Manufacturers (OEMs) & steel makers. A suitable solution for small capacity CRM is to start with a single stand reversing mill (up to 400 ktpy, depending on product mix), which can then be expanded into a twin stand mill (up to 900 ktpy, depending on product mix). The main drawbacks in conventional practice are the off-gauge length in single stand set-up and the long downtime of the mill during the erection of the second stand. For higher productions CRM, it is common practice to directly select a new Pickling Line Tandem Cold Mill (PLTCM), with a high CAPEX. Is there an in-between solution that would allow to start with limited output and CAPEX, without jeopardizing the ultimate expansion goal (1.2 to 2 mtpy), for which PLTCM is the best techno-economical choice? In the absence of a solution, JOHN COCKERILL developed an integrated solution that limits the CAPEX in the first phase of development, without crippling affecting future endeavors through an easy and economically sustainable expansion into a PLTCM, without long production downtime. The solution consists of first installing a twin stand mill, expandable into a tandem mill thanks to a smart design of the line. It is therefore possible to limit the production to 900 ktpy in the first phase of the project and then convert the mill into PLTCM in the second phase to increase the production from 1.2 to 2 mtpy, depending on the market trends and financial capabilities. In summary, JOHN COCKERILL has developed a smart new layout in reversing phase combined with a brand new rolling strategy to optimize productivity and limit off-gauge, compared to conventional solutions (patents pending). In addition the layout enables an easy conversion to tandem mill without high over investments, which is more sustainable financially than the initial purchase of a PLTCM. Long downtimes to allow for capacity extension, detrimental to this phase-by-phase approach, are also avoided. Technical and process description of the new layouts and rolling strategies, together with CAPEX & OPEX descriptions of the phases are detailed in this paper.

Oct 1, 2019

By Richard Harvey, Robert Paul Mawer

In recent times there has been an increase in the demand from Steel plants for a technology that offers the most economical environmentally sustainable solution. In terms of blast furnace off gas cleaning this has seen a drive towards Cyclone technology replacing the older Dustcatchers. Cyclone technology can achieve dust removal efficiencies as high as 95% increasing the dust yield at the primary stage of gas cleaning. The dry dust (rich in Fe and C) can then be recycled to the Sinter Plant or Blast Furnace. Capture of dust at this stage also has the benefit that sludge generation from the secondary stage is also reduced meaning less waste to landfill and / or recovery of some of the by-products for further use. Primetals Technologies already offer a state of the art Tri-Axial Cyclone installed on many sites world-wide, however, this paper focuses on a hybrid of this technology, the DustClone. The DustClone is a low CAPEX unit that is essentially a Cyclone housed inside the Dustcatcher. This unit is aimed at operators who may be carrying out smaller scaled shutdowns / repairs that normally have a reduced CAPEX. This paper describes the technology that Primetals Technologies have developed.

Oct 1, 2019

By Michael McDonald

The cold-rolled steel output of cold-rolling mill (CRM) complexes are sometimes constrained by their batch annealing facilities (BAF). This paper examines a cost-effective solution to increasing capacity and quality of the BAF thereby making additional capacity available for CRM output. The solution involves applying a structured system of scheduling and operation to the BAF, using a proven level-2 software model. The system presented has been applied to a wide variety of BAF with all the leading furnace brands. Whether using traditional HN atmosphere or 100% hydrogen, peak performance can be achieved when using a properly configured, on-line, physical thermodynamic model. Given that it is not practical to place a thermocouple in each coil that is being annealed, various methods have historically been used to estimate the time required to properly anneal all the coils in the charge. This paper examines how the latest technology, in wide use throughout the USA, uses a physical thermodynamic model to shorten average cycle times, thereby increasing productivity and reducing energy consumption. The paper also examines the benefit of building thermodynamically balanced charges to further optimize the BAF operation and improve quality consistency by decreasing mechanical property variations.

