Abu Dhabi 22-23 February 2012 2 nd Metal Bulletin's Middle East Tube and Pipe Conference Matteo Copetti Business Development Manager
2 nd Metal Bulletin's Middle East Tube and Pipe 1. The Arvedi Group We will talk about 2. Sustainable Development: Definition The Sustainable Development applied to the Steel Industry The LEED Construction 3. How to be Successful in the Steel Industry? A Culture of Sustainable Innovation
1 - The ARVEDI GROUP 1 - The Arvedi Group
1 - The Arvedi Group The Arvedi Group was founded in 1963 by Giovanni Arvedi whose family has worked in metal trading and processing since the early 1700s.
1 - The Arvedi Group The Arvedi Group produces over 3 million tpy of steel products, has a turnover of about 2 billion and more than 2.500 employees. Its steelmaking nucleus is composed of six manufacturing companies located in Italy & Brasil operating in three specific sectors: flat rolled steel with Acciaieria Arvedi manufacturer of quality carbon steel coils carbon and stainless steel welded tubes, with Arvedi Tubi Acciaio and Ilta Inox; cold drawn tubes with Metalfer precision cold rolling of stainless steel strip with Arinox carbon steel welded and cold drawn tubes with Arvedi Metalfer Brasil (start of production: July 2012)
1 - The Arvedi Group Carbon steel hot rolled Coils, Pickled and Galvanized Europe s first and the world s second mini-mill for flat steel production, it produces around 3,0 million tonnes per year of hot rolled, pickled and galvanized coils. The no. 1 plant uses Arvedi ISP, In-line Strip Production, patented technology based on in-line thin slab casting and rolling. The no. 2 plant, started up in 2009, achieves an epoch-making innovation with ESP, Endless Strip Production, the continuous casting and rolling process (patented in the most important countries).
1 - The Arvedi Group With production volumes over 500,000 tpy it has always been oriented towards high quality special products using coils from Acciaieria Arvedi. 50% of production is exported. ERW & HSR processes for the manufacturing of round, square and rectangular tubes with a max wall thickness of 16 mm. Carbon Steel Welded Tubes Automotive, line pipe and construction are the main markets. Metalfer Cold Drawn Tubes Metalfer is among the most highly qualified cold drawn tubes companies in Europe. It produces 80,000 tpy of tubes for the automotive market and the hydraulic sector (cylinders).
1 - The Arvedi Group Stainless Steel Tubes Is one of the largest producers in Europe of welded stainless steel tubes, a sector in which it has been operating successfully for about forty years. Production range: OD from 10 mm to 711.2 mm (1/2 to 28 ); Wall thickness from 0.5 mm to 7 mm in austenitic and duplex steels. The most efficient welding technologies, the modern heat plants and the various finishing lines, allow iltainox to satisfy even the most demanding requirements of the various industrial sectors, thanks to a high quality product certified by the most important international testing authorities.
1 - The Arvedi Group Stainless Steel Precision Strips Manufactures thin and ultra thin precision rolled stainless steel strip for special applications in the automotive, chemical, heat exchanger, electronic and biomedical industry. The only Italian manufacturer in the precision strip sector, it has now reached a production capacity of over 50,000 tpy. Over 75% of its production is exported (mainly to Europe, but also to America and the Far & Middle East).
2 Sustainable Development 2 - Sustainable Development
2 Sustainable Development Sustainable Development Development that meets the needs of the present without compromising the ability of future generations to meet their own needs. (*** World Commission on Environment & Development ***) Environmentally sustainable: the economic system must respect the integrity of ecosystems and ensure the resilience of life supporting system. Socially Just: the economic system must ensure all people have access to a decent standard of living and full opportunities for personal and social development. Locally rooted: the economy is a global aggregate of individual communities meeting the needs of its citizens through the responsible, local production and exchange of goods and services.
