Product program for efficient secondary metallurgy

Product program for efficient secondary metallurgy

SMS SIEMAG

SECONDARY METALLURGY

SMS Mevac

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SECONDARY METALLURGY –ADDING VALUE TO YOUR STEEL

Technologies and ApplicationsSMS MEVAC

Content

ADVANCED STEEL QUALITY .............................................................................................................................. 4Preferred technologies ................................................................................................................................................................... 4

ATMOSPHERIC PROCESS TECHNOLOGIES ....................................................................................... 6HMP Hot metal pretreatment stations .................................................................................................................................. 7LTS Ladle treatment stations ..................................................................................................................................................... 7CHS Chemical heating stations ................................................................................................................................................. 8LF Ladle furnaces ............................................................................................................................................................................ 8

VACUUM PROCESS TECHNOLOGIES ........................................................................................................ 10RH and RH-TOP Recirculation degassers ............................................................................................................................. 11RH-TOP Lances ................................................................................................................................................................................ 11RH-RockerType® ................................................................................................................................................................................ 12VD and VD-OB Tank degassers, VOD Vacuum oxygen decarburization units ........................................................ 14Vacuum pumps ................................................................................................................................................................................. 16

AUTOMATION SYSTEMS ........................................................................................................................................ 18Plant and process control systems .......................................................................................................................................... 19

SERVICE SPECTRUM .................................................................................................................................................... 20Lifecycle maintenance ................................................................................................................................................................... 21

ADVANCED STEEL QUALITY ............................................................................................................................... 22 Process routes .................................................................................................................................................................................. 23

FIVE DIMENSIONS OF EXPERTISE

FOR YOUR SUCCESS

SMS Mevac’s product program covers the entirerange of technologies and services for effectivesolutions in secondary metallurgy. We combinefive dimensions of expertise in an holistic approach. In each performance area we deliver outstandingresults:

Advanced steel qualityPerformance and productivityLifecycle maintenance Safety, health, and environmentROI and TCO-driven perspectives

X-eed is the brand name of the overall SMS Mevacportfolio, expressing our continuous striving fordevelopment of enhanced technologies for thebenefit of our worldwide customers.

ADDING VALUE TO YOUR STEEL

Our secondary metallurgy program adds value toyour steel. It meets the requirements of all steelproducers worldwide. We are pleased to supportyou in creating the most efficient processes andprocess routes – tailored to your plant’s needs.

ROI +

TC

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and Environment

Safety, Health, M

aint

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Life

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Advanced

Steel Q

uality Performance +

Productivity


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A PACKAGE OF SUPERIOR

SOLUTIONS

SMS Mevac’s program covers the complete range of technologies and services for advancedsteel quality. This package of secondary metallurgy solutions is an important factor in helping to continuously deliver products with superior benefits to the final customer.

These true assets in the value chain give you maximum flexibility in constantly supporting leading industries with the most appropriateadvanced steel quality. Seize the many opportunities to satisfy growing demand for quality steels in future-oriented markets.

ENGINEERING SUPREMACY

We individually tune and adjust each component of your secondary metallurgy plant. Our total commitment to technologies and services helps to create extraordinarily efficient performance, giving unique competitiveness in economy and ecology.

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INDUSTRIES

Appliance Industry

Appliance Industry

Automotive

Automotive

Automotive

Automotive

Chemical Industry

Building, Architecture

Building, Architecture

Decoration

Electrical Industry

Energy

Energy

Mechanical engineering

Mechanical engineering

Transportation

Transportation

SELECTED FINAL PRODUCTS

Refrigerators

Washing machine drums

Antifriction bearings

Automotive panels, car bodies

Crankshafts

Valve springs, valve cones

Tubes

Facades

Steel bars

Cuttlery

Sheets

Rotor blades for wind turbines

Gas pipes

Punching tools, screw taps, screws

Tin plates

Railroad wheels

Rails

TECHNOLOGIES

VOD, LF, LTS

VOD, LF, LTS

LF, VD, (RH)

(RH), RH-TOP, CHS

LF, VD, (RH)

LF

VOD, LF, LTS

VOD, LF, LTS

LF, LTS

VOD, LF, LTS

(RH), RH-TOP, CHS

VD, LF, (RH)

VD, LF, (RH)

LF, LTS, VD

LF, LTS

LF, VD, (RH)

LF, VD, (RH)

