Reheating Furnaces and Heating Technologies
Reheating Furnaces and Heating Technologies
Reheating Furnaces and Heating Technologies
Ohlerkirchweg 66 41069 Mnchengladbach P.O. Box 100645 41006 Mnchengladbach Germany Tel.: +49 (0) 2161 350-0 Fax: +49 (0) 2161 350-1754 info@sms-meer.com www.sms-meer.com
Via Udine, 103 33017 Tarcento (Udine), Italy Tel.: +39 0432 799 111 Fax: +39 0432 784 556 info@sms-meer.it www.sms-meer.com
Via De Marini 1 16149 Genoa, Italy Tel.: +39 010 2359301 Fax: +39 010 2359304 info@sms-meer.it www.sms-meer.com
The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.
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CONTENTs 2 4 6 8 10 12 14 16 18 20 3 Contents 5 Vast experience on the road to modern reheating 7 Not only billets 9 Economy and environment: todays priorities 11 Walking beam furnaces 13 Walking hearth furnaces 15 Pusher-type furnaces 17 Equipment for pipe mills 19 Ghost in the machine 21 SMS Meer Service
Hier steht die Bildunterschrift der weie Pfeil kann mu aber nicht
SMS MEER
Hier steht die Bildunterschrift der weie Pfeil kann mu aber nicht
The SMS Meer Furnaces Division's excellent reputation has led to a very fast growth and, as a result, several important contracts have been awarded in the last successful years. Further proof of its success is the design and commissioning of more than 30 furnaces delivered worldwide in 2007 and 2008 alone. Nowadays the SMS Meer Furnaces Division has one of the most comprehensive product lines on the market, based on sound technology and a complete range of services.
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Hier steht die Bildunterschrift der weie Pfeil kann mu aber nicht
Charging of slabs to a walking hearth furnace Aceralia Gijon, ArcelorMittal S.A., Spain.
The scope of supply of the SMS Meer Furnaces Division includes all the components, from the furnace itself to the handling facilities for incoming and outgoing raw material and all the extensive auxiliaries including instrumentation for field controls that are required to optimally run the whole system. Electrical equipment and automation are within the SMS Meer scope of supply with software developed in-house, so that the integration of the process and operating sequences is in a single hand.
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A great deal of attention is given to design and component features that allow the lowest possible energy consumption. New materials, components and ideas are continuously tested making possible levels of energy requirement even lower than 260 kcal of heat input for each kilogram of steel reheated from 20 to 1,200 C.
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130 tph walking beam furnace in Kardemir, Turkey. Hier steht die Bildunterschrift der weie Pfeil kann mu aber nicht
RecorD settInG: tHe rAPID DIscHArGe mAcHIne, one BILLet everY 27 seconDs The 190 tph walking beam furnace installed at the JSC Nizhne-Serginskij Metizno-Metallurgicheskij Zavod ZAO "NSMMZ", located at Nizhnie Sergi, Russian Federation is setting new standards in discharge rate, having achieved the impressive speed of one 12 m billet discharged every 27 seconds on average. This has been made possible by further increasing the rigidity of the kick-off machine. The kick-off fingers, internally water cooled, are plated with high nickel stainless steel shields, to enable this machine to withstand even the toughest temperature conditions.
TYPIcAL DAtA: Size range: Production range: Specific consumption: > 120 mm, blooms, slabs or beam blanks > 100 tph 280 kcal/kg
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View of the recent 120/140 tph walking hearth furnace at Stefana, Italy.
RecorD settInG: 16 m sLenDer BILLets unDer A rADIAnt roof Stefana S.p.A., under the project name Dream Steel, has established a brand new 700,000 tpy bar mill, located at Ospitaletto, in the Northern Italian province of Brescia. The market demand for large coils (3.2 tons) as well as the overall benefits due to a better yield, pushed our project engineers to the task of designing a furnace capable of reheating billets with a length of 16 m. This target was achieved with a walking hearth furnace with a suspended roof 16.8 m wide, supporting an impressive battery of 90 radiant burners able to grant the best temperature homogeneity along the reheated piece. Another important feature is the heat maintenance zone, a series of small burners dedicated to retaining the furnace temperature during weekend stoppages and prolonged mill downtimes. The reheating furnace at Stefana is able to feed the mill with a continuous output of 120 tph starting with cold billets or 140 tph when hot charged.
