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2 Metals Technologies Secondary Metallurgy Solutions Technology, mechanical engineering, automation and electrical engineering from a single source – top values in productivity, consumption and availability 070408_SecMet_REV_RZ04.indd 2070408_SecMet_REV_RZ04.indd 221.05.2007 143933 Uhr21.05.2007 143933 Uhr 2 From alloy handling to degassing, desulfurization, and decarburization, the production of high-quality steels without secondary metallurgy is unthink- able. It’s crucial that the entire plant meets all prescribed perance values while at the same time delivering the planned steel quality in a safe, repro- ducible manner. Our work is focused on fulfilling these requirements. You expect... Efficient production and maximum productivity – through application of comprehensive plant expertise Reliable delivery times, prompt com- missioning, fast run-up – and reliable spare part supply Flexible plant design – for the produc- tion of various steel qualities Low, demonstrably reachable consump- tion values – for alloying elements and energy Reliable compliance with environ- mental regulations – including future requirements 070408_SecMet_REV_RZ04.indd Abs12070408_SecMet_REV_RZ04.indd Abs1221.05.2007 143943 Uhr21.05.2007 143943 Uhr 3 Your challenge Refining crude steel, improving perance Perfect teamwork for maximum efficiency High availability, short charge cycle times, low consumption values, and reduced personnel costs are decisive factors for the perance and productivity of your secondary metallurgy. All of this requires basic expertise from your solution provider Only finely tuned process control and automation ensure efficient use of personnel and short cycle times. Only precise scaling of design parame- ters for the material used can guarantee verifiable conance with consump- tion values. And only the correct plant design leads to minimal space costs for the vacuum pump, alloying facility, and metallurgical vessels. Your customers require the best Does your plant need to produce a wide variety of products Do you need to quickly adapt to different requirements Are you looking to reliably fulfill challeng- ing expectations – perhaps in the area of ULC steels, where today a carbon content of less than 20 ppm is often expected This requires mechanics specifically designed for steel mills as well as an efficient automation solution and high- ly developed process models for various steel qualities. But the parameters that influence the process must also be stable and calculable, especially when it comes to the power supply. High plant perance must be long-lasting The expertise of your service and main- tenance personnel has a significant influ- ence on plant operation, safety, and avail- ability. That’s why your solution provider must be able to pass on available knowl- edge to operating personnel, and to sup- port your service experts at any time with necessary spare parts. In short A commitment is needed that goes beyond what’s often seen in the industry today. Environmental require- ments are also growing International agreements and national laws require a reduction of pollution and CO2 emissions. And naturally you also have a responsibility to the people and the country where you are produc- ing. So you should also uate your solution provider on how well they can support increasing environmental re- quirements – both today and tomorrow. 070408_SecMet_REV_RZ04.indd Abs13070408_SecMet_REV_RZ04.indd Abs1321.05.2007 143944 Uhr21.05.2007 143944 Uhr 4 The right approach Our Secondary Metallurgy Solutions for your EAF or BOF steelmaking shop An MES Manufacturing cution Sys- tem solution for optimized production planning and for minimizing of raw materialsconsumption. Our offerings also include power quality solutions for a stable, fault-free energy supply for your secondary metallurgy, even under high power loads. Complying with emission limits – including future standards As a complete plant supplier we can pre- cisely configure the downstream environ- mental technology to the gas exhaust parameters and the secondary metallurgy process cycle. You’re assured of not only fulfilling today’s limit values, but of being prepared for tomorrow’s regulations as well. Ensured perance throughout the entire life-cycle With reliable operation thanks to knowl- edge transfer from our training experts, and assured spare part supply, Siemens VAI’s comprehensive service offerings boost plant availability throughout the entire life-cycle. And we also cover your strategically planned modernization at just the right point in time in terms of both technology and economics. All components from Siemens VAI are built to withstand the highest everyday loads. We achieve this through extensive standardization, many years of teamwork with selected suppliers, certified output controls, and systematic quality assurance. In