SECONDARY METALLURGYLiquid steel of the highest purity

Expertise and experience, reliability and flexibility – these are the hallmarks of SMS Concast. This leading supplier of electric steelmaking and casting technology helps customers worldwide achieve a competitive edge in their markets. SMS Concast offers high-performance plant and machinery for steelmaking, secondary metallurgy and continuous casting.

To perform well in areas such as consulting, engineering, commissioning and service, our employees offer a combination of both outstanding expertise and flexibility. That’s why SMS Concast solutions deliver such excellent benefits for their customers.

SETTING BENCHMARKS WITH

EXPERIENCE

Since 1954, SMS Concast has supplied more continuous casting installations than anyone else in the industry. Over the years, it has designed a great range of innovative products that improve the steelmaking process.

INTEGRATED SOLUTIONS

SMS Concast belongs to the SMS group and is part of the SMS Meer business area. Together, SMS Concast and SMS Meer are able to better serve the growing demand for state-of-the-art minimills. The two companies turned the idea of an integrated plant with an electric arc furnace (EAF) and rolling mill into reality.

SMS CONCASTA technology powerhouse

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MEMBER Of THE SMS GROUPStrong, successful, together

SMS SIEMAG

SMS Siemag has more than 100 years’ experi-ence in reduction processes. Additionally, it is a leader in steelmaking and secondary metallurgy technology. SMS Siemag’s extensive portfolio also includes continuous casting, CSP® technol-ogy, hot and cold rolling mills, strip processing plants, and aluminum plants. The high-quality steel products of SMS Siemag start with thin, medium and thick slabs. SMS Siemag’s products are used in the steel, aluminum and non-ferrous metal industry worldwide.

SMS MEER

SMS Meer is a leading supplier of plant and machinery for steelmaking, tubes, long products, forging and heating technology. Its solutions provide customers with tangible benefits in challenging markets: steel for tire cord, tubes for pipelines, heavy structural profiles, wheels for high-speed trains, and aluminum for use in skyscrapers and offshore wind turbines.

Within the SMS Meer business area, SMS Concast is the specialist in long product steelmaking.

The SMS group is among the leading plant and machinery construction companies for steel, aluminum and non-ferrous metal processing. It comprises two business areas: SMS Siemag and SMS Meer.

TAILOR-MADE SYSTEMSEfficient steelmaking for all grades of steel

From the construction of infrastructure or buildings, to highly specific automotive parts, to everyday items such as nuts and bolts – steel is everywhere. As a leading provider of innovative technologies for the steelmaking industry, SMS Concast offers profession-al secondary metallurgy systems that deliver the ex-act steel quality required, regardless of its application.

THE RIGHT SOLUTION

fOR ANY BUSINESS MODEL

The development, engineering and supply of tai-lor-made secondary metallurgy technologies are driven by the production targets of SMS Concast’s business partners. SMS Concast systems al-low for the production of even the most demand-ing steel grades, as well as the cost-effective manufacture of semi-finished goods or bulk products – irrespective of market demands.

HIGH LEVELS Of EffICIENCY

THROUGH INDIVIDUAL SOLUTIONS

SMS Concast combines state-of-the-art technologies with durable, tried and tested components. The design of all its systems is based on a modular philosophy, a concept which allows mostly standardized elements to be used to meet any and all customer require-ments. SMS Concast rounds off this concept with powerful automation and the latest process tools.

A LOCAL, WORLDWIDE SERVICE

Just like its plants and machinery, SMS Concast’s employees are at work around the world – so plant operators can always find a service representative nearby. Comprehensive customer advice, reliable support for day-to-day operations, and collabora-tion on new developments and improvements are of paramount importance to SMS Concast.

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PLANT LAYOUTFully integrated solutions and perfect set-up

SMS Concast’s experts understand the very spe-cific requirements of steel plants. The engineers create cutting-edge solutions for every steelmaking facility, ensuring high levels of flexibility and out-standing performance. As a result, SMS Concast provides its business partners with all the equip-ment they need to meet their individual de-mands in terms of quality and productivity.

