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Unique development of Structural Strength Steel for long span applications –

presentation made to design engineers by Melvin Hickers

Background

Operational aspect to the unique development

Overview- ArcelorMittal South Africa

Saldanha Works

Casting and unique metallurgy development, start of the development

Vanderbijlpark Works

Rolling and Galvanising operation to achieve mechanical properties

Introduction of new final product in 2015 (example of applications)

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Overview ArcelorMittal South Africa

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7.8 million tonnes

5.6 2.2 Long Steel Products Operation Flat Steel Products Operation

• The flat steel operations at Vanderbijlpark

and Saldanha together have the capacity to produce

5.6 million tonnes of liquid steel per annum, the largest

suppliers of this commodity in Africa

The unique structural grade developed is hot rolled and

\ galvanised here. The final mechanical properties is

achieved via this process

• Vanderbijlpark has the capacity to produce 4.4 million

tonnes of liquid steel per annum

• Product range includes hot rolled steel in coil and plate;

cold rolled; hot-dipped galvanised; electro-galvanised;

colour coated and tinplate coil and sheets

• The unique steel chemistry is produced here via an

optimised casting process

• Saldanha produces 1.2 million tonnes of steel per

annum.

• The unit produces ultra thin hot rolled coil for stringent

applications in the domestic and select export markets

4.4

1.2

• The company's Newcastle and Vereeniging

operations, service some 50% of the local market for

long steel products, while also exporting products

internationally

• About 80% of the company's long steel products are

generated by Newcastle, an integrated steel plant,

while Vereeniging is an electric arc furnace-based

steel works.

• Newcastle works has the capacity to produce 1.8

million tonnes of liquid steel per annum

• The profile products produced include low and

medium-carbon commercial grades, low-carbon

rimming steel substitutes, sulphur containing free-

cutting steels, micro-alloyed steels, high-carbon wire-

rod steels and low, medium and high-alloy steels

• Vereeniging produces 0.4 million tonnes of liquid

steel per annum

1.8

0.4

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4

Durban

Vereeniging

Works

Johannesburg

Newcastle

Works Sishen

Vanderbijlpark

Works

Thabazimbi

South Africa

Saldanha

Works Cape Town

Steel plants

Captive iron ore/coal source

Tsikondeni The unique structural grade developed is hot rolled and galvanised here.

The unique steel chemistry is produced here via an optimised casting process

Overview - ArcelorMittal South Africa 1

Presentation Overview – processes involved

• ArcelorMittal South Africa – Overview

Saldanha Works

• Vanderbijlpark Works

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Saldanha Works

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Statistical information

1.2 million tonnes

• Nov 1995: Saldanha Steel project started

(Iscor and IDC)

• Jan 1996: First bursars, recruited from the

West Coast, sent to Newcastle for training

• Sep 1996: First steel column erected

• Aug 1997: Power available from Eskom

• 14 Jun 1998: First steel produced

• 20 Aug 1998: First hot rolled coil dispatched

• 31 Dec 1998: Corex commissioned

• 13 Jun 1999: Midrex commissioned

• Jun 2005: Full capacity reached

(103 000 tons HRC)

• Oct 2006: Record hot rolled coil production

of 113 336 tons

• September 2007 Record thin (<1.2mm)

production of 31 004 tons

1995

1999

1996

1998

2005

2005

1997

2006

2007

2011

• April 2008: Successful reline of Corex and

Midrex (78 days)

• July 2008: First 0.95mm rolled.

• July 2011: 20 375 tons <1.09

1995

1996

2008

2011

• Electricity consumption: 160 MW

• Daily water consumption: 7000 kilo liters (world best

for integrated steel plant)

• Manpower: 590 permanent employees

• Sales output: 1,2 million ton HRC pa

Head Count end of Q3: 542 (SAL)

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Asset Configuration

• 1 Midrex Plant (DRI Production)

• 1 Corex Plant

• 1 Conarc Plant

• Continuous Caster - Slabs 1

• Hot Rolling Mill 1 (1 250 kt per annum)

• HRC Temper Mill

• Saldanha Works is a largely export-focussed plant

• It is in close proximity to the deep-sea port of

Saldanha

• The plant was commissioned and produced its first

hot rolled coil (HRC) in late 1998

• currently producing at its designed nameplate

capacity of 1.2 million tonnes per annum

1.2 million tonnes

Unique operations

• The plant is distinguished by merging leading edge

technologies to produce high quality ultra thin hot

rolled coil (UTHRC).

