arvedi esp details

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Cremona, 9thOctober 2013

cciaieria rvedi Sp

Presentation for

Industri ll

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The ArvediGroup produces and processes about 4 million tpy of steel products,has a turnover of about 2.2 billion and about 2600 employees.

The steelmaking assets are composed of six manufacturing companies:

Hot rolled pickled and galvanized

steel coils

Black, galvanized and coated

carbon steel welded tubes

Cold drawn carbon steel tubes

Stainless steel welded tubes

Cold rolling of stainless steel

precision strip

Welded and cold drawn carbon

steel tubes

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INDEX

1 ACCIAIERIA ARVEDI WORKS, CREMONA

2 ARVEDI ISP ESP PROCESS AND COSTS

3 ENERGY CONSUMPTION

4 ARVEDI ESP PRODUCTS AND QUALITY

5 THE VALUE OF ARVEDI TECHNOLOGY

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Acciaieria Arvedi Cremona works

Total area : 750,000 m2

Covered area : 150,000 m2

1Melt shop no. 1

2I.S.P. Line

3Melt shop no. 2 (CONSTEEL)

4New E.S.P. Line

5Pickling Line no.16Pickling Line no.2 (Push-Pull)

7Hot dip galvanizing no.1

8Pickling Line no. 3 with Tandemcold rolling mill (2010)

9Hot dip galvanizing no. 2 (2011)

1 2

3

4

5

6

7

89

1.1

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Heat size: 250 tonnesConveyor CONSTEEL: width 2.6 m; total length 105 mShell: 8.5 m diameter (E.B.T.)Transformer: 190 MVA-ACElectrodes Diameter: 700 mm

ESP Melt Shop Consteel EAF

1.2

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Continuous caster

1.3

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THE HOT ROLLING CARBON STEEL MILLS

ESPin operation since 2009

Yearly Capacity: 2.5 mtonnes

Max width: 1570 mm

Thickness range: from 0.80mm up to 12 mm

ISPin operation since 1992

Yearly Capacity: 1.2 mtonnes

Max width: 1260 mm

Thickness range: from 1.00 mm up to 12 mm

1.4

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PRODUCT RANGE

Hot rolled black coilsHot rolled pickled coils

Hot dip galvanized coils

1.5

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FOCUS ON ENDLESS STRIP PRODUCTIONThe new challenge

HRM

Finishing Mill

Steel Grade Thickness range (HR)

DD12 0.8010.00 mm

S235 JR 0.85 12.00 mm

S355 JR 1.80 12.00 mm

S315 MC 1.00 12.00 mm

S355 MC 1.20 12.00 mm

S420 MC 1.20 10.00 mm

S700 MC 1.80 8.00 mm

DP 600 1.20 5.00 mm

DP 1000 1.50 5.00 mm

Main advantages

Tailor-made coil weight

Tailor-made coil

Close thickness tolerances

Arvedi HRC can compete with and

replace CR strip

180 m

1.6

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INDEX






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Arvedi ISP technology is the first in the world to achieve cast-rolling thedirect connection of casting and pre-rolling.

The presence of the Cremona Box, which acts as a buffer, was necessary since

the mass flow achievable in the 1990s in the casting phase was not sufficient to

directly and continuously feed the finishing mill.

It compacts in a single cycle, without semi-finished products and intermediate

handling, the casting and rolling phases.

In only 180 metres it transforms the liquid steel into coils down to 1.0 mm which

traditional processes can achieve only through cold rolling.

Operating since 1992

2.1

THE ARVEDI ISP PROCESS

Arvedi ISP

Casting and pre-rolling (HRM) Cremona BoxFinishing Mill

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Arvedi developed ESP technology, a second-generation plant deriving from

ISP, 15 years after the start-up of ISP and after intense study and applied

research.

ESP is a totally continuous process (an absolute novelty), further reduces

strip thickness, further improves operating costs and lowers the investment

per product unit.

The continuous process became reality thanks to the increase in casting

productivity now sufficient to continuously feed the finishing mill.

Development is towards increasing compact cycles, towards further energy

saving, passing on the competitive advantage to the processing industries

downstream.

THE DEVELOPMENT OF ISP GENERATED ESP

2.2

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Casting Platform

Thin-SlabCaster

High-Reduction Mill

PendulumShear

Plate PusherAnd Piler

CropShear

Inductive EqualizationFurnace

High-PressureDescaler

Finishing Mill

Crop Shear

Cooling Line

High-SpeedFlying Shear

Downcoilers

ARVEDI ESP Endless Strip Production

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ESP A DIRECT EVOLUTION FROM ISP

ISP

ESP

Considerable plant downscaling: the liquid steel is processed in a single cycle and without

interruption in a space of 180-190m against the 800-1200 m of conventional plants (which

are also divided into distinct cycles) and the over 400 m of rival technologies.

