PASSION FOR PROCESS. Long product steelmaking

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1 PASSION FOR PROCESS Long product steelmaking

2 STEEL PRODUCTS Building the world Technology is rapidly moving forwards, enabling us to reach the other side of the world within a few hours, build skyscrapers that dominate the skyline, construct bridges between countries and produce energy using wheels as large as football fields. These are just a few examples of how far technology has come but in a world where technology is progressing so quickly, consumer demands are also increasing in line with the rate of technological advancement. Steel is integral to this progress. Without steel, the wheels of today s industry would grind to a halt: trains would no longer run, ships would no longer set sail and planes would no longer be able to take to the skies. Steel builds our world and keeps it moving. 2

3 Steelmaking is essential to today s society. SMS Concast machines and plants produce a broad range of steel grades. They allow customers to develop a variety of products to speed up technological innovations. SMS Concast helps to build the world and keep it moving, by providing products for energy production, construction and transport. 3

4 SMS CONCAST A technology powerhouse Expertise and experience, reliability and flexibility these are the hallmarks of SMS Concast. This leading supplier of electric steelmaking and casting technology helps customers worldwide achieve a competitive edge in their markets. SMS Concast offers high-performance plant and machinery for steelmaking, secondary metallurgy and continuous casting. To perform well in areas such as consulting, engineering, commissioning and service, our employees offer a combination of both outstanding expertise and flexibility. That s why SMS Concast solutions deliver such excellent benefits for their customers. SETTING BENCHMARKS WITH EXPERIENCE Since 1954, SMS Concast has supplied more continuous casting installations than anyone else in the industry. Over the years, it has designed a great range of innovative products that improve the steelmaking process. INTEGRATED SOLUTIONS SMS Concast belongs to the SMS group and is part of the SMS Meer business area. Together, SMS Concast and SMS Meer are able to better serve the growing demand for state-of-the-art minimills. The two companies turned the idea of an integrated plant with an electric arc furnace (EAF) and rolling mill into reality. 4

5 MEMBER OF THE SMS GROUP Strong, successful, together The SMS group is among the leading plant and machinery construction companies for steel, aluminum and non-ferrous metal processing. It comprises two business areas: SMS Siemag and SMS Meer. SMS SIEMAG SMS Siemag has more than 100 years experience in reduction processes. Additionally, it is a leader in steelmaking and secondary metallurgy technology. SMS Siemag s extensive portfolio also includes continuous casting, CSP technology, hot and cold rolling mills, strip processing plants, and aluminum plants. The high-quality steel products of SMS Siemag start with thin, medium and thick slabs. Its products are used in the steel, aluminum and non-ferrous metal industry worldwide. SMS MEER SMS Meer is a leading supplier of plant and machinery for steelmaking, tubes, long products, forging and heating technology. Its solutions provide customers with tangible benefits in challenging markets: steel for tire cord, tubes for pipelines, heavy structural profiles, wheels for high-speed trains, and aluminum for use in skyscrapers and offshore wind turbines. Within the SMS Meer business area, SMS Concast is the specialist in long product steelmaking. 5

6 SMS CONCAST HISTORY Always innovative Concast AG is founded by Irving Rossi The merger between Schloemann and Siemag forms SMS Schloemann-Siemag, and SMS Schloemann- Siemag becomes main shareholder of Concast AG Schloemann becomes a Concast shareholder Concast begins specializing in the design and engineering of continuous casters for long products COMPANY HISTORY INNOVATIVE POWER Collaboration with Mannesmann on the development of a continuous casting process Conseal: time-efficient preparation of strands before casting 6

7 Concast launches its Electric Arc Furnace (EAF) business (taken over from ABB) SMS Holding becomes a 100 percent shareholder of Concast SMS Concast becomes part of the SMS Meer business area Concast is renamed SMS Concast Convex : technology for more rapid casting Conmould : mold production and refurbishment Trueflow : special plating process Invex : faster casting and direct feeding of billets to rolling mills Concor : strand-guiding roller for optimized internal cooling Concharge : charging concept Conmax : nozzles Conmark : marking machine Conmould : the competence center for mould production and refurbishment Condoor : revolutionary slag-door concept for EAFs 7

8 PORTFOLIO From steelmaking to casting an end-to-end offering RAW MATERIALS STEELMAKING SECONDARY Our solutions are suitable for all individual iron-input materials and combinations: Integrated process automation and a robust design ensure maximum productivity with minimum production costs. Additionally, stateof-the-art technologies minimize emissions: Secondary metallur correct steel compos effectively as possible Storage, handling and charging system for scrap/direct reduced iron (DRI)/ hot briquetted iron (HBI) Hot metal handling and charging system Alternating current (AC) and direct current (DC) electric arc furnace (EAF) with single or multi-bucket charge Chemical-energy technology Scrap-preheating system Fume treatment and dust-collecting plant Material handling and additions system Ladle furnace (LF) Vacuum degasser (VD Vacuum oxygen decarb Trimming/chemical heat Mechanical or steam inje pumps AUTOMATION AND SERVICE AND 8

