SMS group Press releases2019-01-20T22:26:10+00:00 /typo3conf/ext/bm_atomfeed/Resources/Public/Logo/smsgroup_logo.png <![CDATA[Nanjing Iron and Steel Group Co., Ltd. orders upgrade for continuous casting machine from SMS Concast]]> 2019-01-17T15:21:02+00:00 2019-01-17T16:09:00+00:00 China: Steel bloom caster modernization for greater production flexibility

Nanjing Iron and Steel Group Co., Ltd., a leading Chinese steel producer with approximately ten million tons of steel produced per annum, has awarded SMS Concast AG an order to upgrade the four strands of continuous caster CCM4 at its Nanjing plant No. 2. The targets of the project are to improve product quality and productivity and also to increase flexibility in the processing of a vast steel grade portfolio and to reach an annual production of more than 800,000 tons of blooms.

The four-strand continuous casting machine with nominal radius of 12 meters will cast two bloom section sizes, namely 250 x 300 and 320 x 420 millimeters. The product mix will include a large proportion of high-carbon grades like bearing and spring steels and the full range of steel grades to serve the automotive industry. This product portfolio will allow greater production flexibility and responsiveness to the market demand.

The casting machine will be equipped with the latest technological design to make this caster one of the most modern installations worldwide. Features, like dynamic mechanical soft reduction (DMSR) shall improve the inner quality of the blooms by means of soft and hard reduction modules designed to reach the necessary reduction ratios for an accurate control of core porosity and segregation.

The complete control of the soft/hard reduction (DMSR) system is delegated to the COOL real-time solidification model. This online simulation tool is a proprietary system developed by SMS Concast. It dynamically calculates the temperature profile along the entire strand and defines the roll gap and the reduction forces in the respective modules of the straightening unit. The spray cooling is also dynamically readjusted in accordance with the calculated cooling profile.

In addition to the DMSR system, the modernization project includes other technological and digital solutions such as CONFLOW tundish stopper mechanism for a precise control of the steel flow to the mold, INVEX® mold tube technology with the latest mold cooling features and a hydraulic tandem oscillation system allowing several oscillation parameters. The electromagnetic mold and final stirrers (CONSTIR M-EMS and F-EMS) together with the SMS Concast CONSTIR-MWS tool (modulated wave stirring) optimize stirring efficiency with an energy saving of 30 percent and more. The list of technological packages is rounded up by air-mist spray cooling and a bloom deburring technology. The installation of a robot-type slide gate manipulator will be also foreseen to increase safety and unmanned operation on the casting floor.

The electrical and automation system has the prime purpose of automatically controlling the operation of the caster (no-man casting). At the same time, the Level 2 computer system tracks and records all parameters relevant to bloom quality and provides a detailed cast report for each bloom. This preventive software module includes automatic sample cutting, slice by slice identification, computerized bloom tracking, a heat extraction mode, optimized residual length calculation and equipment life time recording.

In order to minimize shutdown times, particular attention was paid to project planning and delivery schedule in order to achieve quick implementation. The modernization is scheduled for completion in the fourth quarter of 2019.

<![CDATA[Nanjing Iron and Steel upgrades electric arc furnace with injector technology from SMS group]]> 2019-01-15T12:26:22+00:00 2019-01-15T13:14:00+00:00 Lower operating costs – higher productivity

Nanjing Iron and Steel Co., Ltd., China, has placed an order with SMS group to supply new SMS group ConSo R6 injectors for the electric arc furnace No. 3 in Luhe, Nanjing. Erection and commissioning of the equipment are scheduled for 2019.

The main goal of the upgrade is to cope with the future reduction of hot metal by replacing it with scrap in the charge. For this purpose, efficient injector technology is required. Furthermore, the upgrade will reduce operating costs and increase productivity.

The injector design was developed using computational fluid dynamics (CFD). The new lightweight construction, ten percent lighter than previous version, is particularly easy to maintain.

The SMS group ConSo R6 water-cooled copper boxes in monoblock design are not susceptible to cracking and effectively prevent water leakage. The integrated flashback detection system allows continuous monitoring of the ConSo R6 injector. The injector, which can be operated in burner or oxygen injector mode, additionally provides for automatic management of the melting profiles, ensuring excellent efficiency.

The SMS group scope of supply includes three ConSo R6 injectors, water-cooled copper boxes, the respective valve stations, an integrated flashback detection system as well as supervision of the erection and commissioning activities.

<![CDATA[Industrie 4.0 system from SMS group for quality assurance at integrated steel plant in Magnitogorsk]]> 2019-01-10T12:06:43+00:00 2019-01-10T13:02:00+00:00 MMK relies on PQA® for quality management across all processes

Magnitogorsk Iron & Steel Works (MMK), Russia, has placed an order with MET/Con, an SMS group company, for the implementation of the quality management system PQA® (Product Quality Analyzer). Together, MMK, SMS group and MET/Con intend to set a milestone with this project and show how the location’s performance and quality levels can be improved thanks to total process and production transparency.

MMK produces around 10 million tons per year quality steel at its site in Magnitogorsk; this steel is used in the construction and automobile industries, for example, and for pipeline and mechanical engineering. As part of a company-wide Industrie 4.0 initiative, MMK will implement the new PQA® quality management system in order to further improve quality levels across all processes in Magnitogorsk, as well as stabilize production processes, improve on-time delivery performance, and thus improve its competitive position.

The PQA® system is a holistic IT solution that operates on know-how based expert rules. Among other things, the advanced software and database solution from QuinLogic GmbH in Aachen, also an SMS group company, is to be used. This approach has been successfully implemented in the past at selected flat steel and long product manufacturers with a wide range of downstream processing stages.

The PQA® system conducts an online analysis of process, production, and quality data from steel production, through casting and rolling, right down to surface finishing and refining. The PQA® expert rules, which can be freely configured and fed with specific know-how, take into account customer and order-specific information in the quality assessment process or when the material is approved for further processing.

