Latest technologies and mill solutions for the production of long products

Latest technologies and mill solutions for the production of long products U. Svejkovsky Executive Vice President Sales Business Unit Long Product Plants SMS Meer GmbH

Agenda Continuous Mill Technology CMT TM - Rebar Mill Tung Ho, Taiwan High Speed Delivery System HSD - High capacity Rebar Mill Jindal Steel & Power Ltd, India Vertical Compact Coiler VCC - Rebar Mill Dechan, Korea MEERdrive Technology - Bar & Wire Rod Mill South Steel Co. / Kingdom of Saudi Arabia Precision Sizing Mill PSM - Flexible SBQ and Wire Rod Mill Kardemir, Turkey 2

Tung Ho Special Edition Dr. T. Nerzak SMS Meer GmbH Mönchengladbach / Germany Continuous Mill Technology CMT TM Tung Ho Steel, Taoyan/Taiwan

Rebar Mill Tung Ho, Taiwan Tung Ho Goals 1.2 million t/y steel (billet) production 800,000 t/y of rebar Reduce as much as possible energy consumption as there is no natural gas available in Taiwan and oil is extremely expensive Reduce environmental impact as much as possible Minimize space requirements Our solution Compact meltshop lay-out INVEX Technology Continuous Caster Direct link with the rolling mill via SMS Elotherm induction heater Flexible continuous rolling mill Straight bar and coiled bar outlets Comprehensive L1 and L2 automation Continuous Mill Technology CMT TM 4

Rebar Mill Tung Ho, Taiwan Location Taoyuan Works, Taiwan Start-up: 2010 No Reheating Furnace! 5

Rebar Mill Tung Ho, Taiwan Meltshop 1.2 million t/y Square billets: 130, 160 and 200 mm 5 3 5 1 2 4 6

Rebar Mill Tung Ho, Taiwan INVEX Technology INVEX design results in enhanced heat transfer on the full mould length Sharp Rounded 7

Rebar Mill Tung Ho, Taiwan Rolling Mill 7 800,000 t/y Rebar: 9.5 43 mm 10 6 7 8 9 11 8

Rebar Mill Tung Ho, Taiwan The Synergic process of Tung Ho Continuous casting machine 6 lines 450 C Induction furnace Rolling mill > 870 C > 950 C 9

Rebar Mill Tung Ho, Taiwan Induction Heating Furnace Main feature: re-heating and axially equalizing billets from CCM to RM Six "high specific power" coils supplied by three IGBT Converters 2.9 MW each Perfect control of temperature in combination with billet speed Top rolling performances and operating flexibility 10

Continuous Mill Technology CMT TM Concepts Type Production capacity [t/year] Product range [in mm] Full cost 1 savings CMT TM 150 (Nanomill) CMT TM 250 (Micromill) CMT TM 350 (Minimill) 100.000-150.000 Rebars Ø 8-36 150.000-250.000 Rebars Ø 8-36 250.000-350.000 Rebars Ø 8-36 Conventional vs CMT TM 150-45 $/t CMT TM 500 (Minimill) 350.000-500.000 (800.000) Rebars Ø 8-36 USD/ton, 2012 prices Scrap @ 400 $/t Electricity @ 0.04 $/kwh Natural gas @ 0.06 $/kwh (1) Auxiliaries (WTP, compressed air, oxygen, cranes and buildings) are excludes 100% scrap -EAF 11

High Speed Delivery System HSD High capacity Rebar Mill Jindal Steel & Power Ltd, India

Rebar Mill Jindal Steel & Power Ltd, India Order: 2013 Production: Furnace capacity: Billets: Steel grades: Finishing sizes: Rolling method: Delivery speed: 1 400 000 t/year 245 t/h Finishing blocks Sq. 165 / 130 mm - 12 m Low to medium carbon Rebars Ø 10-40 mm 2 strand rolling through the finishing blocks for Rebar Ø 8 up to Ø 25 mm 1 strand rolling for Rebar Ø 28 mm up to 40 mm up to 45.0 m/s Finishing line for big sizes 13 HSD

Process Comparison Multi-Slit Rolling Process rolling sizes from 10 (8) mm to 22 mm rebar separation of the rolled billet in more strands (up to 4) low rolling speed (of about 12.5 m/s) separate quenching of each bar cooling bed with lifting aprons on entry roller table. Multi-slit Quenching Line Multi-slit Rolling Four Strand 14

Process Comparison HSD process rolling of sizes from 6 mm to 42 mm rebar only one (1) single strand provision of no-twist block at high speed (up to 45 m/s) drum system for cooling bed entry with HSD (High Speed Delivery System). HSD process - Single Strand Rolling HSD process - No-twist Block Mill 15

Process Comparison HSD - Typical Installations Cooling bed Bar Braking Devices Conveying trough Shear and deviators Rotating Channels Pinch roll 16