Jul 30, 2018

By Kurt Herzog

State-of-the-art automation information technology and connectivity enables the digitalization of steel production that goes far beyond conventional automation of industrial production. Initiatives have been started around the globe to foster digitalization like IIoT (Industrial Internet of Things) in the US, Industrie 4.0 in Germany or China 2025. Primetals Technologies is actively driving the digitalization shaping the future of steel production. Intelligent combination of sensor technology combined with digital models as well as quality and production planning and control systems leads to new dimensions in product quality and production cost reduction. New diagnostic ways allow intuitive fault tracing or processing to support faster maintenance. Digital assistants support both operation and maintenance using context-oriented or self-learned information.

Oct 30, 2017

By Peter Grawenhof

Universal joint shafts and slipper spindles are commonly used in rolling mills to compensate the design- and process-related offset between the motors and work rolls. Although both types of shafts exhibit on the same kinematic principle, there are basic differences regarding the design concepts. These differences become noticeable on many levels and may become very distinct in terms of Life-Cycle-Costs (LCC). In this respect, a critical comparison between universal joint shafts and slipper spindles can be made.

Aug 16, 2017

By Paul Riches

LR Process Expert is a cost-efficient process automation system for all types of long rolling mills, including, rod, bar, section, rail, reversing mills, and flat blocks. The system performs a wide range of tasks for optimized operation – from suggesting pass schedules to calculating and downloading optimized mill settings according to the availability of rolls. LR Process Expert also monitors and collects data from the raw material stage through to the finished product. It delivers valuable mill reports to the operator staff and management so they can easily assess a plant’s performance and optimize production. Defined Key Performance Indicators (KPIs) help to assess a plant’s performance; this system is not limited to one plant but can enable plant-toplant performance at corporate level.

Aug 16, 2017

By Hervé Thomasson

Siemens VAI has made an important Research & Development effort since 10 years on laser welder field. The last step of this program was in 2010, the evolution of its laser welder range by implementing the solid state technology with laser cutting and welding. Since this step, 8 welders were produced by Siemens VAI. Now after more than 1 year of industrial feedback, the results are showing a high level of performances on very demanding processing lines for a large range of products from Silicon steel to High Strength Steel with DP and TRIP grades. This laser welder concept using laser cutting and welding through solid state laser source is also proposed by Siemens VAI for pickling lines and tandem mills with significant advantages compared to standard solution.

Jul 30, 2018

By Paulo Masiero

Sintered titanium carbide has been extensively used since the early 1980s for demanding wear-resistant applications and, in particular, in environments characterized by high temperature and oxidation. Thanks to its physical characteristics, especially its low density, titanium carbide (TiC) has been successfully applied in the manufacture of cassette guide rollers for hot steel rolling. However, the peculiar characteristics of the sintered Ti carbides make it difficult their redressing and hence this has always represented the limit for a more extensive application. Very often iron based alloys are preferred even if, in general, they are less cost effective just because they are easier to be redressed by turning. The availability of a simple, compact, fully automatic and reasonably priced CNC machine; specialized in the grinding of guide rollers and able to operate accurately and efficiently -both in contour and in plunge- can definitively solve TiC’s redressing problems and render its use even more widespread and attractive.

Oct 30, 2017

By Detlef Ehlert

Flexibility in terms of producing high sophisticated products with an exceptional wide range of properties and dimensions requires physical based process models for the generation of optimal set points. Therefore SMS applies since many years an integrated PSC® (pass schedule model), PCFC® (profile, contour and flatness model) and CSC (cooling section control) for the use in hot strip mills, CSP® plants and plate mills offering best possible product tolerances. Focus during the development of the model was made on the best possible physical description of the rolling process to minimize the need of complex adaptation algorithms. As an addition SMS has also developed a microstructure model to ensure the quality control with respect to mechanical properties and to save up the needs of taking samples. Beside of this the modular design of the Microstructure and Material Property Model (MPM) offers additional benefits to improve the accuracy of the other models, e. g. the recrystallization model in the finishing mill. Using the results of that model strain hardening or softening effects during rolling can be predicted and an optimum pass schedule can be calculated to avoid rolling stability problems related to phase transformation.

