steel success strategies xxvii - american metal … · 2012-06-28 · june 18-20, 2012 steel...
TRANSCRIPT
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 1 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
STEEL SUCCESS STRATEGIES XXVIIPREPARE FOR THE TAKE OFF…BAD TIMES TO GOOD TIMESTechnology to the Rescue – Part I
Andreas Flick – Chief Technology OfficerSiemens VAI Metals Technologies GmbHNew York, 2012-06-18
© Siemens AG 2012. All Rights Reserved
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 2 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
Megatrends Global Challenges
Megatrends define the future -Turn challenges into opportunities
Source: UN, Population Reference Bureau, World Population Data Sheet; WTO, International Trade Statistics; bpb
Sustainable developments of cities
Effective, affordable health care
Efficient production processes
Globalization 1950 to 2007: nearly 30-fold increase of
global trade volume
Demographic Change Generation 60+ will double worldwide
until 2050 (from 11% to 22%)
Climate Change Highest CO2 concentration in the
earth atmosphere since 650 000 years
Urbanization 23 Megacities in the year 2015 2030: 60% of all people will live in cities
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 3 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
Extrinsic influences on the steel industryare drivers for a lifecycle partnership
Steel Industry
Market
Materials
Technology Environment
Competition
• Global - Asia• Growth & Crisis• Vertical integrators
• New Co‘s• Mega size• Applications
• CO²• Eco-friendly• Shortages
• Process flexibility• Performance• Differentiation
• Price• Quality• Low Grade
Input
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 4 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
Potentials in every phase of a plant‘s lifecycle –Performance through partnership
Near end of lifetime Consultancy services Feasibility studies
New investments orsubstantial replacements Competence sensitive
Maturity phase Modernisation competence Performance packages Products to upgrade Strong service aspect Price sensitive
Growth phase New plants New products Service models Time to market USP & diff. sensitive
Market introduction Research cooperations Lead customer strategy Leap frog technologies IPR sensitive
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 5 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
Trends in iron ore mining will influenceironmaking process routes decisions
Type of run of mine
Coarse Hematite (He)
Coarse HeDeeper fine He
Coarse & fine HeRich Itabirite (It)
Fine HeRich & poor ItHe/It decrease
Decrease He/ItPoorer It
He depletion
Products profile
Big lumps up to 200 mm
Lump ore natural sinter feed (SF)
Lump ore natural SF
concentrate He
Lump ore natural SF
concentrate SF, concentrate He & It
Lump ore natural SF
concentrate SF, concentrate It
Decades 1940’s 50/60’s 70’s 80/90’s 2000’s
Use
of o
re
0
100% 0
100%Itabirite
Hematite
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 6 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
The role of raw material quality and gas availabilityfor ironmaking process selection is obvious
Fines
Ore with high iron content Ore with low iron content
Beneficiation
Concentrate
Screening
Lump ore
PelletizingSintering
Less CO2, use of off gas for red.