ADVANCED STEEL QUALITIES

Precise analysis adjustment, precise temperature control

Low carbon content, precise analysis adjustment, high steel purity

High steel purity, precise temperature control, precise analysis adjustment, slag management

Low carbon content

High steel purity, precise analysis adjustment, sulphide inclusion modification

High steel purity, oxide inclusion modification

Low carbon content, precise analysis adjustment,precise temperature control

Precise analysis adjustment, precise temperature control

Slag management, high steel purity, oxide inclusion modification

Precise analysis adjustment

Lowest carbon contents, precise analysis adjustment, precise temperature control

High steel purity, precise analysis adjustment

Sulphide inclusion modification, low contents of sulphur and hydrogen

Precise analysis adjustment

High steel purity, precise analysis adjustment

High steel purity, precise analysis adjustment, slag management

Oxide inclusion modification, slag management, precise analysis adjustment

BENEFITS FOR THE FINAL CUSTOMER

Surface quality, clean edges

High resistance to washing solutions

Long service life, low noise

Perfect surface quality, high formability, low weight

Long service life

Long service life, low material consumption

High resistance to corrosion

Perfect surface quality

Long service life, high stability

High resistance to corrosion

Low energy losses

High strength, high wear resistance, long service life

Not sensitive to low temperatures

Low wear, high precision

High strength, low weight

High operating reliability, long service life

High wear resistance

Advanced steel quality

PREFERRED TECHNOLOGIES

ATMOSPHERIC PROCESSTECHNOLOGIES

Atmospheric process technologies

HMP, LTS, CHS, LF


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HOT METAL PRETREATMENT

STATIONS

SMS Mevac’s HMP stations are installed in manysteelmaking plants in order to economically removedetrimental elements from hot metal. Heat sizescover a range up to 350 t. Mono or co-injectionunits for desulphurization agents are available.Our latest Twinjection® technology allows fastreagent delivery without compromising efficiency.

Metallurgical functionsPretreatment of hot metal and adjustment of compositionDesulphurization by powder injectionDephosphorizationDesiliconizationDeslaggingHomogenization of hot metal quality and temperature

KANBARA REACTOR (KR)

As an alternative technology the Kanbara reactorcan be applied in HMP stations to thoroughly disperse the desulphurization reagent.

Metallurgical functionsDesulphurization by a mechanical stirring process Deslagging

LADLE TREATMENT STATIONS

SMS Mevac’s LTS units are installed in EAF andBOF steelmaking plants between the melting andcontinuous casting facilities. Ladle treatmentstations carry out an important set of secondarymetallurgical processes without using large-scale,capital intensive equipment.

Metallurgical functionsDesulphurization by addition of synthetic slag or by powder blowingDeoxidation by addition of aluminum or micro alloysAdjustment of the chemical composition by wire feeding and alloy additionHomogenization of liquid steel by bottom purging or lance stirringAlloying and fine trimmingImprovement of castabilityTemperature adjustment by addition of cooling agentsLiquid steel storage buffer prior to casting

Atmospheric process technologies

HMP, LTS, CHS, LF

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CHEMICAL HEATING STATIONS

CHS by SMS Mevac are incorporated into EAFand BOF steelmaking routes to attain clean steelwith precise chemical composition. A bell or ringis used as the main component, partly immersedinto the liquid steel bath. CHS serve heat sizes ofup to 400 t.

Metallurgical functionsChemical heating by oxidation of aluminum or siliconDesulphurization by metal-slag reactionAlloying and fine trimmingHomogenization of steel quality and temperatureImprovement of castability

LADLE FURNACES

SMS Mevac’s LFs provide electrical heating toadjust accurate steel temperatures to the continuous caster. The LF can also be used tolower the BOF/EAF tapping temperature to compensate for losses due to secondary metallurgical processes like degassing or desulphurization. The power conducting arms aremade of copper or aluminum plates. In addition to

fixed-roof installations, slewing versions are available in order to serve two treatment positionsor two ladle transfer cars for increased productivity.Inert gas roofs for special applications are available.LFs are installed in steelmaking plants with heatsizes of up to 400 t.

Metallurgical functionsElectrical heatingDesulphurization by metal-slag reactionAlloying and fine trimmingSlag managementImprovement of castability Homogenization of ladle contentsBuffer function between melting and continuous casting units to ensure security of sequence casting

VACUUM PROCESSTECHNOLOGIES

Vacuum process technologies

RH, RH-TOP

RH AND RH-TOP RECIRCULATION

DEGASSERS

RH and RH-TOP units are installed in steelmakingplants with heat sizes of up to 400 t.

