NORTH AMERICAN GALVANIZING LINE MARKET STUDY

Transcription

1 I. PLANT IDENTITY A. Name of Company: B. Plant Location: C. Cold Mill Designation: # 2 D. General Phone Number: II. PROSPECT ANALYSIS A. Is This Plant a Prospect for a Pickle Line Project? 1. Candidate: Hot, Good, Poor 2. Action: Present, Future B. Best Application: C. Comment: This facility uses purchased hot bands primarily from XYZ Corp. and processes them through cold rolling, pickling, galvanizing, and painting. This galvanizing line started in 1997 and has been maintained to perform well. There are no present plans for upgrades and improvements but it is recognized that the future operations may include changes in grades and coating weights requiring process changes. III. CONTACT A. Name: John Doe Date: 06/01/04 Title: Area Manager - Galvanizing Address: City / State / Zip: Phone: Fax: B. Name: Jane Doe Date: 06/01/04 Title: MCL Process Manager Phone: Address: Same as above City / State / Zip: Same as above Fax: C. Name: Date: Title: Phone: D. Name: Date: Title: Phone: Page 1

2 IV. CHARACTERIZING THE GALVANIZING PRODUCER A. This Plant is an: Integrated Steel Producer Minimill Steel Producer x Outside Processor Specialty Steel Producer Service Center Tool Processor Other, Specify: B. Describe Galvanizing Line Facilities at this Location Using the Following Table: Type of Facility Total Number of Lines Coupled to Cold Mill Galvanize (GI) 1 Electro-Galvanizing (EGL) Galvanize / Galvanneal Line (GI / GA) Galvalume (AZ) Other Types, Specify: 1. Comment: John said this coating line was supplied by Danieli and began operating in C. Characterize this Galvanizing Line: Line Designation # 2 1. Start-up Year: Type of Hot Dipped Galvanizing: Vertical x Horizontal a. Annealing Furnace Soaking Time:.9-.0 Minutes. Pot Size: D.K. Tons a. Is There a Pre-melt Pot? Yes ( Where Zn Alloy is Preheated ) b. Type of Pot: x Ceramic Steel (Carbon) Stainless Steel 4. Galvanneal Furnace: Induction Heater ( kw) or Gas Fired a. Galvanneal Soaking Zone: Gas Type Electrical Heating (1) Soaking Time? Seconds b. Coating Pot Heater: Inductor Coreless Induction c. Cleaning Section: Vertical Horizontal 5. Comment: 6. Kind of Post Treatment: Oil, Chromate, Phosphate, Resin a. Post Treatment: x Spray x Roll Coater b. Post Treatment Oven: x Induction Heating Gas Heating Electrical Heating Other, Specify: c. Wiper: N2 Wiping x Air Wiping Other Wiping, Specify: 7. Type of Spangle Minimizer: None Other, Specify: Page 2

3 IV. CHARACTERIZING THE GALVANIZING PRODUCER (Cont.) 8. Galvanizing Line Equipment Suppliers: a. Major Mechanical (Line): Danieli b. Major Electrical: Danieli c. Welder: Taylor Winfield d. Wiper: e. Tension Leveller: Danieli f. Skin-Pass Mill: Danieli g. CPC: Fife h. Annealing Furnace: Selas i. Coating Pot: j. Coil Bander: k. Band Cutter: DMC Signode Signode l. Surface Defect Detector: m. Coating Weight Gauge: DMC n. Oiler: Peabody o. Galvanneal Furnace: D. Production of This Metallic Coating Line: 1. Rated Capacity: 220 K Tons / Year 2. Production 200: 200 K Tons / Year. Project Production 2004: 220 K Tons / Year 4. Type of Production as Percent of Total: a. Galvanize: 100 % b. Galvanneal: % c. Galvalume: % d. Galfan: % e. Other, Specify: % 5. Operating Hours: 24 Hours / Day 7 Days / Week 52 Weeks / Year 168 Hours / Week 21 Turns / Week 6. Type of Steels Galvanized (%): x Cold Rolled Hot Rolled a. Source of Steel: Internal Sources or x 7. Share of Production That is Toll Processing: % Buy Steel From Outside Suppliers 8. Dross (Top Dross Only) Rate:.9 % (% of Zinc Alloy) or 1.4 mil. lb. / Year 9. Comment: This line only produces galvanized product primarily for use in construction industry applications. John said the line has those features required to ensure the line produces quality product and satisfy the core customers. He said the receive hot bands from XYZ Corp. Page

