PASSION FOR PROCESS Long product steelmaking

STEEL PRODUCTS Building the world

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Technology is rapidly moving forwards, enabling us to reach the other side of the world within a few hours, build skyscrapers that dominate the skyline, construct bridges between countries and produce energy using wheels as large as football fields. These are just a few examples of how far technology has come but in a world where technology is progressing so quickly, consumer demands are also increasing in line with the rate of technological advancement.

Steel is integral to this progress. Without steel, the wheels of today’s industry would grind to a halt: trains would no longer run, ships would no longer set sail and planes would no longer be able to take to the skies.

Steel builds our world and keeps it moving.

Steelmaking is essential to today’s society. SMS Concast machines and plants produce a broad range of steel grades. They allow customers to develop a variety of products to speed up techno-

logical innovations. SMS Concast helps to build the world and keep it moving, by providing products for energy production, construction and transport.

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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, engi-neering, 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 CONCAST A technology powerhouse

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MEMBER OF THE SMS GROUPStrong, successful, together

SMS SIEMAG

SMS Siemag has more than 100 years’ experience in reduction processes. Additionally, it is a leader in steelmaking and secondary metallurgy technology. SMS Siemag’s extensive portfolio also includes continuous casting, CSP® technology, hot and cold rolling mills, strip processing plants, and alumi-num plants. The high-quality steel products of SMS Siemag start with thin, medium and thick slabs. Its products are used in the steel, alumi-num 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.

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Conseal: time-efficient preparation of strands before casting

Concast begins specializing in the design and engineering of continuous casters for long products

SMS CONCAST HISTORY Always innovative

1990198019701950 1960

Schloemann becomes a Concast shareholder

Collaboration with Mannesmann on the development of a continuous casting process

The merger between Schloemann and Siemag forms SMS Schloemann-Siemag, and SMS Schloemann-Siemag becomes main shareholder of Concast AG

Concast AG is founded by Irving Rossi

COMPANY HISTORY

INNOVATIVE POWER

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Conmould®: mold production and refurbishment

Conmark®: marking machine

Invex®: faster casting and

direct feeding of billets to rolling

mills

Concor®: strand-guiding roller for optimized internal cooling

Condoor®: revolutionary slag-door concept for EAFs

Concharge®: charging concept

Concast launches its Electric Arc Furnace (EAF) business (taken over

from ABB)

20202000 2010

SMS Holding becomes a 100 percent shareholder of Concast

Concast is renamed SMS Concast

Conmould®: the competence center for mould production and refurbishment

SMS Concast becomes part of the SMS Meer business area

Convex®: technology for more

rapid casting Trueflow®: special plating process

Conmax®: nozzles

COMPANY HISTORY

INNOVATIVE POWER

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PORTFOLIO From steelmaking to casting – an end-to-end offering

SECONDARY METALLURGY

Secondary metallurgy systems achieve the correct steel composition as quickly and cost

effectively as possible.

n Ladle furnace (LF)

n Vacuum degasser (VD)

n Vacuum oxygen decarburization

n Trimming/chemical heating station

n Mechanical or steam injection vacuum pumps

STEELMAKING

Integrated process automation and a robust design ensure maximum productivity with

minimum production costs. Additionally, state-of-the-art technologies minimize emissions:

n Alternating current (AC) and direct current (DC) electric arc furnace (EAF) with single

or multi-bucket charge

n Chemical-energy technology

n Scrap-preheating system

n Fume treatment and dust-collecting plant

n Material handling and additions system

Our solutions are suitable for all individual iron-input materials and combinations:

n Storage, handling and charging system for scrap/direct reduced iron (DRI)/

hot briquetted iron (HBI)

n Hot metal handling and charging system

RAW MATERIALS

AUTOMATION AND PROCESS CONTROL

SERVICE AND CONSULTING

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SEMI-FINISHED PRODUCTS

SMS Concast plant and machinery produce a wide range of steel semi-finished products:

n Stainless, bearing and spring steel (bar and wire)

n Special bar quality (SBQ) steels for tire cord, free cutting, forging etc.

n Steel for rails, seamless tubes and welded tubes

n Reinforcing steel bar

CONTINUOUS CASTING

Our continuous casting machines (CCM) pro-duce billets, blooms, rounds and beam blanks,

ranging from construction steel grades to high-quality products for high-end applications.

n Semi-continuous super-jumbo caster

n Continuous combi caster

n Continuous beam-blank caster

n Continuous bloom caster (1000 mm Ø)

n Continuous billet caster

SECONDARY METALLURGY

Secondary metallurgy systems achieve the correct steel composition as quickly and cost

effectively as possible.

n Ladle furnace (LF)

n Vacuum degasser (VD)

n Vacuum oxygen decarburization

n Trimming/chemical heating station

n Mechanical or steam injection vacuum pumps

AUTOMATION AND PROCESS CONTROL

SERVICE AND CONSULTING

MINIMILL EXPERTSIntegrated solutions for greater customer value

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ADVANTAGES

Minimills are part of the SMS group’s DNA. About 40 years ago, SMS turned the idea of a minimill into reality, and the first plants with an EAF and associated rolling mill were built. Since then, SMS minimill technology has continued to set new

benchmarks within the industry. Nowadays, the key benefits of SMS minimills include lower energy consumption, reduced costs and fewer emissions.