HSD High Speed Delivery System 17

Process Comparison Benefits of HSD Process Best size tolerance obtainable due to higher size control. Higher degree of rolling reduction leading to optimal mechanical features Higher yield due to less cobbles, less short tails, crops and less primary scale formation due to less standby of reheating furnace for size adjustment. Shorter time for set up and size change due to simpler pass design and guide adjustment. Longer groove life leading to less frequent groove changes. Less rolling rolls and rings consumption. Less rolling guides components consumption. 18

Process Comparison Achievable Tolerances for Ø 8-16 mm $$$ HSD Slitting -4% -2% 0% +4% Max. allowable weight tolerance as per DIN 488 19

Multi-Slit Rolling vs HSD Conversion Cost Comparison - Example 400.000 t/year Yearly Saving/Earning with HSD Short bars at cooling bed exit 88.000 $ Cobble losses 107.000 $ Size tolerance 6.100.000 $ Losses for out of tolerance & trial bars 102.000 $ Losses for mis-counting on bar counter 65.000 $ Yearly Saving/Earning with slitting Cost gap for energy 205.000 $ Losses for scale formation during size adjustment 53.000 $ Energy losses during size adjustment 10.000 $ Heating energy losses during size adjustment 250.000 $ Cost gap for man power - - Cost gap for spare parts 25.000 $ Cost gap for rolling rings and rolls requirement 30.000 $ Different earning due to different time available for rolling 784.000 $ TOTAL 7.589.000 $ 230.000 $ 20

Multi-Slit Rolling vs HSD Product Marketability Thanks to the more precise rolling size geometry and the better and more constant mechanical characteristics, the bars produced with the HSD are always preferred by final users instead of bars rolled with the slitting. HSD rolled bars are optimal for the use on: - automatic forming machine - benders - electro-welded meshes plants 21

Vertical Compact Coiler VCC Rebar Mill Dechan, Korea

Rebar Mill Dechan, Korea VCC Order: 2009 Production: Furnace capacity: Billets: Steel grades: Finishing sizes: Delivery speed: 450 000 t/year 70 t/h Sq. 130 mm - 12 m (Sq. 150mm future) Low to medium carbon Rebars Ø 10-25 mm up to 35.0 m/s 23

V.C.C. Vertical Compact Coiler Comparison VCC Coil Vs. Wire rod Coil: Ordered winded, no re-winding operations No wire twisting Disorderly winded, re-winding operations required Twisted Wire High density = Approx. 80 % Low density = Approx. 30 % Better transportability Reduced storage space Tilting needed Big storage space required RESULT: VCC Perfect for automatic machines: Drawing machine, electro welded mashes machines, electro welded lattice girder frames, cold rolling mills etc. 24

V.C.C. Vertical Compact Coiler Comparison VCC Coil Vs. Wire rod Coil - Result: Twist free spooling operation (no cobbles in downstream operations). No more off line un-coiling, stretching and re-coiling operation. Final mechanical proprieties complying with narrow standards High density with storage and transport benefits. 25

V.C.C. Vertical Compact Coiler Typical Layout: Unloading device and Strapping machine Pinch rolls Cooling and transferring device Vertical mandrels Vertical distributors Vertical Loopers 26

V.C.C. Vertical Compact Coiler 27

MEERdrive Technology Bar & Wire Rod Mill South Co. / Kingdom of Saudi Arabia

South Steel Co. / Kingdom of Saudi Arabia 10 stand MEERdrive Block HSD Order: 2012 Production: Furnace capacity: Billets: Steel grades: 500 000 t/year 100 t/h Sq. 150 mm / sq. 130 mm - 14 m Low to medium carbon Finishing sizes: Bar Ø 8-40 mm up to 41.0 m/s Wire rod Ø 5.5-16 mm up to 105 m/s 29

Revolutionary MEERdrive concept Conventional drive 30

Revolutionary MEERdrive concept MEERdrive MEERdrive PLUS MEERdrive : Flexible individual drive concept up to 130 m/s 31

Comparison conventional vs MEERdrive concept Conventional MEERdrive No-load power kw Consumption kwh/t No-load power kw Consumption kwh/t Savings kwh/t Distribution gear 300 2.3 - - 2.3 Change-speed gear 500 5.8 - - 5.8 Idling 197 2.3 32 0.4 1.9 Total 997 10.4 32 0.4 10 Energy savings 10 kwh/t process score 32

Revolutionary MEERdrive concept Simplified roll ring management with the MEERdrive concept Conventional roll family concept MEERdrive roll pair concept Re-machining of all roll rings due to fixed reduction ratios Re-machining of individual roll ring pairs Potential savings with the MEERdrive concept (roll rings) Conventional MEERdrive Required roll ring stock: ca. 900 pairs ca. 300 pairs Costs: 1.8 M 600,000 Average roll ring price 1,000 33

