SMS group Press releases2018-09-19T21:22:57+00:00 /typo3conf/ext/bm_atomfeed/Resources/Public/Logo/smsgroup_logo.png <![CDATA[SMS group upgrades rolling mill of Daehan Sinpyeong with new quenching and HSD<sup>®</sup> lines]]> 2018-09-17T10:45:58+00:00 2018-09-17T12:42:00+00:00 HSD® success story to be continued

South-Korean Daehan Steel Co. Ltd. has placed an order with SMS group for a bar mill modernization. This new order further strengthens the longstanding cooperation between SMS group and Daehan Steel.

The rolling mill in Daehan´s Sinpyeong works located in the Busan area is designed to produce 130 tons per hour of rebar in diameters from 16 to 32 millimeters up to grade SD 500.

The modernization project will comprise the replacement of the existing quenching line with a new one designed with latest technology from SMS group, including systems for precise pressure control and exact setting of the water flow rates. In addition, two dividing shears with associated pinch rolls and a bar braking system will be supplied, as well as a HSD® (High Speed Delivery) line that will be integrated into the existing cooling bed. With this new HSD® system, Daehan will be able to feed bars onto the cooling bed via rotating channels, which are precisely synchronized with the soft bar braking unit, the cooling bed cycle movement and the bar position monitoring system. Furthermore, the bars can be cut to all product sizes at any speed. The shears cut bars in diameters up to 32 millimeters. Due to the dedicated control system, the shears provide very tight cutting tolerances even at maximum speed. The newly supplied equipment will be fully integrated by way of an automation package from SMS group.

The main objective of the modernization is to reduce the ferro-alloys content in the billets, which will result in a substantial cost reduction. The upgrade is also aimed at increasing the product range. With the new SMS group equipment Daehan will be able to add 13 millimeter rebar to the size range and produce new steel grades up to SD600.

This latest reference underpins SMS group's modernization expertise and strengthens the longstanding partnership with Daehan.

<![CDATA[Hertwich to supply multi-chamber melting furnace to Hydro Extrusion Lichtervelde NV]]> 2018-09-13T12:22:31+00:00 2018-09-13T14:19:00+00:00 Expansion of melting capacity in Belgium

Hertwich Engineering, a subsidiary of SMS group, has received an order from Hydro Extrusion Lichtervelde NV for the supply of an Ecomelt-PS200 multi-chamber melting furnace including a skimming machine. The plant with a melting capacity of 60,000 tons per year will be installed in the casthouse in Ghlin, Belgium. Commissioning is scheduled for the first half of 2019.

By the acquisition of Sapa, Hydro has considerably expanded the scope, presence and innovative competitive edge of its extrusion division. As a globally leading extrusion plant, Hydro currently supplies more than 30,000 local and global customers in more than 40 countries around the world. In Belgium the company employs around 850 people in their extrusion facilities in Raeren and Lichtervelde and in the aluminum casthouse in Ghlin.

Hydro will increase the recycling capacity in Ghlin by 60,000 tons per year by adding a new Ecomelt-PS200 multi-chamber melting furnace from Hertwich Engineering. With this investment Hydro responses to the growing importance of scrap recycling, both manufacturing and turnaround scrap, within the extrusion industry. With aluminum starting to be intensively used in construction, transportation, industrial and other applications about five decades ago, we now see a corresponding rise in the amount of turnaround scrap. The aluminum industry benefits from this trend by an approx. 95 percent reduction of the energy demand in aluminum production. Hertwich Engineering, which has reached a worldwide leading position with their Ecomelt melting technology, can achieve even higher energy savings using suitable scrap.

The Ecomelt PS furnace to be installed in Ghlin is especially designed for medium to heavily contaminated scrap. The casthouse requires a broad spectrum of different types of scrap: vehicle license plates, wires, machining chips, cables, lithographic sheet, profiles, UBC, spray cans and others - partially loose in bulk, partially shredded, partially briquetted or packetized. The degree of contamination ranges from "clean" all the way up to heavily contaminated with paint and lacquers, rubber and plastic parts, oils, greases, etc. Furthermore, even solid scrap, such as sows, T-bars or ingot stacks are charged.

With this type of furnace the scrap flows through a vertically arranged preheat shaft, which is filled from above. The hot gases flow through the charged material in the shaft from bottom to top while the organic compounds are completely removed. The resulting pyrolysis gases are fed into the main chamber to support the gas heating. At the bottom end of the preheating shaft the decoated and preheated material is immersed in the flowing bath and is immediately melted. The melt flow between the furnace chambers is generated by electro-magnetic liquid metal pumps.

The resulting pyrolysis gas volume when melting heavily contaminated scrap naturally reduces the demand for heating gas more than when melting relatively clean scrap. The energy consumption of this furnace type is between 300 and 550 kWh/ton, depending on the condition of the scrap. The remaining slag (dross) from the melting process is concentrated on the bath surface and must be removed. For this, Hertwich supplies a rail-guided skimming machine for safe, careful and fast cleaning of the furnace.