4 IV. CHARACTERIZING THE GALVANIZING PRODUCER (Cont.) E. What Are Galvanized Product Dimensions? 1. Strip Thickness: a. Minimum:.010 b. Maximum:.040 c. Typical: Strip Width: a. Minimum: 24 b. Maximum: 50 c. Typical: 40. PIW: a. Minimum: b. Maximum: c. Typical: F. Bath Assays % Al; % Pb;. % Fe; 4. % Sb G. Line Speed: Type of Product: Galvanized Exposed Galvannealed Exposed Galvanized Unexposed Galvannealed Unexposed Galvalume Feet / Minute 1. What Mostly Limits Coating Line Speed? Line speed is a direct function of the rate of heating and cooling required for the product coated. H. Identify Major End-Use Markets for Galvanized Product: ( Distribute Percent ) 1. Total Automotive: % a. Exposed: % b. Unexposed: % 2. Appliance: %. Other: 100 % Specify: Construction I. Rate the Relative Impact of the Following Cost Elements (on a scale of 0-10) Regarding Your Galvanizing Line Operation Where "Steel" is a "10". ( Where Steel is NOT a Cost, Base the Relative Rating on the One with the Highest Cost as a "10" ) Steel (if applicable) Zinc and Zinc Alloys Power (Energy) Equipment Maintenance (Non-labor or Capital) Chemicals and Consumables (Non-equipment) Labor (Include Maintenance) Other, Specify: J. Comment: John said depending on the type and end use of the product, the line speed varies from as low as 150 feet per minute to a maximum of 500 feet per minute. He said the entire process is controlled by the amount of heating and cooling is required for the strip in process. John said PIW is not relevant at this line, they coat what is sent to them. Page 4

5 V. THE FUNDAMENTAL PRIORITY A. What Are the Current Fundamental Priorities of This Galvanizing Line Operation, or What Problem, Concern, or Factor Is Having the Greatest Significant Impact On Your Performance? ( Distribute 10 Points As An Indication of Priority Among the Following: ) Increase Productivity 4 Improve Quality (Surface, Shape, Flatness, Gauge Performance 4 Increase Yield Reduce Operating Costs Improve Equipment Reliability Other, Specify: VI. ASSESSING THE ADEQUACY OF THE EXISTING GALVANIZING LINE EQUIPMENT A. Is This Galvanizing Line or the Galvanizing Facilities At This Plant Adequate For Your Needs Yes B. Is the Present Level of Galvanizing Line Automation Adequate For Your Needs Yes C. How Would Your Characterize Your Current Galvanizing Maintenance Program? x Very Good; Good; Adequate; or Inadequate D. Has a Self Accident Diagnosis Device Been Installed? No E. What Limits Increasing Production On the Existing Line? John said major changes required for all facilities. F. When Reject, Reclassification or Designation of Finished Coils is Required, Would You Say the Occurrence is Primarily Due To: 1. Physical Damage 100 % of the time. 2. Coating Characteristics / Failure % of the time. G. Comment: John said substrate condition is the general cause of rejects and reclassification. He also said they take maintenance stops 8-12 hours long, as needed, each month. VII. ASSESSING FUTURE ISSUES FOR GALVANIZING PRODUCTION A. Based On Your Future Market In Two to Five Years, What Different Steel Grades (i.e. bake hardenable, dual phase, TRIP, hot rolled, or others) Do You Expect To Process? Not considered at this time. 1. Is Your Existing Furnace Capable of Processing Those Grades a. If Not, How Do You Plan To Make That Production? B. Comment: John said their focus has been on getting the line to full production. He said at a later time there may be consideration for processing other steel grades. He said the line capabilities would be evaluated at that time. Page 5

