the leading choice for advertising within the international
TRANSCRIPT
The leading choice for advertising within the international steel industry
M e d i a i n f o r M at i o n 2 0 1 3
www.steeltimesint.com
Message from the editor
Editorial statement:Steel Times International shows a total commitment to its editorial integrity by:tnever accepting editorial in return for advertisingtnever printing marketing as editorialtalways editing submitted articles in accordance with its basic principle of impartiality and objectivity
Steel Times International is committed to bringing its readers the latest technological, market & company developments in the steel industry via feature articles including:tSteel-focused articles from industry and academiat in-house authored articles based on contacts with & visits to the leading companies in the fieldtarticles on iron & steel manufacturing processes, company news statistics & conference reports
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Emphasis is placed on iron and steel making issues from all around the world.
www.steeltimesint.com
Steel times international is an english language journal. it contains a digest of global news, events and statistics, as well as more detailed technical articles, company and country profiles, conference reports and regular regional briefings covering USa, China, Japan, Latin america and india.
edited by dr tim Smith, a metallurgist with over 40 years of experience in the ferrous and non-ferrous industries, Steel Times International publishes eight times a year. It can trace its pedigree back to 1866 when it published as ‘The Iron and Coal Trades Review’ and subsequently as ‘Steel & Coal’ before merging with its sister publication ‘Steel Times’ in 2001.
the target readership are managers and Ceos in the steel industry, but it is also widely read by stockholders, members of research organisations, technical consultants, business consultants, economists and financiers.
in addition to its regular eight issues a year it publishes technical supplements and foreign language supplements in Chinese, russian, and Spanish for distribution in the appropriate regions, the latter in Latin america.
the Chinese language issue is translated by industrial and academic personnel in China familiar with the steel industry. it is circulated by the Metallurgical Council of China, Council for the Promotion of international trade (MC-CCPit) and is also taken to various exhibitions within China.
the russian language edition is published to coincide with distribution at the two major shows in Moscow, Litmash and Metal expo, as well as being distributed by our agent in Moscow. translation is by personnel familiar with the steel industry.
in addition, the Steel times international website at www.steeltimesint.com provides news and events updated on a regular basis and a selection of technical articles as well as details about the magazine as a downloadable media pack. for paid subscribers, a pdf version of the magazine is available on application.
For a specimen sample visit www.steeltimesint.com and click on ‘Sample Copy’ at the top of the page.
Dr Tim Smitheditor – Steel times [email protected]
6000 copies of each issue are circulated worldwide to a combination of subscribers and targeted readers of which:59% are primary iron & Steel manufacturers9% are secondary iron & Steel processors9% are Plant & equipment suppliers6% are Stockists and traders4% are non-ferrous metal manufacturers4% are end-users of steel, and7% are ‘Others’ eg financial, consultants, universities and R&D
The Geographic distribution is:45% europe24% north america17% asia6% Latin & South america8% rest of World.
