NEWSa pubblication for our valuable customers worldwideJune 2011 - n.4

Contents

the events of the last 24 months have had a profound impact on all the world economies. In steelmaking and mining, the industries directly served by Tenova, the response to the crisis has seen Asia and South America lead the way down the path to recovery. This has had a direct impact on new plant investments,

where, at global level, the strongest demand is for advanced technologies to improve end

product quality, cut energy consumption and improve environmental impact. Tenova is

responding to the positive prospects offered by the market by maximizing innovation

and, at the same time, enhancing its focus on on-going direct contact with customers

all over the world in order to provide optimal, high-performance solutions for specific

requirements.

Today, a key Tenova strength is the added value offered by a worldwide network of 33

companies and a global-local market approach: by combining direct communication

with customers with the opportunities offered by a major multinational group, entry on

to the different regional markets is facilitated.

tenova, the added value of the global-loCal approaCh

>>>

Gianluigi Nova, Tenova CEO.

a teChnologies

3

5

8

12

14

R&D, the advantages of the network

The benefits of Consteel Evolution

iRecovery and EFSOP, technologies that care for the environment

Pomini Tenova builds a new roll grinder for cluster mills

Tenova I2S focuses on high performance control and automation

b China

16

18

Consteel breaks records in China

Advanced technology wins another record line order

C india

20

22

24

26

Indias strategic role in the Tenova network

Industrial furnaces, a leadership position for Tenova Hypertherm

Sail Bokaro chooses Tenova technology

Tenova TAkRAF focuses on the cement industry

d new realizations

28

33

The success of the Thyssen Alabama project

Tenova Hyl to build the worlds largest direct reduction module

e mining

36 Global Mining: new successes at Tenova TAkRAF

f tenova in the world

40 New frontiers for the Tenova network

44 news

47 events

editorial2 3

This issue of Tenova News attempts to

illustrate this approach with concrete

examples, looking at the most important

projects completed over the past few

months.

One instance is the completion of the

TkS Alabama project, where a consortium

formed by Tenova lOI Italimpianti and

Pomini Tenova with SMS Demag has

constructed the new Thyssenkrupp

production center in Calvert (Alabama),

a facility consolidating the customers

presence on the NAFTA market. The

newly opened Tenova commercial offices

in Vietnam and the Tenova TAkRAF

operating office in Beijing testify to the

constant attention Tenova pays to the Far

East, continuing a strategy introduced

more than ten years ago.

Consteel Evolution and Re-Energy, who

recently became fully paid-up members

of the product portfolio, highlight the

unrivalled expertise Tenova offers in

integrating contiguous technologies for

solutions that advance the frontier of

innovation and environmental protection.

These are strengths the market recognizes

and appreciates, as witnessed by an

important Chinese customers recent

choice of Tenova insoluble anode

electrolytic tinning technology, the cleanest

and best performing technology on the

market. Tenova is to supply two tinning

lines and two electrolytic chromium

coating lines for a new 13 million t/y cold

rolling plant under construction in the

Chinese province of Hubei.

Advanced production performance and

important reductions in greenhouse gas

emissions are also the key to the latest

success in the USA of the direct reduction

technology developed by Tenova Hyl,

who is to supply a 2.5 million t/y DRI

module, the largest ever built to date,

to a new factory in louisiana. All over

the world, the Tenova commitment to

innovation has a constant focus: to deliver

a rapid response to customer needs with

high-profile solutions. technological innovation, with an offer of cutting-edge solutions to raise productivity and reduce the environmental impact of production processes, is proving to be a key growth driver for industrial plant suppliers, both on consolidated Western markets and on markets resuming growth in the Far East and

South America. The speed of the investment upturn varies from region to region, but

in every area the fastest growing market sectors are niches with a higher technology

content. And the preference is for technologies guaranteeing an immediate return in

terms of productivity or cost reductions. In this scenario Tenova looks to the future

as the player offering the broadest and most complete range of new technologies for

steelmaking and the mining industry. Tenova R&D director Carlo Raggio explains: Although investments were shrinking, we stayed in close contact with our customers

and the market. This enabled us to focus our development work to address new

requirements, often relating to energy savings and lower environmental impact, and

the concrete results we have achieved are now part of our product portfolio. The

cross-fertilization generated by the involvement of and cooperation among all the

Tenova Business Areas has helped us cut time-to-market for our R&D projects and,

at the same time, has fuelled development of integrated solutions combining and

enhancing the specific value of adjoining technologies.

r&d, the advantages of the network

teChnologies

Carlo Raggio, Tenova R&D Director.

Ever closer cooperation ties among the Business Areas. R&D projects in partnership with customers. Innovative solutions integrating adjoining technologies. With its network of technology companies covering all the different processes in steelmaking and mining, the Tenova R&D pipeline is able to respond fast to new market requirements.

Bucket Wheel Excavator supplied by Tenova TAkRAF in operation in an open cast mine.

View of an Electric Arc Furnace during the tapping phase.

teChnologies4 teChnologies 5

Plenty of examples could be mentioned,

beginning with the enhancement of

the Consteel process thanks to the

integration of Tenova Goodfellow

know-how in off-gas control systems

and Tenova lOI Italimpianti expertise

in latest-generation burners. Consteel

Evolution raises furnace productivity

without increasing electrical power

consumption. The process can also be

coupled with the technology of the Re

Energy subsidiary to recover a significant

portion of the heat generated by the

furnace and produce steam for industrial

applications.

The expansion of Tenovas network

of companies and its consequent

technological growth in the last few years

has provided an important stimulus for

R&D work. Synergies are not confined

to sales and marketing, but also involve

the networks production units around

the world and development of products

combining different technologies. For

example, the acquisition of Tenova I2S,

a specialist in highly automated cold

rolling mills for special applications,

has completed the offer of the Strip

Processing business unit, with the result

that today Tenova is able to supply the

entire technological process for strip cold

rolling and processing. Tenovas offer

also includes roll grinders, where Pomini

Tenova recently presented an innovative

wheel moving grinder for small-diameter

rolls used in cluster mills for cold rolling

of stainless steel strip. For this product,

Pomini Tenova and Tenova I2S are already

developing a joint promotions strategy for

packages comprising rolling mills and

grinders or automated roll shops.

Tenova adopts a similar approach to

innovation in mining, where Tenova

TAkRAF designs and supplies open-

cast mining equipment and bulk

handling systems. The challenge for

TAkRAF is to reconcile increasingly

demanding productivity requirements

with the reliability needed in the

extreme conditions in which mining

plants have to operate, Raggio explains.

The development of these huge mobile

machines, with lengths of up to 100

meters, heights of 50 meters and weights

normally up 4,000 t, goes hand in hand

with continuous improvements in operator

safety and environmental protection,

for example by cutting dust dispersal or

replacing wheel-based transportation

between the mine and stockpile areas

with automated bulk handling systems.

Completely new mobile mining systems

especially for In-Pit Crushing have been

developed. TAkRAF mining know-how

also complements the expertise of Tenova

Pyromet, a specialist in the design and

construction of submerged arc furnaces

for ferroalloys and non-ferrous ore

processing.

the benefits of Consteel evolution The new scrap charge reheating system realizes the full potential of Consteel thanks to use of the chemical energy from the furnace off-gas and recovery of the heat lost during the process.

f ourty plants: a worldwide reference that confirms the leadership of Consteel as an innovative technology for the electric

furnace meltdown process. A leadership

established thanks to the reliability

of the system and its production and

environmental performance, the result

of continuous research and development

work integrating Tenova know-how over

the entire steelmaking spectrum. This

drive for innovation has now produced

Consteel Evolution, a new system that

realizes the full potential of Consteel

by deploying Tenovas latest expertise in

the area of scrap charge reheating, use

of the chemical energy from the furnace

off-gas and recovery of the heat lost

during the process.

Compared with the traditional system,

Consteel Evolution separates the scrap

charge loading and pre-heating tunnel

into two sections. The first section is

equipped with high-efficiency burners

developed jointly with Tenova lOI

Italimpianti, which speed up the pre-

heating phase and keep it thermally

separate from the EAF process.

As a result the scrap quickly reaches

a higher temperature than with a

conventional Consteel system. The

second section, immediately adjoining

the furnace, channels the rising off-gas.

savings and performanCe Compared to a traditional eaf and Consteel

RefeRence Top chaRge eaf

consTeel consTeel evoluTionTM

Avg. preheating temp. c.a 250 C c.a. 500 C

Specific productivity t/h/MW 2.0 2.5 +25% 3.0 +50%

Scrap charge yield 90% 91.5% +1.5% 91.5% +1.5%

Electric energy kWh/t 395 345 -50 295 -100

Natural gas (total) Nm3/t 7.0 0.5 -6.5 7.0 0.0

Electrodes kg/t 1.20 1.12 -7% 0.95 -20%

Delta transformation cost /t -11.0 -15.0

Steam condenser of the iRecovery system at Georgsmarienhtte plant.

teChnologies6 7

The Tenova Goodfellow EFSOP off-

gas analysis and control system operates

in this second section, maximizing

post-combustion of residual carbon

monoxide.

