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© Siemens AG 2011. All rights reserved. Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR I Page 1 Inspiring the Future by Driving Technology Media Summit Media Summit Metals and Mining Technologies Metals and Mining Technologies Kolkata, India, Kolkata, India, May 10 May 10 - - 12, 2011 12, 2011 Andreas Flick, Siemens VAI © Siemens AG 2011. All rights reserved.

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Page 1: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 1

Inspiring the Future by Driving Technology

Media Summit Media Summit Metals and Mining TechnologiesMetals and Mining Technologies

Kolkata, India, Kolkata, India, May 10May 10--12, 2011 12, 2011

Andreas Flick, Siemens VAI

© Siemens AG 2011. All rights reserved.

Page 2: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 2

Achievements in 2010 Successful kick-offs of Innovations

1st FAC for ALU TCS

Packages at Weifang SanYuan

First 16m³ „Hybrid

Flotation Cell“ installed at Minera

Los

Pelambres

First „LiquiRob

EAF“ at

Riva

Commissioning of „400mm Caster“

and first successful application of „Dynacs

3D“

at

Shougang Shouqin

FAC for ESP project at

Arvedi

First installation of „Gimbal

GT

3000“ at

Tata Steel

NTMK Start up converter steelplant

„MERIM“ pilot and

„Waste Heat Recovery“

for Finex at

Posco

Application of „Dynacs 3D“

and new „VAICON Link“ at voestalpine

„SWGR“ at Dragon

Steel

EA for first

commercial Castrip

plant at

Nucor

1st PFC for Plate SmartCrown

at Dongkuk

First „LiquiRob Sublance“

at TK CSA

Reaching sales release for 50 R&D projects in FY10 sets the path to further growth in the future!

First installation of „EAF RCB Temp“ at Bous

Page 3: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 3

Innovation needs matrix for success It is part of our genes

Market Demand

Technology Know how

Organisation Cooperation

Innovation

State-of-the-art technologies to achieve required quality and productivity levels

Reduced operation and maintenance costs to outperform competition

Integration into existing processes

Speed to market

Localization of service

Page 4: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 4

Our Key Discipline - Mechatronics Vertical integration improves plant performance

Page 5: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 5

SIMETAL Smart Mold

SIMETAL DynaWidth

SIMETAL Mold Expert

SIMETAL LevCon

SIMETAL DynaFlex

SIMETAL DynaJet

SIMETAL Smart SegmentSIMETAL DynaGap Soft Reduction®

SIMETAL Dynacs

Butterfly ladle turret

Tundish car

Standardized design and interfaces

Quick and smooth implementation for new and revamped casters

Fast ramp-ups of machines (Connect & Cast)

Mechatronic slab caster packages Improved operation of new and modernized plants

Mechanics

Fluids Metallurgy

Automation

TechnologicalPackage

Mechanics

Fluids Metallurgy

Automation

MechatronicPackages

Mechatronic package – technology driven

1 3 5 7 1117

2939

5160

7686

23

3

3

4

5

5

6

0

10

20

30

40

50

60

70

80

90

100

1997

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

Bloom machinesSlab machines

No. of DynaGap Soft Reduction®

installations on Siemens VAI casters

Page 6: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 6

Waste heat recovery @ EAF The quantum leap in energy efficiency

870 kWh/t

120 t EAF C-steel scrap based

Electric energy: 390 kWh/t

Fossil energy:Charging coal: 150 kWh/tBlowing coal: 90 kWh/tNatural gas: 80 kWh/t

Additional energy input:Combustibles in scrap: 35 kWh/tElectrode combustion: 15 kWh/t Iron combustion: 70 kWh/tAl, Si: 40 kWh/t

Total energy input: 870 kWh/t

Offgas: 370 kWh/t

Steel: 385 kWh/t

Total energy output: 870 kWh/t

Other losses:Slag: 50 kWh/tCooling water

furnace shell: 60 kWh/tRadiation losses: 5 kWh/t

Heat 2 Power: Add on package (new & modernization) Continuous steam or power generation from EAF

off-gas Increased energy efficiency Reduced carbon foot print (40-50 kg/t steel)

SIMELT - Electrode control

FSM - Foaming Slag Manager

RCB refining combined burner

RCB Temp – on-line steel temperature measurement

Holistic process model (active control of injection & burners via on-line off-gas analysis)

Mechatronic package - market driven

Page 7: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 7

ThyssenKrupp CSA LD Converter 1 & 2 / Brazil LiquiRob at sublance position to increase safety

Mechatronic package – organization driven Start-up September 2010

Functions installed:

measurement and compensation of contact rod deformation

attachment of T, TSO and TSC probes

non functional probes separation

Customer benefit:

highest safety standard

reduced maintenance costs

faster cycle times increased output

Page 8: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 8

Challenge

Utilize waste heat from slag Match requirements of cement industry

on production of cinder from slag Utilize energy on high temperature level No interference with production process

Typical customer benefit

Recovery of >20MWth or >6MWel

from a slag flow of 60 t/h Feasible due to rising energy costs Reduced gas volume due to reduced

gas temperature

Environ- mental benefit

Significantly reduce energy demand and CO2 emissions

Solution Dry granulation of slag with rotating cup

Baosteel COREX® C-3000

Energy recovery from dry slag granulation Reduced emissions and recovered energy

Energy – technology driven

Page 9: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 9

WinLink – Direct feed mini-mill Reduced energy and increased yield at low CAPEX

Energy – market driven

Small sized „market-mill“ concept for local supply at lower CAPEX

Energy and water requirements are reduced due to the direct link of caster and mill