Fixed vessel installations use ladle lifting systems,while movable vessel installations employ vessellifting systems. Fast vessel exchange systemsincrease the plant’s general performance andduplex vessel installations enable furtherincreased output.

The RH process is characterized by short treatment periods, minimal temperature lossesand extremely favorable results for decarburizationand degassing. No special slag measures, extraladle freeboard or porous plugs are required.

RH-TOP LANCES

A short lance design is used to blow from a longdistance, allowing installations in plants withrestricted headroom. Oxygen blowing, powderblowing and gas burner functions may be combined in a single multi-function lance. Videocamera installations can also be incorporated toprovide constant visual monitoring.

Metallurgical functionsDecarburization to lowest levelsHydrogen removalAlloying and fine trimming with high accuracyFast homogenization of the ladle content, even when large quantities of alloys are introducedVacuum carbon deoxidation

With RH-TOP lanceForced decarburizationAdjustment of C:O ratioDesulphurizationAdjustment of steel temperature by chemical heatingSkull removalHeating of vessel by means of integrated gas burner function

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RH, RH-TOP

RH-ROCKERTYPE® – A BOOST

FOR SAFETY

The RH-RockerType® unit has been engineered to significantly increase the performance parametersof RH processes. This well proven yet future-oriented solution gives safe, reliable RH operation.

The origin of RH-RockerType® technology from SMS Mevac goes back to the 1950s. Its main purpose then was to safely lower the vacuumvessel system and immerse the snorkels into theliquid steel in a simple and reliable way. The systemstands out because of its user friendly operationand maintenance.

Recently, RH-RockerType® technology has been further improved. It now smoothly lifts and lowersthe ladle instead of the vacuum vessel system.Many useful features were added.

INCREASED EFFICIENCY

To speed up your intra logistic processes in theRH plant, the ladle lifting RH-RockerType® canuse two ladle cars. One of them brings the ladleto the RH station for treatment. After treatment,another car takes it to the caster area whilst thefirst ladle car brings the next ladle.

This design supports flexible processes, as the firstladle car can be recharged while the ladle is beingtreated. Depending on the layout of the steel shop,this greatly improves your ladle transportationlogistics. The resulting advantages can be implemented both in single treatment stationsas well as in our fast vessel exchange units.

As the alloy system and the vacuum pump arefixed directly to the vacuum vessel system, nospecial conveyors or moving vacuum ductwork are required.

A KEY TO LASTING RELIABILITY

Two hydraulic cylinders are installed to operatethe lifting and lowering processes of the ladle. For normal operations, they are mechanically synchronized. In the case of an electric power failure, the ladle is lowered safely onto the ladlecar in a controlled way by gravity. Maintenance ofthe complete hydraulic system is simple andstraightforward. The RH-RockerType® unit is verywell protected against liquid steel splashes andliquid steel from a ladle break-out.

In comparison to vacuum vessel lifting installations,there is much better access to the vacuum vesselplatform. Similarly the automatic sampler andother auxiliary equipment are easily accessed.

For safety and efficiency reasons RH-RockerType®

technology will play an important role in futureRH secondary metallurgical infrastructure.

RH Ladlerocker (3D)

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VD, VD-OB, VOD

VD AND VD-OB TANK DEGASSERS

SMS Mevac’s tank degassers support EAF andBOF plants, permitting heat sizes of up to 340 tor more. Inert gas is introduced into the bottom ofthe ladle by means of porous plugs. The process ischaracterized by slag-free tapping at the meltingunit. The plant requires an efficient vacuum pumpsystem to meet the specific requirements of thedesired metallurgical process.

Standard tank installations are fixed above orbelow the shop floor. Movable tank installationsor twin tank installations substantially increaseperformance.

Metallurgical functionsHydrogen and nitrogen removalDecarburization to lowest levelsDesulphurization by metal and slag reactionEfficient alloying and fine trimming with high accuracySlag managementImprovement of castabilityHomogenization of ladle contents

Additional applications using VD-OB lance systems:Oxygen blowing for forced decarburization from high initial carbon levels, e.g. for the production of ultra-low carbon steel gradesOxygen blowing for chemical heating by aluminum oxidation

VACUUM OXYGEN

DECARBURIZATION UNITS

FOR STAINLESS STEEL

SMS Mevac has supplied VOD units with heatsizes of up to 200 t, mainly for the production ofstainless steel.