Due to this furnace concept, the energy content of the organic contamination is used efficiently, whereby operating costs are reduced markedly. Furthermore, the minimum emissions (NOx, VOC, CO, dioxins, no salt addition) contribute to a safe and environmentally friendly furnace operation – an aspect that has a high priority within the entire Hydro group.

<![CDATA[Prometal Aciérie contracts SMS group to supply hot rolling mill to widen its production]]> 2018-09-12T13:25:29+00:00 2018-09-12T15:20:00+00:00 First combined rolling mill in Africa

Prometal Aciérie, Cameroon, Africa, has awarded SMS group the order to supply a new hot rolling mill for rebars, sections and wire rod. The new rolling mill will be designed for the production of straight rebars, angles, channels, flats, squares, beams and wire rod coils, enabling Prometal to expand its product portfolio, covering as much as possible of the product mix for long steel products. With this investment, long steel producer Prometal Aciérie, based in Douala, Cameroon, is going to install the first combined rolling mill in the African region.

The rolling mill will be designed for a maximum overall capacity of approx. 300,000 tons per year. Starting with 130 millimeter square billets, which will be heated up in a 60 ton-per-hour modern pusher-type furnace, the mill will be able to produce rebars from 8 to 32 millimeters, sections such as 100-millimeter-high beams and channels, and smooth rounds in coil from 5.5 to 12 millimeters. The state-of-the art HSD® (High Speed Delivery) System allows reaching the full production capacity for the complete size range, increasing the material yield. The high speed finishing block will produce quality wire rod coils at minimized operational costs. Moreover, the rolling mill will be controlled by a Level 2 automation system provided by SMS group.

The combined mill, completely supplied by SMS group, will become the new reference benchmark for the market in terms of high technology, quality, efficiency and low operational costs in Africa.

Commissioning of the new rolling mill is scheduled for December 2019.

<![CDATA[Thöni orders 55-MN aluminum extrusion press line from SMS group]]> 2018-09-11T12:50:36+00:00 2018-09-11T14:46:00+00:00 Automobiles of the future comprising aluminum products from Tyrol

Thöni group, headquartered in Telfs, Austria, has placed an order with SMS group covering a press line for the extrusion of aluminum. The line includes a 55-MN front-loading extrusion press to process billets that have a maximum diameter of 12 inches (304.8 mm) and a maximum length of 1,600 millimeters. This extrusion press is already the fifth one SMS is going to install for Thöni. The extrusion press line is to be established in a new works at the recently developed location at Pfaffenhofen and will produce profiles of aluminum and aluminum alloys for application in the automotive and other markets.

“From the end of 2019, the new line will produce about 8,000 tons per year of high-quality aluminum profiles for the European automotive industry. Through subsequent processing we will refine these products ready for installation,” says Helmut Thöni, CEO and shareholder of Thöni group.

To satisfy its demanding customer base, Thöni group has invested in most advanced extrusion press technology. Billet heating will be done in a patented induction furnace, a combination of induction furnaces from IAS, a subsidiary of SMS group, and a gas-fired furnace from Extrutec GmbH. Aluminum bars will be stored in a warehouse, then heated to approx. 480 °C in an inline furnace, sawed to a maximum length of 1,600 millimeters and transported to the billet loader.

The 55-MN front-loading extrusion press will be built to SMS group’s latest design and be equipped with the highly precise linear guidance system for all moving main components, servo drive technology for all auxiliary functions as well as the proven EcoDraulic concept to reduce energy consumption. In addition, the press will have a modular process control system, part of which will be CADEX/3 (Computer Aided Direct Extrusion) for isothermal and isobaric extruding. The MIDIS (Management Information Diagnostic Indication System) technology package will allow for the administration of all product-relevant data. An IBA measuring and analyzing system integrated into the control system will provide the opportunity of remote diagnosis.

Directly downstream the extrusion press, an advanced runout will be installed by OMAV, another company SMS group is holding a stake in. Two high-performance cooling systems using spray water and air will cool the extruded profiles from an outlet temperature of about 520 °C down to approx. 100 °C. A special challenge here is to adapt the cooling rates to the product extruded in order to prevent profile warping. All cooling parameters will be recorded and managed by MIDIS. This makes sure identical material properties such as strengths can be reproduced in follow-up orders − a must for the automotive industry. One double puller, one flying saw, one stretcher, one final cutting saw and an automation system complete the runout area.

“With this state-of-the-art extrusion press line from SMS group we are setting the course for the growing demand for aluminum components. We have devised the new works for possible expansion by further extrusion press lines right from the start,” supplements Helmut Thöni.

Commissioning is scheduled to take place in summer 2019. Extrusion of the first billet is planned for July 15, 2019.

<![CDATA[Impol Group Slovenia awards final acceptance to SMS group for modernized aluminum cold rolling mill]]> 2018-09-06T13:56:23+00:00 2018-09-06T15:53:00+00:00 40-year-old cold rolling mill with higher performance after revamp to the latest state of the art

After successful modernization of the 40-year-old aluminum cold rolling mill by SMS group at the Slovenska Bistrica facility, the Slovenian aluminum producer Impol Group Slovenia has awarded the final acceptance to SMS group. The previously performed acceptance tests had proven that the rolled products are now fulfilling even stricter quality criteria.

