Russula Newsletter - Linkas Steel · The ANKIROS / ANNOFER / TURKCAST 2010 fairs were visited by...

RUSSULA NEWSLETTER

The Russula Newsletter No. 3 - Copyright © by RUSSULA S.A. March 2011

Introducing Russula´s Mathematical Model for Reheating Furnaces

INSIDE THIS ISSUE:

SPOTLIGHT

Russula Engineering

India

NEWS

Russula runs SAP

ILAFA awards

Russula for best

exhibition stand

Steve Pegg

promoted to Russula

Corporation GM

MAINTENANCE TIPS

AC drives preventa-tive maintenance

RECENT PROJECTS

Russula implements

projects at Gerdau

Ameristeel sites

Manitoba, Carters-ville, Cambridge,

Charlotte and

Knoxville

STEEL MARKET

Robust steel

demand predicted

for India

How to sell more

steel

QUALITY

The history of

quality management

BHUBANESWAR, Orissa State, India

Russula, a pioneer in the field of automation and engineering for long product rolling mill and re-cir-

culating water treatment plants established an office in India in May, 2008 to cater to the Asian market.

India is very well positioned geographically for delivering projects to the Asian market with easy

availability of skilled engineers and experts in the steel sector. This makes India a logical place to have

an office to service the Asian market.

The average 8% year on year increase for India´s GDP is continually increasing the demand for steel,

especially in infrastructure projects. The Steel Policy of India envisages reaching 175 MT by 2020.

With the vast experience, knowledge and support of Russula offices worldwide, Russula Automation and

Engineering Solutions India Private Limited is prepared to provide proven and innovative solutions to

the steel industry in the field of automation and control system for long products and re-circulating

water treatment plants.

Russula Newsletter No. 3 March 2011 - Copyright © by RUSSULA S.A. 2

Spotlight on Russula Engineering India - Bubaneswar, Orissa State, India -

Asia

Russula Engineering India

Bubaneswar

Orissa, India

June

METEC

June 28 – July 2, 2011

Dusseldorf, Germany

www.metec-tradefair.com

Come visit Russula´s Stand at Hall/Stand No. 5E22

Asian Metallurgy 2011

June 9-11, 2011

Bombay Exhibition Center, Goregaon (E) Mumbai, India

www.foundry-planet.com/fileadmin/redakteur/

pdf-dateien/trade-fairs/asian-metallurgy-Brochure.pdf

September

AIKW, Association of International Roll Pass

Designers and Rolling Mill Engineers

September 29 -30, 2011

Udine, Italy

www.aikw.org

Russula will be presenting ´Celsa Atlantic´s Greenfield

1 MT/yr Bar and Wire Rod Mills´. The conceptual design

of the two rolling mills, accomplished two objectives; first

to reduce the assembly and construction time and second

to create technically advanced rolling mills that minimize

maintenance and the required human resources. The bar

mill has a 4 slitting process and the high speed wire rod

mill sustains 90 t/hr. Come find out more!

October

ABM - 48º Seminário de Laminação

October 24-27, 2011

Sao Paolo, Brazil

www.abmbrasil.com.br/seminarios/laminacao/2011

Come visit Russula´s Stand at ABM!

November

ILAFA-52

November 13-16, 2011

Rio de Janeiro, Brazil

www.ilafa.org

Come visit Russula´s Stand No. 41, conveniently located

next to the conference entrance/exit.

UPCOMING EVENTS

3 Russula Newsletter No. 3 March 2011 - Copyright © by RUSSULA S.A.

March

AISTech Training Seminars – Rod and Bar Rolling

February 28-March 3, 2011

Charlotte, NC, USA

www.aist.org/aistech/www.aist.org/calendar

Russula Corporation´s General Manager, Steve Pegg, will

give a presentation on ´Speeds and Drives´. The rolling of

the rod and bar mill sections requires a good understanding

of product and roll speeds. Modern drives employ input

data from roll cutting to mill setup to best eliminate tension

within the rolling process. This presentation will include

low tension and loop regulation, within the drive configu-

ration.

April

Arab Steel Summit

April 4-6, 2011

Doha, Qatar

www.arabsteel.info/total/defaulte.asp

Russula will display its newest developments in water

treatment plant technology. Come check it out!

May

AISTech 2011

May 2-5, 2011

Indianapolis, IN, USA

www.aist.org/aistech/

Russula do Brasil´s Sales Director, Alex Schultz, and

Russula´s Technical Expert Daniel Sánchez will copresent

´The Implementation of Votorantim Metais´s New

Integrated Steel Mill Producing 1 MT in Billets and 0.5

MT Hot Rolled Products.´

IRD, Institute of Roll Design

May 11-14, 2011

Pittsboro, IN USA

www.instituterolldesign.com/ird/

SEAISI

May 23-25, 2011

Singapore

www.seaisi.org/htm/

Steel Fairs 2011

NEWS FROM RUSSULA

Russula Corporation´s Sales and

Engineering Applications Director, Eric

Thorstenson gave a presentation on Drive

Selection for Rolling Mills, in the Long

Product Projects Session at the

annual Iron & Steel Technology

Conference and Exposition (AISTech).

The conference was held in Pittsburgh,

PA, USA this year from May 3-6 with an abundant turnout of

over 6000 attendees.

The Russula paper concentrated on the selection of low

voltage, less than 1000 V, variable speed motor drives for

long product rolling mill applications. Among the selected

principles discussed were:

• Long product rolling process

• Drive selection criteria

• AC vs. DC drives

• Braking

• Rectifier section types

• Common DC Bus AC drives

• Maintenance considerations

• Installation considerations

• Rebuilds vs. buying new

´DC and AC drive technology are at an interesting cross-

roads with implications in rolling mill technology of great

importance. With properly selected drive systems, product

dimensional control is very precise.´ stated Eric Thorstenson.

The presentation was received well and started a lively dis-

cussion.

If you would like to obtain a copy of the presentation and

paper ´Drive Selection for Rolling Mills´, please send your

request to: [email protected]

At its headquarters in A Coruña Spain, Russula implemented

SAP® software solutions for financials, project manage-

ment, production services and sales including SAP Customer

Relationship Management (SAP CRM) applications.

