KARIM KAHOUL SENIOR PRODUCT MANAGER DANIELI CENTRO COMBUSTION HOT DIP GALVANIZING LINE AT ARVEDI: PRODUCING AHSS OVER 800 MPA

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1 KARIM KAHOUL SENIOR PRODUCT MANAGER DANIELI CENTRO COMBUSTION HOT DIP GALVANIZING LINE AT ARVEDI: PRODUCING AHSS OVER 800 MPA

2 HOT DIP GALVANIZING LINE AT ARVEDI INDEX COLD MILL COMPLEX AT ARVEDI AUTOMOTIVE MARKET ANNEALING FURNACE: LAYOUT FLEXIBILITY FURNACE SECTIONS CONCLUSION

3 HOT DIP GALVANIZING LINE AT ARVEDI ^ COLD MILL COMPLEX AT ARVEDI AUTOMOTIVE MARKET ANNEALING FURNACE: LAYOUT FLEXIBILITY FURNACE SECTIONS CONCLUSION COLD MILL COMPLEX AT ARVEDI

4 1 COLD MILL COMPLEX AT ARVEDI FINAL PRODUCTS Automotive > Advanced high strength steel > Non-exposed Industry > White goods > Shelving > Pressure vessels > Structural profiles Construction

5 1 COLD MILL COMPLEX AT ARVEDI COLD MILL COMPLEX OVERVIEW Incoming hot rolled coils: > thickness ranging from 0.8 to 4.0 mm > Widths ranging from 800 to 1,600 mm Outgoing galvanized coils: > Thickness ranging from 0.2 to 2.5 mm > Widths ranging from 800 to 1,570 mm

6 1 COLD MILL COMPLEX AT ARVEDI LARGE COLD MILL COMPLEX WITH TANDEM COLD MILL PLTCM - Turboflo + Dasix > 4 x 6 MW 6-Hi mill stand > Rolling speed up to 1,600 mpm > Rolling force 2,500 t max > Minimum exit thickness 0.2 mm > Steel grades up to TRIP 1,000 Danieli Kohler X-Jet air wiping equipment > In-line scraper, lip cleaner, gap and width adjustment > Closed loop control of zinc thickness layer > Operating speed up to 200 mpm (0.25 mm) on GI Annealing furnace for HDGL/CAL > Direct fired furnace up to 85 tph > 2-P inconel radiant tube heating > Vertical ultra-rapid cooling for 100 C/s/mm in 5% H 2 > Proprietary Low Nox free flame and radiant tube design

7 1 COLD MILL COMPLEX AT ARVEDI MAIN FEATURES PUSH-PULL PICKLING LINE (PPPL) CONTINUOUS PICKLING LINE (CPL) TANDEM COLD MILL (TCM) > Coil preparation station > Single pay-off reel and seven (7) roll flattener unit > Entry crop shear with scarp handling > Three (3) pickling tanks - sixteen (16) meters each tank > Rinsing tank - five (5) stages cascade > Exit looper- pit type > Exit crop shear with scarp handling > Horizontal inspection section > Electrostatic oiler > Tension reel > Double pay-off reels > Laser welder > Entry horizontal looper - six (6) strands > Scale breaker unit - wet type > Four (4) Turbo flow pickling tanks > Rinsing tank five (5) stages cascade > Intermediate horizontal looper - two strand > Side trimmer carousel with scrap chopper > Exit horizontal looper four (4) strand > Horizontal and vertical inspection station > Electrostatic oiler > Tension reel and coupling section for tandem > Three (3) stand six (6)-high tandem mill (2,600 tons force) > Work roll diameter: mm > Intermediate roll diameter: mm > Back-up roll diameter: 1,200-1,350 mm > Rolling speed: 1,130 m/min max. > Positive and negative work and intermediate roll bending > Work roll shifting > Intermediate roll shifting > Basic and selective roll coolant > Carousel reel