With this upgrade, Impol Group Slovenia has invested in the future viability of the facility and has brought about significant improvements of the cold rolling mill’s capability. The strip width and thickness range was enlarged and the maximum coil weight increased. By new setting and control systems, strip quality was improved, particularly regarding the achievement of closer thickness and flatness tolerances. A new strip blow-off system minimizes oil residues and provides a homogeneous strip surface.

The comprehensive upgrade and extension measures comprised technological control systems and measurement instrumentation, entry and exit side equipment of the rolling mill, coil logistics, media plants as well as accompanying modifications of the foundations. SMS group managed to integrate the new components and units in the limited space available of the existing mill.

Thanks to these measures, Impol Group Slovenia is operating an all-around renewed aluminum cold rolling mill that fulfills current market requirements and is well prepared to meet future challenges.

<![CDATA[Aperam orders annealing and pickling line for stainless steel cold strip from SMS group]]> 2018-09-04T12:07:29+00:00 2018-09-04T14:00:00+00:00 High-performance production plant for stainless steel strip in Belgium

Aperam Stainless Belgium has contracted SMS group to supply an annealing and pickling line for stainless steel cold strip to its Genk plant in Belgium. Production start is scheduled for 2020. With this investment in state-of-the-art and future-oriented plant technology, Aperam will enlarge its product range by material grades for the most demanding applications and improve lead time and flexibility to meet the market demand. It will further increase efficiency and cost competitiveness of its plants and continuously enhance the impacts on health, safety and environment.

The line will stand out due to its high degree of automation and resource-saving processes and will be equipped, in addition to a horizontal Drever annealing furnace and a multi-stage pickling section, with a four-high skin-pass mill stand and a side trimmer. The new annealing and pickling line will be the fourth one SMS group is going to install at Aperam’s Genk site.

Besides mechanical equipment, process technology, furnace technology, electrical and automation systems, the scope of supply will also include technical support during installation and commissioning. The line will process both austenitic and ferritic grades.

<![CDATA[Železiarne Podbrezová places order with SMS group to modernize existing push bench]]> 2018-09-03T12:58:46+00:00 2018-09-03T14:55:00+00:00 Reduced future effort for maintenance and repair in tube production

Železiarne Podbrezová has placed an order with SMS group covering the upgrade of its existing push-bench plant in Podbrezová, Slovakia. On this push bench, Železiarne Podbrezová produces seamless tubes in the diameter range from 0.5 inch to 5.5 inches. The modernization order covers two new racks with drive pinions and a new rack guide bed for the push bench as well as 14 new stands for the stretch reducing mill.

The new racks, which have a special gearing, will be supplied in merely three partial lengths (instead of the existing five ones) and with the connecting elements in an even better and stronger version. The rack guide bed will be of robust and single-part design in its cross-section. All individual rack guiding elements are to be supplied in maximum possible lengths so that four elements only will be needed to cover the overall length. As a consequence, the forces and torques in the rack guide bed can be perfectly absorbed and hence significantly reduce the effort for maintenance and repair. The new stands for the stretch reducing mill will be designed for the use of hard metal rolls that can absorb higher rolling forces and permit greater pass diameters to be cut.

“Since we had good experience with SMS group in the past, we again decided to have the modernization made by SMS,” says Milan Srnka, Technical Director at Železiarne Podbrezová.

<![CDATA[Pakistan’s second CCM<sup>®</sup> at ISL successfully put on stream by SMS group]]> 2018-08-30T12:25:38+00:00 2018-08-30T14:20:00+00:00 Additional cold strip capacity of 450,000 tons

Only 14 months after order intake, SMS group has put the new CCM® (Compact Cold Mill) at International Steels Limited (ISL) in Karachi into operation. The Pakistani cold strip producer is now operating the second CCM® supplied by SMS group.

The new CCM® is a twin-stand reversing cold mill, completely supplied by SMS group including the X-Pact® electrical and automation systems and the media plants. During the order placing, ISL attached importance to SMS group supplying the entire mechatronic systems from a single source in order to ensure trouble-free coaction of mechanical equipment and automation system. The short commissioning time proofs this strategy right.

Quality components like the complete mill stands, drive trains and media systems from German manufacturing ensure the quality of the strips rolled. CVC®plus roll shifting technology and two X-Shape flatness measurement rolls as important components of the X-Shape flatness measurement and control system complete the technological components. 

The new CCM® increases ISL’s production significantly. With the commissioning of the second cold rolling mill, ISL’s rolling capacity has increased to approx. one million tons per year, depending on the product mix, thus making the company the largest producer of cold rolled and galvanized products in Pakistan. The new mill is designed to roll strips with a maximum width of 1,250 millimeters down to a final thickness of 0.15 millimeters.