With major offices in Brazil, Argentina, India and the USA,

Russula choose SAP business solutions to unify core

processes globally and better meet customer needs all over

the world. To ensure business continuity, the company is

taking a regional rollout strategy of the SAP business suite.


Thorstenson presents Drive Selection for Rolling Mills at AISTech

Russula Runs SAP

Russula presents at AISTech 2011

New Integrated Steel Mill at Votorantim Metais

May 2, 2011 / 4:30 PM/ Rod & Bar Rolling Technologies

Russula exhibits at AIKW in Lincoln, UK

NEWS FROM RUSSULA


The Association International of Roll Pass Designers and

Rolling Mill Engineers, AIKW, held its 80th annual

conference in Lincoln, England. Russula was one of the key

exhibitors of the conference, which took place from

September 30 to October 1, 2010. Russula exhibited a new

rolling mill simulator station.

The mechanical equipment supplier, Siderimpes presented

´The designing, manufacturing and commissioning of a

special steel rolling mill for the production of high quality

steels for Store Steel in Slovenia´. Russula supplied the

electrical equipment, automation system and complete

electrical start-up support in collaboration with Siderimpes,

from Italy.

AIKW is a registered professional organization for roll pass

designers and rolling mill engineers with a main emphasis

in the field of hot rolled long products. The objectives of the

AIKW is to inform it´s members of the latest developments in

rolling technology and corresponding plant equipment as

well as the promotion of networking between members.

Regular scientific conferences with lectures on current

specialized topics and visits to rolling mills are an important

contribution to these objectives.

AIKW 2011 / Udine Italy / www.aikw.org

Russula was honored to accept the Latin

American Iron & Steel Institute (ILAFA)

award in recognition for the best exhibition

stand for Category A in the 51st ILAFA Congress, from

October 24- 26 2010, in Buenos Aires, Argentina. Mr. Oscar

Machado Koeneke, President of SIVENSA, Venezuela and

Director of ILAFA Venezuela and ILAFA Honorary Member

and Member of ILAFA Executive Committee presented the

award to Russula.

There were a total of 24 companies with trade stands

representing 11 countries. The Congress had a record

turnout of 1,268 delegates; more than 60% were foreign

attendees.

Russula - 2010 Winner! ILAFA awards Russula for best exhibition stand


NEWS FROM RUSSULA


NEWS FROM RUSSULA

Russula is pleased to announce that Steve

Pegg has been appointed as the new

General Manager for Russula Corporation

in North America. Steve has been working

with Russula for the past seven year and

brings a wealth of steel market knowledge

based on his 25+ years experience in the

steel sector. As part of his new role, Steve

will be responsible for sales in Canada,

United States, Mexico and Central

America.

As such the company is relocating its

Sales,Technical Support and Administra-

tion from Atlanta, Georgia to Columbus,

Ohio. In a statement by Steve Pegg ¨The

relocation of the Russula office is a critical

step in our goal to become closer to our

North American Customers and provide

the best quality service and support.¨

Steve Pegg promoted to Russula Corporation GM

A Russula first – ANKIROS exhibition in Istanbul, Turkey

The 10th biannual ANKIROS International Iron-Steel &

Foundry Technology, Machinery and Products Trade Fair,

was held in Istanbul, Turkey in the Tuyap Fair & Congress

Center from 11 to November 14, 2010. The ANKIROS fair

ran concurrently along with two other fairs, the ANNOFER

for non-ferrous metals technology and the TURKAST for

Foundry products. This was the first time Russula exhibited

in this modern technology fair, with the participation of 800

companies from 37 different countries covering a total of

30,000 square meters.

The ANKIROS / ANNOFER / TURKCAST 2010 fairs were

visited by 13,429 sector professionals, 81 % of which were

nationals and 19% internationals. Despite the economic

challenges facing the iron-steel, non-ferrous and foundry

sectors, the number of international national visitors

increased from 2008 by 7.3% and reached 72 countries.

Collectively the three biennial events comprise Eurasia's

biggest trade fair and the third largest professional

metallurgy fair in the world.

Russula North America´s General Manager Steve Pegg

Russula improves troubleshooting and preventativemaintenance at Nucor Steel Seattle

RECENT PROJECTS - RUSSULA CORPORATION

(June 1, 2010) Russula is pleased to announce that it has

commissioned a high speed data acquisition system for

Nucor Steel Seattle, in Seattle, WA. The goal of the project

was to enhance the troubleshooting and preventative

maintenance resources in the rolling mill.

Russula supplied the system, using iba hardware and

software, and the engineering and hardware necessary to

integrate the system with the existing ABB Advant AC450

automation system. Russula was also responsible for

instal-lation supervision, commissioning and training. While

onsite, Russula process experts also provided automation

training and the programming necessary to replace the mill’s

obsolete loop scanners with a readily available modern

alternative.

This project represents the fourth modernization project for

Russula at Nucor Steel Seattle since 2004. In previous

projects, Russula has upgraded an AC drive system, the

principal DC mill drives and the shear positioning control.

This project represents the 10th high speed data acquisition

system from Russula implemented in a rolling mill in North

America.

Gerdau Ameristeel Manitoba awards Russulasecond upgrade project

(June 11, 2010) Russula is pleased to announce that it has

received a contract to modernize the Cooling Bed Rake for

Gerdau Ameristeel Manitoba in Selkirk, Manitoba, Canada.

Russula will supply a new motor, a modern ABB ACS800 AC

drive, positioning control using Allen Bradley’s Contrologix

and integrate them with the rake’s existing automation.

Russula is also responsible for installation supervision,

commissioning and training.

This project represents the second modernization project for

Russula at Gerdau Ameristeel Manitoba. Russula is also

currently modernizing the straightener at the same location.

(August 28, 2010) Russula is pleased to announce that it has

received a contract to modernize the Straightener at Gerdau

Ameristeel Cartersville.

Russula will supply new motors, modern ABB DCS800 DC

drives, and integrate them with the straightener’s existing

automation. Russula is also responsible for installation,


This project represents the second straightener

modernization project for Russula with Gerdau Ameristeel

this year. Russula is also currently modernizing the

straightener at Gerdau Ameristeel Manitoba.

