FURNACE TECHNOLOGIES FOR LATEST GENERATION OF AHSS

Transcription

1 ANDRITZ METALS FURNACE TECHNOLOGIES FOR LATEST GENERATION OF AHSS SEAISI Conference & Exhibition JUNE 2018

2 CHAPTER OVERVIEW MARKET EVOLUTION AUTOMOTIVE STEEL REQUIREMENTS CHALLENGES FOR FURNACE DESIGN 2 SEAISI - JUNE 2018

3 MARKET EVOLUTION IN HOT DIP GALVANIZING AUTOMOTIVE INDUSTRY REQUIREMENTS Development of new grades of AHSS providing lighter and stronger car body for: Improved vehicle crash resistance Improved fuel efficiency Reduced greenhouse gas emissions By 2020, CO 2 emissions in Europe must be reduced to 95 grammes per km By 2025, fuel efficiency in USA must roughly double at 54.5 miles per gallon 3 SEAISI - JUNE 2018

4 MARKET EVOLUTION IN HOT DIP GALVANIZING AHSS : WEIGHT REDUCTION CO 2 emission regulation targets are <95 g/km in 2025 Comparison of global CO 2 regulations for new passenger cars (source ICCT, june 2016) 20% body weight reduction is required 4 SEAISI - JUNE 2018

5 MARKET EVOLUTION IN HOT DIP GALVANIZING AHSS: THE MOST COMPETITIVE CHOICE 5 SEAISI - JUNE 2018

6 MARKET EVOLUTION IN HOT DIP GALVANIZING AHSS : HIGHER STRENGHT & INCREASED FORMABILITY Press hardened steels (PHS) Chemistry Coating 3rd generation of Advanced High Strength Steels Quench & Partitionning (Q&P) Carbide Free Bainite (CFB) 6 SEAISI - JUNE 2018

7 MARKET EVOLUTION IN HOT DIP GALVANIZING 7 SEAISI - JUNE 2018

8 ASEAN CAR DENSITY FORECAST SEAISI - JUNE 2018

9 GROWTH OF AHSS WILL OUTPERFORM THE OVERALL MARKET 9 SEAISI - JUNE 2018

10 EVOLUTION OF NORTH AMERICAN MARKET 40% INCREASE OF AHSS BY SEAISI - JUNE 2018

11 "NEW" AUTOMOTIVE STEELS REQUIREMENTS For 3 rd gen. AHSS, austenitic annealing is required Ac 3 Ac 1 High DFF exit T may be needed RTS Optional slow cooling (~5-10 C/s) to control ferrite fraction and austenite Carbon enrichment Flexible Cooling rate depending on metallurgy and target product : 20 C/s to >150 C/s Rapid heating sections working on partially austenitic steels CONVENTIONAL ANNEALING CYCLE Precise end of cooling temperature for Q&P and CFB products Controlled overaging T and time 11 SEAISI - JUNE 2018

12 CHALLENGES FOR FURNACE DESIGN Ac 3 Ac 1 1 RTS 3 2 FLEXIBILITY 1. Annealing temperature flexibility 2. High soaking temperature 3. High speed cooling 4. Flexible overaging / partitionning Steel coatability 12 SEAISI - JUNE 2018

13 CHALLENGES FOR FURNACE DESIGN Ac 3 Ac 1 1 RTS 3 2 FLEXIBILITY 1. Annealing temperature flexibility 2. High soaking temperature 3. High speed cooling 4. Flexible overaging / partitionning Steel coatability 13 SEAISI - JUNE 2018

14 1. ANNEALING TEMPERATURE FLEXIBILITY ANDRITZ DFF 3 2 Ability to heat the strip up to 750 C in 2 passes SEAISI - JUNE 2018

15 1. ANDRITZ DIRECT FIRED FURNACE ( DFF) DN Burners : Radiative flame Preheating : Radiative waste gas KB Burners : Radiative flame 15 SEAISI - JUNE 2018

16 CHALLENGES FOR FURNACE DESIGN Ac 3 Ac 1 1 RTS 3 2 FLEXIBILITY 1. Annealing temperature flexibility 2. High soaking temperature 3. High speed cooling 4. Flexible overaging / partitionning Steel coatability 16 SEAISI - JUNE 2018

17 2. HIGH ANNEALING TEMPERATURE RADIANT TUBES Radiant tubes commonly used in carbon steels production : Max tube temperature : ~1000 C Working tube temperature : ~ C Risk of increasing tube temperature : lifetime decrease, creep Max strip temperature : ~850 C Other radiant tubes technologies : Fe-Cr-Al, SiC material tubes Max temperature : up to 1250 C Working temperature : ~1100 C Max Strip temperature : ~950 C Special care : exhaust gas temperature, environment (cladding, refractories) 17 SEAISI - JUNE 2018

