ReheatingFurnaces_andHeatingTechnologies

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REhEaTiNg FURNaCES and hEaTiNg TEChNOlOgiESREhEaTiNg FURNaCES hEaTiNg TEChNOlOgiES

SMS MEER gMbh

Ohlerkirchweg 66 41069 Mönchengladbach P.O. Box 100645

41006 Mönchengladbach Germany

Tel.: +49 (0) 2161 350-0 Fax: +49 (0) 2161 350-1754

[email protected] www.sms-meer.com

MEETiNg your ExpECTaTiONS

SMS MEER S.p.a.

Via Udine, 103 33017 Tarcento (Udine), Italy

Tel.: +39 0432 799 111 Fax: +39 0432 784 556


SMS MEER S.p.a. FURNaCES diViSiON

Via De Marini 1 16149 Genoa, Italy

Tel.: +39 010 2359301 Fax: +39 010 2359304


The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.

Hier steht die Bildunterschrift der weiße Pfeil kann muß aber nicht

Reheating furnaces and heating technologies SMS MEER

2 3

Hot air piping.

CONTENTS

2 3 Contents

4 5 Vast experience on the road to modern reheating

6 7 Not only billets

8 9 Economy and environment: today’s priorities

10 11 Walking beam furnaces

12 13 Walking hearth furnaces

14 15 Pusher-type furnaces

16 17 Equipment for pipe mills

18 19 Ghost in the machine

20 21 SMS Meer Service

Hot billets through an inspection door.SMS Meer S.p.A. Furnaces Division in Genoa.

SMS Meer S.p.A. in Tarcento. SMS Meer GmbH in Mönchengladbach.



4

The Furnaces Division, an integral part of

the structure of SMS Meer, can count on

personnel with over 30 years of experi-

ence in the field.

From the very beginning, the SMS Meer

Furnaces Division has focused on the

supply of technologically advanced rehea t-

ing furnaces to fulfill the requirements of

modern rolling mills.

The range of furnaces in the catalogue

complements the full spectrum of steel

rolling mills produced by the SMS Demag

and SMS Meer Business Areas, allowing

the “single source” supply of all equip-

ment and strengthening the SMS group

position as world leader in the construc-

tion of plants for the steel industry.

VaST ExpERiENCE on the road to MOdERN REhEaTiNgVaST ExpERiENCE

MOdERN REhEaTiNg

5

Discharging wall, frontal burners.

The SMS Meer Furnaces Division's ex-

cellent reputation has led to a very fast

growth and, as a result, several impor-

tant contracts have been awarded in the

last successful years. Further proof of its

success is the design and commissioning

of more than 30 furnaces delivered world-

wide in 2007 and 2008 alone. Nowadays

the SMS Meer Furnaces Division has one

of the most comprehensive product lines

on the market, based on sound technology

and a complete range of services.

Hot billet discharging.



6

The extensive technical know-how allows

the SMS Meer Furnaces Division to offer

the correct solution for the reheat ing of

every steel product, ranging from the 1-ton

billets for bar and wire rod production to

the 30-ton slabs for flat products and

including any kind of bloom, beam blank,

ingot, shell or tube. In fact, the product

range includes pusher-type furnaces for

billets, walking beam and walking hearth

furnaces for billets, blooms, beam blanks

and slabs and a number of furnaces

dedicated to the pipe mill industry, such

as rotary hearth furnances. Besides re-

heating, the SMS Meer Furnaces Division

has the knowledge and expertise to

design and supply heat treatment lines

that complete the range of products.

NOT ONly billETSNOT ONly billETS

Charging of slabs to a walking hearth furnace Aceralia Gijon, ArcelorMittal S.A., Spain.

7

The scope of supply of the SMS Meer

Furnaces Division includes all the com-

ponents, from the furnace itself to the

handling facilities for incoming and out-

going raw material and all the extensive

auxiliaries including instrumentation for

field controls that are required to optimally

run the whole system.