<![CDATA[SMS group presents digitalization-driven potentials at the leading trade fair for the aluminum industry held in Düsseldorf]]> 2018-08-29T11:34:07+00:00 2018-08-29T13:28:00+00:00 New impulses for the aluminum industry

During the “ALUMINIUM 2018” trade fair, from 9 – 11 October 2018, Düsseldorf, will once again be in the limelight of the global aluminum industry. SMS group is going to focus its trade fair presence in hall 9 (booth number 9C20) on digitalization and on the momentum Industrie 4.0 and digitalization have on the aluminum producing and processing sectors.

One of the highlights will be the presentation of the Anti Chatter Device for cold rolling mills. This device reduces vibrations occurring in rolling mills, especially in tandem mills. Such vibrations may lead to defects of the rolled stock and damage to the rolling equipment. By reducing the chatter effect, it is possible to increase the rolling speed and the yield while improving the product quality. This pioneering technology is already in use in a first pilot operation. SMS group will also present the X-Shape flatness measuring roll. With its closed roll surface, high-precision flatness measurement capabilities and optical signal transmission, this system plays a key role in cutting-edge measuring and control technology for premium quality cold-rolled aluminum strip.

The data collected by means of intelligent sensor technology is used by SMS group not only to control the plant, but also to digitalize comprehensive production and business processes. An example of this is the PQA® (Product Quality Analyzer), which collects all relevant production and process data, analyzes the data in a continuous manner based on specified rules, provides instructions for action in case of deviations from the specified quality, and evaluates the products after each process step with regard to their suitability for the next step and the attainment of the quality specified for the final product. All this makes PQA® an essential digital tool for quality management.

In terms of service and maintenance, digitalization opens up new possibilities for the entire life cycle of a plant. “Smart Maintenance Solutions” aim at increasing the availability of the plant and the quality of the final products in a sustainable manner by combining various software solutions. In the future, digital plant structures will provide maintenance and repair teams with centralized access to all relevant parameters. The required information will become available from systems such as eDoc, an electronic parts catalog, the IMMS® (Integrated Maintenance Management System) or Genius CM® (Condition Monitoring). SMS group is also going to demonstrate the link between “smart” data and “smart” training an augmented reality environment. Those participating in training benefit from the use of virtual and augmented reality in the form of enhanced learning. For example, complex maintenance work can be immersed in and experienced much more realistically.

Another momentum from digitalization and Industrie 4.0 takes effect in the field of manufacturing technology. At the trade fair, SMS group is going to demonstrate this by way of the example of 3D-printed components which are characterized by enhanced functionality, reduced weight and/or shorter lead times. SMS group is also going to present the competence center for 3D printing in Mönchengladbach, which includes the pilot plant for the production of high-purity metal powder built last year.

In addition to the presentation of their own digital developments, SMS group invites customers and partners to talk about their successful cooperation with SMS group during the implementation of new plant projects, modernization projects or during technical service assignments. In the run-up to the trade fair, further information on the program is available on our micro-site:

<![CDATA[Successful commissioning of SMS group’s fumes treatment system at Uddeholm AB, Sweden]]> 2018-08-27T12:36:56+00:00 2018-08-27T14:32:00+00:00 Modernization with energy-efficient environmental technology of SMS group

SMS group has successfully commissioned the second modernization phase of the fumes treatment system of the electric arc furnace, and final acceptance (FAC) has already been granted.

In phase 1, SMS group had installed a new, more efficient filter system and replaced the canopy hood of the electric arc furnace with an SMS frustum hood. In this connection, the secondary gas line was also renewed, and an axial cyclone was installed as spark separator upstream of the new jet pulse filter. In phase 2, the primary gas line for direct exhausting of the hot fumes from the 60-ton electric arc furnace was renewed.

The scope of supply of phase 2 consisted of a water-cooled fumes section, a gas cooler with bypass, and a radial-flow fan for pressure boosting. The hot fumes forming during the melting process are used to dry and preheat the scrap and adhering ice is removed this way. The installation of a cooler with bypass maintains the entry temperature at the scrap pre-dryer at maximum 300 °C, which prevents the formation of contaminants during scrap drying. The water-cooled components were optimized with regard to pressure losses and already prepared for the future use of an energy recovery system.

The modernization of the fumes treatment system yields quite a number of advantages. The new technology achieves a rise in fumes volume by 66 percent without increasing the energy consumption in comparison with the old system. The SMS frustum hood allows clearly more effective capturing and exhausting of the fumes during furnace charging and tapping. The dust content at the stack outlet is 50 percent below the requested value. The drying of the scrap guarantees safe operation of the furnace, and in the future it will be possible to recover energy by way of the extraction of hot water.

<![CDATA[NLMK DanSteel to revamp and expand heavy-plate rolling mill with SMS group]]> 2018-08-23T12:23:38+00:00 2018-08-23T14:13:00+00:00 Extended product range thanks to new plate cooling system with water treatment equipment, new cooling bed, and revamped cold-plate leveler

NLMK DanSteel A/S, Denmark, has placed an order with SMS group for the large-scale expansion and modernization of its heavy-plate mill in Frederiksvaerk. NLMK DanSteel is implementing these measures to expand its product range further in terms of both grades and sizes.

