Reprint from ALUMINIUM 6/2012 Pages 31 to 35

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1 FURNACE TECHNOLOGY Reprint from ALUMINIUM 6/2012 Pages 31 to 35

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3 In the steel and aluminum industries it was standard practice for many years for investors to split orders for new rolling mills or strip processing plants into three different packages, namely mechanical equipment, electrical equipment and thermal treatment, and award them separately. At the time, customers were used to having to coordinate the individual packages themselves and to take on the responsibility for the resultant interface problems. However, customers are now becoming increasingly interested in plant manufacturers who are willing to supply the whole plant, including process expertise, and are technologically capable of doing so. Fritz Brühl, Executive Vice President Furnace Technology Division at SMS Siemag. SMS Siemag, one of the most successful suppliers of rolling mills and strip processing plants to the steel and aluminum industries, gradually started to change this long-established practice of splitting orders into packages, firstly by combining the packages for mechanical and electrical equipment and, since recently, the furnace technology for thermal processing. This brings the manufacturing process into the foreground, which results in great advantages for both parties: Plant owners are then responsible for fewer interfaces and they can remind the plantmakers of their complete or partial responsibility not only for the proper functioning of the plant but also for the resultant product. This step gave SMS Siemag the opportunity to grow as a result of the ensuing expansion of its business activities and to gain a competitive advantage by taking on overall responsibility. Author: Fritz Brühl, Executive Vice President Furnace Technology Division at SMS Siemag This trend began when the company, which already had a lot of experience in the mechanical aspects of plant manufacturing, also started supplying the drive engineering and the electrics for the control systems. This led quickly to the development of process models, for instance for the consistency of the strip dimensions 3

4 SMS SIEMAG Furnace Technolgy and the strip flatness. This meant that it was already possible, for example, to influence and guarantee the geometry of a rolled product. However, the effects of the thermal treatment on the properties of the rolled product still remained outside the company s control. SMS Siemag saw this as a market opportunity and searched for a solution to integrate the heat treatment of the rolled products into its own portfolio. A start was made five or six years ago. It was triggered by the takeover of Belgium-based Drever International, which at the time was already a leader in the construction of furnaces for continuous strip processing plants such as annealing and galvanizing lines for carbon and stainless steels. Customers are increasingly tending to rely on our expertise to achieve specific material properties. In the long term, the only companies who will survive in the marketplace are those that can reproduce the process in its entirety. This applies just as much to the latest grades of steel like TRIP or dual phase steels as it does to demanding rolled aluminum products, such as those intended for the automotive and aircraft industries. These materials cannot be produced without using a specific heat treatment. In the ensuing years, the market presented SMS Siemag with ever new and different demands regarding the heat treatment of semi-finished rolled products. At first, the company attempted to carry on with Drever s successful business activities and, in parallel, to use that firm s general furnace expertise for new developments also. However, this also resulted in SMS itself acquiring ever more expertise, mostly in close cooperation with the Strip Processing Lines Division, which was responsible for the mechanical equipment. This transition process led to the formation of the new Furnace Technology Division at the beginning of Cooling device used to achieve the desired metallurgical microstructure in heavy plate. The plan for SMS itself to become involved in furnace building took shape about the middle of the past decade. The driving force for this came from the Strip Processing Lines Division, which had always placed orders for furnaces with subsuppliers or consortium partners, including Drever, even where orders were for the supply of complete plants. In the various types of processing line for producing steel strip, it has been evident that the critical process step takes place in the furnace, and that such a step requires expertise and has a defining influence on the material properties of the product. SMS gradually realized that only those plantmakers who have a thorough understanding of every aspect of the treatment process are able to offer their customers added value. Fritz Brühl, Executive Vice President of the Furnace Technology Division at SMS Siemag says: SMS Siemag is well known as a successful supplier of rolling mills and strip processing lines for flat products. It therefore went without saying that the new business unit would also focus on the heat treatment of flat products. Mr Brühl comes to the point: There are two expressions to describe our product portfolio: the one is heat treatment, and the other is flat material. In our opinion, added value and technological challenge are less likely to be found in melting and heating and more in heat treatment heating and cooling the material in a specific manner. To this end, the company has built up its own expertise in recent years in the form of process models for the heat treatment of heavy plate. Just like with strip, cooling after annealing is decisive for the result. The plate must not warp and has to have a high degree of flatness. A roller quench with cooling from the top and the bottom was developed jointly with Drever. The tempering of heavy plate is an area where SMS Siemag has since become active and this has already led to three reference units. In March of this year, the company received its first order for a furnace with integrated cooling for stainless steel plate, including the electrical and automation systems and transport devices. 4