Gerdau Ameristeel Cartersville to ModernizeStraightener


RECENT PROJECTS - RUSSULA CORPORATION

Gerdau Ameristeel Knoxville Upgrades Russula Mill Control Tools

New Finishing End Drivesat Gerdau Ameristeel Charlotte

(September 28, 2010) Russula is proud to announce it has

been awarded a contract for engineering, design and first

phase equipment for the new rolling mill controls at Gerdau

Ameristeel Cambridge.

Russula will supply a new rolling mill control system to

replace the obsolete ABB Masterpiece 200. The new system

will use modern PLC technology, open protocol communi-

cations and consists entirely of “off the shelf” equipment.

The hardware platform will utilize ABB AC800M controllers

with Wonderware HMI, integrated to work with the existing

systems. Russula will supply all engineering for the project

and phase one equipment, commissioning, installation

advisement and training.

This project represents the seventh Gerdau Ameristeel mill to

have a rolling mill control system by Russula.

Russula Chosen for Rolling Mill Control at Gerdau Ameristeel Cambridge

(November 11, 2010) Russula has received an order to

upgrade the PLC programming tools at Gerdau Ameristeel

Knoxville. The Knoxville plant implemented a Russula Mill

Control system in 2002 and a Russula Finishing End

Control system in 2007. Both systems will be upgraded to

the latest programming platform allowing for enhanced

troble-shooting and more advanced OPC communications.

Russula is responsible for supplying the new programming

tool, updating the mill software, comprehensive testing and

commissioning of the upgrade.

(November 17, 2010) Gerdau Ameristeel Charlotte and

Russula have reached an agreement for the modernization of

the rolling mill’s finishing end drives. Obsolete DC drives

will be replaced with ABB DCS800 or ACS800 drives

allowing for enhanced functionality, easier maintenance and

more readily available spare parts. Russula is responsible

for the supply, panel fabrication, installation and startup of

the various drives systems to be installed in March 2011.

Russula has various AC and DC drive systems in operation

at eleven (11) Gerdau Ameristeel rolling mills. This project

represents the twenty-second (22nd) project involving elec-

tric motor drives for Russula and Gerdau Ameristeel.

mill lightschain transfer



MAINTENANCE TIPS

All modern variable speed AC motor drives consist of threemain sections:

1. Mains frequency AC to DC section called a rectifier

(or active front end)

2. Capacitor energy storage/filter section

3. DC to variable frequency AC section called an inverter.

Aluminum electrolytic type

capacitors are used for the

energy storage / filter sec-

tion. Aluminum electrolytic

capacitors are constructed

from two conducting alumi-

num foils, one of which is

coated with an insulating

oxide layer, and a paper

spacer soaked in an elec-

trolyte fluid. This combi-

nation of aluminum foils

and paper is rolled up and

contained in sealed aluminum cans. Typically about the size

of a soda can each.

Older AC drives using GTO switching devices required very

large capacitor banks which were typically mounted in a

distinct section. Modern IBGT based drives require less

capacitance, and generally include the capacitors in the

individual inverter section(s).

These type of capacitors have an inherit storage problem.

The oxide insulating layer will tend to deteriorate in the

absence of a sufficient rejuvenating voltage, and eventually

the capacitor will lose its ability to withstand voltage, if

voltage is not applied.

Individual capacitors, as well as those in inverter modules or

even complete drives purchased as spares are subject to this

deterioration. For this reason Russula recommends rotating

these spare components, from spares storage to a working

drive once per year. Failure to perform this preventative

maintenance may result in shortened life or even immediate

failure of the spares when put into service.

As an alternative to rotating the spares, capacitors in storage

for over a year can often be "reformed" by connecting them

to a voltage source through a resistor and allowing the

resulting current to slowly restore the oxide layer. The drive

module manufacturers, such as ABB or Siemens, publish

“reform” procedures which involve an external power

supply which gradually steps up the voltage over a few days’

time. For spares without voltage for over two years, this

external method of reform is recommended.

The annual rotating procedure is simpler, and provides the

added benefit of practice in replacing the components.

Rotate Your Caps! - AC Drive Preventative Maintenance -

By: Eric Thorstenson, Russula Sales Applications

Easy to Remove ACS800 Multidrive R8i16

Aluminum Electrolytic Capacitor

In the celebration of ILAFA in Buenos Aires, Argentina last

October, it brought Russula to reflect upon an important

milestone in 2007; the Acindar SBQ project followed by the

subsequent opening of a Russula technical office in San

Nicolás, Argentina.

In 2007, Russula supplied the complete water treatment plant

and electrical equipment and installation for Acindar´s

(ArcelorMittal) new 500 kt/y combination bar and wire rod

mill, located in Villa Constitución, Argentina.

The new high-efficiency mill is designed to roll special bar

quality (SBQ) products for high-end industrial applications,

including the automobile industry. Products range in size

from 5.0 to 88.9mm round bars, as well as squares,

hexagonal, flats and rebar.

Revisiting the Acindar SBQ bar and wire rod mill project

RECENT PROJECTS - RUSSULA ARGENTINA


Panoramic view of Acindar SBQ 500kt/y bar and wire rod mill

Billet size: 160x160mm 12.5m

180x180mm 12.5m

Guaranteed production speed

- roll exit 110m/s for 5.5mm & 7mm diam

Design speed

- roll exit 120m/s for 5.5mm & 7mm diam

Guaranteed production speed

- bar exit 18.5m/s

Production Capacities

- Break Down Mill (BDM) 350t/h

- Rolling mill 185t/h

- Reheat furnace 120t/h

Product sizes

- Rounds 15.9 to 88.9mm

- Hexagonal bars 19.05 to 76.2mm

- Squares 25.4 to 76.2mm

- Plate 50 x 7mm to 101.6 x 12.7mm

Acindar (ArcelorMittal) Argentina

Rolling Mill Plant Data

A Compact Water Treatment Plant

The new water treatment plant, supplied on a turnkey basis,

features Russula´s unique technology combination of twin

decanting basins, mechanical ring filters and modular

cooling towers. This was the first water treatment plant of its

kind, implemented in Argentina and designed specifically

for steel production. Due to the Acindar site limitations for

the water treatment installation, Russula designed a very

compact water treatment plant occupying a total area of

3550m2.