2 Sustainable Development A SUSTAINABLE Steel Industry implements energy efficient manufacturing processes, supported by: Renewable Energy Generation: developing and using energy sources such as solar, wind, geothermal and biomass. Green Buildings: constructing new green buildings, retrofitting residential and commercial buildings, and installing other green construction technology (LEED CONSTRUCTIONS). Environment Protection: protecting the environment on individual, organizational or governmental level, for the benefit of the natural environment and humans. Recycling & Waste Reduction: activities related to solid waste and wastewater management treatment and reduction, as well as processing recyclable materials. Energy and Carbon Capture: capturing and storing energy and/or carbon emissions, as well as technologies related to power plants using the integrated gasification combined cycle (IGCC) technique.
2 Sustainable Development The LEED CONSTRUCTION Leadership in Energy and Environmental Design LEED consists of a sets of rating systems for the design, construction and operation of high performance green buildings, homes and neighbourhoods. LEED main targets are: Energy Efficiency Effectiveness LEED certified buildings are intended to use resources more efficiently, they provide healthier work and living environments, which contributes to higher productivity and improved employee health and comfort. LEED certification rewards LEED construction companies being conscientious about the impact on the environment
2 Sustainable Development A SUCCESSFUL BUSINESS IS BUILT AROUND A COMBINATION OF: creating a culture where safety will never be compromised managing projects through an integrated approach to quality, safety and environment protection working with clients to share ideas, provide excellent value, creatively tackle challenges and ultimately achieve the best possible outcomes delivering top quality projects with a pride that extends right through the entire workforce empowering people/employees with the ownership of their projects
3 How to be Successful in the Steel Industry? a Culture of Sustainable Innovation The Arvedi Strategy
Arvedi corporate philosophy essence is expressed in four words: PROCESS AND PRODUCT INNOVATION Giovanni Arvedi, awarded with the Bessemer Gold Medal 2009: "For outstanding services to the steel industry. Awarded to Giovanni Arvedi for his audacious approach to hot strip manufacture with his construction of a compact, in-line casting and rolling process for hot strip at the first ISP plant in Cremona, Italy. He is greatly responsible for the development of this plant in his hometown, and has an open approach to innovation. He has sought to share knowledge of thin slab casting and rolling across Europe. Giovanni is an inspirational leader and displays exceptional personal commitment.
Arvedi ESP Endless Strip Production Cremona 2nd Plant Start-up: Q1 2009 Capacity: 2 3.5 mtpy Strip thickness: 0.8 12.0 mm Width: max. 1,570 mm *** A fully patented Arvedi technology ***
ESP line from the ladle to the finished coil 250 tonnes of liquid steel in 180 m become Hot rolled coils
ESP Main Advantages 1 INCREASED PRODUCTION EFFICIENCY With a totally controlled process, Arvedi ESP offers the advantage, starting from a thin hot rolled product with excellent precision, dimensional and flatness characteristics, of obtaining gauges such as 0.3 and 0.2 mm (and even 0.14-0.12 mm for tinplate) with a limited number of cold rolling passes (lower investment and lower processing costs).
ESP Main Advantages 2 COST REDUCTION Thanks to a fully continuous strip production, direct processing costs are characterised by lower energy consumption, lower costs for consumables and improved liquid steel yield. With Arvedi ESP the energy content of the liquid steel is fully exploited, the casting speed is increased and the energy consumption is reduced. Indirect costs benefit from the higher productivity of the Arvedi ESP plant.
ESP Main Advantages 3 IMPROVED ENVIRONMENTAL PERFORMANCE Lower direct and indirect emissions of greenhouse and noxious gases (NOx and CO), Fully respecting the objectives of the Kyoto Protocol Lower water consumption: 5 times less than the best conventional mills. The considerable descaling of the production works with dimensions up to 10 times smaller than those of traditional steelmaking centres confers Compatibility to the steelmaking activity with the respect for all social and environmental contexts.