SMS group’s scope of supply for the 4.2-m heavy-plate mill includes a new plate cooling system and related water treatment equipment, the installation of a new thick-plate cooling bed, an updated leveling model for the hot-plate leveler, and a revamp of the existing cold-plate leveler. SMS group will also supply all the electrical and automation systems for the equipment, and integrate new functions into the existing automation system. The mechanical and electrical equipment will also be installed by SMS group.

In 2012, SMS group supplied, among other things, a new heavy-plate stand and a hot-plate leveler to NLMK DanSteel. “We had very positive experience at that time, with respect to both plant technology and implementation of the partly highly complex modifications,” explains Allan Thomasen, Technical Manager at NLMK DanSteel. “And that was one of the reasons why we again selected SMS group for the next step.”

The new plate cooling system is to be designed as a laminar cooling system, which is capable of cooling plates with a thickness of between 10 and 260 millimeters. This will allow NLMK DanSteel to produce high-strength plate for line pipes, shipbuilding and offshore wind parks. NLMK DanSteel can also use the cooling system between the various rolling phases for the thermomechanical rolling and manufacture of heavy plate. The X-Pact® cooling model offers up to three cooling phases for each plate. The option of intermediate cooling reduces holding times between the rolling phases and allows for an increase in throughput.

For the plate cooling system SMS group is also supplying a new water treatment system, in which the cooling water is filtered, cooled and fed back into the process in a closed circuit.

A new cooling bed for thick plate is to be installed downstream of the laminar cooling system and existing hot plate leveler. The cooling bed will be used for plates weighing 40 tons and up to 260 millimeters thick, though it is designed to handle plate weights of up to 62 tons in future. The plate is delivered to the cooling bed automatically. At the same time, the X-Pact® electrical and automation system calculates the cooling times for plate removal as a function of the plate temperatures and dimensions.

As far as leveling the high-strength plate is concerned, SMS group is adapting the leveling model used by the hot-plate leveler to suit the extended product range.

The existing cold-plate leveler will also undergo a comprehensive revamp. In addition to the mechanical adjustment system, it will also be fitted with a hydraulic main adjustment system, ensuring the roll gap can be perfectly adjusted and controlled under load. The existing drive unit is to be replaced by a new individual roll drive. What’s more, SMS group is to install a new automation system with leveling model and user interface (HMI).

In order to plan the revamp, SMS group performed a 3D laser survey in advance. Based on this, suitable installation strategies and optimized erection schedules were developed to reduce shutdown times to a minimum, especially as the installation space around the cooling system and cold-plate leveler is extremely limited.

The revamp of the plant will take place in several stages, beginning September 2018 with the modernization of the cold-plate leveler. This shutdown will be used to carry out preparatory work in the area of the mill stand and cooling system, as well as for the heavy-plate cooling bed. Equipment units will then be pre-assembled and wired on site while production is ongoing, in order that they can be installed and commissioned during brief shutdown periods.

<![CDATA[ESTRAL once again counts on extrusion technology from SMS group]]> 2018-08-17T11:39:27+00:00 2018-08-17T13:14:00+00:00 First HybrEx® for Italy

ESTRAL S.p.a., in Manerbio, Italy, has awarded SMS group a contract to supply a HybrEx®28. This extrusion press is the second press the company has ordered from SMS group and the first one of the new HybrEx® series for the Italian aluminum market. It extrudes aluminum billets with a maximum force of 28 MN and a top speed of 20 millimeters per second.

The HybrEx®28 is one of a new generation of extrusion presses that features an innovative drive concept. Compared to conventional extrusion presses, hybrid drive technology significantly reduces energy consumption. Shorter dead cycle times mean productivity can be increased. As a result, the HybrEx®28 fulfills the requirements of an ecoplants solution.

The HybrEx® replaces conventional hydraulic drives for the axes of motion with high-speed electric servo drives in all areas where the speed of movement and acceleration are critical. The electric servo motors are faster and more energy-saving and allow for more precise positioning.

Its really compact design is possible thanks to the hydraulic system concept developed for the HybrEx®. The entire hydraulic drive unit can be integrated in the machine’s soundproof enclosure. The enclosure design not only looks state-of-the-art, it also takes into account all aspects of operational safety, ensuring better machine accessibility.

ESTRAL S.p.a. produces complex, top-quality precision profiles for a wide range of applications. These include both standard profiles and customized special profiles for automotive applications. The HybrEx® with its rigid, three-part triple-layer counter beam and the patented precision guide for container and moving crosshead provides the perfect conditions to achieve just that.

The HybrEx®28 is part of an overall order placed with OMAV S.p.a. for the supply of an integrated extrusion line. This includes a press feed line, a HybrEx® extrusion press, a handling system including sophisticated quenching system, a profile stretcher, and a finishing saw.

The new HybrEx® extrusion press is scheduled to be delivered to ESTRAL in Manerbio still this year.