The water treatment plant is rated for 3,000m3/h and pro-

vides the mill with clean cooled process water. The sludge

from the decanting basins passes through a thickener tank

before being formed into bricks by a press pack filter. An oil

skimmer removes any oil and grease. The ring filters are

self-cleaning.

Russula was responsible for the complete mechanical and

electrical supply and provided detailed civil designs for the

installation, including the embedded rebar and conduits.

Russula also provided extensive installation advisement;




3D CAD drawing of the Russula water treatment plant

Arial view of compact water treatment plant that occupies 3550m2

Water treatment thickner tank, decanting basins and cooling towers

Water Treatment Plant Data

Non-contact water

- Capacity 1,400m3/h

- Supply pressure 4.5 bar

Contact water

- Capacity 3,000m3/h

- Supply pressure 6.5bar



Acindar Maintains 118m/s with Russula Rolling Mill Automation

Russula supplied the complete rolling mill automation, all

the electrical and control equipment, and level 2, AC and DC

drives and an IBA data acquisition system. The combination

mill features controlled temperature rolling, which permits

Acindar to produce thermo-mechanically rolled rod and bar

product. Acindar´s production speed reached 118m/s, well

above the Morgan guarantee of 110m/s due in part to the

consistent and reliable automation system provided by

Russula. The project scope consisted of consulting,

engineering, installation, and start-up and training.

In order to have a successful start-up and reach 118m/s

rolling speeds with excellent product quality, there were

three principal challenges that Russula had to overcome,

states José Luís Casanova, the Russula Project Manager.

To begin with the system integration was complex, the

mechanical supplier Morgan supplied a different electrical

system, which must be integrated with Acindar´s existing

plant management systems and the new control system for

the Greenfield SBQ mill.

¨Russula tackled this problem by first doing a study of all the

different existing solutions available on the market. Then we

evaluated and selected the best solution based on our

know-how from implementing similar projects.¨ says José

Luís Casanova

Second a challenge to all project managers is to complete the

project deadlines; in the case of Acindar the delivery time

spanned approximately 1.5 years. This project was executed

on time and managed well according to Casanova. Russula

follows a standard project management process for purchas-

ing, assembly, delivery, installation and start-up.

And lastly the most important project challenge was for the

SBQ mill to achieve optimum functionality at 110m/s.

¨During the performance test for the mill, we were able to

sustain a consistent production rate of 118m/s for many

hours, much higher than the rolling mill guarantee. On the

control side, this can be attributed to an optimized control

configuration and final drive adjustments.¨ affirms Casanova

Acindar and Russula have had a successful partnership

dating back to 1995, when Russula upgraded the control

system for their other two strand wire rod mill in Villa

Constitución. Since 2002, Russula has completed numerous

electrical projects for Acindar in San Nicolás and Navarro.

This Greenfield SBQ mill marks the 5th and largest project

for Russula with Acindar.

Electrical equipment room

Bar to wire rod division

¨ During the performance test for the mill,

we were able to sustain a consistent

production rate of 118m/s for many

hours, much higher than the rolling mill

guarantee. On the control side, this can

be attributed to an optimized control

configuration and final drive adjustments. ¨

- José Luis Casanova,

Russula Project Manager

TECHNOLOGY


Introducing Russula´s Mathematical Model for Reheating Furnaces

By: José Luis Casanova, Project Manager

The complete set of Russula re-heating furnace control pro-grams result in effective furnacecontrol, improving heating effec-tiveness and heating gas con-sumptions. Short pay-back timesare obtained due to the effective-ness of furnace gas consumptionreduction; especially at installa-tions without any previously existing optimization control program.

Russula has developed and implemen-

ted a Mathematical Model for the

reheating furnace. This Mathematical

Model is currently in operation at two

furnaces after undergoing a testing and

validation process. Russula sponsored

a chair and jointly developed the

Mathematical Model with the Vigo

University Applied Research Depart-

ment (Universidade de Vigo).

The Mathematical Model complements

the existing Russula reheating control

modules including level one control for

combustion and logic; level two for

heating strategies and delay multipliers

and a pyrometer feedback module.

The Level one program is the basic

furnace control and includes two

functions; combustion control and

furnace logic. Combustion control is

responsible to control common regula-

tion functions such as combustion air

pressure control, furnace pressure

control, gas pressure control and

recuperator protection functions;

furnace zone temperature control func-

tions and cooling supervision functions

are also included at this program level.

Furnace logic is the program that

controls all charging, discharging,

hydraulics and walking beam

functions.

The Level two functions generate

automatic heating set-points based on

strategy tables and delay multiplier

tables. A material tracking program is

used at this control level (alternatively

upon customer request the tracking

program could be included as an option

for level one function). The tracking

program keeps track of all the material

(billets, blooms and slabs) inside the

furnace; it detects where different

quality material is located, and decides,

which heating strategy should be

applied to a particular furnace control

zone. This decision is based on

material data information received

from the operator or plant management

software. Information regarding which

strategy should be applied, and data

regarding material speed inside the

furnace are used to automatically

generate set-points for zone tempera-

ture control automatic operation.

Furnace stops are controlled by delay

multiplier tables, which generate the

appropriate lower setpoints in the case

a furnace stop is twice the average time

between two furnace discharges.

The Pyrometer feedback module

corrects automatic temperature set-

points for the heating and preheating

furnace zones. This correction is based

on pyrometer temperature feedback

from the material after leaving the fur-

nace, while it is rolling.

The reheating furnace Mathematical

Model is a program intended to detect

material temperature deviations inside

the furnace against an ideal curve that

could be supplied by furnace construc-

tor or optimized by a rolling company

based on their experience and know-

how. The Mathematical Model pro-

gram estimates material temperature

for each product inside the furnace

based on material speed inside the

furnace, burners’ power and furnace

temperatures. The estimated tempera-

tures obtained are compared against an

ideal curve and the deviation is used to

calculate a correction for the furnace

automatic temperature set-point gene-

ration system. The Main objective for

the Mathematical Model program is to

detect material heating deviations due

to a lack of cadence in material dis-

charging that cannot be corrected by

the delay multipliers control program

and could lead to a material over-

heating or under heating.

The Russula approach to develop the

reheating furnace Mathematical Model

begins with a static analysis on normal/

standard operating conditions. The sta-

tic analysis simulates the material

heating inside a furnace full of material

under fixed power and material speed

conditions.