Yield of products is increased due to endless rolling operation

Direct link mini-mill requires only 50% of space of a conventional mini-mill - compare (a) vs. (b)

Page 10: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 10

Challenge

Impact (energy demand, cost) of: modifications of plant operation raw material usage process modifications changes in plant configuration

Typical customer benefit

support operational decisions support investment decisions, specially

if strong energy impact Modular-designed, expandable and

upgradeable automation package

Environ- mental benefit

Lower consumption of energy, raw materials and resources

Reduced specific CO2 emissions due to efficient carbon

usage

Solution Material and Energy Cost Offline

Simulation and Optimization Dynamic process models

Baosteel COREX® C-3000

Auxiliary plants

powerplant

Ladlefurnace Reheating

furnace

Hotrolling

EAF

Midrex Caster

ESP

Auxiliary plants Auxiliary

plantspowerplant

Ladlefurnace

EAF

Auxiliary plants

Auxiliary plants

powerplant

powerplant

LadlefurnaceLadle

furnace Reheating furnace

Reheating furnace

Hotrolling

Hotrolling

EAFEAF

MidrexMidrex Caster

ESP

Auxiliary plants

Auxiliary plants Auxiliary

plantsAuxiliary

plantspowerplantpowerplant

LadlefurnaceLadle

furnace

EAFEAF

Material and Energy Cost Optimization Simulation of operation to optimize plant efficiency

Energy – organization driven

Page 11: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 11

Power Cooling Microstructure Target Cooling / Rolling

Microstructure Monitor & Quality Package

Integrated model-predictive

Temperature Control

Comprehensive Quality

Feedback

Optimized Cooling Actuator Design

& Topologies

MicroStructureMonitor

Ti, vi, φi T(t)T(t)

C, Mn, Si, Nb, ...

steel properties

Slab

MicroStructureMonitor

Ti, vi, φi T(t)T(t)T(t)T(t)

C, Mn, Si, Nb, ...

steel propertiessteel properties

Slab

AHSS: advanced high strength steel

Quality Improvements in Rolling Process Intensive Cooling for Production of AHSS Grades

Quality – technology driven

Page 12: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 12

Design Criteria

Produces the highest pellet quality homogeneously

Lowest investment costs and small footprint due to circular design

Optimized process for excellent plant performance

Consume as little fuel and electrical energy as possible

Trends of today — Circular Pelletizing Technology Quality process with innovative circular design

Quality – market driven

Main Benefits Applications

Well-proven travelling gate pelletizing process combined with circular dip-rail design

Simple and robust design of equipment and gas flow

Light building structure

Capacity range: 0.8 to 2.4 mt/a

Small iron ore mines

Processing of accumulated recycle fines at DR/ BF plants as well as steel plant residuals

Brownfield pellet capacity expansion at mining site or in steel plants

Specialty pellets from Manganese ore fines

Page 13: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 13

Trends of today — Ultra-thick slab casting Portfolio enlargement to enter new markets

Urbanization Mobility Energy

First 400 mm at Shouqin, 2010Shougang Shouqin, China

250 – 400 mm Start-up 2010

Quality – market driven

Page 14: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 14

EBROS® Endless Rolling Technology Enhanced productivity and quality at reduced maintenance

Gap Time:5 sec interbillet saving means 2,1 hr/day at 150 t/h1,4 hr/day at 100 t/h→ extra productionPower consumption in idle time: 8 kWhWelding consumption: 4-5 kWh→ Save energy→ Save utility→ Save fixed cost

GAPLESS EFFECT

4%

6%

8%

10%

12%

14%

16%

18%

50 75 100 125 150 175

Original Rolling Rate (T/Hr)

Pro

duct

ion

Incr

ease

(%)

150x150x12M 5sec

130x130x12M 5sec

125x125x 9M 3sec

ERT Endless Rolling: Increased Productivity

Maximized Yield

Free coil weight

Homogenous quality

Energy saving

Cost saving

0.0%

0.2%

0.4%

0.6%

0.8%

1.0%

1.2%

1.4%

Met

al lo

ss (%

)

1ton 2ton 2Tx 5BT10 ton

2Tx 50BT100ton

Billet weight

Welding

Cobble

Quality loss

Crop loss

Quality – organization driven

Page 15: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 15

Extended service support Innovations in designs to service local markets

EcoStar Roller MORGOIL Babbitt welder

Stock elements, 100% standardized

Surface ready roller mother cut to required length

wedding

Supply: 3 months 3 weeks = just-in-time

Innovations in service

MORGOIL Babbitt welding manufacturing process

Unique Babbitt welding process and largest sleeve grinder available

Longer service life by more than 10%

Larger turn-down of backup rolls

Reduction in maintenance time & costs

Page 16: Inspiring the Future by Driving Technology - Home - · PDF file · 2011-05-10Start up converter steelplant ... Know how. Organisation ... Inspiring the Future by Driving Technology

© Siemens AG 2011. All rights reserved.Kolkata, India, May 11, 2011 Media Summit Metals and Mining Technologies CC MR IPage 16

New demands will drive change of material in daily life Picture of the future