Electrical equipment and automation are

within the SMS Meer scope of supply

with software developed in-house, so

that the integration of the process and

operating sequences is in a single hand.

Soaking zone frontal burners.

Combustion air blower and recuperator area.

Discharging of a hot bloom from a rotary hearth furnace.



8

The focus of the SMS Meer Furnaces

Division is on continuous improvement

to remain at the forefront of innovation.

Thus, the greatest attention is given to

research and development of new solu-

tions also through partnership with lead-

ing combustion equipment suppliers.

The reduction of pollutants such as NOx,

VOC and SOx is one of the major prio-

rities and the driving force behind the

design of state-of-the-art furnaces in terms

of energy usage and emission level.

The above efforts are reflected in the

latest achievements:

The 200 sh tons per hour walking

beam furnace at Steel Dynamics,

Columbia City (USA) is completely

equipped with ultra-low NOx burners

and will become a standard of compa-

rison for future low-emission furnaces.

The 120 sh stons per hour pusher-

type furnace at Nucor Steel Darlington

consistently operates with measured

emissions approx 46% below the very

strict limit levels (see details on page 15).

SMS Meer is presently able to provide

its furnaces with a complete range of

low NOx, ultra-low NOx and also rege-

nerative burners. Dual-fuel capability,

i.e. the ability to fire both gaseous and

liquid fuels, is also available.

Economy and environment: TOday’S pRiORiTiESTOday’S pRiORiTiES

9

Ultra-low NOx burners.Recuperator and stack.

A great deal of attention is given to

design and component features that

allow the lowest possible energy con-

sumption. New materials, components

and ideas are continuously tested making

possible levels of energy requirement

even lower than 260 kcal of heat input

for each kilogram of steel reheated from

20 to 1,200 °C.



10

Walking beam furnaces achieve optimal

reheating and the greatest output capacity.

Top and bottom fired, the walking beam

furnace is highly suitable for high pro-

duction rates and high quality steel grades.

Billets, heavy blooms, slabs and beam

blanks can be charged.

Walking beam furnaces have many

cooled elements as well as special alloy

parts subject to high temperature and

mechanical stresses. SMS Meer engi-

neers, in synergy with a selected group

of sub-suppliers, pay the greatest atten-

tion to the development of new designs

and materials.

All SMS Meer’s walking beam/hearth

furnaces are characterized by high-opera-

tion flexibility, thanks to the sophisticated

combustion system, but also to fast and

reliable material handling machines. A

well designed discharging machine is

able to avoid any problem of misalign-

ment in the discharging area even when

handling pieces of very different size

and shape. Moreover it virtually elimi-

nates vibrations and positioning errors.

The possibility of reverse movement in

emergency situations as well as manual

handling is also a key advantage.

A wide range of kick-in and kick-off

machines, both electro-mechanically and

hydraulically operated, are available to

match even the most demanding of our

customers' need.

11

WalKiNg bEaM FURNaCESWalKiNg bEaM FURNaCES

RECORd SETTiNg: ThE Rapid diSChaRgE MaChiNE,

ONE billET EVERy 27 SECONdS

Size range: > 120 mm, blooms, slabs or beam blanks

Production range: > 100 tph

Specific consumption: ≤ 280 kcal/kg

The 190 tph walking beam furnace

installed at the JSC Nizhne-Serginskij

Metizno-Metallurgicheskij Zavod – ZAO

"NSMMZ", located at Nizhnie Sergi,

Russian Federation is setting new stan-

dards in discharge rate, having achieved

the impressive speed of one 12 m billet

discharged every 27 seconds on average.

This has been made possible by further

increasing the rigidity of the kick-off

machine. The kick-off fingers, internally

water cooled, are plated with high nickel

stainless steel shields, to enable this

machine to withstand even the toughest

temperature conditions.

130 tph walking beam furnace in Kardemir, Turkey.

Fast portal type kick-off machine as installed at ZAO NSMMZ, Russia.