In general, the material temperature

will be affected by initial conditions in

addition to heating conditions. Heating

conditions are determined by

convection heat exchange between the

material and the gases inside the

furnace and the heat exchange with

burner flames, furnace walls and other

pieces of material through radiation. In

the case of a walking hearth furnace,

conduction heating between the

furnace and the material pieces will

have influence, too. In general, heating

conditions will be affected by:

- product position inside furnace

- flame temperature

- gas temperature inside the furnace

- furnace wall temperatures

- material temperature

- temperatures of other material

pieces

The Static analysis is a mathematically

detailed simulation of furnace material

heating under standard and stable

heating conditions. All mentio-

ned heating conditions are

analysed to generate furnace

and material heating data.

Main output data from this

analysis are shown in these

three graphs:

- fume temperature graphs

- radiation temperature

- material piece temperature

(one graph per each piece)

Figure 1 “Fumes Temperature

Graph” shows the result of a

static analysis inside the fur-

nace with a fume temperature

representation. In the above

example one can see how the

higher temperature fumes are

generated by the heating cen-

tral burners. Also a fume flow

analysis inside the furnace was

conducted and shows how the

fumes flow from the burners to

the fume exit. As well, different

gas tempera-tures close to the

material pieces at the bottom

and upper sides are shown in

the graph. Please note that the

temperature is expressed in

Kelvin degrees.

Figure 2, “Radiation Tempera-

ture”, shows data related with

the burner’s temperature,

furnace wall temperatures and

material pieces temperatures.

Once again data values are in

Kevin degrees. Note that the

furnace wall temperatures can

also be observed on this graph.

Wall temperatures are the

detected value of furnace

thermocouples when properly

installed on the furnace roof or

walls. Furnace fume temperatures or

burner temperatures are higher than

the temperatures observed by furnace

thermocouples on the roof or walls, as

can be seen in analyzing figures 1 and 2

together.


TECHNOLOGY

Figure 1 - Fumes Temperature Graph

Figure 2 - Radiation Temperature

Figure 3 - Material Piece Temperature


TECHNOLOGY

The Figure 3, “Material Piece Tempera-

ture”, plots detailed data of one billet

temperature obtained from furnace sta-

tic analysis. The static analysis gives all

the data for each furnace billet;

analyzing each billet material tempera-

ture in the nucleus and outside the nu-

cleus, and the differences between

material corners and other points.

The static analysis is an intermediate

step to construct the Mathematical

Model; all obtained data must be

analyzed and checked to ensure that

critical information regarding the

furnace (geometrical data, burner

power, walls, materials, ect.) is correct.

Static data can be also being confirmed

with a material thermocouple test along

the furnace.

The thermocouple test is a data

recording operation where a data

acquisition system collects all furnace

parameters (temperatures, powers,

set-points, fume temperature) and the

data from several thermocouples

installed on a test piece that goes

through the furnace in a normal heating

process. Continuous furnace operation

is required to validate the data obtained

from this test in order to be able to

check the data with the static analysis

output data.

The static analysis is a complex

mathematical process that requires

hours of computer calculations.

Russula has developed a simple

modelling system based on the data

obtained from the static analysis to

furnace material temperature on-line

independent of furnace speed and other

heating parameters. This development

based on the modelling techniques is

the furnace Mathematical Model.

The furnace Mathematical Model pre-

dicts on-line, each minute, material

temperature for all material pieces

inside the furnace. This data is

compared with the ideal heating data

and used to correct the automatic

furnace set point generation program.

The most important factor for

validating a model is its repeatability,

the same answer against the same

heating conditions.

Once again, the thermocouple test is a

useful tool to check on-line material

heating prediction. Figure 4 “Thermo-

couple Test Complete” shows the

different values obtained during a real

test. Three thermocouples were

installed on a billet; thermocouples 1

and 3 located close to the billet ends

and thermocouple 2 installed in the

middle of the billet. Mathematical

Model predictions show the billet at

each position in the furnace.

The Mathematical Model program

must have a high repeatability; this

means that results obtained under

similar heating conditions must have

similar temperature values. It is

impossible to repeat the same heating

and material speed conditions from one

production day to the next on a real

installation, but under similar condi-

tions results obtained must be similar.

Figure 4 - Complete Thermocouple Test

Figure 5 - Different Billet Comparative

Thermocouple test

Thermocouple test

TECHNOLOGY


This is the repeatability concept for the

Mathematical Model program.

Billet temperature differences between

model estimation and thermocouple

test values could be adjusted by offset

adjustments, but it is absolutely

necessary to get similar results against

similar input conditions that lead to do

an accurate automatic set point

correction.

Figure 5 “Different Billet Comparative”

shows Mathematical Model data

obtained by two different billets at

different times under similar

production conditions. The same

production speed, same final heating

temperature target and same steel

degree are the conditions for this test.

Graph 5 “Different Billet Comparative”

shows estimated temperature differen-

ces under similar production condition

are lower than 10 ºC in various

positions inside the furnace.

The furnace Mathematical Model gives

a good estimation of material heating

inside the furnace and is used to adjust

heating requirements to optimize

furnace combustion. This adjustment

will finally result in improving of the

heating process and will result in a

positive economic impact by reducing

the gas consumption in the furnace,

reducing the cost per produced ton;

and result in an environmental impact

by reducing atmospheric emissions.

The complete set of Russula reheating

furnace control programs result in

effective furnace control, improving

heating effectiveness and heating gas

consumptions. Short pay-back times

are obtained due to the effectiveness of

furnace gas consumption reduction;

especially at those installations without

any previously existing optimization

control program.

Contact:

Russula

Calle Pasteur 30, 1º

A Coruña Spain 15008

Tel: +34 981 160 344

[email protected]

21 reheating furnace projectsimplemented worldwide

for the leading steel producers

Celsa

Gerdau

Isdemir

Celsa UK

Celsa Huta

ArcelorMittal

M/S Welspun

Celsa Atlantic

Sandvik Steel

Fagersta Stainless

Gerdau Ameristeel

Steel has been an interesting subject

for the last two decades and it con-

tinues to keep the adrenalin high till

date. Crude steel production in 2009

was 1227 Million Metric Tonnes. In

2010 production reached 1413 Million

Metric Tonnes. China steel leads in

terms of crude steel production and

the year on year growth is nearly the

same.