8 1 COLD MILL COMPLEX AT ARVEDI MAIN FEATURES HOT DIP GALVANIZING LINE NO.2 (HDGL) HOT DIP GALVANIZING LINE NO.3 (HDGL) > Double payoff reels > Space for future additional alkaline cleaning > Entry horizontal accumulator six (6) strands > Horizontal annealing furnace and single induction coating pot > Four (4) - Hi skin pass mill (1,000 t) > Tension leveler with four (4) extension cassettes > Horizontal spray type chemical tank for post treatment > Exit vertical accumulator sixteen strands > Tension reel > Double payoff reels > Entry vertical accumulator twenty strands > Space for future addition of alkaline cleaning > Vertical annealing furnace with rapid cooling > Single induction coating pot design > Four (4)-Hi skin pass mill (1,000 t) > Tension leveler with four extension cassettes > Roll coater for post treatment vertical appl. > Space for future painting section > Exit vertical accumulator sixteen (16) strands > Horizontal and vertical inspection section > Tension reel

9 HOT DIP GALVANIZING LINE AT ARVEDI ^ COLD MILL COMPLEX AT ARVEDI AUTOMOTIVE MARKET ANNEALING FURNACE: LAYOUT FLEXIBILITY FURNACE SECTIONS CONCLUSION AUTOMOTIVE MARKET

10 1 OVERVIEW OF THE AUTOMOTIVE SUPPLY CHAIN AUTOMOTIVE STEEL SUPPLY CHAIN AUTOMOTIVE INDUSTRY Order entry Specification requirements Codification Dimensions, availability, reproducibility Process parameter Finished material Test certificate Steelshop Continuous casting Hot rolling mill Cold rolling mill Galvanizing line Inspection line Test items Steel analysis Test items Steel analysis Slab surface Test items Strip surface Test items Strip surface (pickling / rolling) Test items Coating parameters Post treatment data Test items Mechanical properties Strip surface Quality data

11 1 OVERVIEW OF THE AUTOMOTIVE SUPPLY CHAIN PROCESS ROUTE FROM STEELMAKING TO CAR BUILDING: KNOWHOW AND REQUIREMENTS Steelmaking 230 t Continuous casting slabs 25 t Hot rolling mill (coils 25 t, length 1,000 m) Run out table cooling and coiling Cold rolling mill Hot dip galvanizing line Hot dip galvanizing products (coils, length 2,000 m) Strength simulation plates The control of each transformation step requires a tight tolerance and a high level of repeatability of the product quality along the entire process route: each step has selection criteria.

12 1 OVERVIEW OF THE AUTOMOTIVE SUPPLY CHAIN STEEL GRADE SPECTRUM AND FINAL PRODUCT IDENTIFICATION Exposed panels require high drawability, dent resistance, rigidity. Selected grades are IF, IFHSS, BH, Low DP.

13 2 AUTOMOTIVE MARKET THE AUTOMOTIVE MARKET REQUESTS HIGHER SECURITY AND STEEL GRADES CLOSE TO OR OVER 1000 MPA Automotive market pushes towards the development of AHSS grades for CAR-body structural parts. Ultra-Low Carbon steel (ULC) Dual Phase steel (DP) Transformation Induced Plasticity steel (TRIP) Complex Phase steel (CP) Martensitic steel (MS)

14 2 AUTOMOTIVE MARKET AUTOMOTIVE MARKET RELATION BETWEEN THE STRENGTH OF THE STEEL GRADE AND THE PARTS PRODUCED

15 HOT DIP GALVANIZING LINE AT ARVEDI ^ COLD MILL COMPLEX AT ARVEDI AUTOMOTIVE MARKET ANNEALING FURNACE: LAYOUT FLEXIBILITY FURNACE SECTIONS CONCLUSION ANNEALING FURNACE: LAYOUT FLEXIBILITY

16 3 ANNEALING FURNACE: LAYOUT FLEXIBILITY FURNACE LAYOUT FLEXIBILITY DANIELI DESIGNED THE FURNACE LAYOUT IN LINE WITH THE DEVELOPMENT OF NEW AHSS STEEL GRADES TO OBTAIN THE BEST FLEXIBILITY.