Editorial Features List
Foreign Language Issues
Month Features DatesKey Events For Distribution
January/ February
Handling & Scheduling Ladle & slab carriers; cranes; identification; bundling & strapping; fork lifts; scheduling software Analysis & Testing Mechanical testing; non-destructive testing; spectrographic analysis; infra-red imaging; sample preparation; Sample tracking and reporting Conference reportsMetal expo MoscowSteel Success Strategies (europe)
editorial copy date: 16/11/2012 advertising copy date: 19/12/2012
CrU World Steel
March Continuous CastingSlab, billet & thin slab casters; metal level control; electromagnetic stirrers & brakes; mould powders; water spray cooling; bearings; caster maintenance; cut off machines; shearsFurnacesreheat; heat treatment; continuous annealing; furnace control; burners; emissionsConference reportsJSi Paris; adam Smith CiS Summit,
editorial copy date: 21/01/2013 advertising copy date: 13/02/2013
eurocoke Summit
April Electric Steelmakingelectric arc furnaces, scrap, dri & pig charging; burners; control; electrodes; refractories; gunning; flue gas analysis; water panels; power supply; transformersEnvironmentenergy use; Co2 emissions; dust collection; analysis; recycling; water treatmentConference/Expo reportsCrU World Steel; arab iron & Steel Union
editorial copy date: 22/02/2013 advertising copy date: 13/03/2013
aiStech Pittsburgh
May/June Steel Marketsautomotive, Heavy transport, Construction, Packaging, domestic appliancess, Yellow goods (JCBs etc), Shipbuilding, energy (power plant & wind turbines)AutomationLevel 0 – 4 control; PLCs; scheduling; software models; hardware
editorial copy date: 25/03/2013 advertising copy date: 01/05/2013
July/August Steel ProcessingService Centre equipment eg slitters; cut-to-length; pickling; levellers; toll servicesOxygen SteelmakingBasic oxygen steelmaking plant, on-line analysis; ferro alloys, scrap; secondary metallurgy, pretreatments eg de Sulphurisation & Phosphorus removalConference reportaiStech
editorial copy date: 15/05/2013 advertising copy date: 19/06/2013
September Rollingflat and long rolling: mills; shape control; rollsSpecial & Stainless Steelstool, high alloy; wear resistant; stainless steel; powder met; ferro-alloysConference reportSteel Success Strategies (new York)iaBr (Brasil) & MB & duluth ore Conference
editorial copy date: 08/07/2013 advertising copy date: 14/08/2013
CrU north american steel Chicago
World Steel assn
October IronmakingBlast furnace; direct reduction shaft; dr rotary; direct smelting; control; charge; sinter lines; emission control; energy; tuyere injectantsSafety & TrainingSafety equipment – protective clothing, gas monitors; ear & eye protectors; safety training programmes; on-job training; simulation
editorial copy date: 19/08/2013 advertising copy date: 18/09/2013
November/ December
Minimillseaf based long and thin slab caster mills; continuous casting; rolling; scrap, dri & pig charging; controlCoatingContinuous strip coating; galvanising; priming; painting; strip weldingConference reportCrU north americaIndex for 2013
editorial copy date: 16/09/2013 advertising copy date: 16/10/2013
JSi Paris
Issue Month Advertising copy deadline Key Events For DistributionChinese april 7 february 2013 CiSa & MC-CCPit shows
Chinese august 21 June 2013 CiSa & MC-CCPit showsRussian May 29 January 2013 adam Smith CiS
LitmashRussian September 15 May 2013 Metal expo Spanish october 15 July 2013 alacero (ex iLafa)
Annual Buyers’ Guide & Directory 2013 21 february 2013
Readership and circulation
Geographical breakdown of circulationteurope 45% tnorth america 24%tSouth east asia 17%tLatin america 6%tafrica 2%tMiddle east 1% toceana 1%tCaribbean 1%Average net circulation: 6,000 Average readership: 30,000
Readership breakdowntCeo 17% tdirector 43%texecutive 9%tManager 29%tSpecialist 2%
PLUS additional circulation of the foreign language editions:Chinese issue 5,000russian issue 6,000Spanish issue 1,50045%
24%
17%
6%
2%
1%
1%
1%
tTraditional or online the ability to maintain the traditional route to market through the printed issue or the option to utilise a number of online opportunities
tBonus distribution Bonus distribution at key industry events ensures your advertising message is exposed to even more potential prospects.
tDecision makers exposure to a large number of decision makers across the industry
tRespected in the market respected editorial and industry-leading contributors mean articles will be read alongside your advertisements
tFocused advertising Controlled advertising means that Steel times international is not deluged with vast numbers of advertisements. readers take a keener interest in the focused adverts we present to them
Reasons to advertiseFor advertisers, the Steel Times International portfolio offers an attractive mix of print and online options:
58 – May/June 2011 – Steel Times International
Furnaces
CSM as the first step towards a regenerative
flameless solution. The TRG burner is
equipped with an internal honeycomb regener-
ator which can preheat the combustion air up to
1000°C due to both its high thermal capacity
and large specific surface area.
TRG burners work in pairs with typical cycle
times of 30-40 seconds and are controlled by
automatic valves installed in the combustion air
and the flue gas ducts. Operation is:
– the first burner intakes hot flue gases
(T=1300°C) from the combustion chamber
through the cold ceramic honeycomb which
raises the honeycomb to 1200°C. Flue gases
are exhausted at 150-200°C. The gas valve
and combustion air valve are shut off.