Batch system of the finishing mill Endless system along the whole line

Significant energy saving Even higher energy saving

Lower Opex and Capex Even lower Opex and Capex

High quality product and thin gauges Improved quality for some products

(1-1.5 mm) which cannot be be produced and even thinner gauges (0.8-1 mm)

on conventional hot rolling mills

Highly flexible and able to provide a rapid time-to-market service, including just-in-time

ESPISP

2.4

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ESP LINE FROM THE LADLE TO THE FINISHED COIL

250 tonnes ofliquid steel

in 180 mbecome

Hot rolledcoils

2.5

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PROCESS COMPARISON

Standard Thin Slab Casting and Rolling Line

430 m

Mould 55- 65mm

F1

Roller Hearth Furnace

300 m F6

12.0 - 1.2 (1.0)mm

14 m

concept with potential

concept with limiting aspects

Mould 90 mm

Arvedi ESP Line

IH

HRM

12.0 0.8mm

FM

6.7 m

Flying

shear

190 m

2.6

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6

8

10

13

0

5

10

15

20

Thick 1.5 mm Thick 1.2 mm Thick 1 mm (Thick 0.8 mmexpected)

%

16

18

20

24

0

5

10

15

20

25

30

Thick 1.5 mm Thick 1.2 mm Thick 1 mm (Thick 0.8 mmexpected)

%

THIN GAUGE SOFT STEELS THIN GAUGE HSLA STEELS

ESP THIN GAUGE EXTRA PRICE

2.7

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PROCESSING COST

Arvedi ESP simplifies downstream Cold Rolling

ESP hot rolled thin strip has a surface quality, dimensional precision and internal

structure allowing cold rolling to the minimum industrial gauge of 0.20 mm using fewer

rolling passes than the conventional tandem cold rolling process.

In this way a considerable reduction in investment costs is obtained with a remarkable

saving in processing costs.

From 0.8 1.2 mm hot rolled mild steel down to 0.7 0.20 mm cold rolled full hard in

a single passage through only 3 cold rolling stands, without annealing, ready for

galvanizing

CONTINUOUSPICKLING LINE

COLD ROLLING 0.20 / 0.7 mmC.R.C. FULL HARDH.R.C. 0.8/ 1.2 mm

0.20/ 0.7 mmC.R.C.

GALVANIZED

GALVANIZING

LINE

2.8

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INDEX






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ENERGY CONSUMPTION COMPARISONFROM LIQUID STTEL TO 1-mm HOT ROLLED COIL

ESP vs. Conventional Process

TotalCasting and rolling 1

Pickling 1-mm HRC 1.0 mm(3-mm HRC)

ESP KOEKWh/tonne 130 20 4 36 2 186 34,8

m3CH4 0 2.5 0 2.05 2,1

Total KWh 130 44 36 210 36,8

Cold rolling +pickling

CONVENTIONALKWh/tonne 95 10 80 185 34,6

m3CH4 263 2.05 35 63,5 52,1

Total KWh 345 34 416 795 86,7

1 m3CH4 = KWh 9.6

1) Average consumption for 3-mm HRC (80 mm at 6 m/min) 1 KWh electr. = 0,187 KOE

2) Additional consumption to produce 1-mm HRC 1 m3of CH4= 0,82 KOE

3) 100% charge at 600C4) Pickling and skinpass

3.1

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Energy consumption for HRC production,

thickness 2 mm and width 1500 mm,

at a production rate of 330 t/h,

is

131.6 kWh/tonne

TV SD Industrie Service GmbH- Germany

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DECREASE IN ENERGY CONSUMPTION WITH INCREASE

IN CASTING SPEED (1500x3-mm strip)

3.3

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ENERGY COMPARISON OF VARIOUS HOT ROLLED COIL

PRODUCTION TECHNOLOGIES

3.4

Sources: *) VdEh paper, **) SMS paper, ***) Nucor publication

0

100

200

300

400

500

Conv. casting andHSM 20C *)

Conv. casting andHSM 600C *)

Arvedi ESP CSP cast and roll1200C**)

CSP real operations***)

fuel gas

electricity

caster

EnergyConsumptio

n[kWh/t]

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INDEX






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ARVEDI ESP PRODUCTS

Steel Mix A full range of steel grades from low to

high carbon including HSLA (up to 800

MPa), multi phase and TRIP, silicon steel

(3 %) and stainless steel

ATG Thin gauges in substitution of cold rolled products:

0.8 1.2 mm for mild and HSLA

steel up to 420 MPa yield

1.5 2.0 mm for HSLA from 550 to

700 MPa yield1.2 mm for DP 600

4.1

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ESP PRODUCT (1st half 2013)

HSLA 21%HS construction 10%

DP 2%

Corten & high Carbon 2%

Soft Steel Si-free thin gauges 60%

Construction steel 2%Construction steel Si-free 3%

< 1.25 mm 19%

1.26 to 1.6 mm 26%

1.6 to 2.05 mm 22%

2.06 to 8 mm 33%

STEEL GRADES

4.2

< 1.25 mm

19%

1.26 to 1.6 mm

26%1.61 to 2.05 mm

15%

2.06 to 8 mm

33%

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Structure Homogeneous and fine grain structure, absence of central

segregation, high degree of cleanness (K4


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Start up Performance May 2010

-0.20000

-0.15000

-0.10000

-0.05000

0.00000

0.05000

0.10000

0.15000

0.20000

0 0.5 1 1.5 2 2.5 3 3.5 4

Deviation[mm]

Hot Strip Standard

Cold Strip Standard

ESP Values

Narrow Cold Strip Standard

Mean Value

Standard Deviation

Automotive Standard

Thickness [mm]

ESP PRODUCT GAUGE TOLERANCE

Arvedi ESP HRC tolerance is well within the cold rolled automotive standard

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1 mm Endless Rolling Low Carbon

329330334

403410 407

3031 31

11 11 11200

250

300

350

400

450

500

0 1 2 3 4

[MPa]

0

10

20

30

40

50

60

70

80

90

100

Al%,

G

ASTM

ReL Rm A% Grain Size

CenterHead Tail

ESP PRODUCT

MECHANICAL PROPERTIES AND STRUCTURE

Mechanical values and grain structure along the strip are extremely consistent

4.5

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ESP PRODUCT THICKNESS CROSS/LENGTH PROFILE

4.6

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Arvedi Thin Gauge (ATG) - hot rolled strip that can replace cold rolled material

Dimensional values are given for HR coil produced at Acciaieria Arvedi in endless mode

Gauge and flatness

In the following table the dimensional tolerances guaranteed on a hot rolled coil in gauge 1-1.2 mm are compared

with standard UNI EN 10131 for cold rolled.

Crown

The maximum crown value,measured 25 mm from the edge, is 0.03 mmindicating a flat transversal value.

Roughness

The typical roughness values observed on hot rolled coils in gauges 1 - 1.2 mm, pickled and skinpassed:

The surface quality is guaranteed on both sides top and bottom

Allowing ATG to enter the msurface finish class (normal; 0.6 < Ra < 1.9 m) as per standard UNI EN 10130 for

cold rolled strip.

THICKNESS FLATNESS

UNI EN 10131 tolerances ATG tolerances UNI EN 10131 ATGAfter S.P.

normal 0.09 mm close 0.07 mm guaranteed 0.05mm 5 mm 4 mm

Skinpass roll finish Average roughness Ra ( m)

Sand blasted rolls 0.90 - 1.20

A.T.G. ARVEDI THIN GAUGE

4.7

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INDEX






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5.1

ARVEDI AND THE ENVIRONMENT

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TECHNOLOGY COMPATIBLE WITH THE ENVIRONMENT

Considerable energy savings are obtained up to 58% - by fully

exploiting the energy of the liquid steel, simplifying or eliminating

the rolling and annealing relative to the cold rolling process

The impact on the environment is lower thanks to lower energy

consumption, smaller works and fewer emissions of greenhouse

gases

The new ESP process technology meets the requirements

expressed in the Kyoto protocol

5.2

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Lower direct and indirect emissions of greenhouse and noxious

gases (NOx and CO), amounting to:

- 40-50% on normal gauges

- 65-70% on thin gauges

Fully respecting the objectives of the Kyoto protocolLower water consumption: reduced to 50% of the best conventional

mills.

The considerable descaling of the production works with

dimensions up to 10 times smaller than those of traditional

steelmaking centres

renders

Arvedi ISP ESP steelmaking activity compatible with all social and

environmental contexts

Strictly linked to low energy consumption are:

ESP ENVIRONMENTAL PERFORMANCE

5.3

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5.4

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Thank you for your attention.

Federico Mazzolari

Marketing Consultant

Tel. +39 0372 535232

E-mail: [email protected]

Finarvedi SpA

Piazza Lodi, 7

26100 CremonaItaly

38
mailto:[email protected]:[email protected]

arvedi esp details

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