18 2. HIGH ANNEALING TEMPERATURE ELECTRICAL RESISTANCES Electrical radiant tubes: I shape Limited power (40 kw/tube) Max tube temperature : 850 C Less performance than gas radiant tubes Wire or strip resistances: Ni-Cr Wire : 1250 C Molybdenum wire : 1400 C Special care : Surrounding equipment (cladding, refractory) Strip temperature up to 1100 C in Silicon steel furnace 18 SEAISI - JUNE 2018

19 2. HIGH ANNEALING TEMPERATURE INDUCTION HEATING Uniform, high yield rapid heating even on low thickness and high austenite content Used as pre-heating for increase capacity when no space available Ref.: TKS FBA8, Dortmund, Germany Strip temperature ~160 to 300 C Used when end-heating temperature cannot be achieved with existing radiant tubes section: Flux Transverse induction technology Ref.: AM Kessales CAL, Belgium Strip temperature ~ 820 to 900 C Used when end-cooling and overaging temperatures are below the zinc bath temperature (Al-killed, TRIP, Dual- Phase with high austenite content steels) Ref.: VoestAlpine CGL#4, Austria Before zinc bath strip with up 40% austenite ~ 340 to 480 C Ref.: AM Gent CGL#3, Belgium Inductors at different locations after cooling: strip with up 50% austenite ~ 150 to 480 C before zinc bath: strip with up 40% austenite ~ 350 to 480 C strip with up 10% austenite ~ 250 to 480 C Ref.: Tangshan CGL#6, China Before zinc bath ~ 270 to 460 C Ref.: Yieh Phui CGL, China Before zinc bath ~ 270 to 460 C Ref.: Tangshan CGL#6, China Before zinc bath ~ 270 to 460 C Ref.: Baosteel CGL, China Before zinc bath ~ 270 to 460 C Ref.: VoestAlpine CAL, Austria Overaging ~ 270 to 350 C 19 SEAISI - JUNE 2018 Induction coil outside the atmosphere chamber is an ANDRITZ SELAS patent Un seal

20 CHALLENGES FOR FURNACE DESIGN Ac 3 Ac 1 1 RTS 3 2 FLEXIBILITY 1. Annealing temperature flexibility 2. High soaking temperature 3. High speed cooling 4. Flexible overaging / partitionning Steel coatability 20 SEAISI - JUNE 2018

21 3. ANDRITZ COOLING TECHNOLOGIES Radiant cooling (air cooled tubes) Slow jet cooling (HNx tubes) Flexible Chamber (Cooling + soaking) Rapid Jet Coolers (HNx nozzles) Differential Rapid Jet Cooling highest cooling rates by homogeneous temperature distribution Higher H2-concentration for further increase of heat transfer Modular design for different operating modes 2 to 10 C/s 5 to 30 C/s(*) 0 to 40 C/s(*) 15 to 70 C/s(*) 40 to 120 C/s(*) 80 to 200 C/s (*) : 5% H2, 1,0 mm, 750 C->500 C 21 SEAISI - JUNE 2018

22 3. HIGH SPEED COOLING ANDRITZ SELAS PATENTED DRJC Differential Rapid Jet Cooling : up to 100 C/s at 5% H 2 Use of variable H 2 content : up to 170 C/s HOMOGENEOUS STRIP TEMPERATURE Strip temperature control accross width. 22 SEAISI - JUNE 2018

23 3. HIGH SPEED COOLING DIFFERENTIAL RAPID JET COOLING (DRJC) Maximize heat exchange By optimized nozzle design Avoid flatness defects By homogeneous temperature profile along strip with optimized evacuation backflow Increase heat transfer By minimum strip distance (40 mm) with automatic control Horizontal & vertical flexibility By cooler modularization & control Proven technology More than 20 installations in production 23 SEAISI - JUNE 2018

24 3. DRJC DESIGN Optimized nozzle profile Optimized return flow Adjustable nozzle to strip distance during operation Adjustable flow rate over strip width and strip length Strip travel Temperature scanner 24 SEAISI - JUNE 2018

25 3. DRJC DESIGN TEMPERATURE PROFILE CONTROL CENTER CENTER 25 SEAISI - JUNE 2018

26 3. DRJC DESIGN TEMPERATURE PROFILE CONTROL INNER INNER CENTER CENTER INNER INNER 26 SEAISI - JUNE 2018

27 3. DRJC DESIGN TEMPERATURE PROFILE CONTROL OUTER OUTER INNER INNER CENTER CENTER INNER INNER OUTER OUTER 27 SEAISI - JUNE 2018

28 3. DRJC DESIGN TEMPERATURE PROFILE CONTROL SCANNER ACROSS STRIP WIDTH Temperature scanner ± 3 C across strip width 28 SEAISI - JUNE 2018