– The second burner pair is fed with cold com-
bustion air which passes through its regener-
ator heated in the previous cycle, which rais-
es the air temperature to 1000°C. Flue gases
valves are shut off.
TRG burners are characterised by relative
high NOx emissions (~70ppm) due to the high
combustion air temperature. Some reference
data of this burner are given in Table 1 for the
combustion of natural gas.
In a furnace equipped with regenerative
burners there is no need to have a centralised
device for preheating combustion air as this is
performed by means of the regenerators
installed internally or externally on each burner.
A key component of the burner is the regener-
ator.
Two types of regenerators are mainly used on
the burners for the steel industry:
– Honeycomb regenerators; and
– Ceramic ball regenerators.
The differences of these two are not only
related to the shape of the regenerator media,
but also to the chemical composition of the
material and to the requirements for use.
It is necessary to select the best solution of
the form of the regenerator according to the
type of furnace, the type of fuel, the furnace
atmosphere, etc. For this reason Tenova uses
both types for its regenerative burners.
FlexyTech Flameless Regenerative
burnersThe TRGX burner was realised in 2006 when
Tenova decided to integrate flameless technolo-
gy with regenerative combustion to obtain a
burner which is able to guarantee reduction of
both emissions and energy consumption.
The TRGX FlexyTech Flameless
Regenerative burners represent the latest gen-
eration of regenerative burners; they can work
both in flame mode (for cold ignition) and
flameless mode (for best performance in term
of lowering NOx emissions). Thanks to cou-
pled gas and air staging, when working in
flameless mode, NOx emissions are brought
down to 35-40ppm.
Honeycomb regenerators allow a very high
preheating efficiency due to both their high
thermal capacity and high specific surface area
while keeping a very compact geometry. In con-
trast, ball regenerators use alumina balls which
provide better access and easier cleaning of the
regenerative media. Therefore the ball solution
is more suitable when the furnace atmosphere
is particularly dirty which would obstruct the
honeycomb channels after a short period of
operation. But the option using balls makes for
a much bulkier and heavier regenerator than
the honeycomb.As with all regenerative burners, the TRGX
burners work in pairs: when one is firing and
ture of 450°C. The TSN burner capability
includes both a cold start up function (ie with
pilot flame) and low NOx operation (with high
impulse jet). Its geometry was developed in a
way to delay as long as possible the mixing of
fuel and air. In this way the products of com-
bustion can dilute the O2 available in the com-
bustion air, reducing the temperature peak gen-
erated in traditional burners. The experience
obtained with TSN allowed Tenova to start the
new and more ambitious TSX project in 2004
with the aim of developing a natural gas side
burner with the following characteristics:
– NOx emissions below 40ppm at 3% O2 in
dry flue gases;
– Ultra-low CO emissions (below 5ppm);
– No valves on hot air for air staging;
– Least excess air operation for maximum fuel
efficiency;– NOx emissions not affected by air tempera-
ture;– NOx emissions independent of turn-down;
– Air preheating up to 550°C.
Flameless technology was the basis of TSX
burner development and it has been successful-
ly employed in association with highly preheat-
ed combustion air while maintaining low NOx
values, adding exceptional heat transfer unifor-
mity as well as relevant improvements in the
uniformity of the charge temperature.
All of the TSX project goals were reached
through extensive CFD modelling and industri-
al tests. Several thousand Tenova FlexyTech
flameless burners are now installed on reheat-
ing and heat treatment furnaces across the
world.