3-D modeling for nickel-alloy cantilever rolls.

TypiCal daTa:


12

WalKiNg hEaRTh FURNaCESWalKiNg hEaRTh FURNaCES

13

Walking hearth furnaces are the solution

for mills with a production rate up to 140 tph.

Due to its arrangement, with top heating

only, it is recommended for products

having a maximum thickness of 160 mm.

A major advantage of this system is the

very low specific consumption figures,

achieved thanks to the absence of water-

cooled elements inside the furnace.

RECORd SETTiNg: 16 M SlENdER billETS UNdER a RadiaNT ROOF

Stock thickness: ≤ 160 mm

Production range: > 50 to 140 tph

Specific consumption: ≤ 270 kcal/kg

Cooling water consumption: low

Stefana S.p.A., under the project name Dream

Steel, has established a brand new 700,000 tpy

bar mill, located at Ospitaletto, in the Northern

Italian province of Brescia.

The market demand for large coils (3.2 tons)

as well as the overall benefits due to a better

yield, pushed our project engineers to the task

of designing a furnace capable of reheating

billets with a length of 16 m.

This target was achieved with a walking

hearth furnace with a suspended roof 16.8 m

wide, supporting an impressive battery of 90

radiant burners able to grant the best tempe-

rature homogeneity along the reheated piece.

Another important feature is the “heat main-

tenance zone”, a series of small burners dedi-

cated to retaining the furnace temperature

during weekend stoppages and prolonged mill

downtimes.

The reheating furnace at Stefana is able to

feed the mill with a continuous output of 120

tph starting with cold billets or 140 tph when

hot charged.

View of the recent 120/140 tph walking hearth furnace at Stefana, Italy.

TypiCal daTa:


14

pUShER-TypE FURNaCESpUShER-TypE FURNaCES

15

When the goal is a an heavy duty, simple

design furnace for billet reheating, the

right choice is often a pusher-type furnace.

Pusher furnaces are typically suitable

for low-production rate mills of common

steel grades (e.g. rebar).

In top-fired pusher furnaces the benefit

of simple and sturdy construction is com-

bined with low water consumption.

Top and bottom fired pusher-type furnaces

are capable of high production rates. For

simple products it is the inexpensive

alternative to a more sophisticated walk-

ing hearth or walking beam furnace.

Internal water-cooled beams require a

significant cooling water flow.

The 80 tph pusher furnace at ArcelorMittal Zaragoza, Spain.

TypiCal daTa:

Top fired Top and bottom fired

Billet size range: ≤ 160 mm > 120 mm

Production range: 50 to 100 tph > 100 tph

Specific consumption: < 270 kcal/kg < 280 kcal/kg

Cooling water consumption: low medium

Charging sequence.

Billet peel-bar of 120 sh tons per hour pusher-type furnaceat Nucor Steel in Darlington, SC, USA.

RECORd SETTiNg: ThE lOWEST CERTiFiEd NOx ValUES

Besides being a modern and efficient

unit capable of a significant output of

120 sh ton per hour, the new pusher-

type furnace at Nucor Steel Darlington,

USA, represents one of the best

efforts ever in the aim to contain NOx

emissions.

Thanks to the ultra-low NOx burner

technology, this furnace has demon-

strated, since the very first days after

the lighting up, a significant trend to-

wards decreasing pollutants.

The NOx is kept steadily around 0.040

lb/MMbtu (66 mg/Nm3), far below

even the strict local regulation that

permits a maximum level of 0.074

lb/MMbtu (123 mg/Nm3). This achieve-

ment is a real touchstone.

The shape and the temperature control of the flame contributes to containing NOx emissions.

Diagram representing the daily emission at Nucor Steel in Darlington, SC, USA.


16

EQUipMENT for pipE MillSEQUipMENT pipE MillS

Walking beam furnace for tube shells reheating.