5 Floating furnace for solution heat treatment and soft annealing of automotive materials. Tunnel furnaces are an item that the company had previously purchased from partner companies but has now developed further as one of its own products. These furnaces are an integral part of CSP plants, i.e. integrated continuous casting and rolling plants for steel strip, now capable of producing three to four million tons a year. The company is particularly proud of a newly developed furnace roller which offers considerable energy savings over earlier models. HEAT TREATMENT PLANTS FOR FLAT ALUMINIUM PRODUCTS SMS Siemag became involved in the heat treatment of aluminum strip and sheet in 2011 with the acquisition of the expertise and personnel of GATV, with whom it had already cooperated for many years on the steel side. For example, GATV had supplied the drying ovens for strip coating lines. GATV brought with it tried and tested technology for floating furnaces and for catenary furnaces for carbon and silicon steels, which was later used for similar units for aluminum strip. A floating furnace provides not only heating but also cooling, which at GATV is performed with air and water. This is the only way that high cooling rates can be achieved; air alone would not be feasible for achieving such high rates, for example for aircraft materials. The heat treatment of automotive strip is equally demanding, and GATV supplied a suitable heat treatment line to Hydro Aluminium in Grevenbroich in 2008.As part of its own further development, SMS Siemag incorporated the technologies from Drever and GATV into its own heat treatment lines and further improved them technologically. They now complete a comprehensive portfolio that includes hot and cold rolling mills for strip, sheet and plate. Besides this there are the strip treatment and processing lines in which the company will be offering process-oriented integrated solutions in future, comprising the mechanical and electrical equipment as well as heat treatment. Two recent orders marked the first commercial acceptance of this concept. Last year, SMS Siemag supplied a new coating line for aluminum strip with an integrated drying oven based on GATV technology to the Turkish company Asas Alüminiyum. The line is used primarily 5

6 SMS SIEMAG Furnace Technolgy for aluminum strip 900 to 2,100 mm wide and 0.2 to 2.0 mm thick. In addition, it is also possible to use the cleaning section to clean galvanized steel strip 900 to 1,600 mm wide and 0.2 to 1.0 mm thick and to then apply a conversion coating with the chemcoater. Similarly, an order that SMS Siemag received recently from Alcoa Ma aden in Saudi Arabia clearly demonstrates the capabilities of the new division. The company is supplying a cold rolling mill with an annual capacity of 100,000 tons, mainly for automotive and aircraft grade alloys, together with a complete continuous strip annealing line. The centerpiece is a floating furnace with a downstream cooling section. Compared with older annealing lines, which only used air cooling, the new line uses combined air and water cooling. Only a water quench can achieve the rapid cooling needed to achieve aeronautical grades. From a strategic point of view, this order is highly important for the new division. After all, it is the first SMS reference that uses water cooling for aluminum strip. Mr Brühl comments: With the new reference plant we are entering the market with a new technical approach that integrates activities that were previously carried out individually in the company into an overall solution. This approach is opening up a new field of business for SMS Siemag, successfully dealing with the aluminum market in the area of strip processing lines. There are currently a great number of projects aimed at the automotive and aircraft industries. For Mr Brühl, the heat treatment boom is only just beginning in China. He does not see it as being limited to strip, since a further substantial application will be plate annealing furnaces. In this connection, Mr Brühl provides an insight into an additional direction of development being planned by SMS Siemag. The synergies for this come from widespread experience in the heat treatment of heavy steel plate that SMS Siemag has acquired in the recent past. With the two orders from Asas and Alcoa Ma aden, the company feels that its strategy has been fully justified. We made a start last year on the floating furnace side of the business, says Mr Brühl, adding: In contrast to Annealing furnace for the treatment of non-grain-oriented electric steel strip. 6

7 Floating furnace. other areas of application for furnaces in the aluminum sector, we are dealing here with a sophisticated technology that creates added value. This applies above all to the heat treatment (annealing and cooling) of strip in a floating furnace and the annealing of plate in a rollerhearth furnace. In the long term, we want to become established in these segments. SMS Siemag is currently not focusing on other types of furnace design like pusher furnaces for heating of rolling ingots or chamber furnaces for the heat treatment of strip coils. Nevertheless, Brühl does not want to rule out the possibility of the company also dealing with these in the future. A prerequisite, however, would be to find technological approaches that generate added value both for the customer and the company. 7

8 SMS SIEMAG AG Furnace Technology Division Graf-Recke-Strasse Düsseldorf, Germany Phone: Fax: Internet: MEETING your EXPECTATIONS W7//318E 1000/10/12. ky. Printed in Germany The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as 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.

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