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IRON & STEEL REVIEW

April 2009

Indications of recovery in Indian steel industry

SAIL aims higher sales target for FY’10
Steel Authority of India, according to the recent reports have set lofty sales target for itself in the current financial year of 2009-10, by deciding upon to go for huge production of around 12mt of saleable steel. Speaking to the press, the company said that the production plan was formalized through signing the MoU for 2009-10 with the Ministry of Steel recently at the Udyog Bhawan, which focuses upon the production of higher volume of value-added steel products of over 3mt tones to meet the growing requirements of highend user segment.

CDE bags $1 million repeat order from Adhunik Metaliks for Iron Ore Washing Plant ...
After the success of the first CDE installation at their Rourkela plant, Adhunik Metaliks - one of India's largest steel producers has placed a repeat order for their Jamshedpur plant. This order is a result of the impressive results in reduced Alumina and Silica levels and a higher Fe content achieved in their ore through CDE's Iron Ore Washing plant. The washing plant installed at Adhunik's Rourkela plant, has successfully washed about 2 Lakh tons of low grade ore and this washed ore has been effectively utilised for their DRI & Sinter plant. Utilisation of low grade ore by applying the washing process significantly helped Adhunik in sourcing the Iron Ore from various mines in Barbil-Joda, Koira region which was otherwise dependant on very few mines who could provide the required high grade ore for their Kilns. Moreover, feeding of washed ore with comparatively less Alumina, Silica ensures better productivity and improved campaign life in their kiln.

VIEWPOINT
With the general elections in the country slowly getting momentum day after day and the stock markets again on the rise, there is also a percolating flow of good news for the entire Indian steel fraternity at the moment. A revival in demand is foreseen in the near term in the Indian steel sector, according to the recent reports, which is so far battling hard to acquire the lost grip and girth in the domestic as well as in the international market arena. If the Indian steel sector is recovering in real terms, is the million dollar question now.

COMPANY PROFILE
Wire Rod Mill - Servosteel EP 100 Plus & EP 220 Plus
Wire Rod Mill in an integrated steel plant produces wire rods in plain rounds and rebar. The mill is a high speed 4 stand continuous mill. The feedstock is rolled billet. The billets are heated in the walking beam furnace to a high temperature of 1200C and discharge into the group of stand 1 of the roughing mill area. A 4 stand billet switch is provided to fit the 4 stands one by one of the rolling groove of stand 1. A hydraulic pendulum shear is used for sharing purposes. A high pressure de scalar is used for removing the scales from the billets with the help of high pressure water jet. The heated billet pass through the roughing mill area and then intermediate mill area and finally enter into the finishing mill area of the rolling machines. The rolled rods are then formed into a coil by the laying head and cooled by passing through cooling beds. The coils are then compacted and tied in compactors which is ready for supply.

COMPANY NEWS
GEA IHE Systems India:
The GEA Group (Global Engineering Alliance) headquartered in Bochum, Germany, is a globally successful technology group with more than 250 companies in 50 countries.
As a company of GEA Group AG, GEA IHE Systems India is part of the Process Equipment Division. Within this division the company belongs to the GEA IHE Systems, which is an association of GEA companies with focus on industrial heat exchangers. For decades GEA IHE Systems has been one of the leading manufacturers of components for the energy and propulsion industry worldwide.

JSPL braves dark times on a powerful ride with power & long products
Economic development of any nation is associated with the industrial development where rapid industrialization forms the backbone for industrial development. Rapid industrialization is possible only when all its supporting pillars such as steel, automobiles, infrastructure and power sectors simultaneously show strong signs of development. Power sector serves to be the most important pillar as it is the principal indicator of strong infrastructure activities and it is the most essential fuel required by the industries across the globe for smooth running of the production. Rightfully, today world’s most powerful economies – both developed and developing – are marked by the massive development of their power sector. India is no exception and in the country too, special thrust has always been given to the power sector since the commencement of the Five Year planning period.

Increase yield, improve quality and reduce maintenance – the key to success for steel makers
The AGELLIS Group provides real-time measurement systems for the metals industry based on both electromagnetic and microwave technologies. The Electromagnetic systems include the unique EMLI T Tundish Level Measurement System which gives the user true steel running level in their tundish irrespective of amounts of slag and an accurate drain level which allows the operator to safely cast more of the remaining steel in the tundish at the end of a sequence. Sensors are mounted in continuous casting tundishes covering the full height, in order to maintain correct running level and steel pressure head. This system will help to improve quality in the casting process and control the drain level to optimize yield.