The modular software structure comprises a LogicDesigner for flexible rule adaptation, a quality assessment module, and a web-based reporting system. The centerpiece of the quality management system is the DataCorrelator software module, which also covers current topics such as big data analyses and artificial intelligence (AI). Various intelligent mathematical evaluation methods, including pattern recognition options, identify and indicate correlations that can be directly used for process optimization.

<![CDATA[Třinecké železárny awards final acceptance certificate to SMS group for new blooming mill stand]]> 2018-12-18T12:51:41+00:00 2018-12-18T13:44:00+00:00 High process reliability and improved quality following upgrade

Following the commissioning of its new blooming mill stand, the Czech steel company Třinecké železárny has awarded the final acceptance certificate (FAC) to SMS group.

The objectives of the upgrade were to maintain and ensure the operational reliability and plant availability, to create the necessary process stability and to improve quality, tolerances and yield. Due to the advanced age of the plant this upgrade was an essential investment into the future of Třinecké železárny.

The scope of the upgrade included a new ultra-rigid two-high reversing blooming mill stand with shifting unit and hook-type tilter. The blooming mill is used for the preshaping of intermediates – also of high-alloy steels – made from continuously cast material up to 525 millimeters in diameter and ingots up to a weight of 5.3 tons. Moreover, it is also providing the feedstock material for the existing rail, bar and wire rod production at Třinecké železárny, which shows the importance of this critical modernization project. Another core element of this order is the new hydraulic bloom shear with a shear force of around 1,000 tons. The shear is driven by an innovative and energy-efficient variable-speed pump (VSP).

<![CDATA[World’s first high bay container storing system to be ready for 2020 World Expo in Dubai]]> 2018-12-17T11:52:33+00:00 2018-12-17T10:14:00+00:00 Unique joint venture between DP World and SMS group to revolutionize global port logistics

Disruptive technology to radically improve operations

An international joint-venture formed by global trade enabler DP World and industrial engineering specialists SMS group will revolutionize the way that containers are handled in ports. A new and intelligent storing system will be applied for the first time ever at Jebel Ali Terminal 4, in time for the Dubai Expo 2020 world fair.

The High Bay Storage system was originally developed by SMS group subsidiary AMOVA for round the clock handling of metal coils that weigh as much as 50 tons each in racks as high as 50 meters. AMOVA is the first company to transfer this proven technology to the port industry.

Instead of stacking containers directly on top of each other, which has been global standard practice for decades, the system places each container in an individual rack compartment. Containers are stored in an eleven-story rack, creating 200 percent more capacity than a conventional container terminal, or creating the same capacity in less than a third of the space.

Thanks to the rack´s design, each container can be accessed without having to move another one, enabling 100 percent utilization in a terminal yard. The system brings big gains in speed, energy efficiency, better safety and a major reduction in costs. Costs are further cut by the ability to shorten the time taken to load and unload mega-ships by as much as 30 percent.

Sultan Ahmed Bin Sulayem, DP World Group Chairman and CEO, said: “DP World’s experience and expertise in moving cargo coupled with the technology of AMOVA will ensure the system is remarkably efficient and relevant for present and future operations. As a world first in our industry we are tremendously excited by its potential and groundbreaking features. Our engagement in new technologies is a major priority and we have become known for seeking ways that transform the way goods are moved across the world. Innovation is part of our DNA and at the heart of our success.”

Burkhard Dahmen, CEO of SMS group, said: “Our subsidiary AMOVA has optimized this technology in industrial applications for the metals industry over several decades. The application for container terminals is a direct result of our “New Horizon” strategy, in which SMS transfers technology from the metallurgical sector to other industries.”

Dr. Mathias Dobner, CEO of Joint-Venture, said: “This new container handling technology allows cities to use their expensive and sensitive land and waterfront areas more effectively. Our system will significantly increase the productivity of handling ships on the quay. This means that quay walls can be shortened by a third. This disruptive innovation will greatly improve the financial performance of container ports, and well as their overall appearance.”

For DP World media enquiries please contact:

Sana Maadad
Corporate Communications Manager
DP World
Phone: +971 505522610

Mike Vertigans
Senior Corporate Communications Manager
DP World
Phone: +971 566769324

Follow DP World on:

For AMOVA media enquiries contact:

Martin Aufschläger
Vice President Corporate Development & Communications
Phone: +49 (0) 2733 29 7286
Mobile: +49 (0) 151 1711 0612

About DP World:

DP World is a leading enabler of global trade and an integral part of the supply chain. We operate multiple yet related businesses – from marine and inland terminals, maritime services, logistics and ancillary services to technology-driven trade solutions.

We have a portfolio of 78 operating marine and inland terminals supported by over 50 related businesses in over 40 countries across six continents with a significant presence in both high-growth and mature markets. We aim to be essential to the bright future of global trade, ensuring everything we do has a long-lasting positive impact on economies and society.

Our dedicated team of over 36,000 employees from 103 countries cultivates long-standing relationships with governments, shipping lines, importers and exporters, communities, and many other important constituents of the global supply chain, to add value and provide quality services today and tomorrow.

Container handling is the company’s core business and generates more than three quarters of its revenue. In 2017, DP World handled 70.1 million TEU (Twenty-foot Equivalent Units) across our portfolio. With its committed pipeline of developments and expansions, the current gross capacity of 88.2 million TEU is expected to rise to more than 100 million TEU by 2020, in line with market demand. By thinking ahead, foreseeing change and innovating we aim to create the most productive, efficient and safe trade solutions globally.

About AMOVA:

AMOVA GmbH located in Netphen, Germany, has been a specialist in satisfying logistic demands in the metallurgical and rolling mill industry for more than 60 years. The portfolio further includes fully automated solutions meeting the most diverse requirements with respect to packaging for internal and external transportation.