SMS Concast’s modern secondary metallurgy facilities are:

� Ladle furnace, either in single, twin, triple or double-twin units

� Vacuum degassing (VD) installation � Vacuum oxygen decarburization (VOD) installation.

These systems are rounded out with various process-specific and safety features to ensure smooth and efficient operation, including:

� Automatic sampling and temperature measurement � Gas and/or oxygen lance � Camera systems for safe process observation � Level 1 and level 2 automation � Ladle deslagging station.

PLANT AND MACHINERY fOR ANY

CAPACITY

SMS Concast’s concepts for secondary metallurgical systems can vary from single-ladle furnaces for the production of low-alloy steel grades, to twin and triple-ladle furnaces or even multi-ladle furnaces for the pro-duction of high-alloy steel grades with long treatment times. All plant and machinery can be combined with ladle vacuum treatment stations for VD or VOD, also in single, twin or multi-tank systems. For both VD and VOD processes, mechanical vacuum pumps result in improved flexibility, with a significant reduction in ener-gy consumption compared to steam-ejector systems.

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In China’s Jiangsu province, Zhangjiagang Hongchang Wire Rod (ZHW) produces dedi-cated steel grades specifically for the country’s growing automotive industry. The company is part of the Shagang Group, which already operates 71 casting strands supplied by SMS Concast (15 casters). To ensure high stan-dards of quality and efficiency, SMS Concast’s engineers aligned the individual process units with one another: from the electric arc furnace, to the ladle furnace, to the vacuum station – all elements are in tune with each other.

The ladle furnace is designed to perform steel refining quickly and reliably. It is a perfect match for the 110-ton electric arc furnace: together, both units process the steel within just 30 to 35 minutes. As most steel grades produced by ZHW require vacuum degassing, SMS Concast installed a twin-tank vacuum station. A five-stage mechanical vacuum pump allows for a treatment time of just 35 to 45 minutes. This elaborate set-up enables ZHW to ensure correct steel cleanliness and pro-duce steel grades of the highest quality.

TOP-NOTCH qUALITY IN jUST 30 MINUTES

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LADLE fURNACECost-effective performance and increased operational safety

The ladle furnace (LF) is one of the key components of secondary metallurgy systems. Sound ladle furnace operation delivers benefits in terms of steel quality, productivity and cost-efficiency. Process requirements and heat-cycle times are considered to be the main factors when installing a ladle furnace. SMS Concast can provide the right solution: single-ladle treatment stations, twin LFs, or up to triple or double twin-ladle systems using a carousel system. Specialized LF pro-cess tools and design features include minimized draft-roof design, sampling and temperature manipulators, stirring equipment, multi-line wire feeders and modern automated systems. All these features maximize per-formance and operational safety, while ensuring lowest possible energy consumption and emissions.

SATISfIED CUSTOMERS WORLDWIDE

SMS Concast’s long list of case studies and refer-ences is proof of its significant expertise, resulting in highly cost-effective solutions. It can provide support for a range of steel grades, from simple carbon steels and low-alloy steels, to challenging high-alloy and stainless steels. Ladle sizes range from 20 to 350 tons.

VD/VODLadle vacuum treatment stations for extremely pure steel

Depending on the steel grades being produced and the way in which the end product will be used, vacuum treatment may be necessary to achieve the desired level of quality (low H, low N, clean steel = inclusion engineer-ing). To produce high-quality steels, treatment in the ladle furnace is followed by vacuum degassing. SMS Concast sets new benchmarks with its installations of both vacuum degassing and vacuum oxygen decarburization stations.

The main features of the ladle vacuum treatment stations are:

� Generation of a vacuum either via mechanical or steam-ejector pumps

� Vacuum-bag filter and heat exchanger in the suction line

� Compact tank design with emergency volume � Dry, well-protected cover sealing � Water-cooled splash shield � Auxiliaries such as a sampling manipulator, wire

feeder and oxygen-blowing system for VOD.

In these applications, state-of-the-art, automated systems give clients complete control over processes.