Laser solutions for highest accuracy & reliability
At the AISTech 2009 Annual Conference, LAP will present new inline laser measurement systems which increase the share of dimensionally accurate material and improve process security as well as customer satisfaction.

SPECIAL FEATURE
Indian HR & CR Coil Industry – An Overview
Steel is the most widely used material worldwide – next only to paper and concrete. Steel is also most recycled material and every new steel product contains recycled steel. Per capita consumption of steel is taken as an index of the economic development of a country since steel is a basic material for any development activity – be it infrastructure, housing, transportation or capital goods. The per capita consumption of finished steel in India stands at one of the lowest in the world at about 50 kg compared to the global average of 197 kg. Finished steel production is usually divided into two categories viz. Non- Flat products and Flat products. In the total consumption of flat products in India, HR coils / sheets and CR coils/sheets have a major share.

FOCUS
An Advanced High-Strength Steel family car
Steel is reinventing itself to provide signifi cant automotive performance advantages at little or no additional cost to automotive manufacturers or consumers. New grades of Advanced High-Strength Steel (AHSS) provide lighter optimised body designs for improved vehicle crashworthiness, improved fuel economy and reduced total greenhouse gas emissions (GHGs).

Steel and raw materials
The extraction, transport and production of raw materials for steelmaking have an impact on the environment. Efficient use of these natural resources is critical to the sustainability of the steel industry. Steel’s most important contribution to conserving natural resources is its lightweight potential, durability and 100% recyclability

Modernization of hot strip mill of Bokaro Steel Plant
Bokaro Steel Plant was commissioned in 1972, with an initial capacity of 1.7 MT of crude steel production. The plant has been subsequently expanded to its present capacity of 4.36 MT of crude steel production. The main products are hot rolled plates, sheets and coils, cold rolled sheets and coils, galvanized sheets, plan and corrugated and black plates.
Sponge iron faces fall in price as recession plays havoc in manufacturing activities
In the face of economic turmoil, where the recession has cast its evil eye over all the manufacturing activities, persistent fall in demand has lead to a decline in the price of sponge iron of late. According to the industry sources, the prices of sponge iron has plunged to nearly 10% quoting its price to Rs13,000 per tonne compared to Rs15,000. Speaking on this regard, Amitabh Mudgal, Vice President, Monnet Ispat said in his statement to the media that, the fall in the price of sponge iron was a result of combination of factors including an ongoing sluggish trend in manufacturing industries.

STEEL TECHNOLOGY
Using Temperature to Stabilize Coil Coating Processes
Virtually all coaters understand the problems that temperature variations cause in the coating process. In the case of coil coating operations, temperature related viscosity variations can result in significant quality issues with film build, color match, surface finish, etc. The magnitude of these issue cause most coaters to undertake procedures to adjust coating material viscosity in an attempt to control their process. This paper examines the relationship between temperature, viscosity and process variations and addresses many of the associated issues, with the goal of establishing how the implementation of a carefully designed temperature control system can significantly improve quality while reducing operating costs.

An overview on scab, hole & pipe lamination defects in flat steel products: cause & remedy
Surface defects play a major role in distorting the features and characteristics of the flat steel products making them unsuitable for specific application requirements. These are generated at different stages of steel processing that include steel making, casting, hot rolling and cold rolling. It is absolutely necessary to identify the type of defects that are generated, analyze the reasons for their occurrence and implement the measures for their elimination. Today, a plethora of tools like visual, macro and micro level analysis through application of advanced techniques are available to identify the possible cause of the defect and pinpoint the stage of steel processing where the defects have originated. The continuous developments in steel processing and the advent of sophisticated inspection facilities are paving towards minimal defect occurrence in the finished steel products.
Industrial applications of shape memory alloys
In 1970, the first successful demonstration of a shape memory alloy Cryofit tube coupling took place on a U.S. Navy F-14 fighter aircraft. Since that beginning there have been many thousands of patents issued for every conceivable application for shape memory alloys.
The major applications for these alloys are in the field of medicine and orthodontics, with a few other areas of significance such as eyeglass frames, cellular phone antennas, women’s brassiere underwires and automotive devices.
“Variable speed direct hydraulic drive applications and its recent technical developments for the mining and bulk material handling industry for various applications”
The continuously operating Mining industry has always placed a high demand on equipment reliability, productivity, efficiency and performance. In today’s competitive market place these demands are of even more interest. Electro - mechanical drives have in the past been the traditional drive in this industry when variable speed has been called for. Today the Hydraulic Direct Drive solution can in many cases be an alternative to the electro-mechanical drives (see Fig. 1). The hydraulic drives has proved to be a real alternative on applications where Load sharing is essential and in applications where high starting torque is needed and flexible productivity at various capacity needed without sacrificing efficiency using modular flexibility. Hydraulic drives are used in many applications with increased reliability (popularity) and reduced maintenance. Hydraulic direct drives utilise standard components and are very easy to install on the driven machine shaft without the need of gear reducers or foundation.
New ways to make plate part I – attributes of outstanding plate mills
In terms of motor name-plate ratings and the loads and torques applied to the workpiece, plate mills are the most powerful metalworking machines in all of industry. In terms of technical sophistication, though, the plate mill is not so obviously supreme.
This is true even if we confine the comparison to the processes of the steel industry. Plate mills never need to be as fast as rod mills, nor as precise in their dimensional control as strip mills, nor are they as complex in their roll pass design as section mills.