SMS Concast offers the full range of state-of-the-art minimill technology: from logistics solutions for handling raw materials (scrap, DRI, HBI or hot metal) to continuous casting machines using the latest equipment, such as the INVEX® mold system.

CMT™ stands for Continuous Mill Technology, and allows cast billets or blooms to be charged directly into the rolling mill, at a high temperature. This does away with the need for conventional reheating furnaces, making CMT™ crucial to more energy-efficient long product minimills. SMS Concast and SMS Meer developed CMT™ together.

SMS Concast melt-shop technologies, combined with SMS Meer rolling mills, set the benchmarks for long product minimills with capacities from 350,000 to more than 2,000,000 tons per year. Highly efficient, flexible plants around the world are testament to our expertise in minimills. We give customers a competitive edge through:

Maximum safety

Increased profitability

Care-free processes

Superior production results

Customized solutions

Ecologically sustainable

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PLANT LAYOUT (EXAMPLE)

Electric arc furnace

Ladle furnaces

Vacuum degasser

Continuous casting machine

Fume dedusting plant

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transport on rail

transport by over head crane

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TUNG HO STEEL – CONTINUOUS MILL TECHNOLOGYTM

Tung Ho Steel’s plant in Taiwan has implemented the basic minimill concept in an exemplary way, with short processing times and a direct link between the rolling mill and the steel plant. The hot billets running out of the continuous caster (with a capacity of 40 to 45 tons/hour per strand) are immediately brought to a single, uniform temperature in the inductive heating plant. Then the billets run directly into the rebar rolling mill. This means a gas or oil fired reheating furnace upstream of the rolling mill is no longer needed.

The minimill at Tung Ho is a best-practice example of groundbreaking power efficiency.

Ecoplants criteria

Ecological benefit: Emissions savings: 72,000 t CO2 p.a. 410 t So2 p.a. 225 t NOx p.a.

Economic benefit Cost reduction: 11 €/t

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REFERENCES AND PRODUCTSCompanies all over the world rely on SMS Concast

SHAGANG GROUP

Since the early 90s, SMS Concast has been a key supplier of continuous casting technology to the Shagang Group in Jiangsu province, China. The group has ordered as many as 71 casting strands for long products in various machines, all designed by SMS Concast.

JINDAL SOUTH WEST (JSW)

Thanks to the tremendous progress in high-speed casting, especially using SMS Concast’s CONVEX Technology®, JSW has achieved production rates of more than 200,000 tons per year and strand. The modern casting plant at Jindal incorpo-rates all the equipment and technology required for high-quality products: CONVEX Technology® molds, electromagnetic mold stirrers, hydraulic oscillators and Conseal IV systems.

IÇDAS

SMS Concast supplied 100 percent of the plant and machinery at the IÇDAS steel plant (Scrap-preheating, EAF, LF CCM). SMS Concast was able to meet the vast majority of IÇDAS’ requirements, including maximized rate of energy input, reduced downtime, and controlled metallurgi-cal operation through a cutting-edge automated system.

NUCOR STEEL

Nucor Steel is one of the leading steel producers in the United States. SMS Concast is proud to be its chosen supplier for all plant and machinery for EAFs, LF and the CCM.

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TUNG HO STEEL

As an up-and-coming industrial nation, Taiwan is faced with huge challenges. Oil and gas must be imported, resulting in high energy costs. Tung Ho Steel near Taipei therefore commissioned a high-performance plant with low energy consumption and minimum emissions. The solution: CMT™ technology from SMS Concast.

CONCOR™

The new cooled Concor™ strand-guiding roller developed by SMS Concast combines several benefits: space-effi-cient installation, intensive internal cooling of all critical components and lifetime lubrication. The roller comprises two innovative bearing shells and has an exceptionally long service life.

Find out more by watching our videos at http://videos.sms-concast.ch

Watch the video

Watch the video

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Reconciling sustainability with economic growth is a challenge facing almost all markets worldwide. Particularly in the metal industry, where there is a comparatively high potential for energy savings, this issue is playing an increasingly important role. The SMS group has recognized this and offers plant and machinery that give equal consideration to both aspects. Ecoplants is the new line of sustainable solutions from SMS.