This subdivision improves stabilization

of the thermal flow: in the section where

the off-gas mixes with the fumes from

the pre-heating burners, the temperature

and available energy are constant with

respect to both a traditional EAF and

the conventional Consteel system,

thereby creating the ideal operating

conditions for implementation of a Re

Energy residual heat recovery system.

The main strength of Consteel

Evolution is the sharp reduction in

power consumption, which translates

into a significant increase in the plants

specific productivity, says Mauro Bianchi Ferri, Tenova Metal Making Marketing & Sales Vice President.

A normal modern EAF, charged from

scrap baskets through the roof, produces

no more than two tons of steel per hour

per installed MW. Data from operating

Consteel systems reflect specific

productivity of 2.5 tons/hour, while our

simulations for Consteel Evolution

indicate increased specific productivity

up to 3 tons/hour per available MW,

a 50% improvement with respect to a

traditional EAF. Other advantages are

the reduction of harmful emissions,

thanks to the stable high temperature

of the off-gas, and the possibility to

recover a significant portion of residual

heat, thereby raising the overall energy

efficiency of the process.

Although four Tenova operating units

and the Centro Sviluppo Materiali

(CSM), our Research Centre partner,

have been working on Consteel

Evolution in recent months, the

development project was kept strictly

under wraps until July 2010, when all

the international patents protecting the

process know-how were registered. The

start-up of the promotional campaign

has already elicited a positive market

response, especially in areas where

electric power is more expensive, like

Japan and Europe.

Without doubt our customers are aware

of the potential of the new version,

adds Bianchi Ferri. The system offers

the greatest benefits for medium/large

plants, where the savings on electricity

bills for the same production volumes

are particularly attractive. Moreover,

Consteel systems can be upgraded to

the Evolution version by a revamp of

the preheating tunnel, so the investment

outlay is limited and the production

stoppage for the plant conversion is kept

to a minimum.Simulations for Consteel Evolution indicate increased specific productivity up to 3 tons/hour/MW, a 50% improvement with respect to a traditional EAF

Consteel Evolution technology: view of the complete process.

TENOVA

GOODFELLOW

RE ENERG Y

teChnologies 9

ireCovery and efsop, teChnologies that Care for the environment The optimization of the overall energy balance of the EAF reduces energy consumption and greenhouse gas emissions, without limiting the productive performance.

s teel production in an electric arc furnace (EAF) is an energy-intensive and, as far as traditional furnaces are concerned, a quite

inefficient process. Almost 50% of the

global energy, deployed in the process in

the form of electrical or chemical energy

and used for melting, is lost into the

atmosphere in the form of heat, together

with significant amounts of greenhouse

gases (GHG). Technology providers have

been working for years to improve EAF

energy efficiency, but now steelmakers

are pressing even more for systems that

effectively cut energy consumption and

GHG emissions without limiting furnace

performance and productivity. Tenova

is meeting the challenge, says Tenova

Metal Making Marketing and Sales Vice

President Mauro Bianchi Ferri, with an approach designed to optimize the

overall energy balance: A good 70% of

energy lost during the melting process is

due to the process off-gas, in the form

of unused heat and chemical energy.

Tenova Goodfellows EFSOP technology

enables steelmakers to keep the meltdown

process under constant control in order

to optimize the chemical energy used and

thereby reduce the global energy in the

furnace. At the same time, a significant

portion of lost heat associated with the

off-gas can also be recovered, for example

to produce industrial steam or electrical

energy with a co-generation plant. This

is the goal of iRecovery technology the process developed by Tenova Re Energy,

the new group company in Dsseldorf,

which specializes in engineering and

construction of heat recovery systems,

not only for the steel industry but for all

energy-intensive industrial processes.

Through continuous, dynamic

measurement of off-gas, the EFSOP

system enables real-time intervention in

the process in order to optimize use of

chemical energy. Data from operating

plants indicates that in an EAF with an

annual production capacity of 1 million

tons, reduction of electric power through

the EFSOP system is approximately 14

Steam drums and collectors in the Georgsmarienhtte EAF cooling tower.

Integration of EFSOP and i Recovery technology permits recovery of up to 25% of total energy supplied to the EAF

sCheme of 2-stage heat reCovery for an eaf

sTeaM ouTTakesTeaM ouTTake

feed waTeR

ciRculaTing puMpssTeaM-waTeR-Mix

elecTRic aRc fuRnace

Max 1.500-1.800c

ecs wasTe gas ducT

sTeaM dRuM wasTe heaT boileR

~ 600c

~ 200c

pRessuRized waTeR aT boiling poinT, i.e. 220c

teChnology10 11

kWh per ton of steel produced, while

GHG emissions fall by 18%. When

EFSOP is combined with iRecovery technology, the energy and environmental

benefits are even greater. Integration of

the two systems permits recovery of up to

25% of total energy supplied to the EAF

and 50% of energy that would otherwise

be lost as heat in the atmosphere,

Bianchi Ferri explains. For example, a

furnace with 80 MW nominal power

can recover approximately 15 thermal

MW in the form of steam, which can

be used in the steel plants production

processes, for instance for the vacuum

degassing plant, or to power a turbine

generator, or in a district heating system

in urban areas close to industrial sites.

iRecovery is based on heat exchangers using water at high pressure (15-40 bar)

and accumulation tanks that compensate

for heat interruptions between meltdown

cycles. In stable operating conditions,

a 140 t/h EAF guarantees continuous

production of 20 t/h of steam; thanks

to heat recovery, further reductions in

overall GHG emissions are possible.

It is no coincidence that some countries

are already introducing incentives to

shorten amortization on heat recovery

plants, which today is ranging between 4

to 6 years, adds Bianchi Ferri. In Canada,

for example, the Province of Ontario is

introducing a program for large energy

users which funds electricity production

projects based on heat recovery.

In other countries, similar incentives

are being developed to turn recovery

technology into a concrete, immediate

industrial option for energy-intensive

industries.

average efsop operating results in global markets

% decrease (average)

Electrical Consumption 3,3

Oxygen Consumption 1,0

Natural Gas Consumtion 14,0

Charge Carbon Consumption 28,3

Injected Carbon Consumption 9,5

Power ON Time 2,9

% increase (average)

Productivity 5,2

Yield 0,7

ToTal aveRage savings (us$/Ton) 2,2

Tenova iRecovery transferring 14 bar steam to a plants steam network.

Performance Parameter Improvement over 40 Running EFSOP installed on EAF.

teChnologies 13

pomini tenova builds a new roll grinder for Cluster millsCompletely designed by the technical department of Pomini Tenova, the new roll grinder achieves superior performance to conventional machines.

a n entirely new concept in high-performance grinders, developed with an engineering approach that kept time-to-market to

a minimum: with the new MW479,

Pomini Tenova is aiming to set a new

benchmark in grinders for the small rolls

employed by cluster mills used mainly

to roll ultra-thin stainless steel strip.

The introduction of the new model in

its production range will enable Pomini

Tenova to enhance its references in this

particular sector which accounts for

almost 10% of the entire roll grinder

market where it also has significant

potential technological and commercial

synergies with Tenova I2S, a primary

player in cold rolling mills. In order

to address the needs and expectations

of the most advanced and demanding

cluster mill users, weve decided to

target the market with a completely

innovative machine, right from the basic

idea, says Pomini Tenova Senior Vice-

President Paolo Gaboardi. The MW479 is a moving wheel roll

grinder for cluster mills, a solution

that delivers superior performance

and marks a major advance in terms

of ease of operation and maintenance

requirements, which have been

minimized through a modern, rational

design approach. Three patents have

already been registered to protect the

engineering solutions used to apply the

technology to the new machine. The

development project involved the entire

Pomini Tenova Technical Office, whose

engineering work focused on a series of

basic concepts, such as the moving wheel

solution, a self-bearing structure to cut

erection time, automated operation and

extensive use of standard components

to maximize interchangeability and

simplify maintenance work. A decisive

contribution to the project came from

the insights and expertise of Thomas

Anderson, a widely experienced project

engineer and today head of Pomini

Tenova Nordic. Each new solution was

carefully analyzed and corroborated

with brainstorming sessions and

analyses by the entire project team and

independent consultants. Use of state-

of-the-art design software, such as Finite

Element solid Modeling with CAD 3D,

substantially reduced development

time for the prototype on which the

final function tests and fine tuning

mw479 teChniCal dataMaximum diameter that can be ground with a new wheel of 610mm 250 mm

Maximum distance between centres 2500 mm

Wheel motor power 15 kW

to optimize performance under any

operating conditions are currently being

completed. Confirming Pomini Tenovas

credibility and reputation for reliability,

five key customers have already chosen

the new grinder, and a total of eleven

machines have already been sold, to be

delivered over the next six months.