AMOVA has been successful in translating the knowledge of these demands into other industrial sectors. Another field AMOVA has become a specialist in is high-bay stores for containers. Sea containers of different sizes are carried to fully automated high-bay stores where they are kept in space- and time-saving arrangement until repackaging or reloading (by ship, rail or road).

<![CDATA[Mukand Sumi Special Steel orders SBQ mill from SMS group]]> 2018-12-13T10:57:13+00:00 2018-12-13T11:45:00+00:00 Meeting all market requirements with flexibility and precision

Mukand Sumi Special Steel Ltd. (MSSSL), a joint venture of Mukand Ltd., India, and Sumitomo Corporation, Japan, has placed an order with SMS group for the supply of a state-of-the art Special Bar Quality (SBQ) rolling mill for the production of straight round and hexagon bars, wire rod and bar-in-coils. The new mill will be installed near Hospet in Karnataka, India, adjoining Mukand’s existing steel making facilities. Mukand and Sumitomo Corporation are aiming to export specialty steels across the globe from this unit.

In a first stage, the mill will have an annual capacity of 400,000 tons, but will already be prepared for a capacity increase to 600,000 tons per year in a second stage.

The mill will comprise a walking-beam reheating furnace with a capacity of 75 tons per hour in the first stage and 110 tons per hour in a second stage, 18 housingless two-high stands in H/V arrangement, a Precision Sizing Mill (PSM®), shears, cooling lines, cooling bed with finishing facilities, a wire rod line with a ten-stand wire rod block, laying head, Loop Cooling Conveyor (LCC®), coil handling equipment and a coil compactor.

A pouring reel line with two coilers specially designed for scratch-free guiding of finished products will complete the mill. The heart of the mill is an advanced three-roll PSM® with hydraulic roll adjustment under load. All finished sizes with diameters ranging from 17 to 65 millimeters can be produced cost-effectively even in small batches at a maximum speed of 14 meters per second.

Wire rod in diameters from 5.5 to 22 millimeters will be produced on the wire rod block at a maximum speed of 90 meters per second. The layout of the wire rod outlet will also consider a future upgrade with a MEERdrive®PLUS sizing block.

“With this new mill, we will be able to expand our position as a leading specialty steel supplier for the fast-growing Indian and worldwide automotive and engineering industries,” says Arvind M. Kulkarni, Director, Mukand Sumi Special Steel Ltd.

Commissioning of the new SBQ mill is scheduled for the second quarter of 2020.

<![CDATA[Grand opening ceremony of the world’s largest, pull-down die forging press supplied by SMS group at Weber Metals in California]]> 2018-12-10T12:46:36+00:00 2018-12-10T13:40:00+00:00 New dimension for the future of forging

On October 23, 2018, OTTO FUCHS Group celebrated the grand opening of its new 60k die forging press at the location of its U.S. subsidiary Weber Metals in Paramount, California. It is the largest single investment in the company’s over 100-year history. Numerous guests from industry, economy and politics attended the opening ceremony. Completely set up by SMS group, the new press, with a force of 540 MN (60,000 short tons), is the worldwide strongest and most advanced hydraulic pull-down die forging press in pit-mounted design.

“The new forging press from SMS group is our flagship and will ensure the competitiveness and also the technological leadership of OTTO FUCHS for the next 30 years,” says Dr.-Ing. Klaus Welschof, Head of Aerospace Division, OTTO FUCHS KG.

In the course of the event, visitors had the opportunity to experience the dimensions and the unique power of the press. The high-ranking representatives from economy and politics as well as those from SMS´ customer OTTO FUCHS and Weber Metals were equally impressed and excited. In total, SMS group used about 9,000 tons of steel to build the plant, which is more than once used for the Eiffel Tower.

SMS group was responsible for the mechanical equipment, electrical and automation systems, hydraulic equipment as well as the complete erection of the plant including commissioning. Forging of first reference pieces was also part of the supply scope. The forging results were impressive right from the beginning, confirming the success of the partnership-based cooperation and meticulous planning coordination between Weber Metals and SMS group.

“The SMS slogan of being the ‘Leading partner in the world of metals’ has definitely proved to be true. For the construction of this press, we had to make our choice from several partners and decided in favor of SMS because they came with a vast range of know-how which perfectly complemented that of our company. SMS complied with our wishes, and jointly we have built something really great,” says Dr.-Ing. Hinrich Mählmann, personally liable partner of OTTO FUCHS KG.

Anyone standing in front of the press during the opening ceremony could hardly imagine the routes the giant steel parts had gone. The huge components had mainly been manufactured in Europe and Asia and then been shipped to the U.S.A. according to a masterpiece of logistics and planning. In particular, the items concerned are 34 cast and forged parts with weights between 100 and 330 tons installed in the press. Also, the earth and installation work, and the auxiliary assembly aids specifically designed for this project, were record-breaking.

Size is not an end in itself

The die forging press, also named 60k press as it can exert a force of 60,000 short tons (U.S.), will serve Weber Metals to make products for the aerospace industry from forged aluminum and titanium. Forgings of these high-performance materials are used in the fuselage, in the wings, the undercarriage and the engines. The size of the plant is not an end in itself nor does it serve the pursuit of world records, but follows a clear future-oriented strategy: The new die forging press opens up completely new perspectives to designers and manufacturers in the aerospace industry for larger, weight-opti­mized but also structure-optimized components that offer increased safety at less weight. In the future, such parts will allow for the design of aircrafts featuring higher transport capacities, improved safety and minimized fuel consumption. These new, larger and lighter compo­nents are key to the future of mobility. Moreover, thanks to its enormous forging power the plant can shape even new high-strength and ultra-high-strength materials. Companies able to offer such raw materials will find markets that could not be served so far, which means clear competitive advantages and added value. SMS group supports customers in tapping this potential by providing plant solutions and tailored technology and to enable its customer, like OTTO FUCHS in this case, establish in promising markets.