17

Tube rolling and heat treatment represent

one of the core competences of SMS

Meer and an important segment of its

business. The process also relies on cri-

tical reheating profiles where the SMS

Meer Furnaces Division can offer exten-

sive know-how and a full techno logical

and metallurgical integration.

Besides rotary hearth furnaces for

blooms and ingots and walking beam

furnaces for reheating shells and tubes,

SMS Meer can provide the whole heat

treatment line, complete with all the

necessary handling equipment, quench-

ing tanks, descaling rings, quenching

heads, normalization beds, pipe straight-

ening machines, saw cutters.

ThE adVaNCEd TEChNOlOgy OF ThE QUENChiNg hEad

The quenching head is a ring-type de-

vice allowing the automatic regulation

in angle of the spray nozzles according

to the different pipe outside diameters

and the regulation in height for the

alignment of the pipe pass line with

respect to the head axis. This ensures

that the water stream strikes the

periphery of the pipe along the direc-

tion of travel, and combined with the

accurate control of the water pressure

and flow, allows the desired depth and

uniformity of the marten sitic structure.

Inclined rollers are installed between

the rings to transport the pipes at the

required technological speed and con-

fer a proper rotating spin.

Sophisticated automation is once

more the key of the process, since

quenching head set-up parameters

are managed automatically by the

control system of the upstream

austenitising/hardening furnace.

Water spray quenching head.

Nozzle angle adjustment for different diameters of pipe. Each module has more than 1,100 nozzles.

Rotary hearth furnace for bloom reheating.

Walking beam furnace for shell reheating.

Walking beam furnace for hardening treatment.Rotary hearth furnace at Vitkovice Valcovna Trub, Czech Republic.


18

ghOST in the MaChiNEghOST MaChiNE

19

Steel makers are globally headed towards

higher quality. Quality in steel reheating

means high performance components

and ultimate levels of auto mation, and

these are the elements characterising

the supplies of the SMS Meer Furnaces

Division. Achieving a uniformly heated

product, avoiding negative effects such

as metal decarburisation or high scale

formation, is the result of accurate temp-

erature curve simulation.

This is especially important when special

grade steels are being reheated, and

the expertise of SMS metallurgists and

soft ware programmers are the key ingre-

dients for setting up the most effec tive

heating recipe. Moreover, the furnace also

has to be quick to react to the de vel op ing

conditions of the process, and to adapt

the combustion system accordingly.Material handling management. Material tracking screen.

Combustion system management. Software for management of heating zones and combustion parameters of a rotary hearth furnace.

Of particular note here is the new com-

bustion control system designed for both

the RHF of Valcovna Trub TZ, in Ostrava,

Czech Republic and the heat treatment

furnaces in Pervouralsky Novotrubny

Works, Russia. This new concept, which

involves on/off burners firing with a pulse

sequence managed by the Level 2 logic,

allows utmost accuracy of the thermal

profile and the best optimization in fuel

consumption to be achieved.

Reheating curve set up by the automation software.


20

SMS MEER SERViCESMS MEER SERViCE

21

SMS Meer addresses customer requests

with tailor-made equipment, which is the best

way to provide cost effective solutions still

applying the state of the art technology.

This can be achieved thanks to the exper-

tise of our team, which can guide the custo-

mer throughout all the phases of realization

and commissioning of a reheating furnace.

iN SUMMaRy, WE CaN

ENSURE:

The right configuration based on the

customer’s requirements, determined

by SMS Meer in close cooperation

with customer’s staff.

Reliable technical solutions: long life

time of the installed plants.

Trouble-free installation: SMS Meer

commissioning experts are able to

assist the customer during all the

erection steps, supervising the whole

manufacturing process.

On-site training: through the guidance

of SMS Meer technical staff, the

customer’s engineers are quickly led

to complete their learning curve and

to run the furnace by themselves.

Spare parts and after sale assistance

through SMS Meer Service organization.