The MW479 roll grinder under assembly in the Pomini Tenova factory, Castellanza, Italy.Five customers have already chosen the new roll

grinder, for a total of eleven machines already sold

teChnologies 15

tenova i2s foCuses on high performanCe Control and automationThe Field Programmable Gate Array is state of the art technology for full real-time control of the cold rolling process.

t echnological innovation applied to automation and control of the rolling process is the foundation on which Tenova I2S has

established its acknowledged leadership

in high-performance cold rolling mills.

Beginning in the 1970s, the company has

applied the know-how built up through

intensive in-house R&D work to develop

new hardware platforms and software

packages that enable important advances

in machine operating performance

and end product quality. Progress has

been particularly significant in the area

of rolled strip thickness and flatness,

where steelmakers require ever tighter

tolerances. Since the early 1980s,

Tenova I2S rolling mills have employed

high performance Automatic Gauge

Control (AGC) systems, which control

the thickness of the material being rolled

through precise regulation of the inter-

roll distance, rolling force, coil tension

and rolling speed. The value of the AGC

system is confirmed by the more than

350 systems installed to date around the

world. Now, the possibilities offered by

latest-generation software and hardware

have enabled new developments to meet

growing market demand for operating

flexibility and superior end-product

quality. The result is Field Programmable

Gate Array technology (FPGA): based on

an innovative hardware/software platform

developed by Tenova I2S, which provides

real-time management of the AGC system

and all control equipment associated with

the mill, to adapt the rolling process to

meet specific operating requirements. The

hardware platform is fully configurable

and able to interface with any Master

controller used on the mill in order to

optimize rolling operations. Today, the

FPGA AGC system is the technological

heart of the new high-speed cluster mills

developed by Tenova I2S for rolling very

thin stainless steel and special alloy strip

down to 0.02 millimeters, used in hi-tech

industry applications. The first several

systems of this type installed to date

have met with the full satisfaction of the

customers, outperforming expectations

for production and quality requirements.

The FPGA system is the technological heart of the new high-speed cluster mills developed by Tenova I2S for rolling very thin stainless steel

FPGA internal architecture and component arrangement.

Main control pulpit of Tenova I2S ZR22B-52 Sendzimir Mill.

Hierarchical block diagram illustration of the typical AGC systems network topology, components and their interconnections.

pRogRaMMableinTeRconnecT

logic blocks

i/o blocks

high levelsysTeMs

coMMunicaTions & conTRol neTwoRk

daTabaseseRveRs

dRivesysTeM

cooRdinaToR

gaugingsysTeM

supeRvisoR

MasTeRconTRolling

plc

opeRaToRsTaTion

agcs hMiuseR inTeRface

Tenova i2s - agc sysTeM

Tenova i2s - agc Real-TiMe conTRolleR

coRe 2 duo pRocessoR

coRe # 1Real-TiMe opeRaTing sysTeM

coRe # 2windows xp pRo

acg conTRol

cylindeRconTRol

gaugeinTeRface

TachinTeRface

encodeR inTeRfacefpga

seRvo conTRolfpga

seRvo conTRol

& feedbackTension TRiMfoR Roll gapcoMpensaTion

wRapcounTing

enTRyTensionconTRol

Thicknessgauge

woRk Rollspeed

MaTeRial flow

Roll foRcecylindeRs

sTRipTachoMeTeR

opcseRveR

hMipackage

Thick

ne

ssM

easu

Re

Me

nT

spe

ed

/le

ng

ThM

easu

Re

Me

nT

16 17

tenova is to construct the biggest Melting Unit ever built in China for MCC Beris Jiangsu Heavey Industry Corporation - Feida Group. The plant will be located in Jiangsu province, an industrial area near Shanghai which is home to Chinas most advanced production facilities. It will be equipped

with a Consteel plant and a 250 t/h EAF feeding a continuous casting unit for

slab production. We have now installed at least ten Consteel furnaces in China,

but none as big as this one, says Giuliano Fanutti, Area Sales Manager for China and South East Asia. Chen Jie, Business Development Manager for Metal Making, China, notes that: The customer originally intended to install two smaller production

units, with locally made equipment. But after conducting a thorough technical study,

they decided our proposal of a single bigger plant would be more advantageous,

permitting greater flexibility thanks to the continuous charging possibilities offered

by Consteel, the fact that, overall, the structure would take up less space and, above

all, optimization of production costs and environmental friendship. The plant will

become operational in the second half of 2011, and its construction has brought

together all Tenovas top technological experts in Italy and China. The process and the

engineering were perfected in Milan, says Guido Molteni, Vice General Manager of Tenova China. Some high-tech components, particularly those linked with

automation, came from Italy, but the metal and structural parts, which make up about

Consteel breaks reCords in China

China

The new plant, with a capacity of 250 mt/h of steel, will be built in Jiangsu province, near Shanghai, one of Chinas most advanced industry parks.

80 percent of the supply, were built by

Tenova Timec in China. This solution not

only enabled us to optimize construction

costs while maintaining a very high level

of quality, but permitted us to save time

and cut shipping costs. One of the keys to

the success of the project is that Tenovas

advanced technology prevailed over local

suppliers offers, in a highly competitive

economic context. On the Chinese

market, adds Giuliano Fanutti, there are

customers who are very conscious of the

quality of their equipment and interested

in investing in technologies offering

performance levels that bring benefits

for production in terms of dependability,

quality, cost containment and decreased

environmental impact. I think these are

the reasons why Beris and the Feida

Group chose Tenova to make this plant.

The project will also be a very important

reference, opening up good prospects for

the future. The size and characteristics

of the project are already attracting a lot

of interest among major local producers,

concludes Guido Molteni, including

those who initially didnt even take into

consideration the benefits offered by

our technology, which combines furnace

and Consteel to permit unprecedented

flexibility in operations and production

capacity.

The impressive Consteel system installed at Acciaieria Arvedi, Cremona, Italy. Similar equipment will be provided to the plant in China.

Started from 1997 Tenova has installed 11 Consteel systems in China, out of 40 installations in the world, a tangible proof of the great operational flexibility and versatility of the technology that is well appreciated in the Country.

Consteel systems in China: 14 years of Continuous suCCess

feicheng

xining

wuxi

ezhou

guiyang

shaoguan

Tonghua

shizuishan

danyang

Jiaxing

anshan

19China

advanCed teChnology wins another reCord line order The largest order ever awarded to Tenova Strip Processing is for construction of 4 high-speed lines.

t enova Strip Processing was awarded an order for four high-speed lines two insoluble-anode electrolytic tinning lines and two

electrolytic chrome plating lines for

Three Gorges Quan Tong Colored and

Galvanized Plate Co. China. The four

hi-tech lines Tenova shall be installing

will be used to produce materials of

superior quality which will be one of the

most advanced and distinctive features

of the plant, whose annual production

capacity will be 13 million metric tons.

The Tenova lines will produce tin- or

chrome-plated steel and are designed

for 1,250 mm wide strip at thicknesses

between 0.14 and 0.55 mm, with an

entry speed of 450 m/minute and an exit

speed of 600 m/minute. Insoluble-anode

technology is the key to the Tenova tinning

process, explains Giovanni Gallarati, Tenova Strip Processing Marketing &

Sales Director, It delivers excellent

performance while minimizing operating

costs and environmental impact, and

enables a degree of tin coating control

impossible with traditional technology.

We were certainly chosen on the strength

of our references in this sector.

Tenova has installed more than 40

tinning lines to date, including eight

lines in the past eight years, of which

six in China alone. The plants built

in Spain for Arcelol-Mittar, in Turkey

for Erdemir and in China for Dajing

Metal Co. Jiangsu provided significant

evidence of the quality and performance

of Tenova electrolytic plating. This will

unquestionably be an important order,

2 eleCtrolytiC tinning lines (psa eleCtrolyte)2 eleCtrolytiC Chromium Coating lines

teChnologiCal features in eleCtrolytiC tinning lines

Material to be processed Cold rolled annealed and tempered low carbon steel

final use Cans and packaging

strip dimensions Thickness 0.140.55 mm - Width 10001250 mm

line performances Entry/Exit 600 mpm - Line Speed 450 mpm

in terms of both plant engineering and

construction, adds Gallarati.

We shall be making use of all the skills

and production expertise of the Tenova

network. The electrolytic cells will be

built by Tenova Timec in China, the

tension levelers by Pomini Tenova in

Italy and the thickness gauges will be

produced by Tenova I2S in the USA.

In selecting Tenova Strip Processing

lines for its high-quality production, the

customer has chosen the most advanced

technology on the market. This order

confirms the importance of Tenova

on-going investment in research and

innovation. It also demonstrates that

cutting-edge technology is a vital strategic

element to attract emerging producers as

well as established manufacturers and

to succeed on the highly competitive

Chinese market.