17 Temperature 3 ANNEALING FURNACE: LAYOUT FLEXIBILITY ALLOY MODEL AND IMPACT ON FURNACE LAYOUT The development strategy of new steel grades is the permanent search for trade-off between alloying elements of the incoming coil, costs for the production of the steel grades and investments in furnace aggregates. Heating, soaking Si, Al, P Si, Al, P A c3 Cooling Si, Al, P, V, Nb Ferrite C, Mn, Cr, Mo A c1 C, Mn, Nb M Bainite Al C, Mn, Si Mo, Nb Time

18 3 ANNEALING FURNACE: LAYOUT FLEXIBILITY ALLOY MODEL AND IMPACT ON FURNACE LAYOUT ALLOYING ELEMENT C ( %) Mn ( %) EFFECT AND REASON OF ADDING > Austenite stabilizer > Strengthens martensite > Determines the phase distribution > Austenite stabilizer > Solid solution strengtheners of ferrite > Retards ferrite formation Si > Promotes ferritic transformation Cr, Mo (up to 0.4%) V (up to 0.06%) Nb (up to 0.04%) > Austenite stabilizers > Retards pearlite and bainite formation > Austenite stabilizer > Precipitation strengtheners > Refines microstructure > Austenite stabilizer > Reduces M s temperature > Refines microstructure and promotes ferrite transformation from non-recrystallized austenite STEEL C Mn Si Al Cr Nb Other DP " P: 0.05 " " " P: 0.03 TRIP " " " P: 0.1 " Cu, Ni " " Mo: 0.3

19 3 ANNEALING FURNACE: LAYOUT FLEXIBILITY LAYOUT

20 Strip temperature [ºC] 3 ANNEALING FURNACE: LAYOUT FLEXIBILITY HEATING CYCLE FOR HOT DIP GALVANIZING Vertical furnace annealing and cooling cycle Strip path [m]

21 HOT DIP GALVANIZING LINE AT ARVEDI ^ COLD MILL COMPLEX AT ARVEDI AUTOMOTIVE MARKET ANNEALING FURNACE: LAYOUT FLEXIBILITY FURNACE SECTIONS CONCLUSION FURNACE SECTIONS

22 4 FURNACE SECTIONS DANIELI TECHNOLOGY: HEATING SECTIONS FREE FLAME The Free Flame section allows to heat the strip up to 750 ºC. The direct impingement panel allows to control strip surface pre-oxidation when processing high alloy steel grades. RADIANT TUBE TFB-REK DCC self-reku burner: fuel and air staging achieves flame stability and best flame pattern, reducing NOx pollution and minimizing un-burnt production during the light-up phase. 2P-type radiant tube temperature uniformity combined with TFB-REK is superior compared to W-type RT ΔT is reduced from 150 C to 40 C.

23 4 FURNACE SECTIONS THEORITICAL BACKGROUNG OF AHSS SURFACE CONDITIONING

24 4 FURNACE SECTIONS PROCESS CONTROL KNOW HOW DURING SURFACE CONDITONING The precise control of the desired surface layer combines the effect of Preoxyidation and Reduction by monitoring The strip temparature The atmosphre content in the radiant tube section The time the strip stays in each section