Similar to VD, the VOD units are designed tomeet the specific requirements of the plant layout as well as the individual processes of our customers.

Metallurgical functions enhanced by our efficientoxygen lance are:Forced decarburization under vacuum for low chromium oxidationChemical heatingHomogenization of ladle contentsAlloying and fine trimming


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VACUUM PUMPS


EFFECTIVE VACUUM TREATMENT

High-performance vacuum pumps from SMSMevac are the heart of secondary metallurgicalvacuum processes. For both recirculation ortank degassing processes, our vacuum pump technologies are tuned to your specific steel conditions and to your individual plant and production requirements.

Our vacuum pump systems precisely controlthe rate of pressure reduction from atmosphericlevel to low vacuum pressure. During the varioustreatment steps the vacuum level is accuratelycontrolled to match the system’s metallurgicalneeds.

In order to deliver optimum results high suctioncapacity, low energy consumption and optimalreliability are essential elements of our design.

VACUUM PUMP TECHNOLOGY

FOR YOUR PROCESS

Three technologies form the cornerstones ofSMS Mevac’s vacuum systems:steam ejector vacuum pumpssteam ejectors with water ring pumpsdry mechanical pump systems.

The selection of a specific technology dependson the respective conditions in the secondarymetallurgical plant. Availability of utilities, metallurgical needs and the balance of operationaland investment costs are basic considerationsfor our individual, high performance concepts.

PIONEERING EXPERIENCE

SMS Mevac has decades of pioneering experiencein various vacuum pump technologies.

In 1956 SMS Mevac built its first steam ejectorvacuum pump for vacuum treatment processingof liquid steel. Since 1960, we also designedplants with mechanical vacuum pumps.

In 1985 our four stage steam ejectors replacedthe former five stage version for high coolingwater temperatures. For advanced splash control,our RH-SC® with variable steam nozzles waslaunched in 2000. And in 2006 we introduced ourTriple-S-technology for reduced consumption ofcooling water.

This set of advanced innovations has a provenrecord of success in many hundreds of applicationsall over the globe.

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AUTOMATION SYSTEMS Automation systems

PLANT AND PROCESS CONTROL SYSTEMSSMS MEVAC’S

AUTOMATION SYSTEMS

Advanced electrical systems, automation andinstrumentation bring together the balance of product quality, safety, energy and media consumption and reliable operations. SMS Mevac’sLevel 1 and Level 2 automation systems linkthese functions, giving highly efficient plantoperation.

MANAGEMENT SUPPORT AND

CONTINUOUS IMPROVEMENT

Secondary metallurgy automation is linked to thesteelwork’s Level 3 system, giving full information,providing reporting systems and supporting thescheduling of heats.

Metallurgical and thermal models, least cost calculations and process simulation assist yourspecialists to continuously improve yourprocesses.

OPERATOR SUPPORT

Ergonomic HMIs are supported by state-of theart technology. Operators obtain up-to-the-minute information to safely control secondarymetallurgical processes.

Maximum safety is provided by interlock indication on HMI, sequence control, equipmentand functional interlocks, pin pointing failuresand monitoring of critical processes such asmedia flow and possible leakage.

A WELL PROVEN BRAND

SMS Mevac and SMS Siemag express their greatpassion for steelmaking by sharing the unmatchedautomation brand X-Pact for their plant and processcontrol systems.

This gives additional assurance of highest qualityto our customers.

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SERVICE SPECTRUM Service spectrum

LIFECYCLE MAINTENANCE

LIFECYCLE-ORIENTED CARE

Secondary metallurgical plants from SMS Mevacare highly reliable and maintenance friendly.Care for our customer’s plant starts even beforehanding over.

Our vast spectrum of consulting services beginswith the feasibility study – based on the individualstrategy of the customer. We discuss alternativesolutions with regard to technologies and economics. By using extended 3D simulationprograms we fine-tune the final layout of eachcomponent.

TRAINING PROGRAMS

Individual training packages provide soundknowledge and motivation to the prospectiveteams - from operation routines to automationdetails and safety measures.

A combination of initial off-site training coursesat the SMS Mevac headquarters or at suitablepartner plants plus continuous on-site workshopsprovide advanced know-how for successful long-term operations.