Vertical looper tower of a Tinning line.

production capacity 100.000 350.000 t/y

Material to be processed Cold rolled annealed and tempered low carbon steel

final use Cans and packaging

strip dimensions Thickness 0,1 0,6 mmWidth 465 1,400 mm

line performances Entry/Exit sectionSpeed up to 700 m/minProcess speed up to 600 m/min

Electrolytic Tinning Lines have always been a key business activity for Tenova as well as an important research and process development area. On the right, the general technical data of Tenova Strip Processing Electrolytic Tinning Lines.

20 21

having come through the 2009 crisis relatively unscathed, the Indian economy is once again growing fast. In 2010 Indias GDP rose by 8.6%, the highest increment of the past three years and one of the largest at world level. The countrys key economic sectors are all working to meet the growth

challenge, generated so far not by exports as in other emerging countries, but by rising

domestic demand and important investment in infrastructures. So the Indian economy

will continue to progress at a rapid pace during the next few years, with very favorable

prospects for heavy industry in general and for steel in particular. Analysts expect Indias

steel production to expand by 7% in 2011 and subsequently to maintain significant

growth rates, with the result that by 2015 India will be the worlds second-largest

steelmaker, preceded only by China and outranking the USA and Japan. This level of

expansion will require massive investment to boost the countrys annual production

capacity, which will have to more than double from todays 70 million metric tons.

Investment not only by domestic producers, but also by the top international steel

groups. India offers very favorable conditions for heavy industry and mining, with

plentiful resources of iron, coal and other ores.

In this positive scenario Tenova is investing heavily to strengthen its operations: since

2008 it has increased its workforce in India from 15 to 420 people, employed by

four operating companies. Its main locations are in the Mumbai area, with Tenova

indias strategiC role in the tenova network

india

Indias steel industry capacities will increase significantly in next five years. Tenova operates with four companies in this strongly expanding market.

Multiform and Tenova Hypertherm,

in Chennai with Tenova TAkRAF and

in kolkata with Tenova lOI Wesman.

Tenovas strong local roots and well

distributed geographical base enable it to

maintain very close ties with customers

and the local markets and to respond

faster to needs and requirements on a

rapidly expanding market. In fact, India

accounts for approximately 10% of Tenova

global revenues, and is expected to grow

further, achieving a leading position

in our backlog. yet Indias importance

inside the Tenova global network is not

limited to the contracts acquired and

the potential of the local market. The

presence of highly qualified engineers

and the widespread use of English have

enabled the local operating companies to

create engineering hubs providing high-

profile design and executive engineering

expertise for the entire Tenova system.

A further demonstration of the growing

importance of the Indian subcontinent

within the Tenova network.

The Indian market contributes around 10% of the global revenue of Tenova

Tenova took part in the eighth edition of MMMM (Minerals, Metals, Metallurgy and Materials), the most important Conference & Exhibition in India for the steel industry and all related technologies. Tenova presented its brand, companies and the full range of products and solutions to the key people in the Indian steel industry.

tenova at mmmm eXhibition

23india

industrial furnaCes, a leadership position for tenova hyperthermThe Indian company, a brand of Tenova LOI Italimpianti, has a 60% share of the reheating furnace market and is a key player in the current expansion of new plant investments, driven by rising demand for high-quality steel products.

in parallel with the rapid expansion of the Indian steel industry, the industrial furnace market is enjoying a period of growth, with hi-tech plant

suppliers at the forefront of the trend.

According to official estimates, Indian

demand for steel will continue to grow

until at least 2016, at an average annual

rate of 10%. Demand for steel products

will grow at a particularly fast pace at

the high end of the market, targeting

top-grade products for sophisticated

applications in automotives and

mechanics. Consequently, production

investments are putting priority on plant

and equipment with a higher technology

content, able to deliver end products

offering greater quality and reliability.

In industrial furnaces, key components

of the steel-making process, Tenova

Hypertherm leads the reheating market

with a 60% share, thanks to its local

roots and access to the technologies

developed by Tenova lOI Italimpianti.

The Mumbai office is an important hub

in the Tenova lOI Italimpianti global

production network. Tenova Hypertherm

has established strong permanent ties

with all the top steelmakers in India and

during 2010 acquired an important series

of supply contracts of significant value

in terms of equipment and technology.

key orders placed during the year

include an order for a roller furnace for

the second line of CSP of Bhushan Steel

&Power, to join the furnaces supplied

previously. In May, through Tenova

Hypertherm, Tenova lOI Italimpianti

signed a contract to supply a 60 t/h

reheating furnace to kalyani Gerdau

Steels, a Company in Brazils Gerdau

group. Other important acquisitions

in 2010 were a contract with the Steel

Authority of India (SAIl), Indias

leading steelmaker, for a 225 t/h walking

beam furnace for flat products, to be

installed in the Roukela Steel factory,

and a turnkey contract with Bhushan

Steel ltd. India for a 300 t/h walking

beam furnace.

The positive trend in new orders

continues this year: in January a contract

was signed for the revamping of a 300

t/h walking beam furnace for Tata Steel

India. India will continue to be the

Tenova lOI Italimpianti core market

over the next few years, with annual

investments in reheating furnaces

expected to rise rapidly from the current

50 million euro to approximately 100

million euro in five years time.

The state companies controlled by

SAIl Bokaro Steel, Bhilai Steel and

NMD Steel have introduced the

most ambitious growth programs, with

projects to revamp existing lines as well

as install new plants. Meanwhile, all

the main Indian producers led by Tata

Steel and POSCO have planned an

investment program in Orissa State. An

exciting outlook for Tenova Hypertherm,

which continues to invest in know-how

and specialized resources in order to take

advantage of every new opportunity.

200 t/h Walking Beam furnace supplied to JSW, India.

In industrial furnaces Tenova Hypertherm leads the reheating market with a 60% share

25india

sail bokaro Chooses tenova teChnologyPomini Tenova and Tenova Strip Processing will supply an automatic Roll Shop and an Inspection and Recoiling Line for SAIL Bokaro plant expansion.

t enova will help expand the plant in Bokaro Steel City (Jharkhand State, India), one of the biggest productive units controlled by the Steel

Authority of India (SAIl), the countrys

public sector steel company.

Pomini Tenova will supply an automatic

Roll Shop, while Tenova Strip Processing

will supply an Inspection and Recoiling

line for carbon steel strip. The two

Tenova plants will equip a new cold

rolling mill which will produce 1.2

million tons of high quality carbon steel

strip a year, destined primarily for the

automotive industry. These are the first

two contracts Tenova has acquired from

SAIl. The project is a valuable reference

in a market as important as India. The

negotiations were complicated, but the

features of the Roll Shop meet all of the

customers very strict requirements, say

Paolo Gaboardi, Senior Vice President of Pomini Tenova, and Niraj Kumar, Pomini Tenova Service Director. The

Roll Shop consists of three grinders

and is complete with all the auxiliary

equipment required for Rolls and Chocks

movement, loading and maintenance,

with a very high level of automation.

Tenova Strip Processing will supply an

automated tension levelling, inspection

and recoiling line for final control of

strip prior to distribution on the market.

The line, which will operate downstream

of a new cold skinpass mill, can control

strips weighing 30 tons and measuring

800-1560 millimetres wide and 0.25

to 2.0 millimetres thick at a speed of

500 metres per minute. According to

Giovanni Gallarati, Marketing & Sales Director at Tenova Strip Processing,

The plant is equipped with latest

generation strip tension, inspection and

control systems. The handling system

provides the best possible protection

of the strip surface to guarantee the

high finishing standards required by

the automotive industry. The plant

will be supplied turnkey, complete

with all auxiliary components, within 24

months of the signature of the contract.

The project will be executed jointly by

Strip Processing and Tenova Multiform,

Tenovas new Indian company near

Mumbai, with over 130 employees and

workshops specialising in process lines

and cold rolling mills.roll shop main Contents and teChniCal features

inspeCtion and reCoiling line, main teChniCal data

Total Mill production 1.2 MTPA ( PLTCM, HDGL - SPM , SPM )

grinders 2 Work Roll Grinder and 1 Combination Grinder with Future expansion possibility

grinding output / month 1720 Work Rolls and Intermediate Rolls 40 BackUp Rolls 800 Work rolls ( Texturing )

Maintenance equipment Dechockers for WR and BUR, Chock Tilter and other equipment

loading and Transportation Automatic Roll Loader, and all Lifting Beams for Roll and Chock Transportation, Future expansion possibility for one Loader

other equipment Turn Key Supply includes EDT machine, Cleaning and Washing machines and other equipment required in Roll Shop for Rolls and Chock Maintenance

grinding accuracy Accuracy on reference rolls to 2 m/m on profile error and taper, 2 m on roundness

Roll change time on grinder (from loading rack) Less than 6 minutes

kind of steel Cold rolled, annealed and skin-passed low carbon steel strip

kind of material CQ, DQ, DDQ, EDDQ, IF, IF-HSS, BH

yield strength (minmax.) 140440 N/mm

Tensile strength (min-max.) 270700 N/mm

width (mm) 8001550

Thickness (mm) 0,252

ys (kg/mm2) 140440

Total production (ton/year) 550.000 (350.000 for tension levelling, 200.000 for inspection only)

max weight (ton) 30

Max elongation % 2

Max speed of the line (m/min) 500

View of a cold rolling mill installed by Pomini Tenova.