SERViCE OVER ThE WhOlE

liFE CyClE

As manufacturers we know every detail

and every single component of our fur-

naces. Our service experts know exactly

how the reliable and productive operation

can be assured over the whole life cycle

of the plant. Thanks to our service, both

the furnaces and the know-how of the

plant operators are constantly kept in

step with the latest market demands.

In concrete terms, service from SMS Meer

means for our customers:

Increased productivity

Increased availability

Improved product quality

Reduced operating costs

Safeguarding of the plant value

yOUR CONTaCT paRTNER

WORldWidE

Our furnaces are in operation around the

world, and our organisational structure

for service is oriented to this global pres-

ence: International teams for immediate

proximity to the customer, high flexibility

for quick reactions and bundled compe-

tence for comprehensive support. Thanks

to the close links and coordination at

SMS Meer, the customer thus receives the

full range of services from a single source.

ERECTiON aNd

COMMiSSiONiNg

The aim of a new or modernised plant

is: Optimum production start-up with

high added value. We handle all the

steps necessary for this: From the site

management and OEM commissioning

through the installation of the mechanical,

3-D modeling of discharging area.

hydraulic and electronic equipment through

to all the necessary performance tests.

Our service naturally also includes the

training of the operating personnel.

STaRT-Up SUppORT

Through the advice of our experts on

site, our customers are assured of a

stable production process from the very

beginning. Start-up problems that could

lead to costly faults or standstills are

thus ruled out from the start. The result:

Maximum productivity and product quality.

OEM SpaRE paRTS SERViCE

Our high-quality OEM spare parts are pre-

cision manufactured for our furnaces and

make a major contribution to the long-term

value retention. Thanks to our intelligent

spare parts stocking concepts, we are able

to identify critical parts and hence ensure

efficient spare parts management – with

parts availability in the minimum of time.

EQUipMENT ChECKS

With our equipment checks for furnaces,

we identify weaknesses in the plants and

optimisation potentials through thorough

machine inspections using the latest

measurement technologies. These stan-

dardised and thorough checks help to

avoid unforeseen machine standstills.

EQUipMENT aUdiTS FOR

plaNT OpTiMiSaTiON

The equipment audits provides holistic,

systematic analyses of the plant enginee-

ring, processes, maintenance and organi-

sation. The findings from the audit allow

more efficient processes and new pro-

cess technologies to be integrated. At the

same time, the results can also be used

for well-founded investment decisions.

MaiNTENaNCE MaNagE-

MENT

What maintenance concept is the right

concept for the individual customer’s

requirements? Our experts draw up a

customised maintenance concept and

make a major contribution to ensuring

maximum plant availability on economi-

cally attractive terms. Our spectrum ran-

ges from the consultation through to the

outsourcing of the maintenance.

MOdERNiSaTiON

Our furnaces are designed for decades

of operation. But technology does not

stand still. With specially tailored modern-

isation concepts, our experts ensure a

longer plant service life and hence an

improved investment efficiency.

TRaiNiNg pROgRaMMES

In international competition, the latest

know-how of the plant operators is

just as important as innovative plant

technologies. We offer comprehensive

knowledge transfer here. Whether on

site or in the SMS Meer training centre,

we instruct the customer’s experts in, for

example, maintenance questions.

SDI is a primary beam producer in the US. At the new medium section mill in Columbia City, Indiana, the 200 sh tons per hour walking beam furnace reheats blooms and beam blanks to feed the 15 stand continuous rolling mill. SMS Meer supplied the equipment for the entire mill.

Erection of 200 sh tons per hour walking beam furnace at SDI.


22

bROad RaNgE OF

pROdUCTS, iNdiVidUal

SOlUTiONS

SMS Meer reheating furnaces and heating

technologies are tailored to your individual

requirements. Our product range offers you

a broad choice of different performance

para meters.

We can therefore offer you configurations

in which all the components are ideally

tailored to one another – both technically

and economically.

SMS MEER S.p.a. FURNaCES diViSiON

Via De Marini 1 16149 Genoa, Italy

Tel.: +39 010 2359301 Fax: +39 010 2359304


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