Revolutionary MEERdrive concept Absolute sizing flexibility Conventional MEERdrive Fixed gear ratios Fixed reduction ratios between the stands Very high flexibility in the roll sizing strategy / design Free choice of reduction ratios between the single stands Tight limits in the roll setting to compensate wear or differences in spread of different material grades Free setting range Technical progress in addition to savings potential Improved dimension tolerances and metallurgical properties with significantly increased flexibility of the rolling mill 34

Precision Sizing Mill PSM SBQ and Wire Rod Mill Kardemir A.S. / Turkey

Kardemir A.S. / Turkey 3-roll Sizing Block PSM 380/4 4 stand MEERdrive PLUS Block (Future) Order: 10 stand 2013 MEERdrive Production: 700 000 t/year Block Furnace capacity: 130 t/h Billets: Sq. 170 mm / 150 mm - 6 m to 12 m Steel grades: Low and high carbon steel, low alloy steel, ball bearing steel, free cutting steel, spring steel, cold heading steel Finishing sizes: Wire Rod: Ø 5.5-25 mm Rebar cooling bed line: Ø 8-40 mm Bar in Coil: Ø 20-55 mm SBQ Bar: Ø 20-100 mm Rolling speed: Wire Rod via LCC : up to 120 m/s Rebar cooling bed line: up to 41 m/s SBQ Bar via cooling bed/pouring reel: up to 15.0 m/s 36

Key feature of the 3-roll PSM : Full Process Transparency Adjustment under load capability - by closed loop Hydraulic Capsule Control System (HCCS) Rolling Force & Roll Position Detection - Compensation of mill spring, feeder variations, impact settling Monitor Control - Compensation of varying rolling conditions (Temperature wedges, steel grades, cross sectional variations) Automatic Gap Setting - Actual Diameter Feedback - Head / Tail Compensation 37

Individual Roll Force and Roll Position Measurement Roll pos. Roll force Roll pos. Roll force For each stand & roll => Process Transperancy!! Roll pos. Roll force 38

Automatic stand change for maximum flexibility 40

Adjustment under load capability by Hydraulic Capsule Control System F 41

Main advantages of the 3-roll PSM Highest Utilization - single family rolling - less down time. minimized upstream mill changes. minimized stand/roll/groove changes - quick changing of stands + 10-15% utilization* Maximum Flexibility - for all steel grades - at any time - free-size rolling (9% of dia. / max. 3mm) - infinite sizes (NOT ONLY discrete sizes) 42 *as compared to a conventional 2-High sizing mill

Single Pass Family Rolling Principle with the PSM Example Individual Up Stream Mill Configuration Wire Rod Mill Pouring Reel PSM Cooling bed PSM 380/4 29,5 22,5 16,0 19,3 mm 19,3 25,0 mm 79,0 61,0 48,0 37,0 25,0 32,2 mm 32,2 42,0 mm 42,0 52,5 mm 52,5 69,2 mm Pre-Finishing or Finished Sizes 99,5 69,2 90,0 mm Any diameter, any grade, any time 13-150mm possible depending on PSM size 43

Main advantages of the 3-roll PSM Excellent Quality - closest tolerances ( 0.1 mm) - excellent surfaces - as required mechanical properties (TMR) - by minimized human errors High Economy - low operational costs - high yield - less inventory (e.g. rolls, guides) - free product planning - just in time rolling possibility 44

Enhanced quality thanks to PSM and MEERgauge Conventional 3-roll stand Froll PSM 3-roll cassette Froll Source: Rolling Mills, Jianan Zhou, China 2009 Rolling force is absorbed in the stand Spring (stand modulus) Wear (initial pass impact) No adjustment under load Rolling force is absorbed in the frame; cassette at no force Spring is compensated No wear in the cassette Adjustment under load 45

Enhanced quality thanks to PSM and MEERgauge Concept integration PSM MEERgauge Hydraulic adjustment Control algorithm Measuring device Measuring principle: Shadowgraph Measuring principle: Light-section Conventional measurement with interpolated contour Real contour with lightsection concept 46

Enhanced quality thanks to PSM and MEERgauge Ø 60 mm with 0.056 mm ovality Jens Eisbach, Rolling mill manager Deutsche Edelstahlwerke Siegen with the 3-roll PSM we can safely roll tolerances within the range of 1/8 DIN EN 10060... 47

Enhanced quality thanks to PSM and MEERgauge Higher accuracy for higher yield DIN 1/2 DIN 1/4 DIN 1/8 DIN Increase in yield % DIN 1/2 DIN 1/4 DIN 1/8 DIN Ø 60 Percentage - 1.6% 2.5% 2.9% Tolerance according to DIN EN10060 ± 1 mm Energy savings kwh/t DIN 1/2 DIN 1/4 DIN 1/8 DIN Process score - 5.7 8.6 10 Total score - 103 160 187 48