Tension levelling and Recoiling line.

27india

tenova takraf foCuses on the Cement industryThanks to innovative technological solutions, Tenova TAKRAF has won a 50% market share as a supplier to the Indian cement industry, an area set for important growth over the next few years.

t he cement industry has been TAkRAF Indias mainstay in the last 5 years and will continue to be a priority sector for the company in

the coming years.

Since completing our first installation

six years ago, we have supplied more

than 150 machines, says Kalyana Krishnan Gopal, Sales Director. A full range of stackers and scraper-type

reclaimers have been developed to

meet specific customer requirements.

Currently our market share in India for

this type of equipment is around 50%.

Customer satisfaction has resulted in

several repeat orders. We have also

supplied equipment to cement plants in

Africa and the Gulf countries.

With India forecasting healthy GDP

growth of around 8% over the next few

years, the Indian cement industry is in

a comfortable position. The countrys

fast-growing economy requires a

more intensive pace of development

in infrastructure. India is the worlds

second-largest cement producer, but

its per capita cement consumption is

still a paltry 180 kg, whereas in other

emerging economies like China or

Brazil, the figures are 1,100 kg and 290

kg respectively. Blessed with massive

local limestone reserves, the Indian

cement industry is poised to grow at a

staggering 10% over the next 10 years.

TAkRAFs success stems directly

from its R&D work on new equipment

enabling important advances in plant

operating performance and end product

quality. TAkRAF has been a supplier

of stockpile equipment for bulk

materials for many years. Synchronized

stacking and reclaiming are essential

for proper blending in cement plants.

TAkRAF India has developed special

equipment to stack the limestone in a

pre-programmed sequence and reclaim

the material as a representative sample

of the stockpile. This method ensures

that the limestone conveyed out of the

stockpile is blended to a high degree.

Due to the high level of automation

and safety features on the equipment,

stockpiling and reclamation operations

are fully automated, controlled from the

cement plant DCS.

2010 was a good year for us, says

Gopal. We began with a major

breakthrough right here in Chennai.

For years, Madras Cement had been

buying from our competitor. In January,

they chose Tenova TAkRAF to supply

three large circular blending systems for

limestone and one longitudinal system

for coal. Two of the circular systems

have a 100 m diameter, the third system

has an 82 m diameter. Nine months

later, when Madras Cement wanted to

procure two longitudinal systems with

portal scrapers, they chose us again.

Vicat, a major French cement maker,

recently set up their first cement plant

in India, in karnataka. After lengthy

technical discussions, in the first half

of 2010 they ordered six machines

from Tenova TAkRAF for their cement

plant. Six months later, they ordered two

machines for their captive power plant.

In 2009, we made inroads into

Chettinad Cement on their brownfield

expansion project near Chennai.

Chettinad Cement again chose Tenova

TAkRAF for their greenfield project

in karnataka. So far we have supplied

Chettinad Cement with 14 machines,

and the customer is expected to set up

two more plants in the second half of

2011.

Tenova TAkRAF Circular Blending System for limestone (Jordan).

28 29

officially opened on December 16, after just three years of work, Thyssenkrupp Steel USA and Thyssenkrupp Stainless USAs new five billion dollar plant in Calvert (Alabama) is one of the largest foreign industrial investments ever made in the USA. It also confirms the Thyssenkrupp

groups strategy targeting expansion on the NAFTA market. As Thyssenkrupp AG

Chief Executive Officer Ekkehard Schulz observed at the opening ceremony, Our processing facilities in Alabama are of the highest international standard and set a

benchmark for steel production sites in the USA. When fully operational, the new

facility will have an annual production capacity of more than four million metric tons a

year of high-quality carbon steel strip and one million metric tons of stainless steel strip.

The plant is a state-of-the-art operation set up at the heart of the NAFTA market, where

Thyssenkrupp intends to become a supplier of choice for Americas most advanced

industries, notably automotives. The facility is fully equipped to produce the highest

quality coiled carbon steel bands for sale as hot rolled and substrate for cold rolled and

coated products. The hot strip mill is capable of rolling thicknesses ranging from 1.5 mm

up through 25.4 mm, and the state-of-the-art continuous pickle tandem mill will have

the capability of rolling from 0.3 mm up through 3 mm for both exposed and unexposed

applications. The central element of the plant is a wide hot strip mill with a capacity of

over five million metric tons per year. The first coil was produced here in July. The cold

rolling mill started operation in September. The coating lines of Thyssenkrupp Steel USA

will be completed step-by-step. The first cold-rolled products have already been shipped

the suCCess of the thyssen alabama projeCt

new realizations

After just three years of work, the new ThyssenKrupp AG facility in Calvert (Alabama) has begun production. In a consortium with SMS Demag, Tenova LOI Italimpianti and Pomini Tenova supplied cutting-edge technology and equipment for engineering systems and solutions.

The Tenova lOI Italimpiantifurnaces for the Calvert plant.

31new realizations30

to customers. In the future the hot strip

mill will also be used by Thyssenkrupp

Stainless USA. Stainless operations got

underway in September 2010 with one

cold rolling mill and an annual capacity

of around 100,000 tons. Tenova is one

of the main technology partners on the

project. In 2007, the consortium set up

by SMS Demag and Tenova, with the

lOI Italimpianti and Pomini Tenova

Business Areas, was awarded a contract to

supply the hot and the cold rolling mills,

three 420 t/h walking beam reheating

furnaces and two complete automated roll

shops, each comprising four roll grinders.

The package presented by Tenova was

a decisive element in TkS choice of

supplier, together with the advantages of

an organization with permanent operations

in Germany and the USA, and so in a

position to maintain an on-going technical

dialogue with TkS at every stage, from

design to plant commissioning. The start-

up of on-site erection operations in June

2009 for the first of the three Tenova

lOI Italimpianti reheating furnaces and

December 2009 for the two Pomini Tenova

roll shops highlighted the contribution

of Tenova Cores role as system integrator,

coordinating assembly work for reheating

furnaces, and the positive reflections of

Pomini Tenovas 100% in-house design

approach to erection activities. The Calvert

facility has been constructed entirely with

European technologies, plant, components

and standards, but was assembled by an

American contractor and workers. The

requisites for the three furnaces and the

two roll shops are cutting edge in terms

of operating performance and automation.

The fact that TkS is a long-standing

customer of the business area certainly

facilitated communication, says Nicola Cavero, Tenova lOI Italimpianti Senior Vice President. The three furnaces for the

US factory are the same size and category

as the furnace delivered to the TkS plant in

Duisburg (Germany) in 2005. They deploy

The requisites for the three furnaces and the two roll shops are cutting edge in terms of operating performance and automation

Wide shot of the Pomini Tenova roll shop for TkS hot strip mill.

View of the Flexytech TSX Flameless Burners installed at the Alabama facility.

and develop all the innovative concepts to

optimize combustion under any operating

conditions, reduce emissions and, above

all, enhance automation and the slab

feed control systems. For example, the

top limit for NOx emissions specified

by TkS was 100 mg per cubic meter,

whereas the limit in Europe is 400 mg

per cubic meter. So the project involved

an intense engineering effort, which also

addressed TkS need to simplify plant

management once production began.

For instance, new engineering solutions

have been implemented to facilitate

access to system components in order

to simplify maintenance. A high level of

customization is also a feature of the two

roll shops. In terms of automation and

ancillary components, this is the most

complete project ever supplied by Pomini

Tenova, says Paolo Gaboardi, Pomini Tenova Senior Vice President. Not only

do the new shops condense the expertise

acquired from installation of more than

thirty roll shops to date, they also deploy

innovative solutions developed in response

to the needs of the future plant operators.

Their input provided us with guidelines for

the design of the components and ancillary

plant, and, above all, enabled us to develop

powerful new automation software

packages, with more intuitive, versatile

user interfaces. The two roll shops are

Pomini Tenovas most important reference

ever, as Paolo Gaboardi notes: We are

represented in Americas most important

and innovative steel mill, with a project

bringing together our entire catalogue of

equipment and auxiliary systems for roll

shop automation and employing advanced

technical solutions. A unique showcase

for increasing the visibility of the Tenova

brand and Pominis know-how.

new realizations32 new realizations 33

tenova hyl to build the worlds largest direCt reduCtion moduleNucor Corporation, the leading steel producer in the United States, has chosen Energiron ZR for a 2.5 mt/y DRI production plant in Louisiana.

i t will be the largest Direct Reduced Iron (DRI) production plant in the world, confirming the reliability and effectiveness of Energiron

ZR technology.