9 METALLURGY CONTINUOUS CASTING SEMI-FINISHED PRODUCTS gy systems achieve the ition as quickly and cost. Our continuous casting machines (CCM) produce billets, blooms, rounds and beam blanks, ranging from construction steel grades to high-quality products for high-end applications. SMS Concast plant and machinery produce a wide range of steel semi-finished products: ) urization ing station ction vacuum Semi-continuous super-jumbo caster Continuous combi caster Continuous beam-blank caster Continuous bloom caster (1000 mm Ø) Continuous billet caster Stainless, bearing and spring steel (bar and wire) Special bar quality (SBQ) steels for tire cord, free cutting, forging etc. Steel for rails, seamless tubes and welded tubes Reinforcing steel bar PROCESS CONTROL CONSULTING 9

10 MINIMILL EXPERTS Integrated solutions for greater customer value benchmarks within the industry. Nowadays, the key benefits of SMS minimills include lower energy consumption, reduced costs and fewer emissions. SMS Concast offers the full range of state-of-theart minimill technology: from logistics solutions for handling raw materials (scrap, DRI, HBI or hot metal) to continuous casting machines using the latest equipment, such as the INVEX mold system. CMT stands for Continuous Mill Technology, and allows cast billets or blooms to be charged directly into the rolling mill, at a high temperature. This does away with the need for conventional reheating furnaces, making CMT crucial to more energyefficient long product minimills. SMS Concast and SMS Meer developed CMT together. Minimills are part of the SMS group s DNA. About 40 years ago, SMS turned the idea of a minimill into reality, and the first plants with an EAF and associated rolling mill were built. Since then, SMS minimill technology has continued to set new SMS Concast melt-shop technologies, combined with SMS Meer rolling mills, set the benchmarks for long product minimills with capacities from 350,000 to more than 2,000,000 tons per year. Highly efficient, flexible plants around the world are testament to our expertise in minimills. We give customers a competitive edge through: PLANT LAYOUT (EXAMPLE) ADVANTAGES Electric arc furnace Ladle furnaces Vacuum degasser Continuous casting machine Fume dedusting plant 2 Customized solutions Increased profitability Maximum safety Care-free processes 10 3 transport on rail transport by over head crane 4 Superior production results Ecologically sustainable

11 TUNG HO STEEL CONTINUOUS MILL TECHNOLOGY TM Tung Ho Steel s plant in Taiwan has implemented the basic minimill concept in an exemplary way, with short processing times and a direct link between the rolling mill and the steel plant. The hot billets running out of the continuous caster (with a capacity of 40 to 45 tons/hour per strand) are immediately brought to a single, uniform temperature in the inductive heating plant. Then the billets run directly into the rebar rolling mill. This means a gas or oil fired reheating furnace upstream of the rolling mill is no longer needed. The minimill at Tung Ho is a best-practice example of groundbreaking power efficiency. Ecoplants criteria Ecological benefit: Emissions savings: 72,000 t CO 2 p.a. 410 t So 2 p.a. 225 t NO x p.a. Economic benefit Cost reduction: 11 /t 11

12 REFERENCES AND PRODUCTS Companies all over the world rely on SMS Concast SHAGANG GROUP Since the early 90s, SMS Concast has been a key supplier of continuous casting technology to the Shagang Group in Jiangsu province, China. The group has ordered as many as 71 casting strands for long products in various machines, all designed by SMS Concast. Watch the video JINDAL SOUTH WEST (JSW) Thanks to the tremendous progress in high-speed casting, especially using SMS Concast s CONVEX Technology, JSW has achieved production rates of more than 200,000 tons per year and strand. The modern casting plant at Jindal incorporates all the equipment and technology required for high-quality products: CONVEX Technology molds, electromagnetic mold stirrers, hydraulic oscillators and Conseal IV systems. Watch the video IÇDAS SMS Concast supplied 100 percent of the plant and machinery at the IÇDAS steel plant (Scrap-preheating, EAF, LF CCM). SMS Concast was able to meet the vast majority of IÇDAS requirements, including maximized rate of energy input, reduced downtime, and controlled metallurgical operation through a cutting-edge automated system. Watch the video NUCOR STEEL Nucor Steel is one of the leading steel producers in the United States. SMS Concast is proud to be its chosen supplier for all plant and machinery for EAFs, LF and the CCM. Watch the video 12

13 TUNG HO STEEL As an up-and-coming industrial nation, Taiwan is faced with huge challenges. Oil and gas must be imported, resulting in high energy costs. Tung Ho Steel near Taipei therefore commissioned a high-performance plant with low energy consumption and minimum emissions. The solution: CMT technology from SMS Concast. Watch the video CONCOR The new cooled Concor strand-guiding roller developed by SMS Concast combines several benefits: space-efficient installation, intensive internal cooling of all critical components and lifetime lubrication. The roller comprises two innovative bearing shells and has an exceptionally long service life. Watch the video Find out more by watching our videos at 13