• plant is the only steel mill in the world to have

successfully combined the Corex/Midrex process into

a continuous chain

• This configuration replaces the need for coke ovens

and blast furnaces

• The plant is a world leader in emission control and

environmental management

• Facilities and technologies at Saldanha Works were

specifically designed to produce 'clean' steel

• The continuous production chain is exceptionally

short, taking only 16 hours from the time iron ore

enters the Corex or Midrex units to the rolled

product.

• The individual processes are linked very closely with

virtually no process stock between the units

Saldanha Works

Initial product development casting the steel 2

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Saldanha Works Process Flow 2

Vanderbijlpark Works Final product development

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History/Statistical information Asset Configuration

• 3 Electric Arc Furnaces – Not in operation

• 1 Continuous Casters (V3) – Not in operation

• 2050mm Hot Strip Mill (7 Stand)

• 5mm Temper Mill + 6mm Temper Mill

• 3650mm Plate Mill

• 2 Pickling Line

• 2 Tandem Cold Mills

• 3 Temper Mill

• 2 Batch Annealers

• Electrolytic Galvanising Line

• 3 Galvanising Lines

• 2 Continuous Annealing Line

• Paint Line

• Electrolytic Tinning Line

• The Works was established in 1942

• Area of site: 2,300 Ha

• Perimeter: 20 km

• Rail networks: 254 km and 34 locomotives

• Daily electricity consumption: 6.93 GWh (230 000

families)

• Manpower ±4,896 permanent

4.4 million tonnes

Asset Configuration

• 5 Coke Oven Batteries (55-57 ovens each)

producing 1.4 million tons/year,

• Sinter plant with 2 strands, combined design capacity

of 230 kilo tons/month

• 2 Blast Furnaces

• 6 Rotary kilns, 2 of which are coupled to a power

generation plant

• 3 Basic Oxygen Furnaces

• 2 Continuous Casters (V1 + V2)

Head count end of Q3: 4 693 (VDB)

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Process Flow and optimisation to achieve mechanical properties

10 Slab exports

Galv and Colour Sheet

Cold Rolled Sheet

EG Sheet

Plate

2050mm Hot Strip Mill (7 Stand)

Plate Mill

Continuous Pickling Line Annealing process

Cold Mill

Hot Rolled Coil

Hot Rolled Pickled and Oiled Coil

Electrolytic

Galvanising Line

Electrolytic Tinning

and DWI Line

Finishing

units

Hot-dip

Galvanising Line

Annealing process

Slabs

Rolling

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Vanderbijlpark Works

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Slab

– On special

request

Cold Rolled Coil

• W = 800-1800mm

• T = 0.4-2mm

• Cold rolled or

annealed

• Various surface

finishes

Hot Rolled Pickle

& Oil

– Hot Rolled coil

pickles in HCl

and coated with a

rust preventative

oil

Plate1

– As Rolled &

Heat Treated

• L = 4-15m

• W = 0.9-3.2m

• T = 4.5-100mm

Electrogalvanised

Coil

• W = 850–1600mm

• T = 0.47–1.80mm

• Coating = Equal

or Differential

Hot Rolled Coil1

• W = 760-1870mm

• T = 1.6-16mm

• M = 17-31ton

Hot Dipped

Galvanised Coil

– W = 762-1225mm

– T = 0.27-3mm

– Coating = Z100-Z650

– Spangle = Regular &

Minimised

– Passivation and

Oiling available

Tin & DWI Coil

– W = 650-950mm

– T = 0.21-0.45mm

– Coating = Equal

or Differential

Galvanised and

Colour Coil –

Chromadek®

W – 775- 1225mm

T = 0.4-1.6mm

Vanderbijlpark Works

Product range produced 3

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Final product introduced in 2015 4

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