Nucor, Americas top steelmaker, has

signed a contract with Tenova Hyl

for construction of a new plant with a

2.5 mt annual production capacity at

the Nucor steel louisiana facility in

St James Parish (louisiana). The new

plant will turn out highly metalized,

high carbon DRI for top-grade steel

production at the steel plants of various

Nucor Group facilities.

Tenova Hyl will supply a complete

module, excluding ancillary plants and

material handling systems, through

to plant commissioning and start-up,

scheduled for the Spring of 2013.

The new project confirms all the

strengths of Energiron ZR, the only iron

ore direct reduction process technology

not to generate the reducing gas in

a conventional reformer plant, but

directly in the reactor, which is fed with

natural gas.

The technology was developed entirely

by Tenova Hyl and has been available

on an industrial scale since the end

of the 1990s, when a direct reduction

module began production at the Ternium

facility in Monterrey (Mexico).

Tenova Hyl CEO Roberto Pancaldi explains: Today the self-reforming

Energiron ZR process is the state-of-

the-art for DRI production. Wherever

natural gas is available, it is the most

competitive, flexible and environmentally

clean solution for upstream integration

with electric furnace charging.

After a full technical and economic

analysis, these were the characteristics

that convinced Nucor, a long-time

leading steel producer. Energiron ZR

is also the only process able to produce

DRI with a 96% metallic iron content

and over 3.5% carbon content in the

form of cementite (Fe3C), which does

not react with atmospheric oxygen. As

a result, the DRI is much more stable

and can be more easily stored and

transported.

Through continuous investment in

R&D, over the past ten years Tenova

Hyl has fully developed the most

beneficial intrinsic characteristics of

ZR technology, which in many ways

now ranks as a competitive alternative

to the blast-furnace steel production

cycle. The reactor where the direct

reduction process takes place operates

at an internal pressure of approximately

The Energiron ZR process is the most efficient direct reduction method in the field

View of the roll shop cooling down area.

new realizations34 35

7 bar; this optimizes the entry and

circulation of the reducing gas, while

simultaneously ensuring very high

specific productivity of over 10 mt/hour

per square meter of reactor surface. By

changing the dimensions of the reactor,

the size of the plant can be tailored

to the specific needs of the customer,

beginning with Micro-Modules for

production of 200,000 mt/year.

The 2.5 million mt/year for Nucor

will have a reactor diameter of just six

point five meters, but the maximum

theoretical productivity limit has not yet

been reached.

The greatest potential of the ZR

process, however, lies in the area of

environmental impact: the by-products

of the reduction reaction, which uses

hydrogen and carbon monoxide from

natural gas or alternative sources like

syngas and coke oven gas, are steam

and carbon dioxide (CO2), extracted by

a special capture system before the top

gases are re-circulated and re-used. The

ZR process complies with the strictest

environmental standards governing

toxic emissions and greenhouse gas,

Pancaldi observes.

The capture system means the CO2

produced by the reaction can be

stocked and sold on the technical gas

market. Given the good results achieved

with other plants already in operation,

Nucor too is taking advantage of this

opportunity, which will reduce operating

costs still further.

Together with high energy efficiency, the

low level of CO2 atmospheric emissions

makes the ZR process an attractive

alternative to the blast furnace process,

as Pancaldi explains: The CO2 per ton

of final liquid steel generated in the

Energiron ZR and EAF production chain

is approximately half that of the blast

furnace Oxygen converter cycle, and

almost half that CO2 can be captured

and either sold or sequestrated And if

you also consider that the great majority

of blast furnaces operating around the

world have an annual capacity of less

than 2 million mt of cast iron, then from

the production viewpoint too, the two

processes are equivalent today.

Not to mention that for equivalent

production capacity, the overall

investment in Energiron ZR is far

smaller.

17

Reducing gas souRces Natural Gas Reformed Gas Coal Gasification COG Others

paRTial oxidaTion and RefoRMing ReacTions2H2 + O2 > 2H202CH4 + O2 > 2CO + 4H2CH4 + H2O > CO + 3H2OCO + H2O > CO2 + H2

ReducTion and caRbuRizaTion ReacTionsFe2O3 + 3H2 > 2Fe + 3H2OFe2O3 + 3CO > 2Fe + 3CO23Fe + CH4 > Fe3C + 2H2

energiron direCt reduCtion proCess

The recent Nucor project makes a total of 12 million tons of new Energiron plant capacity since 2006.

dRi

ng

fuel

oxygen

pg heaTeR

huMidifieR

co2

Rg coMpRessoR

Tg heaTRecupeRaToR

h2o

h2o

cg coMpRessoR

dR shafT

iRon one

3736

in Chile, Tenova TAkRAF has just been awarded a 50 million euro contract by BHP Billiton to relocate two crushers at the Escondida copper mine. We have been in Chile since 1994 and it is our single most important market, accounting for 20 to 25 per cent of all our revenues, Tenova TAkRAF Germany Sales

Director Thomas Eckel tells us. Besides BHP Billiton, we also have strong ties with Codelco, the State-owned company which is the other major player in the mining

sector. On the Chinese market, Tenova TAkRAF has won a contract to build one

of the Asias largest bucket wheel excavators, at the Zhahanaoer coal mine, for the

CPE Mengdong Energy Group. This order confirms the huge growth potential of the

Chinese market in this sector with respect to a generally difficult global situation,

comments Eckel. I should point out that this is the first system of this kind to be

built in China for 15 years. Moreover, we were awarded the contract just eight months

after our entry on to the local market, while our international competitors have been

here for many years. And to consolidate our local operations, we have opened an

office in Beijing. Another important success for Tenova TAkRAF is the award of a

project in Mauritania: the company has just signed a 35 million euro contract to supply

equipment for the re-organization of the Nouadhibou port terminal in Mauritania, the

loading hub for iron ore extracted at the Zoureat mine. This is a new market for us in

a country with enormous potential in the iron mining industry, says Thomas Eckel.

Our customer, the National Industry and Mines Company, is already planning to

expand the plant, and there will certainly be a role for us.

global mining: new suCCesses at tenova takraf

mining

The latest projects won in Chile, China and Mauritania confirm Tenova TAKRAFs global leadership in the mining business, both on its traditional markets and in areas where it is a more recent entrant.

Chile: new orders with an historiC Customer

The Escondida Ore Access project awarded to Tenova TAKRAF in Chile by BHP Billiton involves the relocation of two crushers, explains Tenova TAKRAF Chile Managing Director Christian Cavagnaro. It comprises all the engineering, the partial restructuring of the two crushing systems and the construction of a new conveyor system over a distance of about five kilometers, with an hourly capacity of 8,800 metric tons. Escondida is the worlds largest copper mine and operates to a major extent with equipment from Tenova TAKRAF. The latest order confirms the superior performance of the machines and the reliability of the service provided, which has always kept the system in top working order. We have a long-standing relationship with this customer, based on mutual esteem and trust, says Christian Cavagnaro, and

every two years or so, they award us a new order. So we are confident that, for the future too, we shall continue to play a significant role in the important modernization and enlargement projects planned at the Escondida mine.

Escondida W9 conveyor extension after semi-mobile crushing plant relocation, Escondida copper mine Chile.

mining38 39

China: a reCord-breaking projeCt on a Competitive market

mauritania: important first steps in a new Continent

With an hourly capacity of 10,000 metric tons and a wheel diameter of 12 meters, the bucket wheel excavator Tenova TAKRAF is to build at the Zhahanaoer coal mine for the CPE Mengdong Energy Group will be Asias largest. The 44 meter boom can excavate terraces with a block height of 30 meters and a block width of 50 meters, says Tenova TAKRAF Asia CEO Holger Lieberwirth, and the excavator will operate under extreme conditions. The Zhahanaoer coal mine, with an estimated 827.93 million tons of lignite at depths ranging from 85 to 356 meters, is located north west of the city of Tongliao in Inner Mongolia, where the temperatures fluctuate from 39C above zero to 39 below. The system will begin operations in October 2013: this is the 56th excavator of this type built by the company. Similar systems built by Tenova TAKRAF more than 30 years ago in Kazakhstan for the Ekibastus mine, are still operating, in even more severe climatic conditions.

We were awarded this project thanks to our positioning as world constructors of giant bucket wheel excavators adds Holger Lieberwirth. The customer was also familiar with the excellent performance of similar equipment built by Tenova TAKRAF some 15 years ago at Yuan Bao Shan. Another source of satisfaction is that the contract marks our return to the important Chinese market, where we intend to establish ourselves as a fully fledged member of the local community, making synergetic use of local materials and workers and international contacts and experience.