14 ECOPLANTS Act economically grow sustainably ecoplants Reconciling sustainability with economic growth is a challenge facing practically all markets worldwide. Particularly in the metal industry with its comparatively high energy savings potential, this topic is playing an ever more important role. SMS Meer has recognised this and offers machines and plants which give equal consideration to both aspects. Ecoplants is the new hallmark from SMS Meer for sustainable solutions. ECONOMIC AND ECOLOGICAL ADVANTAGES RECONCILED Ecoplants reduce raw material input, emissions and energy consumption and improve the recycling quota. These factors are examined and measured on every reference plant. If these are satisfied, SMS Meer rates the corresponding product and the respective reference plant as an ecoplants solution provided a further crucial condition is also met: Every ecoplants solution has to offer the plant owner real tangible economic advantages. VERIFIABLE SUSTAINABLE SOLUTIONS The economic and ecological advantages of the ecoplants solutions can be clearly proven through the direct comparison with the previous technology. The CO 2 savings per year are thereby just as important today for many companies as the cost reduction per tonne. We were able to up production, cut costs thanks to energy-efficient processes and do something for the environment at the same time. So we not only save on emissions, but also hard cash. Tim Hsu, Tung Ho Steel 14

15 Find out more on our website: portfolio/ecoplants.html 15

16 SERVICE One step ahead of the competition SMS Concast s business partners have long been satisfied with their plant and machinery. Not least because SMS Concast s employees take care of plant operator s needs across the entire lifetime of a plant, even after commissioning. SMS Concast is always on hand to provide the required service from short-term emergency operations to regular maintenance work. And if customers wish to train their staff or need support with production, our specialists are ready to help. SMS Concast experts analyze processes and show ways in which they can be optimized. There is always a demand for new ways to make production more reliable and profitable. That is where the SMS Concast Service comes in, with concepts for process optimization or maintenance. And when market requirements change, our plant and machinery change with them: SMS Concast modernizes veteran plants and adapts them to current requirements. Thanks to increased productivity and product quality, the customer always remains one step ahead of the competition. ORGANIZING SPARE PARTS PROPERLY Spare parts must always be available to keep production downtime to a minimum. At the same time, investment and storage costs must be kept low. That s why SMS Concast supplies wear and spare parts quickly and reliably for all stages of production, supporting customers with spare parts management. SMS Concast s employees know exactly which parts must be stocked for which machine. SMS Concast can even handle stocktaking. REGULAR MAINTENANCE SAFEGUARDS EFFICIENCY SMS Concast conducts equipment checks and performs maintenance and monitoring, either on-site at the customer s plant or online via a remote service. SMS Concast can also assume responsibility for all maintenance services, as part of an all-inclusive, user-friendly package, upon request. ACHIEVING MORE THROUGH MODERNIZATION Plants designed for eternity also need to be re-equipped from time to time, as markets and production processes are continuously changing. Working together with its customers, SMS Concast finds the right solution for every modernization project. This allows business partners to maintain a strong market position, even decades later. 16

17 FIELD SERVICE FOR EMERGENCIES Even in emergencies, customers can rely on SMS Concast Service: the technicians help with troubleshooting and repair damages quickly and easily, ensuring that the customer s plant is up and running again as quickly as possible. TRAINING AND SUPPORT FOR STAFF How should plant and machinery be operated, maintained and overhauled? To help its customers find answers to these questions, SMS Concast shares its expertise. Technical procedures, methods and skills are typical areas in which SMS Concast offers workforce training. The training ensures employees are knowledgeable about every aspect, so that they can significantly contribute to their company s success. CONSULTING PROVIDES CERTAINTY Whether it s advice on a maintenance concept, consulting on processes or a feasibility study SMS Concast helps its customers come to decisions. SMS Concast s consultants look into the customer s problems and develop suitable solutions. But that is only the beginning: SMS Concast can also provide support with implementing the solution. RECYCLING MOLDS: THE SMS CONCAST MOLD CENTER SMS Concast s patented manufacturing process enables it to recondition used mold tubes several times over, cost-effectively and sustainably. Casthouse operators simply collect the used molds and send them to SMS Concast, where specialists restore the hard-chromium plating of the inner surface. With the exception of plate molds, mold wall thickness remains the same over the entire life of a product. A reconditioned mold tube delivers exactly the same performance as new tubes, and has the same service life. Plant operators therefore benefit from a significant reduction in costs for wear and spare parts. The manufacturing concept even allows for geometric changes, for example, for larger or smaller cross sections. A further benefit is that the external geometry of the tube remains unchanged. This means plant operators can easily switch formats or enlarge their product portfolio with SMS Concast mold tubes. 17

18 CLOSE TO CUSTOMERS Think local, act global Barueri, Brazil Shanghai, China Redcar, United Kingdom Pune, India Tarcento, Italy 18 SMS Meer sites SMS Concast sites

19 Barcelona, Spain Zurich, Switzerland Bangkok, Thailand IMPRINT SMS Concast AG, Jean-Pierre Papadopoulos (Editor), Toedistrasse 9, 8027 Zurich, Switzerland Phone: , Fax: , 19

20 SMS Concast Toedistrasse Zurich Phone: Fax: sales@sms-concast.ch MEETING your EXPECTATIONS B.04/13 en Printed in Switzerland 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.