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The success story of an outstanding technology Stephan Krmer,Christoph Klein, Dr. Jens Kempken, Jrgen Mller
SMS Siemag AG, Germany
MMMM 2011 - 8th International Exhibition + Conference 11 - 14 February 2011
Confidential SMS Siemag AG
1,400
1,200
800
600
400
200
Post-war boom
0 1950 1954 1958 1962 1966 1970 1974
Stagnation
1978 Year 1982 1986 1990 1994
New boom
1998 2002 2006
Worldwide stagnation of steel consumption, reduction of production capacities in Europe and America No investment in new hot flat rolling facilities Mini-mill concept using electric steel making already established for long products
MMMM 2011 - 8th International Exhibition + Conference 11 - 14 February 2011
11 - 14 February 2011
Market demands
Technology
11 - 14 February 2011
Tailor made and economical production plants Minimized investment and operation costs
11 - 14 February 2011
Pendulum shear
CSP mill
Laminar cooling
CSP casters
Downcoilers
Thin slab thickness: 50 - 90 mm Strip thickness: 0.8 - ca. 16 mm Strip width: 800 - 1,880 mm
MMMM 2011 - 8th International Exhibition + Conference
8% 6% 4% 2% 0%
1.3% Si
1.8% Si
2.4% Si
10%
Casting concepts
Tunnel furnace FM
FM
Inductive heating
Steckel Mill
11 - 14 February 2011
Reference: 1 Handan
Reference: 1 Saldanha
11 - 14 February 2011
10 7 1 6 2 11 25 4 Remark: 1) Plant converted into Thick Slab Plant 2) Thin slab caster SMS, Rolling Mill MHI
20 9
18 3 19 23 28 24 17 16 27 8 26 21 22 15 12 13 5
10
1 2 3 4 5 6 7 8 9 10
Nucor Crawfordsville Nucor Hickman AST/TKAST 1) Ternium Hylsa (Hylsa) Hyundai (Hanbo) Gallatin SDI ISPAT Industries AM Sestao (ACB) AM Riverdale (ACME)
USA USA Italy Mexico Korea USA USA India Spain USA
11 12 13 14 15 16 17 18 19 20
Nucor Berkeley GJS (NSM) Megasteel Saldanha Zhujiang Handan Baotou TKS EZDK (ANSDK) Corus 2)
14
USA Thailand Malaysia South Africa China China China Germany Egypt Netherlands
21 22 23 24 25 26 27 28
3rd strand Maximized utilization of rolling plants of a steel corporation Production of advanced steel grades Ferritic rolling Thin-gauge rolling Increase of production with 2nd strand
Confidential SMS Siemag AG
Minimized overall investment cost and appropriate capacity Most economic process for hot strip production
1990
1995
2000
2005
2010
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11
CSP plant Nucor Crawfordsville 1989 Finishing stands 4 Downcoilers 1 Strip thickness 2.5 - 12.7 mm Production 990,000 tn sh/year
MMMM 2011 - 8th International Exhibition + Conference 11 - 14 February 2011
Confidential SMS Siemag AG
Casters 1
12
Greenfieldsupply from a single source Complete electrics and automation system Two phases
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Design capacity
09/07 10/07 11/07 12/07 01/08 02/08 03/08 04/08 05/08 06/08
and overall project responsibility Quick entry into the market and cash flow generation Reliablility for minimill operators
MMMM 2011 - 8th International Exhibition + Conference 11 - 14 February 2011
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1989
1995
2000
2005
2010
2015
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Others 1%
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Heat size / TTT time 150 tons / 36 min BOF Slab thickness 52 90 mm Slab width 900 1,600 mm Containment length 10.3 m
MMMM 2011 - 8th International Exhibition + Conference
RHF length Final thickness Rolling speed Main drive power mill
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No. 1 2 3 4 5 6 7 8
Group Silicon grades High quality carbon steel Carbon & structural Container steel Automotive body HSLA Pipe steel Low & ultra low carbon
Grade 50W310 50W1300 08, 08 Al, 10 45 Q195, Q215, Q235 SPAH, 09 Cu P Ti Re DP, Trip Q345 Q460 API X42 API X70 LC, ELC, ULC
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Thickness
Deviation of thickness
+/- 12 m
Temperature
+/-12 K
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First 3-strand CSP plant: Essar Steel, India Capacity: up to approx. 3.5 million tpy Commissioning: 2nd quarter 2011(strand 1 and 2), end 2011 (strand 3)
MMMM 2011 - 8th International Exhibition + Conference 11 - 14 February 2011
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Extension of thin/medium slab line with second strand for thick slabs Flexible use of thick and thin/medium slabs Extension of product spectrum (e.g. heavy gauge pipe grades, stainless steel) Reference: G Steel, Thailand
MMMM 2011 - 8th International Exhibition + Conference 11 - 14 February 2011
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Characteristics Slab thickness: 80 100 mm Casting speed: up to 6 m/min Inline stand for a high reduction to reduce the load in the finishing mill
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Benefits Reliable production of thin and ultra-thin strip Homogeneity of metallurgical and mechanical properties Batch operation mode possible Compact layout with economic equipment Low investment and operation costs
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Ladle Pinch roll/looper Tundish Belt caster Equalization Belt Caster Inertization Shear
Strip thickness: 8 - 20 mm Technical Benefits Width: 900 - 1,600 mm Casting speed: 10 - 30 m/min
Rolling mill
Technical benefits Fast solidification No mould powder required No bending and straightening of cast strip Suitable ratio of thickness reduction by rolling
MMMM 2011 - 8th International Exhibition + Conference
Economical benefits
Confidential SMS Siemag AG
Compact plant layout, low investment costs High flexibility in production rate and amount Easy to integrate in the different steel making routes
11 - 14 February 2011
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2050
Near net-shape casting technology
? 10%
60%
Conventional casting and hot rolling mill
11 - 14 February 2011
Confidential SMS Siemag AG
30%
Thin slab casting and rolling plant
MMMM 2011 - 8th International Exhibition + Conference
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