addition, we guarantee that parts cri- tical to perance will be produced in Germany. The result Assured delivery times, high availability and a long plant life-cycle. Coordinated layout – optimized process Just as decisive as component quality is the optimization of plant layout and process. Our experience helps us precisely coor- dinate movement cycles in order to mini- mize secondary processing times and use electrical and thermal energy more efficiently. And by holistically taking all upstream and downstream plants into account, the individual cycle times can be “cleanly” balanced. Automation with power – for productivity and quality All secondary metallurgy processes, from ladle furnace to vacuum treatment plant, are covered using an easily integrated automation solution from Siemens VAI. In addition to process control, it also offers Continuously developed process mod- els for the reliable, reproducible pro- duction of various steel qualities. 070408_SecMet_REV_RZ04.indd Abs14070408_SecMet_REV_RZ04.indd Abs1421.05.2007 143945 Uhr21.05.2007 143945 Uhr 5 What does working with Siemens VAI stand for It stands for thirty years of vacuum technology under the name of VAI FUCHS, 100 years of Siemens experience as partner to the metals industry – and an installed base of 180 secondary metallurgical plants. This unique combination of technology, mechanical and electrical engineering, and au- tomation under the name of Siemens VAI is your guarantee that all your requirements will be met. Good reasons for our Secondary Metallurgy Solutions Reliable fulfillment of the contractual conditions – through a reliable plant from an experienced partner Faster, more reliable run-up – using operator-friendly plants in combination with the process expertise of Siemens VAI Highest productivity, flexible process management and availability – using perfectly coordinated technology, auto- mation and process models Always at the forefront of technical developments, for example through T-COB lance, the two-stage vacuum pump and powerful automation solutions Fast amortization – thanks to mini - mized consumption figures, high avail- ability and assured productivity 070408_SecMet_REV_RZ04.indd Abs15070408_SecMet_REV_RZ04.indd Abs1521.05.2007 143946 Uhr21.05.2007 143946 Uhr 6 The VD process During vacuum treatment the carbon, oxygen, nitrogen, hydrogen, and sulfur contents are reduced in different process steps depending on the melt composi- tion. A vacuum alloy hopper system allows for compositional adjustments. Good homogenization and high alloy yields are characteristic features of this process. De- pending on the metal lurgical reactions in the ladle, a freeboard of 600–1,200 mm is required. In order to increase producti- vity, the VD system can also be designed or expanded to a twin-vessel system. Vacuum tank degassing systems VD Proven and reliable 80 -t VD plant, Acc. Venete S.P.A., Camin, Italy Vacuum tank degassing is one of the old- est degassing techniques in use in the steel industry for improving steel quality. A teeming ladle is placed in a vacuum tank, which is connected to a vacuum pump system. The ladle is equipped with 1–3 porous plugs through which inert gas is injected into the melt to promote stirring. Metallurgical reactions such as degassing, deoxidation, decarburization, desulfurization and alloying take place under vacuum conditions. Vacuum alloying hopper Vacuum cover TV camera Suction line Slide gate T Highlight CaSi Injection; slag stopper unit between BOF converter and ladle furnace Our solution Installation of two 330t LF including alloy system, complete Automation and Auxilliaries. Complete metallurgical support. The result Extension of product range e.g. very low sulfur content steel grades for gas pipes and marine pipes Decrease of BOF converter tapping temperature Increase of productivity 070408_SecMet_REV_RZ04.indd Abs116070408_SecMet_REV_RZ04.indd Abs11621.05.2007 144027 Uhr21.05.2007 144027 Uhr 17 Secondary Metallurgy Solutions from Siemens VAI comprise the 35 years of experience in plant construction embodied by global market leader VAI FUCHS until 2005. The integration of Voestalpine Industrieanlagenbau GmbH – and therefore of VAI FUCHS GmbH – into Siemens AG placed our expertise in complete systems on a new basis. The success stories presented below provide just a brief impression of our comprehensive experience. Optimized logistics – boosting productivity Customer Sollac Mditerrane Groupe ARCELOR, Fos-sur- Mer, France Plant type RH plants with TOP lance, 315 tons heat size Our solution Complete implementation of a RH plant with the possibility to move the ladle car under the vacuum unit. The result Very high productivity increase through sophisticated logistic concept. The first and largest Customer Maanshan ISCO, Maanshan, China Plant type RH twin plant with T-COB lance and twin ladle furnace, 330 tons heat size Our solution