Not only strong, but also highly precise

The hydraulic die forging press has a force of 60,000 short tons (U.S.) and a die clamping area of 6,000 x 3,000 millimeters. The working stroke is 2,000 millimeters The press is designed for hot and cold forming. An essential feature of the press is its balancing system with latest valve technology and highly sensitive electronics being perfectly harmonized and interacting. The result is extremely high precision in the forging operation.

<![CDATA[JFE Chita Works orders second premium threading machine from SMS group]]> 2018-12-06T13:04:42+00:00 2018-12-06T14:00:00+00:00 High output of premium threads

SMS group has received a new order from JFE Steel Corporation, Chita works, Chukyo Industrial Zone, Japan, for a premium threading machine.

This new machine, which will be JFE´s second threading machine from SMS group, will enable the producer of premium threads to expand its production capacities.

The threading machine of type TCG 43/4 is able to thread pipes in the diameter range from 139.7 to 406.4 millimeters with wall thick­nesses from 7.0 to 50.8 millimeters and lengths of up to 15 meters.

The machine operates according to the "stationary tool – rotating pipe" principle. With this method it can cut standardized inside and outside threads as well as all premium threads.

Thanks to latest FMEA (Failure Mode and Effects Analysis) technology and temperature control, the machine has an outstanding stability and produces threads of highest quality. The powerful drive achieves excellent acceleration and deceleration rates, resulting in a high output of premium threads and of high performance chromium grades. The pipe threads comply with the production standards for all API 5CT steel grades, JFE grades and other international standards.

<![CDATA[Fuzhou Wuhang Steel orders TMbaR mill from SMS group]]> 2018-12-04T12:57:12+00:00 2018-12-04T13:51:00+00:00 Production of fine-grained products by thermomechanical rolling

Fuzhou Wuhang, China, has placed an order with SMS group to upgrade its existing mill with the TMbaR technology for thermomechanical rolling of rebar. This is the third order for a TMbaR mill in China within one year, right after Yancheng Lianxin Steel and Laigang Yongfeng Steel placed their orders.

Fuzhou Wuhang, located in the Changle District of Fuzhou, focuses on the economic and efficient production of structural steel products. It has an annual capacity of about two million tons.

The new line will be designed for an annual production of 700,000 tons of rebar in diameters ranging between 10 and 18 millimeters at a maximum rolling speed of 45 meters per second and the possibility to produce rounds in the 14 to 20 millimeter range. SMS group will supply all key equipment including the electrics and the automation package. The plant is scheduled to be started up by mid 2019.

Fuzhou Wuhang chose SMS group´s TMbaR technology in order to be able to respond to the ever increasing quality requirements in the market while cutting production costs. Technological highlights of the equipment to be supplied are the well proven loop technology which allows achieving an ideal temperature across the feeder section within an optimized mill bay length, and SMS group´s MEERdrive® finishing blocks. The single drive concept of these blocks provides utmost technological and economic benefits over other drive concepts in terms of overall processing costs. The robust cartridge-type design makes for consistently high performance with minimized maintenance requirements. The equipment has been specially designed for long rolling campaigns under the high rolling load demanded by the TMbaR process. In combination with the state-of-the-art High Speed Delivery (HSD®) system, the TMbaR technology offers exceptional technological and economical benefits which have convinced Fuzhou Wuhang to place this order with SMS group.

By putting its trust in the long-standing experience of SMS group and in the advanced TMbaR technology, Fuzhou Wuhang is expanding the cooperation between Wuhang and SMS group and will be able to respond better and faster to market demands, achieve improved material properties and save on alloys and operating costs.

<![CDATA[SMS group wins German Design Award 2019]]> 2018-11-26T14:19:36+00:00 2018-11-26T15:09:00+00:00 Additively manufactured 3D spray head for forging plants wins design award in the category “Industry”

A small machine component winning a design award is probably a first in the history of the German Design Award and certainly worth noting. The component for which plant and mechanical engineering company SMS group has received the German Design Award 2019 in the category “Industry” is a spray head used to cool dies in forging presses. All involved in the various teams that have been working towards the common goal of adopting an entirely new approach to designing and producing a machine component were excited about the news. Not only the component as such was relevant for the judges, but also the fact that it exemplifies the various aspects of Additive Manufacturing, a technology that has been opening a whole range of new possibilities for the design and functional layout of components. Every year the German Design Council organizes the German Design Award, one of the most recognized design awards worldwide. This Award recognizes innovative products and projects, and the companies or individuals who have fabricated and designed them.

New way of thinking brings about components optimized for specific functions

Axel Roßbach: Research and Development Extrusion and Forging Presses, SMS group GmbH: “Winning the Design Award makes us extremely proud. It is recognition of many teams within SMS group whose work is characterized by a highly interdisciplinary approach. The spray head is a milestone innovation marking a new era in the design of plant and machine components, enabled by the game-changing potential of 3D printing and function-optimized design. The design of a machine part is today no longer limited by the constraints imposed by conventional – process-optimized – forming and machining techniques. Supported by latest software and computer technology, we can now give a component exactly the design that fulfils its designated function in the best possible way. Another important aspect is that we have used new materials. Therefore the Award honors not only a new design, but above all the new way of thinking lived within SMS group, which has materialized in a global approach to Additive Manufacturing.” According to Axel Roßbach, the new spray head is an example of how nowadays, in the digital age, different disciplines interact and what opportunities Additive Manufacturing holds in store. The new spray head solution produced by 3D printing is the result of a joint effort by the Forging Plants Department, the Additive Manufacturing Project Team and the simulation technology experts of SMS group.