6 VIII. FURNACE AND APC COOLING SYSTEM A. How Would You Rate the Adequacy of Your Existing Furnace and APC Cooling Equipment ( On a Scale of 0-10, Where 10 is the Best 8 1. Does Your APC (After Pot) Strip Cooling System Provide Adequate Cooling and Strip Stability Yes a. If NO, What's the Problem? B. Do You Have Any Problems, Concerns, or Issues With Your Coating Line Furnace(s) and APC (After Pot) Cooling Equipment? 1. Describe the Problem: 2. Do You Plan To Make Any Modifications or Improvements to Address These Issues No. What Are Your Primary Objectives of These Changes In the Next Two Years Increase Production Improving Product Quality By Reducing Emissions Reducing Operating Cost Reducing Downtime 4. What is the Schedule for Implementation? 5. What Could Hinder Implementation of These Improvements? 6. Who Is (Are) the Key Decision Maker(s) for Implementing the Improvements? a. Name: b. Name: Title: Title: C. What New Technologies Are You Considering On the Furnace or APC Cooling Equipment? More Fuel Efficient and / or Lower Emission Burners Better Insulating Materials Longer Life Radiant Tubes Improved Roll Coatings x Other, Specify: None at this time. D. If You Now Have a Plate Type Heat Exchanger On Your Galvanizing Line, Would You Be Interested In Having It Serviced By An OEM Heat Exchanger Manufacturer? E. Comment: John said they have three coolers before and three after the top roll, and followed by a water quench. He said this system is quite adequate for this line and product coated. Page 6

7 IX. GALVANIZING BATH CHEMISTRY CONTROL A. On This Line, Do You Produce Galvanneal and Galvanized Product? If YES How Long Does the Transition Take? Hours or Turns 2. Is Transition Time An Issue?. How Long Is the Average Cycle Between GA / GI Transitions? Weeks 4. Is a 2400 Pound Transition Brightener Strip Jumbo of Interest To Your Operations Staff No a. What Would Be the Basis For Your Interest? ( Distribute 10 Points Among These Two ) Health and Safety Concerns vs. Productivity Concerns B. What Alloys or Techniques Do You Now Use To Modify the Chemistry of the Galvanizing Bath? x Al Brightener Bar ( 1. % Al ) Lead; x Antimony; Silicon; Other, Specify: C. What Problems Do You Experience With Chemistry Control of the Galvanizing Bath? Not an issue. D. How Important Would It Be To Reduce Transition Time From Galvanneal to Galvanized Grades? ( On a Scale of 0-10 ) 1. Are You Interested In New Technologies to Increase Aluminum Content to the Bath That Would Facilitate Faster Transitions From Galvanneal to Galvanize? E. Comment: John said this line only produces galvanized product. X. REPROCESSING GALVANIZED STEEL COILS A. Do You Ever Have to Reprocess Coated Coils for Any Reason, for Example, Because of Some Defect in the Metallic Coating Applied? No 1. If YES, Do You Pickle Those Coils to Remove the Zinc? a. If YES, Does the Zinc Contaminate the Spent Pickle Liquor Such That It Has a Negative Impact on Recycling the Spent Pickle Liquor? B. Comment: John said they do not reprocess galvanized strip. He said they have a test that requires the use of HCL to remove the zinc coating but they do not reprocess galvanized coils. Page 7

8 XI. ZINC CONSUMPTION A. Nominal Chemistry and Annual Consumption of Ingot Addition to the Coating Pot: 1. What is the Total Annual Consumption of Zinc Metal (all alloys) At Your Facility At: a. At Maximum Operating Capacity? b. At Usual Operating Capacity? 18,000 Tons Total Tons (1) 0 (SHG) (2) (CGGs) () (4) Aim % Aluminum (<.25 to 1%) (5) Other, Specify: c. Comment:.5% % Lead (max) (.00 or.001) Tons or Percent Trace 18, d. Other Than Aluminum and Lead, What Elements Are Specified in the Ingot (with specified level)? Other Elements Level B. Regarding CW (Coating Weight): 1. What is the Range of Coating Weight Produced With This CGL and What is the Most Common CW? HDL: Lower Limit: G0 Upper Limit: G100 Common: G50 GA: Lower Limit: Upper Limit: Common: 2. Are You Planning to Produce Lower Coating Weight in the Future? No C. Pot Chemistry: 1. How is the Coating Pot Chemistry Measured and Controlled? The lab is responsible for testing the molten zinc. Samples are taken on a repetitive schedule and they are measured by a spectrometer. The bath chemistry is controlled with manual additions. 2. Are You Planning to Modify the Chemistry Measurement / Control System in the Coming Year? No a. If YES, Are You Considering the Future Use of (or improvements to) an Automated Feeder System?. Comment: Jane said the present method for analysis of the bath is accepted and produces effective results. Page 8