Regenerative burners
The development of the TRG regenerative
burner was started in 1999 in cooperation with
Fig 2 (Left) Roadmap for Tenova FlexyTech combustion technologyFig 3 Development timeline for Tenova FlexyTech® burners
Fig 5 A pair of TRGX burner prototypes (1.5MW each) working in
flame (left) and flameless mode (right)
Fig 4 Velocity fields in the FlexyTech TRGX CFD model
TS TSN TSX TRX TLX
TRGX
TRG
Flame
RegenerativeFlame
RegenerativeFlame & Flameless
Dilutedflame
Flame &Flameless
Flame &Flameless
20022003
2006
2004-2005 2005-2006
Flame &Flameless
OngoingR&D
Projects
OngoingR&D
Projects
129122116110103979084777164585245393226191360
TENOVA FLEX2_Layout 1 5/23/11 12:38 PM Page 2
52 – May/June 2011 – Steel Times International
Company profile
MMK invited Steel Times International tovisit its works in Magnitogorsk to see theresults of its $5bn investment over thepast five years which includes a 5m wideplate mill, a new caster, a cold mill com-plex including galvanising and colourcoating line and improved environmentalprotection. An additional $2.1bn hasbeen invested in a new mill in Turkey tosupply the Middle East market and$0.5bn in the Belon coal mine. By Alex Gurov*
100% of the scrap needs of the Group).Minerals complete the picture with Belon (a4.2Mt/y coal mine), Prioskolsky GOK (workinga 2bnt iron ore deposit over the next 50 years tomeet MMK’s steel production needs) andMMK has a long-term agreement with iron oresupplier ENRC of Kazakhstan to cover 70% ofits needs until 2017. The MMK Group's revenue in 2010 totalledUS$7.719bn, EBITDA was $1.606bn, and theprofit for the period $232M. Investments in 2010MMK’s dynamic growth stems from the contin-uing modernisation of the its production assets,adoption of its technology, implementation ofmany promising projects and integration intothe global economy.MKK’s investment strategy is for a ‘high-return from high-quality projects’ and it usesequipment from world leading engineeringcompanies, including SMS Siemag, Danieli,Fata Hunter, Fives Stein and others. MMK’slong-term modernisation programme is aimedat satisfying the growing demand and require-ments of Russian customers and raising thelevel of production of value added products.About $5bn of investment has been spent onthis over the past five years at the Magnitogorsksite plus $2.1bn at a new mill in Turkey and$0.5bn to upgrade the Belon coal mine.
Wide PlatePlate Mill 5000 and Continuous Caster No6are currently the key investment projects to
grow the company’s presence in the domesticmarket. A contract for the supply of equipmentwas signed with SMS Siemag in November2006 and the Mill was put on stream in July2009. The mill is designed to produce heavy-gaugeplate of strength class up to X120 and up to4800mm wide for oil and gas pipelines andshipbuilding and bridge building. Mill 5000 produces about 1.5Mt/y, including0.3Mt/y of heat treated plate. In 2010 the millreached full capacity and currently runs at100% utilisation rate. Plate is supplied toChelyabinsk (ChTPZ), Volzhsky (TMK) andVyksa (OMK) pipe plants with about equal vol-umes of 110kt per month to make large diame-ter line-pipe for such applications as Gazprom’soil and gas pipeline projects. MMK’s plates account for about 43% of totalRussia needs for large diameter pipe producerswhich is currently about 50kt per month.Another large-scale investment project near-ing finalisation is a new cold rolling complex(Mill 2000) supplied by SMS Siemag as aturnkey project.
This 2Mt/y facility will turn out high-strengthsteels for manufacturing exposed and internalautomobile parts, household appliances andconstruction materials. The rolling mill and pickling line will be com-missioned in July 2011, while full-cycle produc-tion at the facility will be commissioned by mid-2012. The old Hot Strip Mill 2500 is also beingrevamped.
THE birth of the MMK Works took place on 1of February 1932 when the first tap of pig ironfrom blast furnace N1 was carried out. Twoyears later rolling mill ‘500’ started up – a500mm wide blooming/plate mill which workeduntil 2006 during which time it rolled 54Mt ofproduct – giving rise to the legendary integrat-ed Russian steel works ‘Magnitka’ and, along-side it the city of Magnitogorsk grew. Today, mill500 has gone to the SMS museum in Germanywhile two stands from mills 300 and 250replaced in 2005 by wider modern mills fromDanieli stand as industrial sculptures in the cityof Magnitogorsk.