Implementation of the first and largest plant of this type a twin plant with quick-change vessels. The result Significantly higher productivity and plant availability than with single RH plants. Twins Customer Salzgitter AG, Salzgitter, Germany Plant type VD plant, 210 tons heat size Our solution Installation of two twin ladle furnaces in combination with three VD units for degassing and decarburization. The result Increased productivity through arrangement of a ladle furnace and a VD unit each on one track. Maximum production, low costs Customer Azovstal, Mariupol, Ukraine Plant type VD-OB plant, 350 tons heat size Our solution Implementation of the largest twin-VD plant worldwide. The result Optimum operating costs through the large charge size. 070408_SecMet_REV_RZ04.indd Abs117070408_SecMet_REV_RZ04.indd Abs11721.05.2007 144030 Uhr21.05.2007 144030 Uhr 18 Completely Integrated Solutions with Siemens VAI Integrated offerings for higher plant perance Optimized processes We lay the foundation for optimized processes with proven, leading products worldwide, including mechanical and technological engineering for metal production, rolling and strip processing as well as process control engineering, drive engineering and power supply. Inte- grated online and offline process models reflect decades of practical experience and help to ensure reliable, reproducible quality. Our process engineering expertise fuses these products into complete plant solu- tions that also accommodate the upstream and downstream processes. These solu- tions are the basis for optimal resource use, minimized waiting times and reduced maintenance and spare parts costs, as well as wide flexibility with respect to raw materials and the resulting products. Efficient production control A further factor for competitive produc- tion is the quality of ination process- ing. Production data must be consoli- dated and compared with planning data to ensure optimal production flow. As a leading supplier for the metals indus- try Siemens VAI offers integrated infor- mation technology across all automation levels – from the sensor to the Enterprise Resource Planning system. Patented solu- tions, such as for direct reduction plants, electric arc furnaces, hot strip mills, profile rolling or processing lines, enable systematic quality assurance, efficient lo- gistics, flexible production planning and scheduling, end-to-end tracking and trac- ing from raw materials to the end product and back, and much more. Maximized life-cycle returns Services from Siemens VAI help to ensure high profitability for your plant through- out the entire life-cycle. Reliable project implementation by our specialists sets the course for quick start-up and repay- ment of funds as scheduled. During the operating phase, preventive maintenance, standardized components and component design that meets the requirements of steel plants help keep maintenance costs low. A reliable spare parts supply – with in-house workshops for key components – ensures high avail- ability. And modernization at the right time guarantees a high level of competi- tiveness and compliance with environ- mental regulations in the future. Higher availability Measurable process improvement Greater productivity Integrated ination technology Reduced life-cycle costs Maximum protection of your investment 070408_SecMet_REV_RZ04.indd Abs118070408_SecMet_REV_RZ04.indd Abs11821.05.2007 144030 Uhr21.05.2007 144030 Uhr 19 Perfect integration of every aspect Completely Integrated Solutions from Siemens VAI – your benefits from an integrated concept High process quality, lower energy costs and in- creased throughput – by taking all process steps into account Reproducible high product quality and efficient use of charging materials – thanks to integrated process models High enterprise quality, low life-cycle costs and unique investment protection – through flexible production based on metal-specific MES systems, intelligent plant design and integrated planning. Completely Integrated Solutions offer a comprehensive range of products and services, tailored and refined to the specific requirements of your plant. The key to this approach is the close inter- linking of plant construction, process engineering, electrical and automation engineering, sensors and actuators, as well as ination technology and life-cycle services, seamlessly integrated by Siemens VAI. 070408_SecMet_REV_RZ04.indd Abs119070408_SecMet_REV_RZ04.indd Abs11921.05.2007 144032 Uhr21.05.2007 144032 Uhr www.siemens- For further ination contact Siemens VAI Metals Technologies GmbH Schifferstr. 22 47059 Duisburg, Germany Phone 49 0 20331820 Fax 49 0 2033182100 E-mail secondarymetallurgy.metals Headquarters Siemens VAI Metals Technologies GmbH P.O. Box 4, Turmstr. 44 A 4031 Linz, Austria E-mail contact.metals The ination provided in this brochure conta
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