29 3. DRJC DESIGN TEMPERATURE PROFILE CONTROL FAN & PRESSURE CONTROL Mod.1 Mod.2 Mod.3 Close loop control with scanner (center) Close loop control with scanner Modularity Speed variation of all fans Adjustment across the strip width (pressure) 3 directions Mod.4 29 SEAISI - JUNE 2018

30 3. DRJC : EXAMPLES OF LINE RESULTS Design Results 30 SEAISI - JUNE 2018

31 3. DRJC : EXAMPLES OF LINE RESULTS At 5% H 2 31 SEAISI - JUNE 2018

32 CHALLENGES FOR FURNACE DESIGN Ac 3 Ac 1 1 RTS 3 2 FLEXIBILITY 1. Annealing temperature flexibility 2. High soaking temperature 3. High speed cooling 4. Flexible overaging / partitionning Steel coatability 32 SEAISI - JUNE 2018

33 CHALLENGES FOR FURNACE DESIGN Ac 3 Ac 1 1 RTS 3 2 FLEXIBILITY 1. Annealing temperature flexibility 2. High soaking temperature 3. High speed cooling 4. Flexible overaging / partitionning Steel coatability 33 SEAISI - JUNE 2018

34 After Coating In Heating Zone 5. STEEL COATABILITY Preferential oxidation of Mn and Si - Non wettable oxides in Zn bath MnO SiO 2 MnSiO 3 MnO Fe Fe Bare spots after coating Fe Zn Zn Zn Zn Zn Fe 34 SEAISI - JUNE 2018

35 5. PREOXIDATION IN DFF ALLOWS COATING OF HIGH Mn/Si STEELS Operation Where Fe Heating AHSS strip up to 750 C Preheat + DFF RTH1 FeO Fe Ultra rapid Oxidation Last Zone of DFF Preoxidation chamber Fe Reduction of FeO RTH + RTS Zn Fe Defectless Zinc Coating Zn bath 35 SEAISI - JUNE 2018

36 5. PREOXIDATION IN DFF HOMOGENEOUS OXIDATION Radiant cup burners: Homogeneous O 2 at the burners Multiple burners: Homogeneous O 2 across strip width Air/gas premix + Trimming: Identical air/gas ratio for all burners + Trimming for narrow strip Natural Gas Comb. Air 36SEAISI - JUNE 2018

37 5. PREOXIDATION IN DFF ACCURATE OXIDATION Accurate thickness of the oxide layer ( nm) through: Accurate setting of air/gas ratio Accurate control of O 2 rate in the waste gas A too thin layer will give coating problems A too thick layer could lead to roll pickup and incomplete reduction Permanent WG analysis 37 SEAISI - JUNE 2018

38 ANDRITZ REFERENCES DEDICATED TO AHSS & 3RD GEN AHSS Customer Works Line Country Start-up Product Coating Pre- oxidation ArcelorMittal Cleveland CGL USA Auto / AHSS GI/GA YES Tata Steel Llanwern CGL UK Auto / AHSS GI/GA YES Voestalpine Linz CAL Austria Auto / AHSS / GEN3 - - ThyssenKrupp Dortmund CGL 8 Germany Auto / AHSS GI YES Voestalpine Linz CGL 4 Austria 2007 Auto / AHSS GI YES Voestalpine Linz CGL 5 Austria 2010 Auto / AHSS GI/GA YES Tagal Chongqing CGL China 2015 Auto / AHSS GI/GA/Al YES Baosteel Shanghai CGL China 2015 Auto / AHSS GI/Al-Si YES ArcelorMittal Kessales CAL Belgium 2016 Auto / GEN3 EG - JVD YES ArcelorMittal Gent CGL 3 Belgium 2018 Auto / GEN3 GI YES ArcelorMittal Florange CGL France 2019 Auto GI/Al-Si YES ThyssenKrupp Dortmund CGL 10 Germany 2020 Auto / AHSS / GEN3 GI/Zn-Mg YES HBIS Laoting CAL China 2020 Auto / AHSS / GEN SEAISI - JUNE 2018

39 THANK YOU!

40 YOUR CONTACTS Nadine BANLIN Sales Director ANDRITZ Selas SAS 4, avenue Laurent Cely, Hall A, Tours d Asnieres Asnieres-sur-Seine, France p: m: nadine.banlin@andritz.com Alain DETHIER Director Technology ANDRITZ Technologies Pvt. Ltd Magnolia, Block B, Level 4 Manyata Embassy Business Park, Nagawara Bangalore , India p: +91 (80) m: alain.dethier@andritz.com Ajoy CHAKRABARTI Sales Director ANDRITZ Technologies Pvt. Ltd Plot No. 22, 6 th Floor, Block KB Bhakta Towers Sector-II, Salt Lake City Kolkata , India p: +91 (33) / 59 m: ajoy.chakrabarti@andritz.com 40 SEAISI - JUNE 2018

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