MAINTENANCE AND SPARE-PARTS

Monitoring of the plant’s performance by our specialists and preventive maintenance packageseffectively reduce costly down times needed forfault-finding and trouble-shooting activities. Ourafter sales service supplies the required OEMspare parts for our customer’s plants ensuringcontinuous high performance of the equipment.

UPGRADING, MODERNIZATION,

AND REVAMPING

Depending on your plant’s lifecycle stage, a periodic up-date of special innovations andimprovements provides optimum return on yourinvestment. Our specialists’ recommendationsfocus on metallurgy, process technology, engineering and automation.

SMS Mevac is very experienced in careful planning to ensure minimum down times for therequired activities. Fast return on investment aftermodernization supports our customer’s economicand market targets.

For these reasons, our broad service spectrumprovides efficient lifecycle maintenance to ourcustomer’s secondary metallurgical operations.

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Advanced steel quality

PROCESS ROUTES

INTEGRATED PROCESSES

A growing number of advanced steel qualitiesare based on sequential treatment in a series ofsecondary metallurgy stations. These processroutes combine complementary technologies toproduce steels at unique quality levels. Finishedproducts with high performance profiles originatefrom these high quality steels.

Consistent reproducibility makes them preferredqualities for high level industrial applications.The technology of the steelmaking process andthe required steel quality determine the mostsuitable process route. SMS Mevac’s full rangeof secondary metallurgy technology permits abroad spectrum of combinations. Integratedtechnologies for atmospheric and vacuumprocesses determine the choice of the mostappropriate routes.

LINE PIPE STEELS

Micro-alloyed line-pipe steels with high strengthand HIC-resistant profiles can be produced on BOFor EAF routes. Secondary metallurgy equipment

consists of SMS Mevac VD vacuum degassers andLF ladle furnaces for the EAF route, alternativelySMS Mevac LTS ladle treatment stations, RH-TOPrecirculation degassers, LF ladle furnaces and anHMP hot metal pretreatment station to serve theBOF route.

EXTRA DEEP DRAWING STEELS

The EAF route, for example for automotiveapplications uses SMS Mevac VD-OB vacuumdegassers and LF ladle furnaces. The BOF routecombines SMS Mevac HMP desulphurizationunits, LTS ladle treatment stations and VD-OBtank degassers or RH-TOP recirculationdegassers.

STAINLESS STEELS

The Duplex process route especially for the production of ferritic grades combines SMS MevacVOD vacuum oxygen decarburization technologyand LF ladle furnaces. The Triplex route is supportedby SMS Mevac HMP desulphurization units andVOD vacuum oxygen decarburization technology.

STEELMAKING PROCESS ROUTE – BOF

Micro-alloyed high-strength steels e.g. for line pipes or ship building

SMS Mevac LTS Ladle treatment station- Shape control, Ca-treatment

SMS Mevac RH-TOP Recirculation degasser- Degassing of H, N, final trimming, cleanliness

SMS Mevac LF Ladle furnace- Analysis, slag conditioning, temperature adjustment

BOF Basic oxygen furnace

SMS Mevac HMP Hot metal pretreatment station- Desulphurization

STAINLESS STEEL PROCESS ROUTE

Stainless steelsfor ferritic low carbon and low nitrogen grades

SMS Mevac LF Ladle furnace- Slag conditioning- Temperature adjustment- Shape control- Cleanliness

SMS Mevac VOD Vacuum oxygen decarburization unit- Decarburization- Desulphurization- Final trimming

EAF Electric arc furnace, deslagging unit

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ADVANCED STEEL QUALITY

STEELMAKING PROCESS ROUTE – EAF

Extra-deep drawing steels e.g. for automotive applications

SMS Mevac VD-OB Vacuum tank degasser- Decarburization- Deoxidation- Final trimming- Temperature adjustment

SMS Mevac LF Ladle furnace- Temperature adjustment

EAF Electric arc furnace, deslagging unit

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SMS MEVAC GMBH

Bamlerstr. 3a45141 Essen, Germany

Phone: +49(0) 201 6323-0Telefax: +49(0) 201 6323-200

E-Mail: [email protected]:www.sms-mevac.com

H5/305E

1.500/05/2011 . MM .Printed in Germany

MEETING your EXPECTATIONS

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

RH-SC®, RH-RockerType® and Twinjection®

are registered trademarks of SMS Mevac.

Product program for efficient secondary metallurgy

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