Only one tenth of the weight of the conventionally produced component

Common spray heads are heavy and complicated to produce. Their heavy weight impairs the productivity of the forging press. Against this, the new spray head has been designed with a view to how it can fulfill its function in the most efficient way. It is significantly smaller, features flow optimized channels and cools the dies specifically and as required in each individual case. Die areas subjected to intensive heating are cooled at a correspondingly – precisely calculated – higher rate than areas less hot. Additionally, these spray heads can be produced virtually just in time. Axel Roßbach: “Although the spray head is only a small component, it nevertheless ideally represents the potential of Additive Manufacturing. The innovative manufacturing methods enabled by 3D printing form the basis for Industrie 4.0. The example of the 3D-printed spray head makes this clear and measurable. Made of plastics, it weighs only one tenth of what a conventional one would weigh. A 3D spray head made of metal weighs up to 70 percent less. It is less expensive, more efficient and can be easily customized and instantly produced. “

Lower costs, higher productivity

All this provides numerous advantages for drop forging operations. Drop forging presses are being constantly optimized with a view to achieving shortest cycle times and maximized service life of the dies. Spray heads for cooling and lubricating the dies perform a key function in the forging process as without them the dies would not be able to withstand the constant and extremely high stress acting on them during operation. The spray heads are introduced between the open dies awaiting the next forging stroke. The innovative SMS group solution means not only a reduction in weight and costs, but also reduced wear of the supporting arms which introduce the spray heads between the dies. Due to the significantly lower mass to be accelerated, cycle times of the - usually automated - processes can be shortened. Another key advantage for the press operator is the possibility of producing customized spray heads “on demand”, i.e. the spare heads are available in virtually no time, without incurring the high costs of keeping them physically in stock. Also the environment benefits as the production of the spray heads consumes no more material than absolutely necessary. SMS group plans to also print current-conducting elements and sensors into the spray heads. This will make it possible to actuate the valves electrically and generate condition messages of the systems. The thus gained added value and the potential for process optimization make the 3D-printed spraying system for drop forging operations a technology ready for Industrie 4.0. Robert Banse, a member of the R & D Project Team SMS group: “We are in no way restricted by any manufacturing constraints. Therefore we can adopt a creative technological approach to designing and start out from the function the component is going to perform. In other words: We develop the perfect design for the function at hand ready, knowing that it can be produced in the 3D printer.”

Filigree shape proves successful under harsh operating conditions

One of the first customers using the new spray head in practice is Bharat Forge in Ennepetal, Germany. For Bharat Forge, the spray head was specifically designed to allow switching between water and a graphite-based spraying fluid. Both the forge operator and SMS group are extremely satisfied with the performance of the spray head. Bharat Forge: “The spraying pattern is much more homogeneous now. The dies are cleaner. Consequently the overall consumption of spraying fluid has decreased. Also handling is easier than with the conventionally manufactured spray heads. Accumulations of material, as frequently occurring inside the former spray heads, have not been found thanks to the flow-optimized design of the fluid channels.“

Only one facet of the overall concept of Additive Manufacturing

Although the Design Award-winning spray head is in the focus of attention above all due to its extraordinary design, this is only one facet of the many activities underway at SMS group in the area of Additive Manufacturing. As the “Leading Partner in the World of Metals”, the company’s plans and strategies are of much wider scope. SMS group is not going to limit its AM activities to the design and production of innovative machine components, but will also offer integrated solutions for the complete process chain of Additive Manufacturing on the market.

A main area of Additive Manufacturing is 3D printing of metal. In 3D printing, a laser melts fine-grained metal powder at selected, exactly defined locations. The components rebuilt up layer upon layer: A wafer-thin layer of metal powder is spread out on a powder bed. Then the laser melts the powder at the programmed spots. When this has been completed, another thin layer of powder is applied, and so forth... With this technique it is possible to make components of a complexity not feasible with conventional techniques. SMS group has been very active in the field of Additive Manufacturing for many years and has recently commissioned a pilot plant for industrial-scale production of AM-grade metal powder. This powder features very specific properties, which are very likely to propel a completely new growth sector. It is extremely homogeneous and forms the basis of Additive Manufacturing. The powder consists of perfectly round minute spheres measuring only 15 to 45 micrometers (one thousandth of a millimeter). It is hard to imagine how these microscopic particles are produced in a 13 meters tall and complex high-tech plant. Markus Hüllen, Vice President 3D Competence Center of SMS group: “The successful commissioning of the powder atomization plant marks a milestone for SMS group because it ensures the quality we need to make high-quality 3D-printed metal components. Our objective is to master – and allow our customers to master - the complete process chain of this innovative technology. This is why we deliberately chose to not build a small-scale but an industrial-scale pilot plant. Only this way can we test the process under realistic conditions, i.e. at high temperatures and pressures and in long production campaigns. We also work with a cooperation partner: Additive Industries, developers and providers of selective laser melting systems for 3D metal powder printing. We plan to set up a demonstration plant at the SMS group facilities in Mönchengladbach, which will comprise all process steps of Additive Manufacturing. “

Bright prospects as a supplier of integrated AM solutions

Additively manufactured components are already used in a number of industries. These “enabler” industries include the aerospace industry, the automotive industry, medical engineering, prototype and tool making, and plant and mechanical engineering. The Demo Center at the Mönchengladbach facilities will be the first of its kind as it will allow customers to experience the complete process chain of Additive Manufacturing, i.e. from powder production in the powder atomization plant, powder handling, 3D printing, heat treatment and machining to inspection, quality checks, logistics and the automation system. SMS group has been cooperating with Additive Industries in the development of processes that keep the powder under vacuum during all process steps. This prevents the powder from contaminating in any way and ensures that the components produced will be of highest quality. Markus Hüllen: “As systems provider and the “Leading Partner in the World of Metals”, our objective is to offer our customers complete Additive Manufacturing plants on a turnkey basis. By integrating the entire process chain from powder production down to the finished products, we ensure a high and reproducible powder quality for series production. The pilot plant will allow us to optimize the processes so as to maximize productivity and minimize total costs. Our customers will receive modular, scalable solutions tailored to their individual requirements. With our world-spanning service and support network, we are always readily available for our customers to accompany them on their way into the world of Additive Manufacturing.“

“New Horizon” strategy program unlocks the potential of future-oriented technologies

Although the new spraying system for drop forging plants is only a small object, it is – in the true sense of the word – a prize example of the exciting developments the plant and mechanical engineering sector is going to see in the very near future. With its corporate-wide strategy program “New Horizon”, SMS group is bundling all future-oriented activities in connection with Additive Manufacturing, digitalization, Industrie 4.0 and new high-tech materials. The reason behind this strategy is the fact that all these areas are interconnected and can only be advanced in a concerted approach. The strategy has worked out well. Numerous projects, such as learning steel mills, plants for the production of high-performance materials, and environmental technology that provides both ecological and economic benefits have already been successfully implemented. The new 3D-printed spray heads certainly fits into this category.