In Mauritania, at the Nouadhibou port terminal, which is linked by rail to the Zoureat mine, Tenova TAKRAF is to install a conveyor system linking the materials deposit with the port, and a continuous ship loader with an hourly capacity of 12,000 metric tons. In addition to the two equipment supplies, the contract provides for the demolition of the existing systems and a series of plant modifications, explains Tenova TAKRAF Germany Project Director Norbert Neumann. One of the most complex aspects will be the integration of the new units with the old components still in operation. But the greatest challenge will be to keep to a minimum the plant shutdown for the start-up of the new equipment. Project execution time has been set at 30 months from the date of the contract, worth a total of 26 million euro. About two thirds of the contract value relates to the design and construction of the conveyor system, to be handled by our Leipzig office, says Tenova TAKRAF Italy Sales & Marketing VP Pietro Bibolini. One third relates to construction of the continuous

ship loader, to be handled by our Genoa team. Our references as ship loader constructors were a vital factor in the acquisition of this project. The customer was highly impressed by our systems in Brazil, among the worlds largest with an annual capacity of approximately 110 million tons. Just recently Tenova TAKRAF Germany signed a further contract with SNIM Mauritania worth another 22 mill . Under this contract Tenova TAKRAF will supplky two conveying bridges for handling and disposal of waste material. This new investment is in context with the expansion of capacities at the iron ore mine site in Zouerate.

SRs 2000.32/5.0 Bucket Wheel Excavator, similar machine will be installed in the Zhahanaoer coal mine, China.

Mobile Stacking Bridge, length 420 m, similar machine will be installed in the Guelb II project of SNIM, Mauritania.

4140

o ver the past few years the Tenova network has achieved further growth in all five continents, expanding its operations in line with the development of the emerging markets. Specifically, Tenova has strengthened its presence in the worlds fastest growing

industrial regions and today it is active all over the world, deploying a glocal strategy

that combines its global vision with strongly rooted local operations.

Three new locations have joined the network over the last year:

In Beijing, the mission of the new Tenova TAkRAF unit is to broaden and develop

Tenova TAkRAFs presence in mining, an industry with important growth prospects

where demand for high-tech, energy-efficient equipment is rising constantly.

Tenova has been active in China for a number of years with Tenova lOI Italimpianti

in Tianjin; Tenova Timec, a workshop in Tanggu, the Tianjin industrial district, and

Tenova Industrial Technologies in Beijing.

Tenova TAkRAF has been operating from the Beijing office since 2008; in 2009

it won its first contract for one of the biggest Bucket Wheel Excavators, a success

subsequently confirmed by other orders from the Chinese mining industry.

The newly set-up mining office has a staff of 18, active in sales, engineering,

procurement, quality control, project management, project and finance control.

In Vietnam, a very promising market on the international scene, Tenova has opened

new frontiers for the tenova network

tenova in the world

Think global and act local, is the Tenova strategy to grow in new emerging markets as well as well-established industrial areas. The goal is to create an increasingly customer-oriented network.

a new office in Ho Chi Minh City. The

southern part of the country was chosen,

because the majority of investments are

located around Ho Chi Minh City, where

many industry parks are springing up.

The new office will be Tenovas

bridgehead into the whole Indochina

region and will handle sales, engineering,

project execution, procurement and

customer service activities.

The investment decision was immediately

confirmed by the acquisition of two

interesting contracts by Tenova key

Technologies and Pomini Tenova. For the

first contract, Tenova key Technologies is

to build a turnkey plant to regenerate acid

and remove silicon from hydrochloric

acid pickling baths for the cold rolling

mill of China Steel Sumikin Vietnam (a

joint venture set up by China Steel Corp.

of Taiwan and Japans Sumitomo).

For the same customer and at the same

plant, located in the Phu My area (Ho

Chi Minh City), Pomini Tenova will

supply a complete Roll Shop.

To strengthen its position in small roll

grinders, Pomini Tenova has established

a company in Sweden, Pomini Tenova

Nordic AB.

The location is Vallentuna, where

important customers are within close

traveling distance. The new company will

focus on development and servicing for

Pomini Tenova small roll grinders, but it

will also provide service and rebuilds for

any brand of roll grinder on the market.

The new product line of small roll

grinders includes the MW 479 Cluster

Mill Roll Grinder, on the market since the

middle of 2010. More than 10 units are

currently under assembly at the Pomini

Tenova plant in Castellanza, Italy, and

will soon be ready for delivery to leading

steel makers around the world. The

international expansion strategy pursued

over the last years has strengthened

Tenovas position as a global player.

Following the establishment of the

new offices, the network now has more

than 30 operating companies and 3,000

people across 21 countries. Thanks to

its integrated network, Tenova provides

unique solutions through a unified

approach that translates into perceptible

added value and tangible benefits,

constituting a technological benchmark

for its customers.

Tenova has strengthened its presence in the worlds fastest growing industrial regions and today it is active all over the world

43tenova in the world42

wien - ausTRia

liege - belgiuM

dsseldoRf - geRMany

essen - geRMany

lauchhaMMeR - geRMany

leipzig - geRMany

genoa - iTaly

Milan - iTaly

vaRese - iTaly

vallenTuna - sweden

calgaRy - canada

ToRonTo - canada

denveR - usa

piTTsbuRgh - usa

yalesville - usa

MonTeRRey - Mexico

belo hoRizonTe - bRazil

so paulo - bRazil

sanTiago - chile JohannesbuRg - souTh afRica bRisbane - ausTRalia

beiJing - china

shanghai - china

Tanggu - china

TianJin - china

chennai - india

kolkaTa - india

MuMbai - india

alMaTy - kazakhsTan

TaschkenT - uzbekisTan

ho chi Minh ciTy - vieTnaM

sofia - bulgaRia

kaTowice - poland

TaRgu Jiu - RoMania

Moscow - Russia

the tenova networkTenova operates through more than 30 companies located in 21 countries in 5 continents

44 45

news

TENOVATENOVA INCREASES ITS ACHIEVEMENTS AND ITS PRESENCE IN VIETNAMTenova has opened a new Representative

Office in Ho Chi Minh City, Vietnam, one of

the worlds most promising markets.

The new offices opening has also been

greeted by the acquisition of two new orders

from China Steel Sumikin Vietnam: Tenova

key Technologies, the Austrian company part

of the Tenova Group, has been awarded the

order for a turnkey plant for acid regeneration

and removal of silicon dioxide from the

baths on a hydrochloric acid pickling line,

installed at the cold rolling mill complex of

China Steel Sumikin Vietnam, a joint venture

between Taiwans China Steel Corp. and

Japans Sumitomo. For the same customer

and at the same facility, located in the Phu

My district (Ho Chi Minh City), Pomini

Tenova will supply a complete Roll Shop

which includes three CNC Roll grinders

complete with automatic loaders and Roll

Shop Management System.

TENOVA LOI ITALIMPIANTITENOVA REVAMPS TENARIS DALMINE ROTARY HEARTH FURNACETenova lOI Italimpianti has successfully

coordinated the project to revamp the rotary

hearth furnace on the Tenaris medium-pipe

line. The goal was to charge larger billets

up to a length of 5,300 mm and to improve

productivity by about 35%. A significant

savings in fuel consumption (by about 15%)

has also been achieved.

ALUMINIUM NORF ORDERS TWIN-CHAMBER MELTING FURNACE (TCF) FROM LOI ITALIMPIANTIAt the beginning of the year Alunorf has

placed a contract with lOI Thermprocess

for a TCF twin-chamber melting furnace

for stage two of the recycling centre. The

new recycling system is to be designed for

a daily throughput of 150 tonnes of liquid

metal, which will be produced entirely from

aluminium scrap.

GERDAU AOMINAS SELECTED TENOVA LOI ITALIMPIANTI TO SUPPLY TWO WALKING BEAM FURNACES FOR THE NEW STECKEL/PLATE MILLGERDAU ACOMINAS and Tenova lOI

Italimpianti signed, at the end of July 2010,

a contract for the supply of two Walking

Beam Furnaces for Slabs to be installed in

the new Plate/Steckel mills of the GERDAU

ACOMINAS Plant, Ouro Branco, Brazil.

The two walking beam furnaces, having

a production of 220/265 t/h each, will be

designed according to the last innovative

concepts of lOI Italimpianti in the field of

high quality reheating furnaces FlexyTech

technology saving energy and offering the

maximum protection of the environment

aspect.

TENOVA LOI ITALIMPIANTI STARTS-UP A WALKING BEAM FURNACE IN TAIWANIn June Tenova lOI Italimpianti has

successfully completed the start-up of a 200

metric tons/hour walking beam reheating

furnace for billets in the new rolling mill

at the kaohsiung China Steel Corporation

(Taiwan). The new fuel-efficient furnace

is equipped with Tenovas state-of-the-art

Flexytech low NOx burners as well as with

an advanced thermal model-based level 2

control system.