A REAL PROCESS & PRODUCT INNOVATION, DESIGNED & DEVELOPED ON A BASE OF GREEN PRINCIPLES, BRINGS TO... Simplification and shortening of the production cycle. The most compact in the world: only 170/190 m from liquid steel to coil. High product quality and new products. Computerised automation for optimum process control and reduced transformation costs. High degree of flexibility and rapid response to the market. Lower invested capital per unit of product and improved job conditions. Environmentally-friendly, sensitive to the need to conserve natural resources, minimized pollution.
Products Steel Mix Thin gauges - ATG Quality characteristics Structure Resistance Precision Arvedi ESP PRODUCTS A full range of steel grades from low to high carbon including HSLA (up to 800 MPa), multi phase and TRIP, silicon steel (3 %) and stainless. For replacement of cold rolled products: 0.8 1.2 mm for mild and HSLA steel up to 420 MPa yield. 1.5 2.0 mm for HSLA from 550 to 700 MPa yield. 1.2 mm for DP 600. Homogenous, fine grain: Low carbon ASTM 10 12 HSLA ASTM 13 14 No segregation. Constant on the whole coil. Greater resistance to fatigue. Three times greater resilience at low temperatures than standard values. Thickness, flatness and tolerances comparable with those of cold rolled products.
The INTEGRATION between HR Coils & Welded Tubes productions From Acciaieria Arvedi tailor-made & high quality HR COILS are delivered daily to the Arvedi Tubi Acciaio premises, where they are transformed into resistant, precise and high-quality WELDED STEEL TUBES.
The synergies with to rely on top quality raw material i.e. Tailor made special steels HRC with close tolerances HRC produced in an environmentally-friendly way allow for manufacturing tubes and pipes in an extended size range: OD 17.2 323.9 mm; sq. 250 x 250; rect. 300 x 200 ; x 16 mm thickness OD 6 273 mm x 15 mm cold drawn (Metalfer) focused on: 1. HOT STRETCH REDUCED welded tubes to replace seamless 2. ERW (cold-formed) tubes for special applications: Automotive Thermal and Heat exchangers Water & Gas distribution, Line Pipe Civil engineering and construction (round, square and rectangular hollow sections)
1 - Advantages of Welded & HSR Tubes vs Seamless Tubes Similar technical features: OD/T ratio 3.5 Carbon equivalent (Ceq) value around 0.40-0.43% are currently welded High and homogenous mechanical properties Cost competitiveness Market conditions OCTG market strong = shortage of Seamless HRC supply stable over the years Better dimensional characteristics: Eccentricity: 3.5 % vs 5%-7% of Seamless Polygonization is insignificant
2 - ERW tubes for special applications HRC tubes thanks to: Mills for tubes with low OD/Thickness ratio (minimum 6); Specific forming technology aiming to the highest ERW tube precision: (+/- 0.04 mm deviation on the OD); Zero eccentricity (based on Arvedi HRC) Integrated Welding Control System. ERW tubes ERW special tubes for oil&gas marginal field production DOM ERW tubes idraulic cilinders
2 - ERW tubes for special applications (Example 1) Round and Hollow sections for heavy duty (to replace beams) 250.x250.x16. mm Ferrari Word Abu Dhabi
2 - ERW tubes for special applications (Example 2) Round and Hollow sections for heavy duty (to replace beams) PROJECT: RZESZOW STADIUM (POLAND) CLIENT: ThyssenKrupp Energostal Poland APPLICATION: Civil Infrastructures 244.5x7.1 mm S355J2H
2 - ERW tubes for special applications (Example 3) Round and Hollow sections for heavy duty (to replace beams) PROJECT: Tunnels strengthening (Italy) MATERIAL: 193.7 x 5.0 mm S275 APPLICATION: Civil Infrastructures
2 - ERW tubes for OTCG (Example 4) (Oil Country Tubular Goods) Casing & Tubing API 5 CT Line Pipe API 5 L
The drive for innovation is like a being that takes root and grows within us until it involves us totally. At this point we must give birth to the project Giovanni Arvedi