<![CDATA[Ternium Argentina awards SMS group FAC for successful upgrade of gas cleaning plants]]> 2018-11-21T14:36:52+00:00 2018-11-21T15:33:00+00:00 Effective environmental engineering from SMS group

Ternium Argentina, based in San Nicolas, Argentina, has awarded SMS group the final acceptance certificate for the upgraded BOF gas cleaning plants at its San Nicolas works.

As part of a planned increase in the production capacity of the three 190-ton converters, the gas cleaning plants, installed in the 1970s, were upgraded to the state of the art and now provide far more efficient cleaning results. Offgas emissions were reduced to below 25 mg/Nm³; the legal limit is 50 mg/Nm³.

Cesar Alejandro Parisi, Ternium Argentina, Head of Plant Development Department for Hot Rolling Mill and Steelplant:

“This upgrade of our gas cleaning plants means we are ideally equipped to meet the environmental challenges of the future. The performance of SMS group’s environmental technology comes up to and even exceeds our expectations.”

For the revamp of the three scrubbers, SMS group supplied key components as well as two main induced-draft fans for gas cleaning. The venturi throat, developed by SMS group, features a new type of nozzle geometry and arrangement, which ensures extraction of a larger quantity of dust particles.

The scope of supply also included the measuring technology for the venturi scrubber and the whole gas cleaning plant, including the cooling stack, as well as the supervision of the erection work and commissioning.

<![CDATA[Henan Mingtai grants SMS group final acceptance of high-performance aluminum cold mill]]> 2018-11-19T14:18:58+00:00 2018-11-19T15:11:00+00:00 High-quality wide aluminum strip

On October 18, 2018, the Chinese aluminum producer Henan Mingtai Al. Industrial Co., Ltd. has granted SMS group the final acceptance certificate for the new aluminum cold rolling mill established at the Gongyi location. Henan Mingtai is very satisfied with the plant since regular operation could be started soon after a short and efficient commissioning and ramp-up phase.

The six-high cold rolling mill with CVC®plus (Continuously Variable Crown) rolls a wide range of materials and alloys up to a maximum strip width of 2,650 millimeters. The portfolio includes, for example, sophisticated material grades and qualities for automotive body application.

Henan Mingtai now owns a high-yield mill producing strips of excellent quality and featuring the most advanced rolling technology, with core components, including CVC®plus technology for roll shifting and the new inductive and particularly energy-efficient roll barrel heating system, made in Germany by SMS group.

<![CDATA[Bornay S.L. trusts in high-precision tube welding line from SMS group]]> 2018-11-09T10:32:28+00:00 2018-11-09T11:27:00+00:00 High yield strength and close tolerances

Spanish welded steel tube specialist Bornay S.L. has ordered an HF (High Frequency) tube welding line, type RD 40, from SMS group for its Alicante works. SMS group is the single-source supplier of all technical equipment from strip preparation to the cut-off-saw.

The new machine will produce round tubes with diameters from 10 to 40 millimeters and wall thicknesses from 0.75 to 4.5 millimeters, as well as squares in dimensions from 10 x 10 millimeters to 30 x 30 millimeters and rectangulars in dimensions from 20 x 10 millimeters to 40 x 20 millimeters with wall thicknesses ranging between 1.00 and 4.00 millimeters.

The tube welding line to be commissioned in the first quarter of 2020 will achieve a production speed of maximum 120 meters per minute. Here, Bornay can produce high-quality tubes with round, square and rectangular cross-sections. They can be used, among others, as precision tubes for the automotive sector, but also for metallic furniture or in the agricultural sector.

“Our requirements with regard to the new welded tube plant were very high since we produce tubes for mechanical applications that require a high level of precision in their finishing. The engineers from SMS group have designed a plant meeting our needs.” says Juan Bornay, Managing Director, Bornay S.L.

<![CDATA[POSCO Pohang modernizes its wire rod and bar-in-coil mill #2 with SMS group]]> 2018-11-09T10:41:34+00:00 2018-11-08T13:12:00+00:00 Quality, process and plant efficiency will be highlighted with the new pouring reel for special steels in South Korea

Pohang Iron and Steel Company (POSCO), the fifth largest steel producer in the world and largest in Korea, has awarded SMS group the order to modernize its existing wire rod mill at its Pohang works.

The plant presently produces 540,000 tons per year of wire rod and bar-in-coils for automotive applications in the diameter range from 14 up to 42 millimeters with coils up to two tons.

The target of the modernization includes the replacement of some equipment along the mill (existing descaler and additional one on the rolling mill), a new cropping shear, a shiftable water cooling line, pouring reel machines with walking beam conveyor, cooling fans and hoods assuring in-line treatment of coils.

The project foresees to widen coiled round products up to 55 millimeters diameter and smaller products rolled at 22 meters per second. The mechanical areas will be connected with a scratch-free conveying system that, combined with the automation package supplied by SMS group, will grant POSCO a quality improvement on the rolled surface of the bars and a better coil shape and formation. Further implementations are the off-line simulation process with CCT® (Controlled Cooling Technology) and quick changing system of the water cooling line in less than five minutes to grant better plant efficiency. These features will give POSCO the possibility to better supply the automotive and special steels market.

This latest modernization project further underlines SMS group's upgrade expertise and its position as a leading supplier of rolling mills for quality steels in all size ranges.