Russian steel leaderMagnitogorsk Iron and Steel Works today ranksamong the world’s largest steelmakers.Producing 11.4Mt of crude steel in 2010,MMK is one of Russia’s largest fully integratedsteel producers occupying about 120km2 ofland. At Q1 2011 MMK produced 17.7% of thesteel products sold on the Russian market. In2010 MMK’s share of this market averaged17.3%, with the next closest Russian steel com-panies, Severstal and NLMK taking 17% and15%, respectively.MMK is the number one producer in thedomestic market of hot rolled steel (37%), gal-vanized flat products (27%) and tin plate(100%). It ranks second for rolled sections(47%) and third for cold-rolled strip (22%) andcolour coated flat products (25%).Historically, the bulk of MMK’s productshave been sold to customers in the Urals (37%)and the Volga Regions (30%) which todayaccount for two thirds of MMK’s sales. MMK’skey domestic customers have traditionally beenpipe makers (37% of all domestic sales in2010), machine builders (13%), construction(11%) and metalware producers (10%).MKK’s success largely became possiblethanks to the adoption of many high-marginproducts to meet domestic demand, includingthose which replaced imports. The share ofvalue-added products in 2010 was 38% (up 7%on 2009).
The company’s products are sold to 60 coun-tries worldwide. In 2010 exports were 3.2Mt or31.2% of total shipments of which hot rolledsteel accounted for 79%. MMK’s traditional keymarkets are the Middle East (about 15% of totalproduction), Asia (6%) and Europe (but exportsto Europe incur $50-60/t in transport costs.The MMK Group includes the MMK Iron &Steelworks, MMK-Atakas (Turkey), MMKMetiz (a hardware producer making 450kt in2010), Intercos-IV (a metals service centre in StPetersburg) and Profit (a company supplying
MMK – The revival of a legendary Russian works in Magnitogorsk
*Steel Times International, Moscow
Magnitogorsk Iron and Steel Works ranks among the world's largest steel producers
producing 11.4Mt of crude steel in 2010
MMK Group production figures in 2010– Crude steel reached 11.419Mt, 19% higher y-o-y. – Finished steel products amounted to 10.4Mt (+18%). – The share of higher value-added products (HVA) of the MMK Group grew to 38% (compared to
31% in 2009) and in Q4 2010 it reached an historical level of 42%. – Production of iron ore for its own needs amounted to 4.680Mt (+18%).
MMK_Layout 1 5/10/11 2:33 PM Page 1
22 – May/June 2011 – Steel Times International
Ironmaking
Coal based DRI quality and raw materials:
Experiences at Bhushan Steel
reductant at its works in the state of Orissa,
India. The plant and machinery has been sup-
plied by the former Lurgi company of Germany
(this SLRN technology now being owned by
Outotec of Finland). Similar to other coal
based DRI plants, Bhushan controls its process
performance and product quality by controlling
the input materials. This paper summarises
observations regarding the dependence of DRI
quality on the physical characteristics of the
input materials.The monthly plant data was analysed to see
the influence of ore and coal quality parameters
on the quality of DRI produced.
Raw Materials The raw materials required for coal based DRI
production are iron ore and non-coking coal
and dolomite for sulphur capture.
Iron OreThe DR process involves the removal of oxygen
in the solid state thus concentrating any impu-
rities in the oxide (ore) feed. DRI containing a
high level of gangue has adverse effects during
subsequent melting in electric furnaces by
affecting flux power and increasing refractory
consumption during steelmaking. High gangue
in the DRI also results in increased slag vol-
umes, poses handling problem and adversely
affects furnace productivity. Hence the gangue
content of ore should be minimal and the iron
content as high as possible. The process
requires adequate reducibility and resistance to
degradation during reduction. Hence the pre-
ferred iron ore is haematite with a Fe content of
62-66% and having low gangue and decrepitat-
ing characteristics. Size is an important charac-
teristic as this determines the retention time for
complete reduction of a particular ore feed.
During the early days of operations at
Bhushan the iron ore was washed in a scrubber
and sized to 5-20mm for use. Presently thanks
to a better understanding of the process, it has
become standard practice to use +5 to
+18mm ore size as feed and the scrubbing to
wash the ore has been suspended.