<![CDATA[JSW orders high-speed billet caster from SMS Concast]]> 2018-08-15T15:48:39+00:00 2018-08-15T17:42:00+00:00 New order from Jindal Group

JSW Steel Ltd. in Toranagallu, India, belonging to Jindal Group, has awarded SMS Concast, a company of SMS group, an order covering a 5(6)-strand high-speed billet caster. This project is part of a bigger expansion plan, and the main objective is a productivity increase.

The existing steel plant consists of a 160-ton electric arc furnace, ladle furnace, billet caster and rolling mill and shall increase the annual production to 1,500,000 tons of steel after installation of the new billet caster. The caster will be designed for fast casting of square billets with an edge length of 165 millimeters.

SMS Concast’s caster configuration will allow the common use of spares in two different steel meltshops. This is one big feature to decrease OPEX.

Furthermore, latest technology will be applied to reach the specified productivity and OPEX targets. One special product is the low- maintenance oscillation drive called CONDRIVE, another the advanced INVEX® mold technology.

The CONDRIVE mold oscillation represents a totally new approach combining the advantages of hydraulic and mechanic drives in one. Due to the innovative torque drive, the amplitude, frequency and oscillation profile can be adjusted online and independently. Thus it grants full functionality, however without the hydraulic system drawbacks in terms of maintenance and piping. In this context, CONDRIVE is one part of the advanced maintenance concept with a view to reduced spare parts inventory.

Regarding productivity, the SMS Concast-developed INVEX® mold allows for very high strand throughputs in the area of 790 kg/min. The special tube geometry and enhanced water cooling features allow the mold to achieve efficient heat transfer and thus a more uniform solidification at the faces and in the corner areas, thus enabling higher casting speeds.

“Considering the very good performance of the existing SMS Concast equipment, its advanced technology and reduced OPEX, we have decided to go for another co-operation in order to implement our expansion plan,” says Mr. Purushottam Prasad from JSW Steel Ltd.

<![CDATA[SMS group presents solid balance sheet]]> 2018-08-14T10:32:30+00:00 2018-08-13T10:30:00+00:00 •     Order intake increases from EUR 2,680 million to EUR 2,870 million

•     Sales decrease slightly from EUR 3,052 million to EUR 2,887 million

•     Net result increases to EUR 23 million

•     Efficiency-boosting program takes effect and enables targeted investment in growth fields

Sound financial situation

SMS group order intake in the past business year totaled EUR 2,870 million. This was EUR 190 million up on the previous year (2016: EUR 2,680 million). Sales, at EUR 2,887 million, were lower than in the previous year by EUR 165 million.

The subsidiaries of SMS group were able to boost orders. Order intake by manufacturing technology company elexis exceeded the previous year’s figure (EUR 184 million) by EUR 26 million and totaled EUR 210 million. Induction technology specialist Elotherm generated EUR 73 million (2016: EUR 66 million).

SMS group recorded a net result of EUR 23 million, slightly higher than the previous year’s figure (EUR 14 million). Included in this total are accruals for restructuring to the amount of EUR 73 million.

The equity ratio remained unchanged at 19 percent, having now maintained this level for several years. A liquidity of EUR 1.1 billion continues to secure the company’s financial independence.

The regional breakdown of SMS group sales remained balanced: Asia 33 percent (2016: 34 percent), Europe: 31 percent (2016: 30 percent), America: 25 percent (2016: 28 percent), Russia: 7 percent (2016: 6 percent), Africa: 4 percent (2016: 2 percent).

The order backlog of SMS group totaled EUR 3,472 million, which was roughly at the level of the previous year (EUR 3,566 million).

In business year 2017, SMS group had an average of 14,305 employees (2016: 13,903). Compared to the previous year, this was an increase of 402 employees, due in particular to the expansion of service activities abroad.

Burkhardt Dahmen, CEO: “SMS group is the global market leader in plant and machinery construction for the steel and nonferrous metals industry. We’ve worked hard to sustainably strengthen our position as the most modern, high-performance company in the industry. This is above all thanks to the outstanding efforts of our employees.”

Efficiency-boosting program takes effect and enables targeted investment

In order to adjust competitively to the lower global market volume in metallurgical plant construction, SMS is cutting overcapacities and reducing equipment and materials costs. By 2020, the company will scale back 500 of the current 4,150 jobs in Germany, with 300 jobs affected in 2018. This necessary personnel adjustment is being carried out in a socially responsible manner, largely avoiding redundancies and concentrating instead on semi-retirement arrangements and individual contractual solutions.

The essential focus of the efficiency-boosting program is on the competitiveness of the products, in terms of both properties and price. With a targeted innovation campaign as well as high investment in technologies, products, and new business fields, the company is extending its technological edge even further.

Torsten Heising, CFO: “Maintaining and strengthening the leading position of SMS group is our most important goal. All areas of the company have achieved significant improvements in efficiency and processes, working in close partnership with the employee representative bodies. This enables us to continue to invest in important growth segments.”

Expansion of service business on track

The company continues to pusue its strategy of growth in services. The medium-term goal is to expand the service volume to around one third of total business volume. Apart from the classic spare parts business, this includes modernization packages designed to boost the performance of customers’ plants. In line with its partnership approach, SMS is increasingly offering consultancy and providing extensive maintenance and repair services for its customers.