<![CDATA[Aurubis orders new Peirce-Smith converters from SMS group]]> 2018-11-06T10:16:21+00:00 2018-11-06T11:11:00+00:00 Hamburg-based Aurubis AG is to take delivery of new converters, which will be supplied by SMS group and used to produce blister copper, an important stage in the copper production process.

The converters will be installed at the company’s headquarters in Hamburg. They are scheduled to be put into operation in fall 2019. The converters measure 15’ x 38‘. Aurubis AG is installing the new converters in order to strengthen and consolidate its global position as an integrated copper group and the world’s largest copper recycler.

The new converter design already takes future optimization into account to allow for more efficient production processes.

SMS group has been commissioned with the engineering, delivery, and installation of the converters.

SMS group is a group of companies internationally active in plant construction and mechanical engineering for the steel and nonferrous metals industry. It has some 14,000 employees who generate worldwide sales of about EUR 3 billion. The sole owner of the holding company SMS GmbH is the Familie Weiss Foundation.

<![CDATA[E-MAX and Technical Service of SMS group prolong service contract]]> 2018-10-31T14:51:45+00:00 2018-10-31T15:47:00+00:00 Flexible service package for long-term high availability in aluminum production

ALUMINIUM 2018, the leading trade show for the aluminum industry took place in Düsseldorf from 9 to 11 October. In addition to discussing the big topics of the future at the SMS group booth, representatives of SMS group’s Technical Service also presented its service concept for extrusion press operators. This concept is characterized by a strong focus on quality, productivity and safety of production. Numerous guests, among them Dimitri Fotij, CEO, and Stijn Kusters, Plant Manager, of Belgium-based E-MAX PROFILES, came to Düsseldorf to discuss and exchange information with the service experts of SMS group.

Several years ago, E-MAX Profiles and SMS group had signed a first contract for a comprehensive service package related to the two SMS group-supplied light-metal extrusion presses designed for pressing forces of 25 and 35 MN, respectively. E-MAX has been extremely satisfied with the quality of the technical service provided by SMS group. Therefore Dimitri Fotij and Stijn Kusters came to Düsseldorf to discuss and sign a follow-up contract. “The market for aluminum profiles is extremely competitive. SMS group has proved to be a strategically essential partner in safeguarding the high availability and productivity of our machines in the long run,” explains Fotij.  “We plan and perform the service activities in close coordination with our customers, always bearing in mind their production schedules. We set great store by a regular exchange of views and ideas with the plant operators because this allows both sides to benefit from the cooperation and further develop their skills on a continuous basis,” says Ben Zander, Head of Modernization and Maintenance Services for Hydraulic Presses at SMS group.

E-MAX belongs to Belgium-based Vaessen Industries. The company offers a comprehensive portfolio of products, from aluminum extrusion billets down to high-quality extruded profiles, which it further processes and finishes for a wide range of applications. By offering X-ECO, i.e. alloys produced in a sustainable way from recycled aluminum, E-MAX has set a milestone in terms of sustainability and environmental awareness.

<![CDATA[Semi-continuous billet mill from SMS group at Formosa Ha Tinh Steel Corporation in full operation]]> 2018-10-30T12:40:46+00:00 2018-10-30T13:19:00+00:00 Designed for maximized productivity of large-size billet rolling

The new semi-continuous billet mill supplied by SMS group to Formosa Ha Tinh Steel Corporation in the Ha Tinh province, Vietnam, has commenced full commercial production. Formosa issued the FAC (Final Acceptance Certificate) to SMS group in June. Jimmy Chen, Head of Long Product Rolling Mills at Formosa, states: “SMS group convinced us with its outstanding number of reference mills and the best technological concept. Our new mill is considered the newest and most modern billet mill in the world with latest design CBD (Compact Breakdown) breakdown mill stand and ultra-rigid CS stands of the latest generation. The CS stands are just the perfect solution for the finishing of large-size billets due to its rigidity and sturdy design.”

The new billet mill is designed for a capacity of 1,000,000 tons per year of special steel grades in the first phase and up to 2,000,000 tons per year in a second expansion. It is producing 160 and 180 millimeter square billets from blooms of 260 x 300 millimeters and 360 x 450 millimeters in size.

The blooms, reheated up to 1,250 degrees Celcius, are descaled by means of high-pressure water. The reversible two-high blooming mill stand is equipped with sideguard manipulators and hook-type tilters on the entry and exit side. The state-of-the-art stand design includes a hydraulic unjamming device, roll force measurement, ultra-rigid hydraulically activated keeper plates and roll shifting, to mention but the main highlights. All functions are fully automatic and roll change is performed in less than 25 minutes.

Provision has been made for a four-sided flame scarfing machine to be installed after the blooming mill. Before entering the continuous mill, the head of the leader pass can be cut off by means of a 10,000 kN bloom shear and the leader section is tilted through 45 degrees with the bar turner. The four-stand continuous mill is of H/V (horizontal/vertical) design. All stands are of CS design.

A key feature of the mill is the 3,800 kN four-crank shear designed to cut billets of up to 180 millimeters square into lengths of 10 or 12 meters and essential in safeguarding high utilization and low production costs. Also the head and tail ends are cut. As the lifetime of the shear blade is much longer than in saw-type cutting, the specific cutting costs are approx. 10 times lower. At the same time, utilization of the mill is much higher.

All billets are cooled on two turn-over type cooling beds where they receive their final high straightness. Each billet is marked with a stamped number and weighed separately at the end of the cooling bed. Both, billet ID and weight are reported to the Level 2 system which forms the basis of a well-organized storage system and production planning for the downstream mills.

The loading area of the mill boasts four loading beds. Via three of the loading beds, the billets can be sent directly to the storage bays of the downstream rolling mills. Alternatively, they are sent to an intermediate storage area where they cool down to below 50 degree

Celsius so that they can be processed through the fully automatic inspection and grinding line which was also supplied by SMS group.