TENOVA RECEIVES THE ACCEPTANCE CERTIFICATE FOR THE PIT FURNACE SUPPLIED TO VALLOUREC & MANNESMANN (GERMANY)In June VAllOUREC & MANNESMANN

TUBES Deutschland GmbH has issued the

Acceptance Certificate for the pit furnace

installed in Dsseldorf-Reisholz realized

by Tenova lOI Italimpianti. The new pit,

supplied in addition to the existing ones,

has load capacity of 220 t of round pieces

having different steel qualities and heated

up to 1,320C and it is equipped with the

newest innovative combustion technology

considering the use of lOW-NOx High-

Speed-Burners, designed for running

with natural gas and controlled in on / off

sequential mode.

TENOVA MELT SHOPS THE 20TH TENOVAS CONSTEEL IN ASIA: FINAL ACCEPTANCE CERTIFICATE ACHIEVED IN JAPAN FOR THE BIGGEST CONSTEEL IN THE WORLDAfter the recent Consteel start-up in korea,

China and Vietnam, Tenova has successfully

commissioned a new Consteel plant in

Japan. Tokyo Steel has equipped its new steel

plant in Tahara (Japan), which is going to

produce 2.5 M tons/year of quality steel, with

360 tons of steel per hour Consteel system,

the highest installed capacity Consteel in

the world. The new giant Consteel system

has been coupled with an electric arc furnace

of 300 tons nominal tapping capacity and 420

tons total capacity.

THE PREMIER PUTIN STARTED UP THE NEW TENOVA MELT SHOPS AT ISHVESK, RUSSIAAt the presence of the Russian Prime

Minister Mr. Putin, the new Tenova Melting

complex located at Izhevsk steelworks in

Udmurtia Republic, Russia has been started

up on September the 7th.

Tenova contract covered a full-scale

upgrading of the melt shop n23 of Izhstal

OAO plant, owned by the Mechel group,

among Russias top mining and metals

companies. Tenova supplied a new electric

arc furnace (EAF), ladle Furnace (lF) and

a vacuum degassing station. The EAF will

provide a capacity of 40 tonnes.

Tenova will also provide the auxiliaries

plant such as fume dedusting system, water

treatment plant and the ferroalloy plant.

TENOVA PYROMETPOS-HIMETAL SIGNS REPEAT ORDER WITH TENOVA PYROMETIn January 2011, Dongbu Corporation

contracted Tenova Pyromet to design and

supply a ladle furnace and a slag holding

furnace for the PosHimetal project.

The slag holding furnace comprises of a

furnace whose complete shell tilts on a set of

rollers. The electrodes are retracted from the

furnace when the tilting operation occurs.

Tenova Pyromet has supplied furnace

equipment for many manganese operations,

but this project is unique in the methods and

processes used to produce a low phosphorous

and low carbon manganese product.

TENOVA PYROMET AND TENOVA CORE TO SUPPLY ARMSTRONG WORLD INDUSTRIES A SUBMERGED ARC FURNACE FOR BLAST FURNACE AND FERROALLOY SLAG SMELTINGIn September Tenova Core, in conjunction

with Tenova Pyromet (South Africa), has been

contracted to design and supply a 12.5 MVA

submerged arc furnace (SAF) for Armstrong

World Industries new 30,000 square foot

manufacturing plant, located in Millwood,

West Virginia. The SAF will feature advanced

electrode clamping technology and a single

phase transformer with three independent

on-load tap changes as well as state-of-the-art

process control systems.

TENOVA GOODFELLOW SUSTAINABLE DEVELOPMENT TECHNOLOGY CANADA PARTNERS WITH TENOVA GOODFELLOW INC. ON ENERGY EFFICIENCY PROJECT AT ARCELORMITTAL DOFASCOFebruary 2011 - Tenova Goodfellow Inc.

(TGI) is pleased to announce a contribution

agreement with Sustainable Development

Technology Canada (SDTC) to demonstrate

TGIs proprietary Next Gen Energy

Efficiency Breakthrough Technology System

for the Electric Arc Furnace (EAF) industry.

TGIs second SDTC supported project to

develop leading edge clean technology will

be completed in collaboration with Canadas

leading steel producer ArcelorMittal Dofasco.

TENOVA GOODFELLOW RECEIVES FOUR NEW ORDERS FOR EFSOP INSTALLATIONS FROM CELSA GROUP (SPAIN)In February 2010, Tenova Goodfellow

installed its proprietary EFSOP system on

the 140 ton EAF #2 at Celsa Barcelona,

with the objective of improving performance

and operating cost primarily by reducing

electricity, oxygen, methane, injected carbon

and charge carbon use. Prior to EFSOP

optimization, a performance guarantee was

mutually agreed upon by both parties. In May

2010, Celsa Barcelona signed off that Tenova

Goodfellow had successfully fulfilled the

performance guarantee as per the contract.

TENOVA GOODFELLOW ACHIEVES EAF SAVINGS AND INSTALLS EFSOP WATER DETECTION SYSTEM AT ARCELORMITTAL CONTRECOEUR OUEST INC., CANADAIn October ArcelorMittal Contrecour Ouest

Inc. has confirmed that Tenova Goodfellow

Inc. has achieved EAF operating savings

of over US$ 2.00 per ton liquid steel using

the EFSOP system at its plant just east of

Montreal Canada. These savings include

significant reductions in electrical energy,

natural gas and charged carbon, as well as

increased productivity.

The performance benefits were accomplished

through a combination of various EFSOP

optimization strategies.

TENOVA CORETENOVA CORE CONTRACTED FOR MATERIAL HANDLING SYSTEMAt the beginning of the year Tenova Core

received an additional contract from

Armstrong World Industries to provide a

complete material handling feed system for

the new 12.5 MVA submerged arc furnace

(SAF) at Armstrongs new Millwood, West

Virginia facility. Tenova Core, in conjunction

with Tenova Pyromet (South Africa), was

contracted earlier to supply the new SAF.

METALLIX CONTRACTS TENOVA CORE FOR ROLLER HEARTH FURNACEAt the beginning of 2011 Tenova Core has

been contracted by Metallix Refining, Inc.

to design and supply a custom roller hearth

type furnace. The furnace will be installed as

part of the precious metal recovery process at

Metallixs Greenville, NC, refinery.

TENOVA CORE CONTRACTED FOR CONSTEEL REVAMPIn December Gerdau Ameristeel has

contracted Tenova Core to provide a major

revamp of the existing Consteel system

located at the Charlotte, North Carolina

plant. Consteel is the continuous

steelmaking process, which preheats and

feeds scrap and other raw materials directly

into the EAF via a patented conveying system

through the EAF sidewall.

TENOVA CORE TO SUPPLY ARMSTRONG WORLD INDUSTRIES A SUBMERGED ARC FURNACE FOR BLAST FURNACE AND FERROALLOY SLAG SMELTINGIn September Tenova Core, in conjunction

with Tenova Pyromet (South Africa), has

recently been contracted to design and supply

a 12.5 MVA submerged arc furnace (SAF)

for Armstrong World Industries new 30,000

square foot manufacturing plant, located in

Millwood, West Virginia.

The SAF will feature advanced electrode

clamping technology and a single phase

transformer with three independent on-load

tap changes as well as state-of-the-art process

control systems.

TENOVA CORE INSTALLS PLATE HEAT TREATING FURNACE FOR OUTOKUMPUIn September Tenova Core has completed

the successful start-up of a walking hearth

plate heat treating furnace at Outokumpus

stainless plant located in New Castle,

Indiana. The furnace was installed as part of

a plant upgrade project.

The walking hearth furnace features state-of-

the-art low NOx burners as well as a complete

47news46

control and automation system that includes

an advanced level 1 tracking system. Tenova

Core also designed and supplied a custom jet

air and water mist cooling system to reduce

the temperature of the stainless plate product

after it exits the furnace.

TENOVA I2STENOVA I2S TO SUPPLY A NEW 4 HIGH TEMPER MILL FOR OLYMPIC STEEL, INC. IN GARY, INDIANAIn November Tenova I2S has signed a

contract with Olympic Steel, Inc. to supply a

444 & 1067 x 2134mm 4 High Temper Mill

at the companys planned new site at U.S.

Steels Gary Works plant in Gary, Indiana.

The new Tenova I2S Mill will be the third

Temper Mill supplied to Olympic Steel, Inc..

The first two Temper Mills are located at

Olympic Steel, Inc. facilities in Cleveland,

Ohio and Bettendorf, Iowa and have been in

operation for over a decade. Olympic Steel,

Inc. is a national steel service center.

TENOVA I2S WON A NEW CONTRACT FOR A 4 HIGH REVERS