ECOPLANTS Act economically, grow sustainably

ecoplants

ECONOMIC AND ECOLOGICAL

BENEFITS RECONCILED

Ecoplants reduce raw-material input, emissions and energy consumption and improve recycling quotas. These factors are examined and assessed at every reference plant. If they are satisfi ed, SMS rates the product and plant as an “ecoplants” solution – provided a further crucial condition is also met: each ecoplants solution must also offer the plant owner tangible economic benefi ts.

TRIED-AND-TESTED SOLUTIONS

The economic and ecological benefi ts of ecoplants solutions can be proven through a direct comparison with the technology that was previously in place. For many companies today, the volume of CO2 savings per year are equally as important as the cost reduc-tion per ton.

“We were able to up production, cut costs thanks to energy-efficient processes and do something for the environment at the same time. So we not only save on emis-sions, but also hard cash.”

Tim Hsu, Tung Ho Steel

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Find out more on our website: www.sms-concast.ch/en/portfolio/ecoplants.html

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SERVICEOne step ahead of the competition

SMS Concast’s business partners have long been satisfied with their plant and machinery. Not least because SMS Concast’s employees take care of plant operator’s needs across the entire lifetime of a plant, even after commissioning. SMS Concast is always on hand to provide the required service – from short-term emergency operations to regular maintenance work. And if customers wish to train their staff or need support with production, our specialists are ready to help. SMS Concast experts analyze processes and show ways in which they can be optimized.

There is always a demand for new ways to make production more reliable and profitable. That is

where the SMS Concast Service comes in, with concepts for process optimization or maintenance. And when market requirements change, our plant and machinery change with them: SMS Concast modernizes veteran plants and adapts them to current requirements. Thanks to increased produc-tivity and product quality, the customer always remains one step ahead of the competition.

ORGANIZING SPARE

PARTS PROPERLY

Spare parts must always be available to keep production downtime to a minimum. At the same time, investment and storage costs must be kept low. That’s why SMS Concast supplies wear and spare parts quickly and reliably for all stages of production, supporting customers with spare parts management. SMS Concast’s employees know exactly which parts must be stocked for which machine. SMS Concast can even handle stock-taking.

REGULAR MAINTENANCE

SAFEGUARDS EFFICIENCY

SMS Concast conducts equipment checks and performs maintenance and monitoring, either on-site at the customer’s plant or online via a remote service. SMS Concast can also assume responsibility for all maintenance services, as part of an all-inclusive, user-friendly package, upon request.

ACHIEVING MORE THROUGH

MODERNIZATION

“Plants designed for eternity” also need to be re-equipped from time to time, as markets and production processes are continuously changing. Working together with its customers, SMS Concast finds the right solution for every modernization project. This allows business partners to maintain a strong market position, even decades later.

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FIELD SERVICE FOR EMERGENCIES

Even in emergencies, customers can rely on SMS Concast Service: the technicians help with troubleshooting and repair damages quickly and easily, ensuring that the customer’s plant is up and running again as quickly as possible.

TRAINING AND SUPPORT FOR STAFF

How should plant and machinery be operated, maintained and overhauled? To help its customers find answers to these questions, SMS Concast shares its expertise. Technical procedures, methods and skills are typical areas in which SMS Concast offers workforce training. The training ensures employees are knowledgeable about every aspect, so that they can significantly contribute to their company’s success.

CONSULTING PROVIDES CERTAINTY

Whether it’s advice on a maintenance concept, consulting on processes or a feasibility study – SMS Concast helps its customers come to decisions. SMS Concast’s consultants look into the customer’s problems and develop suitable solutions. But that is only the beginning: SMS Concast can also provide support with implementing the solution.

RECYCLING MOLDS: THE

SMS CONCAST MOLD CENTER

SMS Concast’s patented manufacturing process enables it to recondition used mold tubes several times over, cost-effectively and sustainably. Casthouse operators simply collect the used molds and send them to SMS Concast, where specialists restore the hard-chromium plating of the inner surface. With the exception of plate molds, mold wall thickness remains the same over the entire life of a product. A reconditioned mold tube delivers exactly the same performance as new tubes, and has the same service life. Plant operators therefore benefit from a signifi-cant reduction in costs for wear and spare parts.

The manufacturing concept even allows for geometric changes, for example, for larger or smaller cross sections. A further benefit is that the external geometry of the tube remains unchanged. This means plant operators can easily switch formats or enlarge their product portfolio with SMS Concast mold tubes.

1818 SMS Concast sitesSMS Meer sites

CLOSE TO CUSTOMERS Think local, act global

Barueri, Brazil

Shanghai, China

Redcar, United Kingdom

Pune, India

Tarcento, Italy

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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

Barcelona, Spain Zurich, Switzerland Bangkok, Thailand

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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.

SMS Concast

Toedistrasse 9

8027 Zurich

Phone: +41 44 204 65 11

Fax: +41 44 202 81 22

sales@sms-concast.ch

www.sms-concast.chMEETING your EXPECTATIONS