SMS group also supplied the complete electrical and automation package, including complete Level 1 and Level 2 automation.

<![CDATA[Aurubis orders new Peirce-Smith converters from SMS group]]> 2018-11-02T14:08:37+00:00 2018-10-26T12:53:00+00:00 Hamburg-based Aurubis AG is to take delivery of new converters, which will be supplied by SMS group and used to produce blister copper, an important stage in the copper production process.

The converters will be installed at the company’s headquarters in Hamburg. They are scheduled to be put into operation in fall 2019. The converters measure 15’ x 38‘. Aurubis AG is installing the new converters in order to strengthen and consolidate its global position as an integrated copper group and the world’s largest copper recycler.

The new converter design already takes future optimization into account to allow for more efficient production processes.

SMS group has been commissioned with the engineering, delivery, and installation of the converters.

<![CDATA[Shandong Rizhao grants SMS group FAC for high-capacity hot strip mill]]> 2018-10-25T11:49:12+00:00 2018-10-25T13:43:00+00:00 Chinese steel producer Shandong Iron & Steel Rizhao has issued the Final Acceptance Certificate for the new high-capacity hot strip only seven months after rolling the first coil.

The hot strip mill is part of a large-scale order which the Chinese steel producer had placed with SMS group. The complete order comprises the hot strip mill, a coupled pickling line and tandem cold mill (PL/TCM), two continuous annealing lines (CAL) and a hot-dip galvanizing line (HDGL). The production plants are located on the eastern coastal area of China in the province of Shandong.

The high-capacity hot strip mill has a maximum annual capacity of 4.8 million tons and produces strips with a maximum width of 1,900 millimeters. The final strip thicknesses range between 1.2 and 25.4 millimeters. The main mill equipment includes a descaler in the roughing mill, a slab sizing press, a two-high reversing roughing mill stand, a four-high reversing roughing mill stand with edger, heat panels on the delay roller table to the finishing mill, a crop shear, a descaler at the entry side of the finishing mill, seven finishing mill stands, a laminar strip cooling section and three down coilers for the finish-rolled hot strip.

This mill configuration provides Shandong Iron & Steel Rizhao high flexibility in hot wide strip production. One reason for this flexibility is the slab sizing press at the entry of the hot strip mill which achieves width reductions of up to 350 millimeters. The two high-capacity roughing mill stands allow Shandong Iron and Steel Rizhao a great variation in pass schedule calculation. The heat panels on the delay roller table reduce temperature losses in the transfer bar resulting in decreased energy costs and making for more stable rolling in the finishing train. The powerful finishing stands are able to roll with forces of up to 52 MN (F1-F4) and 40 MN (F5-F7). For thickness control all finishing mill stands are equipped with hydraulic screwdown actuators. The proven CVC®plus system (Continuously Variable Crown) with integrated work roll bending ensures a high-quality strip profile, strip contour and strip flatness.

The PCFC® system (Profile, Contour and Flatness Control) calculates the correct shifting position of the specially ground work rolls and the setup values for work roll bending, resulting in the ideal roll gap for each strip rolled. By taking into account the varying rolling conditions, narrowest geometrical tolerances are guaranteed, providing for efficient further processing of the hot strip in the downstream coupled pickling line and tandem cold mill and in the strip processing lines.

Before the final acceptance the required dimension range of strip thicknesses between 1.2 and 25.4 millimeters and strip widths of up to 1,900 millimeters had been successfully rolled. The grades rolled included steels for the automotive industry, for construction applications as well as X80 pipe grades. Thanks to the proven profile, contour and flatness control (PCFC®) system and the sophisticated CVC®plus actuators, the geometric target values specified for the thickness profile and the strip flatness were safely achieved.

The customer Shandong Iron & Steel Rizhao commented very positively on the trouble-free commissioning of the high-performance hot strip mill: “With the plant engineering and process technology from SMS group we can now produce hot wide strip as primary material for the automotive and pipe manufacturing industries in a highly efficient way.”

<![CDATA[MY VIET INDUSTRIES grants final acceptance for push-pull pickling line and Compact Cold Mill supplied by SMS group]]> 2018-10-23T11:07:08+00:00 2018-10-23T12:59:00+00:00 Commissioning rapidly and successfully completed

Vietnamese cold strip producer MY VIET INDUSTRIES Co. Ltd. has granted Esmech Equipment Pvt. Ltd., a company of SMS group, the final acceptance for the supplied push-pull pickling line and the CCM® (Compact Cold Mill).

My Viet had put the push-pull pickling line and the twin-stand cold rolling mill into operation in May 2018. In July 2018, after six weeks of hot commissioning and performance optimization, Esmech Equipment Pvt. Ltd. received the final acceptance certificate.

MY VIET INDUSTRIES Co. Ltd. is a reputed supplier of coated steel products for the construction industry. The new cold strip mill in the Hung Yen Province, south of Hanoi was added to an existing works as a backward integration in order to provide the existing facilities with the required cold rolled strip and to supply the additionally produced strip to the Vietnamese industry. The mill will produce approximately 400,000 tons per year of low carbon strip in widths of up to 1,250 millimeters and final thicknesses down to 0.15 millimeters for numerous construction and industrial applications.

The push-pull pickling line is realized as a turbulent pickling bath, comprises a double entry section and four pickling tanks completely made of granite. The design allows for high process speeds and safe and eco-friendly processes.

The pickling line can process strips with widths in the range from 600 up to 1,250 millimeters and thicknesses of up to 4 millimeters. The process speed can be varied between 15 and 120 meters per minute.

The CCM® is equipped with high-tech components manufactured at the German workshops of SMS group. The components include the well-proven CVC®plus (Continuously Variable Crown) roll shifting technology and roll bending devices, which ensure premium rolling results and high production efficiency. The mill also features automatic flatness control, modern actuators, an interactive roll pass calculation module and level-2 automation. All this makes MY VIET INDUSTRIES Co. Ltd. perfectly set not only for current but also for future customer requirements.