Steel industry reformsin 1991 and 1992 haveled to strong and sustainable growth in India’s steel industry

Since its independence, India has

experienced steady growth in the steel

industry, thanks in part to the

successive governments that have

supported the industry and pushed

for its robust development and private

investors who have taken advantage

of the opportunity to help build the

steel industry in India.

1991 A substantial number of

economic reforms were introduced by

the Indian government. These reforms

boosted the development process of a

number of industries, in particular the

steel industry in India, which has

subsequently developed quite rapidly.

The 1991 reforms allowed for no licen-

ses to be required for capacity creation,

except for some locations. Also, once

India’s steel industry was moved from

the listing of the industries that were

reserved exclusively for the public sec-

tor, huge foreign investments were

made in this industry.

1992 Yet another reform for India’s

steel industry came in 1992, when

every type of control over the pricing

and distribution system was removed

making the modern Indian Steel

Industry extremely efficient as well as

competitive. In addition to this a

number of other goverment measures

have also stimulated the growth of the

industry such as unrestricted external

trade, low import duties and an easy

tax structure.

Robust Steel Demand Predicted for IndiaBy: Abanis Nayak, Russula Engineering India General Manager

STEEL MARKET


STEEL MARKET


Current Indian SteelSector Scenario

The Indian Steel Industry has been

moving from strength to strength and

according to the Annual Report 2009-10

by the Ministry of Steel, India has

emerged as the fifth largest producer of

steel in the world and is likely to

become the second largest producer of

crude steel by 2015-16.

With a strong demand from autos and

engineering services, the domestic steel

demand in India remains robust, as per

Moody's sectorial analysis on Asia's

steel sector. According to the analysis,

the outlook for the domestic operating

environment is positive, driven by

robust growth in infrastructure, autos

and construction and constrains on

additional supply by 2011.

Recently, Mr Virbhadra Singh, Minister

for Steel, said that India will become the

world's second-largest steel producer

by 2012, with a capacity of 124 million

tonnes (MT) as part of the push being

given to assist overall infrastructure

development.

Production

India's steel production during 2009-10

was 64.88 million tonne (MT), up 11 %

from a year ago, according to Mr A Sai

Pratap, Minister of State for Steel.

During the end of the second quarter in

September 2010, steel majors Tata Steel

and Steel Authority of India Ltd (SAIL)

reported a high growth in steel sales.

SAIL registered sales of 3.17 MT in the

period under review, while Tata Steel's

total sales for the quarter stood at 1.66

MT which is around 14 % higher than

the corresponding quarter last year.

Meanwhile, JSW Steel's production

during the quarter grew by 8 % to 3.14

MT on the back of a steady rise in

demand.

Consumption

The domestic steel consumption grew

by 9.8 % to 29.82 MT during April-

September 2010 over the year ago

period, on the back of steady demand

from sectors like automobile and

consumer durables. As per the

provisional data from the Ministry of

Steel, consumption was at 27.15 MT in

the same period a year ago. In Septem-

ber 2010, steel consumption rose 4.1 %

to 4.72 MT, against 4.53 MT in the year-

ago period.

Investments

A host of steel companies have lined up

major investment proposals. Further-

more, with an expanding consumer

market, the Indian steel industry is li-

kely to receive huge domestic and

foreign investments.

The domestic steel sector has attracted a

staggering investment of about US$ 238

billion, according to Mr A Sai Prathap,

Minister of State for Steel. This consists

of nearly 222 MoUs signed between the

investors and various state govern-

ments mostly in the states of Orissa,

Jharkhand, Chhattisgarh and West

Bengal.

• Tata Steel plans to invest US$

226.17 million to commission its

proposed ferroalloys plant and bar

mill at its industrial park at Gopal-

pur and a greenfield steel plant at

Kalinga Nagar.

• Essar Steel plans to expand its ex

clusive steel showrooms, Hyper-

mart and retail outlet, Expressmart

in Madhya Pradesh.

• JSW Steel plans to invest US$ 17

billion over the next 10 years to

ramp up capacity from 7.8 million

tonne per annum (MTPA) to 32

mtpa through greenfield and

brownfield projects.

• Jindal Steel has completed the ac-

quisition of Oman-based Shadeed

Iron and Steel Co LLC for US$ 464

million.

• Japan's Nippon Steel will begin a

manufacturing operation in India

making steel pipes for use in auto

mobiles and plans to invest US$ 37

million on production and sales

operations.

Government Initiative

As per the Press Information Bureau

(PIB), during 2009, the government

took a number of fiscal and administra-

tive steps to contain steel prices. Central

value added tax (CENVAT) on steel

items was reduced from 14 % to 10 %

with effect from February 2009.

Moreover, in the Union Budget 2010-11,

the government has allocated US$ 37.4

billion to the infrastructure sector and

has increased the allocation for road

transport by 13 % to US$ 4.3 billion

which will further promote the steel

industry.

Conclusion

The growth of the steel sector in India

will be robust thanks to the domestic

demand and Government Initiative.

Reprinted from Dalal Street by web invitation: www.dsij.in/Research/Ar-

ticles/articlesfull/tabid/768/ArticleID/1631/Default.aspx

(8/30/2010)

Soon after taking charge of the Min-

istry of Steel, Virbhadra Singh, Min-

ister of Steel, interacted with repre-

sentatives from the steel industry and

took steps to implement some of their

demands. Singh set the steel industry

on the growth path with significant

growth in production.

At a time when the statistics show a much lower per capita

steel consumption in the country, what is your assessment of

the steel sector in India?

A low per capita consumption only indicates the future de-

mand potential. As you know, steel demand in the country

is pegged to the gross domestic product and its increase is

also similarly linked to growth in GDP. What we are most

interested is in improving the availability of steel in order to

cater to the growing steel demand in the country. Per capita

steel consumption will automatically improve as steel de-

mand grows and also the supply is ensured to fulfill the de-

mand.