Leader in digitalization

Possibly the most important area of development is enabling customers to meet their challenges with the performance-boosting “learning factory” strategy. In this area, SMS group already supplies its customers with extensive service packages.

For the customer Big River Steel in the US, SMS successfully commissioned an entire plant complex in the form of a “Learning Steel Mill” in 2017. Developed jointly with the customer, the concept fulfilled all expectations. As a result, SMS recently received a confirmation for an expansion stage.

New Horizon growth program strengthened

The company is also investing more in the production and processing of new high-tech materials and efficient, intelligent green technologies. To increase growth in adjacent markets and industries, all activities come together in the company-wide New Horizon strategy program. The first customer projects have already been successfully completed.

For example, SMS group is currently constructing the world’s first “UrbanGold” plant. With this completely innovative plant, it is possible to cost-effectively recycle valuable and high-purity metals from electronic scrap such as PCBs. The recovered materials include copper, nickel, gold, silver and platinum.

SMS group has built and commissioned an innovative, industrial-scale pilot plant for producing high-purity metal powder and new materials used in additive manufacturing – or 3D printing with laser technologies. The metal powder consists of microscopic, homogenous particles that form the basic materials for customized or novel-design products. The company is also building a demo center for the entire additive manufacturing process chain – from metal powder to the high-quality finished product.

SMS group’s extensive know-how in handling heavy loads in rolling mills was the starting point for an innovation in port logistics. A new type of storage system for containers enables operators to fully automatically stack or handle more containers on a smaller floorspace with greater speed and flexibility.

Paul Wurth group, which also belongs to SMS group, has developed a new solution for the use of decentralized energy generation. This utilizes eco-friendly, resource-saving energy sources such as W2E (waste-to-energy), B2E (biomass-to-energy) and cogeneration plants.

Burkhard Dahmen: “Quality workmanship and innovative drive are our most important hallmarks. Our customers expect precision results and creative solutions to highly complex problems. And we are using those same strengths to further develop SMS group itself. With New Horizon and our digitalization offensive, we have launched a sophisticated growth program that will sustainably strengthen our company’s leading position.”

<![CDATA[ArcelorMittal Bremen will upgrade its hot strip mill with the aid of SMS group]]> 2018-08-15T14:34:45+00:00 2018-08-10T11:00:00+00:00 CVC®plus system for finishing mill to influence strip geometry

ArcelorMittal Bremen, Germany, has contracted SMS group to modernize its hot strip mill with the objective of improving hot strip tolerances.

The upgrade will comprise the installation of a CVC®plus work roll shifting system with integrated bending mechanism and of new drive spindles in the first three mill stands of the finishing line, plus the installation of a new PCFC® (Profile, Contour and Flatness Control). The modernization will provide ArcelorMittal Bremen with a powerful actuator to influence strip profile and strip flatness.

The facility in Bremen is the third hot strip mill of the ArcelorMittal group to be equipped with the CVC®plus system (Continuously Variable Crown) by SMS group within a short period. Axial shifting of the work rolls, that come with the special CVC®plus crown, combined with roll bending system and the technological process model PCFC® permit the roll gap to be perfectly adjusted to changing process conditions and hence to produce strips with close geometrical tolerances. The drive spindles to be supplied to ArcelorMittal Bremen will be SIEFLEX® HT gear-type self-aligning spindles (High Torque) developed by SMS group.

Finishing stands F1 to F3 will be modernized in two steps during the regular annual maintenance downtimes in October 2018 and October 2019. The PCFC® will be integrated before the second downtime already and run in parallel to the existing control system. Thanks to this so-called shadow mode, it will be possible to check all functions, interaction with the automation environment as well as model adjustment prior to commissioning, and finally to ensure the smooth start of production.