9 XI. ZINC CONSUMPTION (Cont.) D. Customer Service: 1. What Problems or Issues Would You Like to See Addressed By Your Zinc Metal Supplier? None a. If the Response is of a Technical Nature, What Type of Technical Assistance Would Be of Most Benefit To Your Company / Facility? E. Comment: XII. TOP DROSS GENERATION, DISPOSITION, AND REMOVAL Name of Person: John Doe Title: Area Manager - Galvanizing A. Dross Generation 1. Amount Shipped 200 (per line): 1400 K lbs. 2. Disposition: x Top Dross is Sold Outright, or Sent to Toll Processor. If Top Dross is Sold Outright... a. 65 % of LME Received for Top Dross, or b. Range: 72% - 75% 76% - 78% 79% - 82% c. Sold To Whom: XXX Corp. / YYY Corp. d. Term Period (if on-going): 1 Year Expiration of Contract (month / year): 7/04 4. Toll Processing: a. Who Is Your Dross Toll Processor? b. Fee: (1) Does This Include Transportation Both Ways? (2) Comment: c. Term Period (if on-going): 1 Year Expiration of Contract (month / year): 7/04 Page 9

10 XII. TOP DROSS GENERATION, DISPOSITION, AND REMOVAL (Cont.) B. Dross Removal Method: x Manual or Other, Describe Equipment: 1. If Manual... a. Is Drossing a Dangerous Situation? Yes (1) Explain: John said the most common problem is splashing of the molten zinc and dross. b. How Many Workers Does it Take to Dross? 1 c. Amount Generated Per Drossing Cycle: D.K. lbs. 2. If Other Than Manual... a. What was Original Price of Equipment? $ Per Unit b. Describe Other (operating and maintenance) Costs that are Associated with This Equipment: c. Approximately What Percent of Zinc Savings? % D. Analysis of Top Dross: 50-70% - ZN; 2-5% - AL; Trace - Antimony E. Comment: John said they have done some thinking and evaluation of a robotic solution for removing top dross. He said if future changes increased the production of dross such a system could prove cost effective. He said they visited the Nucor facility in South Carolina to observe their robotic system. He said they were impressed but right now their dross production does not justify the purchase. Page 10

11 XIII. PLANS TO ADD OR UPGRADE GALVANIZING EQUIPMENT A. Are There Any Plans or Considerations to Replace, Install New, or Upgrade Any Galvanizing or Related Lines At This Facility? No 1. If YES, Describe Plans in Table Below: Type * N-New or U-Upgrade Scope P-Planned or C-Considered Approx. Value Is Money Allocated? Year of Order * GI=Galvanize; EGL=Electro-Galv; GA=Galvanneal O=Other, Specify: B. Comment: John said the plant processing equipment is performing satisfactorily and also based on the present business conditions. There are no plans for spending on upgrades and improvements. XIV. BATH CHEMISTRY (FOR EGL) A. Type of Electrolyte Bath: 1. Aim Zinc Concentration: B. How is the Electrolyte Bath Chemistry Measured and Controlled? C. Are You Planning to Modify this Measurement and Control System in the Coming Year 1. If Yes, Explain: D. Comment: XV. PERFORMANCE SATISFACTION A. If You Are Satisfied With the Present Performance of Either the Annealing or Galvanneal Furnaces in Terms of Either Tons Per Turn, BTU Per Turn, or Your Galvanzing Operation, Would You Be Interested in B. Comment: Page 11