We are also interested in improving the general steel con-

sumption through innovative design, technological and pro-

duct based solutions. There are a number of areas, where

steel usage is cost economical and can provide a better solu-

tion. These areas range from architectural buildings, airports,

railway station, flyovers, roads, etc. to rural housing and

household applications. One of our objectives is to identify

and promote innovative applications of steel in engineering,

architecture, construction and household applications.

How do you look forward to sector’s growth in terms of de-

mand and consumption over the next few years?

Over the last five years, between 2004-05 and 2008-09, steel

consumption growth in the country has been 9.6 per cent per

annum. Earlier, the National Steel Policy 2005 had estimated

an average consumption growth of 6.9 per cent. Then in

2007-08, the steel consumption growth in the country has

touched a figure of nearly 13 per cent. I believe that the ave-

rage growth of steel consumption in the country, for the next

five years, can be estimated to be higher than 10 per cent per

annum.

How do you think that the country’s annual steel produc-

tion target of 124 million tones can be achieved by 2012?

We have realistically projected a steel capacity of nearly 120

million tones in country by December 2012. Nearly 36

million tons of brownfield capacity additional projects are

going on as per schedule. Apart from this, a number of small

and medium units in the secondary sector are also coming

up fast. Except one or two Greenfield projects, we are

expecting all other steel capacity projects, as envisaged, will

be on stream by December 2012.

With the present production at 55-60 million tones, the In-

dian steel sector is the fifth largest in the world, much be-

hind China’s 500 million ton sector. How do you see China’s

role as the potential challenge to India?

The present steel capacity in the country is nearly 65 million

tons. In terms of current rate of demand growth, the steel re-

quirement in the country would double within five to six

years. Therefore, we must double our capacity within two

years to fulfill the domestic demand. Also, once our steel pro-

duction capacity is at a comfortable level, we will certainly

aim at quality and competitiveness of our steel products on

a par with the best global standards. We are continuously

watchful towards sustenance of our steel industry and take

appropriate steps, whenever, required to maintain a healthy

growth of the steel sector in India.

Now coming on China, we need to understand that every

economy has its own requirements depending upon its

supply, demand, capacity and most importantly the phase

of economic cycle it is passing through. After China, our steel

industry is the second fastest growing sector in the world in

terms of demand and production. We have become the third

largest steel producer in the year 2009, from being the

seventh largest three to four years back. We have great po-

tential for economic growth and currently our main concern

is to synergise all available resources to facilitate the pro-

duction and capacity building to meet the future steel requi-

rement in the country.

Interview with India´s Minister of Steel,Virbhadra Singh

STEEL MARKET

21 Russula Newsletter No. 3 March 2011 - Copyright © by RUSSULA

STEEL MARKET


What’s your opinion on export of iron ore to other country?

Don’t you think that an increase in export duty on iron ore

will help the domestic sector to conserve it for long-term

utilization?

We are of the view that the precious raw material like iron

ore is non-renewable natural resource and should be con-

served for long-term utilization of domestic steel industry.

We are regularly taking up the issue with Ministry of Finance

for imposition of appropriate export duty on iron ore to dis-

courage its export. As a result of our efforts, export duty on

iron ore lumps has been increased recently from 10 per cent

to 15 per cent ad valorem. We feel that to effectively dis-

courage export of iron ore, we further need to increase

export duty on iron ore to at least 20 per cent ad valorem on

all varieties of iron ore.

In my opinion, I feel that the government should impose a

ban on exports of iron ore. Others may differ on this issue,

but we should see what United States and China are doing to

conserve their resource of iron ore and oil in that order.

Several international companies like ArcelorMittal and

Posco have delayed their projects due to some government’s

regulatory hurdles. What’s your opinion on this and how do

you plan to solve the issue?

Some of the greenfield projects have affected by the issue of

land acquisition. We are hopeful that there will be a political

consensus with regard to land acquisition and R&R policy. It

is a key issue not only for steel industry and infrastructure

development in general. We are hopeful of a solution.

There is no regulatory hurdle on Posco, ArcelorMittal or any

other entrepreneur planning to set up steel plants in the

country. There are certain procedural formalities and critical

requirements, especially for the greenfield projects. Since

ArcelorMittal and Posco are high capacity steel proposals

with a much larger level of integration, there are certain de-

lays. But I am sure all the hurdles will be gradually overcome

and these Greenfield will commence their executions soon.

At the ministry level, we have constituted an inter-ministerial

group, headed by Secretary, Steel with representatives from

the concerned central ministries / departments and state

governments, where major steel projects are located. This

group has been actively monitoring and coordinating on all

impeding issues and the infrastructure requirements of the

upcoming steel projects.

Rising prices have become a vital issue today, how do you

plan to check steel prices from escalating?

I keep a very close watch on prices. The recent spurt in

prices has not been a happy development. In my view that

was not warranted. We organised a meeting with major steel

producers of the country to see that there is no speculative in-

crease in prices. The results are for everyone to see as steel

prices have fallen by 5 to 10 per cent after the meeting. In a

deregulated market, the prices are determined by the inter-

play of market forces. The current rise in price of steel is at-

tributable to increase in price of steel making inputs one

hand and strong domestic demand for steel on the other

hand. Government through various policy measures tries to

maintain stability in terms of price and availability. For in-

stance, the import duty on steel has been reduced over the

years and currently stands at the lowest slab of 5 per cent.

The import duty on melting scrap has been brought down to

nil. Similarly, the general excise duty rate has been reduced

to 10 per cent which will also help in checking the rise in

price of steel.

STEEL MARKET


How to Sell More Steel By: Mary House, Marketing Department

An interview with Ali Riza-Bekem and Levent Danisman

from the trading company Linkas Steel in Istanbul, Turkey

reveals the criteria one trading company uses to buy steel

from steel manufacturers.

You buy and resell steel, - who are your main customers?

Our main customers are central steel distributors in various

countries, which mainly supply the steel to the construction

companies and manufacturing industries. We trade all kinds

of steel; flats such as HRC or CRC, or longs such as reinfor-

cing bars and merchant bars. The long products consist of 70-

80% of our sales volume. A smaller amount of our business

is for the steel producers themselves; selling billets and

occasionally slabs for rolling into semi-finished and finished

products.

How do you find new customers?

We participate in a lot of trade fairs and conferences like IRE-

PAS/Steel Orbis/SBB/Metalexpert conferences and events.

