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© 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.
© 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
© 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
© 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
© 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
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50
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1997
2000
2001
2002
2003
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2005
2006
2007
2008
2009
2010
Bloom machinesSlab machines
No. of DynaGap Soft Reduction®
installations on Siemens VAI casters
© 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
© 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
© 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
© 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)
© 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
© 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
© 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
© 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
© 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
© 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
© 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