REDUCING EMISSIONS

AND ENERGY CONSUMPTION

SMS Concast is constantly challenging itself to develop new technologies that further reduce emissions, with the aim of improving or replacing existing steelmaking technologies. SMS Concast combines this focus on state-of-the-art technology with in-depth, expert knowledge: our specialists have successfully imple-mented VD/VOD-systems with mechanical vacuum pumps for all ladle sizes around the world. Compared to conventional steam-ejector systems, these mechan-ical systems offer the following benefits:

� Low energy consumption � Maximum flexibility thanks to “vacuum on

demand”, with no lead time � No cooling water impurity from process gases.

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VACUUM GENERATIONReduced operating costs thanks to mechanical vacuum pumps

For many years, steam-ejector pumps have been the only aggregate system to generate vacuum for the degassing of liquid steel. This is because they produce sufficient suction capacity at acceptable in-vestment costs. However, they do have serious disad-vantages when it comes to operating costs, such as high energy consumption for steam generation or the disposal of contaminated water and hazardous sub-stances. Furthermore, steam is not always available in the required quantity and flow.

MECHANICAL PUMPS: ECONOMIC

AND ECOLOGICAL ADVANTAGES

SMS Concast has developed dry mechanical vacuum pump systems and adapted them to the specific requirements of a steelmaking environment. These pumps offer significant benefits in terms of operating costs and environmental friendliness. The multi-level design featuring high-volume flow-roots blowers and screw-compressors, combined with efficient off-gas cleaning, results in a cost-effective and eco-friendly solution and offers a valuable substitute for steam-ejector pumps. SMS Concast manufactures roots blowers and screw compressors with high tolerances to achieve high levels of efficiency. To ensure a long and smooth service life, engineers install specially designed filter systems upstream of the pump unit, comprising a cyclone and bag filter.

MAXIMUM OPERATIONAL SAfETY

As some dust and slag particles are at risk of igniting spontaneously when exposed to oxygen, it is essen-tial to take precautions against any oxygen entering the filter before the filter bags have been cleaned with inert gas. SMS Concast employs a dust monitor-ing system that alerts workers in the event of a filter malfunction, so that corrective action can be taken long before the vacuum pumps are put at risk.

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SECONDARY METALLURGY

TECHNOLOGY INCLUDES:

� Advanced electrode regulation for ladle furnaces

� Heat and mass balance model � Chemical-activity model � Steel-slag interaction model � Element-fading model for vacuum degassers � Most cost-effective, recipe-addition model � Addition control for alloys/wires � Stirring control � Process analysis and simulation � Metallurgical data management � Production-delay detection � Equipment tracking.

AUTOMATIONFrom melting to casting, everything’s under control

Thanks to a ladle furnace and vacuum degasser, steel plant operators can achieve high-quality steel and avoid delays in the production cycle. In order for this to happen, all activities across the various process areas must be synchronized. SMS Concast offers automa-tion and control systems specifically for LF, VD or VOD to ensure correct control of all process steps, with advanced thermodynamic and chemical modeling.

MATHEMATICAL MODELS

REDUCE COSTS

Complex mathematical models, fed with real-time data captured by the automated systems, estimate the thermal exchanges within the molten steel. They evaluate the changes of the steel temperature dur-ing each process, taking into account:

� The heating effects of arcing � Chemical reactions � Energy losses due to material additions � Stirring gas � Continuous dissipation of heat.

Chemical-activity models estimate the activity factors and values for each element in both steel and slag, based on their current composition and temperature. Finally, the most cost-effective, recipe-addition model suggests the best additional materials to achieve the

product targets, based on estimated steel compo-sition and temperature. While looking for the best possible mix of additions, the model also considers constraints related to relevant formulas defined by the metallurgist.

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MEETING your EXPECTATIONS

SMS CONCAST

Toedistrasse 9

8027 Zurich

Switzerland

Phone: +41 44 204 65-11

Fax: +41 44 204 69-21

sales@sms-concast.ch

www.sms-concast.ch

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.

IMPRINT SMS Concast AG, Jean-Pierre Papadopoulos (Editor), Toedistrasse 9, 8027 Zurich, Switzerland Phone: +41 44 204 65-11, Fax: +41 44 204 69-21, sales@sms-concast.ch, www.sms-concast.ch