<![CDATA[KEMPER orders logistics systems from AMOVA]]> 2018-08-08T13:17:39+00:00 2018-08-07T22:00:00+00:00 <![CDATA[voestalpine contracts SMS group to supply main melting-area components for new stainless steel plant in Kapfenberg, Austria]]> 2018-07-27T05:55:50+00:00 2018-07-26T22:00:00+00:00 ® electrical and automation systems. The X-Pact® MES 4.0 production planning system and the innovative X-Pact® process guidance system (PGS) will lay the foundation for digitalization of the most-advanced stainless steel plant worldwide. The manufacturing execution system X-Pact® MES 4.0 is the holistic, modular solution for planning and control of the entire metallurgical process chain and of all production facilities. Based on planning modules, it considers the interaction of all factors relevant for decision, such as plant condition, product quality and energy consumption, i.e. horizontal networking takes place. Reporting is completely web-based and provides detailed data analyses. For all facilities within the plant, the automation concept X-Pact® process guidance will merge process-oriented operation of the different automation levels in a uniform look and feel. The modular design will provide a basis for reporting, tracking, material management and for metallurgical models. New sensors can be added respectively available data be transferred shortly. All components of the stainless steel plant will be monitored in a central control station. SMS group will furthermore supply the technological equipment for the Kapfenberg training center where the complete plant complex will be digitally visualized for training purposes. The supply scope of SMS group includes basic and detail engineering, mechatronic plant technology, supervision of erection on site and commissioning of the above mentioned components. To make sure transition of production from the existing to the new stainless steel plant will be accomplished smoothly, it is planned to train the customer’s staff on site and in the test center of SMS group in Germany.]]> <![CDATA[For its tandem cold mill, PAO Severstal again relies on the modernization expertise of SMS group]]> 2018-07-19T12:06:57+00:00 2018-07-18T22:00:00+00:00 ®. By these measures, the rolling mill “2100” was very well prepared to satisfy the increasing material requirements of PAO Severstal’s customers, especially regarding high-grade carbon steels, high-strength steels and micro-alloyed silicon steels.]]> <![CDATA[Lianxin Steel and Shandong Laigang Yongfeng order TMbaR mill from SMS group]]> 2018-07-13T11:37:59+00:00 2018-07-12T22:00:00+00:00 ® finishing block. Besides its rigid design, which allows rolling forces so far unattained in the market, the MEERdrive® block is equipped with a single drive which provides the flexibility required to optimally control recrystallization after rolling. Two companies have now decided in favor of the TMbaR technology: Lianxin Steel and Shandong Laigang Yongfeng. Lianxin Steel has ordered a TMbaR mill for its Dafeng site. The plant will be designed for an annual production of 1,000,000 tons of rebar with diameters ranging between 8 and 40 millimeters at a maximum rolling speed of 45 meters per second. SMS group will supply all rolling mill stands for the roughing, intermediate and finishing mills, including two six-stand MEERdrive® finishing blocks, shears, water boxes as well as the double HSD® system. Additionally, the complete package of electrical and automation systems as well as supervision of erection and commissioning are in the scope of supply. The plant is scheduled to be started up by the end of 2018. The TMbaR mill for Shandong Laigang Yongfeng´s Dezhou site is part of a capacity conversion program using the EAF-based production route to replace the existing facilities. The new plant will be designed for an annual production of 1,000,000 tons of rebar in diameters ranging between 8 and 32 millimeters. This includes straight bars with diameters between 8 and 25 millimeters to be rolled at a maximum speed of 45 meters per second and bar-in-coil in diameters ranging from 8 to 32 millimeters to be rolled at a maximum speed of 35 meters per second. Yongfeng is going to install two five-strand continuous casting machines supplied by SMS Concast as well as a new high-speed rolling area, including two six-stand MEERdrive® finishing blocks, cooling and equalizing lines, a high-speed outlet consisting of a two-strand HSD® (High-Speed Delivery) system with dividing shears and pinch roll unit as well as a VCC® (Vertical Compact Coiler) system for coils weighing up to five tons. Additionally, the electrical and automation systems for the three mechanical packages and supervision of erection and commissioning will be supplied. The plant is scheduled to start production in 2019. Both companies put their trust in the long-standing experience of SMS group and its one-step-ahead TMbaR technology, which will allow Lianxin Steel and Shandong Laigang Yongfeng to respond better and faster to market demands, achieve improved material properties and save on alloys and operating costs.]]> <![CDATA[HMT Höfer Metall Technik signs service agreement for extrusion presses with SMS group]]> 2018-07-11T11:33:42+00:00 2018-07-10T22:00:00+00:00 ® and its 18-MN-GIA extrusion press. With this contract, HMT aims to increase productivity, assure quality and enhance production security and reliability. The concept for the comprehensive service package has been developed in close cooperation with HMT. The package specifically includes equipment checks, alignment checks, inspections for cracks as well as optimizations of the hydraulic and control systems. During equipment checks, SMS group service specialists will examine the condition of the plants and discuss the results directly on site with HMT. The customer will be provided a detailed report laying out maintenance and repair recommendations and − should the examination reveal the need − a quote for spare parts or consultation about modernization measures. The alignment checks will involve measurements of the geometric alignment of the extrusion presses. The correct alignment is the basis for a consistently high-quality extruded product. By having crack inspections performed, HMT prevents unforeseen line stops and achieves higher security of production. The Technical Service specialists of SMS group know the most critical and most severely stressed areas of the plant components. This knowledge allows them to take a pinpoint approach to maintenance and service. In case of a failure, recommendations for action can be immediately derived. Optimizations of the hydraulic and control systems ensure that HMT will operate the presses at a consistently high level of productivity. Optimization measures will be aimed at reducing non-productive times and eliminating pressure shocks. HMT operates one of the most modern extrusion press shops in Germany, offering a wide range of extruded high-quality profiles and downstream processing capacities. Christian Schwarz, Managing Director of HMT: “Our maintenance processes have a strong focus on product quality, productivity and reliability of production. We constantly strive to sophisticate this approach. This is why we have devised a service concept together with SMS group that perfectly meets our individual needs. SMS group is the perfect partner for us as it has the necessary technological expertise to support us in planning and implementing our maintenance activities. We look forward to working with SMS group as a team in mastering this challenging task.“]]>