Less CO2 by use of nat. gas
Less CO2, off-gas used for power or DR
plant
CO2 Emission baseline
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 7 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
coke
sinter offgas + cooler
BF slag BOF slagBOF gas
Reheating furnace off-
gas
EAF off- gas
coke gas
7428 78 46 35 19 '30
T [°C]
height ~ Tmax
1600
800
0
area ~ calorific output [MW]
el. Power [MW]
Primary end has largest potential of waste heat recovery in iron & steelmaking plants
… CO2 free generation of electrical power
7428 78 46 35 19 '30
Waste heat recovery – “CO2 free” provision of process steam and electrical power
FINEX, DR Plant
Finex, DR Sinter Cooler Dry Granulation of Blast Furnace Slag
EAF Waste Heat Recovery
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 8 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
Energy efficiency turns into money -The new Quantum EAF
< 280 kWh/t with scrap
Reduced power installation
100% scrap preheating
Pure flat bath operation
Charging, tapping, taphole refilling during power – on
Minimized furnace movements
Lowest tap-to-tap time of 33 minutes
Low noise emissions
Offgas treatment
Scrap charging
Scrap preheating
Scrap loading
EAF
2
3
4
5
1
1
2
3
4
5
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 9 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
Cutting of process time with continuous melting –FAST Slag Free Tapping
Siphon typetapping
mechanism
Continuous DRI melting
Integrated siphon system allows power-on during taphole refilling
Pure flat bath operation
Lowest flicker and net disturbances
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 10 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
1.2 – 25.4 x 2100 mm(0.05” – 1” x 83”)
HSS grades
Form follows function - Expanding the product envelope to cope with market demands in casting & rolling
Thick coiled plate in a HSM
Coil 0.8 x 1500 mm(0.03” x 59”)
Ultra thin HRC
Section size up to ø1200 mm (47”)
Slab thickness up to400 mm (16”)
Ultra thick slabs Ultra large bloomsShouqin CC3, China
AM FSMer Powercoiler, France
ESP plant Arvedi, Italy
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 11 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
Pushing the limits of mechanical properties by metallurgical treatment during manufacturing
Source: voestalpine – phs (press hardening steels) - patented
cold forming and heating pressing and hardening 1500 MPa
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 12 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
Widening the product portfolio by metallurgical modelling and new equipment capabilities
Intensive cooling section with power cooling
Optimum surface quality and solidification with soft reduction
TIME 18016014012010080604020
900
850
800
750
700
650
600
550
500
450 Coiling temperature control
Cooling curve control
Striptemperature
cooling zone 1(main cooling)
cooling zone 3(fine tuning)
cooling zone 2(main cooling)
Microstructure control
600
700
800
900
274 276 278 280 282 284 286 288 290 292 294
temperature
time [s]
0.0
0.1
0.2
0.3
0.4
0.5
ferrite fraction, pearlite fraction
surface temperature [°C] core temperature [°C]ferrite fraction pearlite fraction
Before Year 2000
Since Year 2000 Since Year 2006
Rol
ling
Prediction of phase transformation in real-time
Assure predefined strand surface temperature distribution
Optimal roll gap adjustment
DynaPhase
Dynacs 3D
DynaGap Soft Reduction
Cas
ting
Actual process dataand events
Gap setpoints for: Tapered strand gap DynaGap Soft Reduction®
Liquid core reduction
DynaGapSystemDynaGap
practice setup
more than 140 strands installed worldwide!
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 13 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
Endless operation – another step towards Just-in-Time production
LFEAF
Billet casterRolling MillInduction heatingWater treatment facility
2
3
4
5
6
7
Scrap yard1
Dispatch area8
1
23
456
78
WinLink – Endless production of long products
10–20 mm 0.8–12.7mm 90–110 mm
70–90 mm180 m
ESP – Endless strip production – From liquid steel to HRC in just 7 minutes
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 14 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
The role of LiquiRob® solutions to increase the safety conditions in liquid steel area
Temperature measuring / Neuves Maisons, Fra
Sublance / ThyssenKrupp CSA, Brazil
Oxy lancing of ladle / voestalpine CC7, Austria
Celox measurement / voestalpine CC7, Austria
In B
OF’
sIn
EA
F’s
In c
aste
rs
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
June 18-20, 2012Page 15 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
Integrated Condition Monitoring System -Value adding knowledge management solution
Mechatronics
Technological controls(level 1)
Process models(level 2)
Additional systems
CM InfoBroker
Fingerprints
Fingerprints
Fingerprints
Fingerprints
Fingerprints
Plant tree (status)
Vibration monitoring
::
Plug&Play
CM InfoPackages(snapshots)
Productionteam
Production plant
A. Flick, CTO© Siemens AG 2012. All Rights Reserved
Page 16 STEEL SUCCESS STRATEGIES XXVII, Technology to the Rescue Part I
IT4Metals- Manufacturing Execution System -The steps towards a digital plant operation
AutomationDistributed Control System
MESManufacturing ExecutionSystem
ERPEnterprise Resource Planning
Process Level
Production Control Systems
Connected Server