25 4 FURNACE SECTIONS PROCESS CONTROL KNOW HOW DURING SURFACE CONDITONING TEST IN OUR RESEARCH CENTERS

26 4 FURNACE SECTIONS PROCESS CONTROL KNOW HOW DURING SURFACE CONDITONING TEST IN OUR RESEARCH CENTERS

27 4 FURNACE SECTIONS PROCESS CONTROL KNOW HOW DURING SURFACE CONDITONING TEST IN OUR RESEARCH CENTERS

28 4 FURNACE SECTIONS PROCESS CONTROL KNOW HOW DURING SURFACE CONDITONING TEST IN OUR RESEARCH CENTERS

29 4 FURNACE SECTIONS PROCESS CONTROL KNOW HOW DURING SURFACE CONDITONING TEST IN OUR RESEARCH CENTERS

30 4 FURNACE SECTIONS PROCESS CONTROL KNOW HOW DURING SURFACE CONDITONING TEST IN OUR RESEARCH CENTERS

31 4 FURNACE SECTIONS DANIELI TECHNOLOGY: COOLING SECTIONS SLOW COOLING CCS (< 25 ºC / SEC) A slow cooling section is required to decrease the temperature to AC 1 ( 670 C), where final rapid cooling commences or to ensure achievement of full cooling spectrum flexibility when low cooling rates below 25 ºC / sec are required. Currently the CCS module is without jet-coolers. RAPID COOLING CCR (UP TO 130 ºC / SEC) The rapid cooling aggregate must ensure perfect and homogeneous cooling for low cooling and high cooling requirements for both exposed panels and AHSS combining control along the strip width and cooling rate control.

32 4 FURNACE SECTIONS DANIELI TECHNOLOGY: OVER-AGING OVER-AGING AND REHEATING SECTION Over-aging time and cooling below MS point is a metallurgical necessity to ensure the client s request includes Dual phase steels, Trip steels, Complex phase steels and further 3 rd Generation AHSS steel grades such their product portfolio. In the initial phase the over-aging process is composed of 2 passes which can be extended to 6 passes based on future developments.

33 4 FURNACE SECTIONS INDUCTION HEATING BEFORE ZINC POT Induction booster to heat the strip from a minimum of 320 C up to 460 C.

34 4 FURNACE SECTIONS DANIELI TECHNOLOGY: AIR KNIFE > Hot gauge coating measurements help to correct the zinc wiping performance on both sides of the strip within seconds > Pot temperature control > Dross formation control on the pot surface > Al content control > Alloy presence control in the zinc pot when producing AHSS > Second pot requirement to produce GI as alternative coating > Pot level control +/- 2 mm > Zinc feeding system management COATING QUALITY MANAGEMENT

35 4 FURNACE SECTIONS DANIELI TECHNOLOGY: COOLING TOWER > Soft and efficient wet zinc cooling in the first part of the cooling tower to avoid surface damage > Strong cooling avoiding vibrations after zinc solidification temperature > Strong vibrations in the cooling tower can influence the zinc coating quality on the air knifes

36 HOT DIP GALVANIZING LINE AT ARVEDI ^ COLD MILL COMPLEX AT ARVEDI AUTOMOTIVE MARKET ANNEALING FURNACE: LAYOUT FLEXIBILITY FURNACE SECTIONS CONCLUSION CONCLUSION

37 5 CONCLUSION PRODUCTION OF EXPOSED PANELS > ARVEDI & DANIELI SHARED A SMOOTH AND REALISTIC METHOD OF DEVELOPING NEW AHSS STEEL GRADES AND WERE READY TO RESPOND TO MARKET REQUIREMENTS > DANIELI WAS ABLE TO DESIGN AND CONSTRUCT A MODULAR FURNACE LAYOUT CONCEPT, WHICH CAN BE UPGRADED IN A FEW WEEKS SHOUTDOWN TIME > THIS STRATEGY ALLOWS TO QUICKLY START INVESTMENT PROGRAMMES AND GREATLY IMPROVES PAYBACK OVER TIME

38 UPDATE 06/2015 KARIM KAHOUL SENIOR PRODUCT MANAGER DANIELI CENTRO COMBUSTION METEC & 2 ND ESTAD 2015 CCD CONGRESS CENTER DÜSSELDORF, GERMANY JUNE 2015 HOT DIP GALVANIZING LINE AT ARVEDI: PRODUCING AHSS OVER 800 MPA