Aug 16, 2017

By Wan-sub Kim, Joon-Tae Lee, Seongkyu See, Yong-Kyu Park

Softening heat treatment of CHQ alloy steel (Cr-Mo Steel) is a bottleneck process that requires 90% or more of the entire manufacturing process. In order to reduce the property deviation between edge and center and remove the low-temperature structure problems, CHQ products is heat treated by customers. This technology comes from the idea to solve the problem by applying the concept of “In-line isothermal transformation through initial quenching + heat source addition. Consider the stability of field operations, durability from high ambient temperature and fall of scale, Instantaneous heating and cooling control was required for the conversion of slow cooling and rapid cooling products. An electric heating system was applied to the underside of Stelmor air-cooling nozzle. Using the Scan Pyrometer, the feedback control was performed and fine temperature control was performed through the thermocouple by zone. Through the this technology, it is possible to develop and expand products that can be shortened or omitted by the heat treatment process of customers.

Oct 1, 2019

By Francois Mignard

With a limited global steel production growth, automotive application market shows interesting volumes and trends especially in emerging countries. The recent period has again enabled Siemens VAI to confirm a position amongst leading suppliers of new plants serving high-end steel production in particular for unexposed and exposed automotive material. With a series of recent plant references in operation and under construction, relevant answers to such sustained level of performances are highlighted along the downstream processes. Designed for a wide range of applications, Siemens VAI processing lines includes advanced technological and state-of–the art equipment, among them, Solid state laser welder, Pickling Tunnel tanks, Skin pass mill and Tension leveller, Side trimmer with dynamic width adjustment, and new generation of Automatic surface inspection systems. With a continuous aim of driving improvements, Siemens VAI has also developed Global Quality Monitoring solutions notably through advanced software which provide just-in-time warnings and assist steel makers in the daily operation of their lines. As lifecycle partner, Siemens VAI offers solutions and services in metallurgical expertise from metallurgical modelling, through physical simulation on rolling, annealing and galvanizing processes, and enables Siemens to accompany our customers along with their project definition till fulfilment of highest market requirements.

Jul 30, 2018

By Paul Riches

Today’s steel producers face the dual challenge of ensuring on-time delivery and ever demanding product requirements, while also running a lean operation. Every day the management of a long rolling plant requires continuous optimization of both operating and business practices. Imagine a long rolling facility, where individual pieces of equipment communicate with each other, where sensor information can be used not only for control purposes but to also monitor the condition of the equipment, where models are used to verify the process is within working limits and the equipment raises alerts to operators when it requires maintenance! Utilizing the ongoing evolution in technology though data collection, communication, internet of things, control techniques and smart sensors, there is now more information available than ever before. The collection and analysis of this information will both advance control and monitoring of plant performance; revolutionizing long rolling mill plants worldwide and optimizing the entire value chain, along with improved and more flexible production.

Oct 30, 2017

By Filippo Verlezza

Conventional wire rod blocks have some limitations. They can only roll with fixed reduction ratios which always require the same rolling diameters within the block. With MEERdrive® SMS, as a pioneer, has introduced an innovative drive concept for wire rod blocks that can overcome the limitations of conventional solutions. The clue: the concept is based on individual drives for each stand position. The exigent wire rod market demand and the available technology melt in a new variant of MEERdrive®, the MEERdrive®PLUS, which represents a sizing block solution for finished size rolling and allows conventional as well as thermomechanical rolling. Further “one family rolling” is also possible, since all roll / size changes will occur in this block.

Oct 30, 2017

By Paul Pugsley

The need for dimensional measurement of products has always been there, now with the industry 4 push to further understand measure and to record process parameters is more important than ever. This applies to both flat and long products, camera systems have always provided the method to measure, stereo Linescan cameras for flat products and innovative applications using 2D and Linescan cameras for long products. Instrumentation will become more important to producers enabling processes to be better controlled and understood, that aim being to make the production process understandable more repeatable and less reliant on operator influence. Primetals Technologies Ltd offer solutions for all types of products.

Oct 30, 2017