CoalNon-coking coal is used both as reductant and
BHUSHAN Steel is operating eight DRI kilns
using coal as the reductant to feed its EAF, IF
and Conarc units on site. The plant has made
remarkable improvements as regards to DRI
quality since its start-up in 2006. The perform-
ance of the kilns has been improved by optimis-
ing the ore and coal size feed. The dependence of conventional blast fur-
nace ironmaking on metallurgical coke and
scarce availability of the required grade of coal
for coke production in India makes it necessary
to search for alternative ironmaking technolo-
gies. Thus direct reduction has increasingly
become an important means of iron production
in the world with over 60Mt produced in 2010
or 6.6% of output of world iron. In this process, reduction is carried out below
the melting point of the iron and gangue mate-
rials using gas or coal as the reducing agent. The
products from such processes are called Direct
Reduced Iron (DRI) or sponge iron after its
porous appearance. The DRI retains the origi-
nal external shape of the lump ore or pellet
charged. Reduction decreases the weight by approxi-
mately 30% due to the removal of oxygen and
the apparent density of the sponge is in the
order of 4.4g/cc compared with 7.8gm/cc for
solid iron. The pores occupy about 54% of the
volume. Coal produced DRI contains up to
about 90% metallic iron, typically 1-4% carbon
along with any gangue from the ore consisting
mainly of alumina and silica. Bhushan Steel is operating eight DRI rotat-
ing kilns each of 500t/day capacity using coal as
The particle size of the ore and coal are
the most important parameters in the
quality of DRI produced in a coal fired
DRI kiln although the LOI is also impor-
tant as this loss improves the reducibility
of the ore by making it more porous. The
iron content of the ore is less important
although a high gangue content or high
ash content of the coal is undesirable
because of the additional energy penalty
is causes in both DRI production and
subsequent melting to produce steel.
By U S Yadav,* Ajay Jha** and
A K Verma***
*Asst Vice President, **Deputy General Manager, ***Chief Operating Officer, Bhushan Steel Ltd Angul, Orissa, India
Bhushan Steel is operating eight coal fired DRI kilns each of 500t/day capacity
Met
allis
atio
n,
%
Met
allis
atio
n,
%
FeO
,%
Fig 1 Inter relation between FeO content in
DRI and metallisation
Fig 3 Influence of iron content on FeO
content of DRIFig 2 Influence of iron content in ore on
metallisation
yadi coal_Layout 1 5/24/11 9:48 AM Page 1
00 – May/June 2011 – Steel Times International
USA Update
Sales of plate are rising rapidly in USAlargely due to increased demand fromrail car manufacturers following a growing number of rail freightmovements as the US pulls further out of recession. By Manik Mehta, New York
of steel plate rose to as high as $1080 per shortton at one point. Contrary to the expectations of some indus-try pundits, who had thought that the risingcurve in prices of steel plate would halt andthen decline, demand in the railcar industry hastriggered a sharp rise in prices which would alsokeep the order books of suppliers full, at least,in the short term.
The latest report by the Association ofAmerican Railroads, the trade organisation of
THE economic recovery combined with risingdomestic shipments of all kinds of productsthrough the rail mode of transportation, is pos-itively impacting demand for certain steel sup-plies. As demand for freight railcars grows, theneed for steel to manufacture railcars alsogrows. Experts say between 18 and 20 tons ofsteel, mostly plate, are required for each railcar.Industry analysts maintain that the freightrailcar market has buoyed the US plate demandbut has also led to price increases. Indeed, therailcar industry is emerging as one of the majorsteel plate consuming industry segments. Prices
the US freight railway industry, reported thatthere was a 7.9% increase in freight carload vol-ume – this excluded grain and coal – to 4.6 mil-lion rail cars in the first quarter of the year,compared to the previous-year period. This isan extension of the rise in demand that startedin the final quarter of last year and continuedinto 2011. This trend also marks a reversal of the rail-road industry’s fortunes. The 2010 fiscal yearbrought in change for the railroad industry after
Steel industry to benefit fromdemand for freight railcars
A 7.9% increase in freight carload volume is buoying US plate demand for new railcars
USA copy_Layout 1 5/10/11 10:19 AM Page 1
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