STEEL INTERNATIONAL
Largest Blast Furnace in India blown in at JSW Steel Ltd
In February 2009, blast furnace No. 3, which had been installed in the Toranagallu steelworks of the Indian company JSW Steel Ltd. and had been equipped by Siemens VAI Metals Technologies, was commissioned successfully. With an internal volume of over 4,019 cubic meters and a nominal annual capacity of 2.8 million metric tons of iron, it is the largest blast furnace existing in India today. This increases the production capacity of JSW Steel at Vijayanagar works to around seven million metric tons of steel per year. A cyclone separator developed by Siemens VAI is being used for the first time to clean the top gas in Toranagallu. This solution makes it possible to flexibly control the efficiency of dedusting and, as a result, to maximize the recovery of dust containing iron and avoid an excessive concentration of zinc or other heavy elements in the recycled dust.

CAKE OVEN
Introduction of modern equipment in Indian coke oven plants
In the recent years a trend has set in India to modernize the equipment of Coke Oven plants during their reconstruction. Also the green field projects under execution and those to be finalized stipulate such equipment.
While our company Bhilai Engineering Corporation (BEC) had designed and supplied modern equipment to all the areas of steel plants, this paper deals with Coke Oven area – Servicing Machines, other equipment and equipment of Coke Dry Cooling Plant. Modern features of the equipment – several introduced by BEC for the first time in India are enumerated.

REFRACTORY
Present economic crisis and some new thoughts on the research, development and applications for the refractories in the next decade
The current world economic environment is turbulent and frightening. This has come from a consequential irrational exuberance, a dash of greed and failure to acknowledge the complexities of over-clever financial instruments. To understand this crisis and also to face the challenges of this uncertain world let me start with the story of “BLACK SWAN”. Before Australia was discovered it was believed that all Swans are white as there was no evidence of any other kinds of Swan in our Hemisphere. The Dutch explorer ‘Willem De Vlamingh first discovered in the area which is now Perth in the western Australia in the 17th century the Black Swan. First they did not believe their eyes as Swans were by definition white. The Black Swan phenomena is principally concerned with the problems of uncertainty and knowledge.

ROLL GRINDERS
Tenova Pomini Roll grinders “Made in Italy” technology success
Tenova Pomini`s strategy for the supply of roll shop grinding systems revolves around the development of in-house technology rather than buying it in. In doing this it takes complete responsibility for all activities connected to the design, engineering and development of the software managing machine automation. This approach is linked to the strategic decision to address our production towards the high-end of the market, developing complete automated roll shops as well as automated grinders. Tenova Pomini’s effective approach to innovation, allowing extremely rapid transfer of ideas and new solutions to industrial production, is a key source of competitiveness. Its success lies in close cooperation between the three technical offices (mechanical, automation and software) and the interdisciplinary nature of the R&D operations coordinated by the roll shop plant design office, with its strong focus on innovation.

STEEL INDUSTRY
Motors in the steel industry
International steel markets are changing. Over the past few years, the global steel industry has experienced a growth rate which is unprecedented in its history. Steel is still in great demand throughout the world. This fact alone means that there is a boom in the field of rolling mill technology, especially for thick sheet, hot and cold rolling mills, so that project enquiries to plant constructors, and as a result to component suppliers are continually increasing. In the growth markets of China and India, as well as Brazil and Russia, there is a great demand for drive components.

FACE TO FACE
A firewall against the crisis
In spite of the economic crisis, Herwig Haunschmid, the vatron CEO, sees opportunities through innovation. His company offers precisely what is needed when the heat is on. Namely, process optimisation and enhanced quality in combination with simultaneous resource conservation. Herwig Haunschmid is convinced that crises also represent chances. A thesis that he intends to prove with vatron.

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