We follow and pick certain markets where there is import

potential, and we visit those markets to develop relation-

ships with local players. Sometimes, we work through

agents who have a good local understanding and who are

well connected with the potential customers. Of course, we

also use the internet for locating new customers.

How is the market now in Turkey, two years after the

crisis?

The market is recovering. We see that the customers are

coming back with more inquiries. The quantities are not yet

back to pre-crisis times, and we still think it will take another

1-2 years before we reach the pre-crisis trading levels. Cus-

tomers tend to run with minimum stocks due to weaker de-

mand and market volatility.

What are the criteria your customers use to purchase steel?

For the long products, it is a very competitive market where

price and delivery time are the main determining factors. For

a product like wire rod, which is usually further processed,

quality becomes an important criteria in mill selection. For

the flat steel products which are usually intended for manu-

facturing industries, quality has a higher importance. But

still, price is the main factor when carbon steels are concer-

ned in general.

In a market down cycle, does this criteria change?

In a downturn market, on-time delivery becomes very criti-

cal as the customers tend to prefer getting the material as

soon as possible to sell it through their distribution channels

before the price drops further.

What do you see are the biggest challenges steel manufactu-

rers face today?

In the first place, due to the low demand, most mills are

operating at reduced capacities. The margins have decreased

considerably, and mill efficiency has become more important

than before. As most distributors keep lower stocks, the

order sizes have decreased. Steel manufacturers are forced to

do more size changes, which add more manufacturing costs

and lower their plant efficiency.

Raw material supply is becoming a very critical issue, too.

There were a lot of new investments prior to the crisis which

have increased the requirement for scrap. The scrap short-

age is a challenge for mini-mills.

STEEL MARKET

Ali Riza-Bekem left, Levent Danisman right

Logistics is becoming very important as well, because pre-

viously overseas shipments used to go in bulk, and now

there is a tendency towards container shipments, which re-

quire more material handling.

How do you select which steel mill to fill a particular cus-

tomer request?

Well not all steel plants make the same products. Most im-

portant is if the steel manufacturer makes the exact product

requested at a certain, price, quality and can meet the deli-

very time. If all of these fall into place, the relationship we

have with the supplier in general becomes the determining

factor as to the final mill selection.

Our job is to keep in close contact with all the steel mills at all

times so we know which mill is the best for a certain grade

and quality at the best price and delivery time. So depen-

ding on the customer´s priorities - price, delivery time,

quality, we know which will be the best mill to cover the cus-

tomers’ needs.

You may have contact with many steel manufacturers,

which supply exactly the same product. In the moment you

have an order to fill, how do you decide whom to call?

We will try to select a mill which is easier to work with in

terms of operations. We tend to go with the mills who are

faster problem solvers – in case there are any issues with the

deal they will help to solve the problems. Resolving pro-

blems such as operational issues, size changes, production

and operational flexibility are important. Long term

co-operation is also important.

Think of one of your best steel suppliers, why do you call

him more than other suppliers?

It is important in our business to have a quick reply. When

we send an inquiry we want an immediate reply. Response

time is vital in a changing market. In fluctuating markets it

has become more common that steel mills do not respect the

agreements as much and naturally we want to work with

mills who respect the agreements.

How can steel producers be more competitive?

Before the crisis it was all about cutting on already high mar-

gins. But today the margins are tight and competitiveness

will highly depend on having good technology. The specu-

lative aspect of the business in terms of raw material sour-

cing and end product sales strategies requires the mill to be

very fast decision makers and to follow the world markets

and trends, in order take the right positions. It is not enough

to be just a good steel producer today – a mill needs to be

able to read the market well, too.

STEEL MARKET


¨ It is not enough to be just a

good steel producer today –

a mill needs to be able to read

the market well, too. ¨- Linkas Steel

QUALITY

The history of quality management is part of the history of

management itself. Initially, civilizations relied on arts and

crafts to improve the quality of the products distributed

within society.

The Industrial Revolution and the rise of mass consumption

led to emerging issues in management and specifically in

quality management. In 1924 W. A. Shewhart, a physicist at

Bell Laboratories of AT&T, developed a method for produc-

tion quality control applying statistical techniques taken

from engineering and manufacturing. Then during World

War II, W. E. Deming used these methods in the manufac-

ture of munition and other products of strategic importance.

In the mid-50s, Japan decided to make quality improvement

a national imperative in the reconstruction of its economy

based on the theories of W.A. Shewhart, W.E. Deming and J.

Juran. The Japanese worked with quality tools designed by

Deming such as control charts and continuous improvement.

It was at this time that the idea of opening a continuous

learning service came to fruition. One of its theories came

from Taiichi Ono Toyota's production manager. From the

70´s this initiative became a success mainly in the automo-

tive industry.

Since 1980, some of the U.S. states, created new organizations

dedicated to promoting quality such as the Nation Advisor

Council for Quality (NACQ). In April 1990, 21 of the largest

American companies, such as IBM, AT&T,

joined the GEMI (Global Environmental Management Initia-

tive) to begin the quality control process including environ-

mental criteria (TQEM: Total Quality Environmental

Management). This association was created in response to

the first legal measures related to the impact of industry on

health and the environment.

The standards have been progressively integrated to meet

the demands of civil society: global risks, climate change, etc.

In RUSSULA, the challenges of sustainable development

have been translated into concepts of social responsibility,

health and education.

Some milestones:

- 1970 (USA.): First quality assurance law passed for

nuclear power plant construction

- 1991 (USA.): First environmental standard (EQS) on the

quality of soil

- 1993 (USA): First environmental quality standards for

health

The History of Quality ManagementBy: Elvira Martínez Fernández, Quality and Environmental Director, Russula S.A.


w w w . r u s s u l a . c o m

EUROPE

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15008, A Coruña, Spain

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Russula Industrial

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Russula Corporation

Columbus, OH, USA

T: +1 614 403 5658


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04029-200 Brazil

T: +55 11 5044 8847

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San Nicolás, Argentina

T: +54 3461 453013

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Russula Engineering - Sales & Technical

First Floor

Plot No. 150, Jayadev Vihar,

Nayapalli VIP Area, Unit - 16

Bhubaneswar , INDIA

T: +91 9938115906

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