TYPIcAL DAtA: Stock thickness: Production range: Specific consumption: Cooling water consumption: 160 mm > 50 to 140 tph 270 kcal/kg low
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PUSHER-TYPE FURNACES
When the goal is a an heavy duty, simple design furnace for billet reheating, the right choice is often a pusher-type furnace. Pusher furnaces are typically suitable for low-production rate mills of common steel grades (e.g. rebar). In top-fired pusher furnaces the benefit of simple and sturdy construction is combined with low water consumption. Top and bottom fired pusher-type furnaces are capable of high production rates. For simple products it is the inexpensive alternative to a more sophisticated walking hearth or walking beam furnace. Internal water-cooled beams require a significant cooling water flow.
Charging sequence.
RecorD settInG: tHe Lowest certIfIeD NOX vALues Besides being a modern and efficient unit capable of a significant output of 120 sh ton per hour, the new pushertype furnace at Nucor Steel Darlington, USA, represents one of the best efforts ever in the aim to contain NOx emissions. Thanks to the ultra-low NOx burner technology, this furnace has demonstrated, since the very first days after the lighting up, a significant trend towards decreasing pollutants. The NOx is kept steadily around 0.040 lb/MMbtu (66 mg/Nm3), far below even the strict local regulation that permits a maximum level of 0.074 lb/MMbtu (123 mg/Nm3). This achievement is a real touchstone.
The shape and the temperature control of the flame contributes to containing NOx emissions.
Billet peel-bar of 120 sh tons per hour pusher-type furnace at Nucor Steel in Darlington, SC, USA.
TYPIcAL DAtA: Top fired Billet size range: Production range: Specific consumption: Cooling water consumption: 160 mm 50 to 100 tph < 270 kcal/kg low Top and bottom fired > 120 mm > 100 tph < 280 kcal/kg medium
Diagram representing the daily emission at Nucor Steel in Darlington, SC, USA.
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THe ADvAnceD tecHnoLoGY of tHe QuencHInG HeAD The quenching head is a ring-type device allowing the automatic regulation in angle of the spray nozzles according to the different pipe outside diameters and the regulation in height for the alignment of the pipe pass line with respect to the head axis. This ensures that the water stream strikes the periphery of the pipe along the direction of travel, and combined with the accurate control of the water pressure and flow, allows the desired depth and uniformity of the marten sitic structure. Inclined rollers are installed between the rings to transport the pipes at the required technological speed and confer a proper rotating spin. Sophisticated automation is once more the key of the process, since quenching head set-up parameters are managed automatically by the control system of the upstream austenitising/hardening furnace.
Nozzle angle adjustment for different diameters of pipe. Each module has more than 1,100 nozzles.
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Software for management of heating zones and combustion parameters of a rotary hearth furnace.
Of particular note here is the new combustion control system designed for both the RHF of Valcovna Trub TZ, in Ostrava, Czech Republic and the heat treatment furnaces in Pervouralsky Novotrubny Works, Russia. This new concept, which involves on/off burners firing with a pulse sequence managed by the Level 2 logic, allows utmost accuracy of the thermal profile and the best optimization in fuel consumption to be achieved.
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hydraulic and electronic equipment through to all the necessary performance tests. Our service naturally also includes the training of the operating personnel. StArt-uP suPPort Through the advice of our experts on site, our customers are assured of a stable production process from the very beginning. Start-up problems that could lead to costly faults or standstills are thus ruled out from the start. The result: Maximum productivity and product quality. OEM sPAre PArts servIce Our high-quality OEM spare parts are precision manufactured for our furnaces and make a major contribution to the long-term value retention. Thanks to our intelligent spare parts stocking concepts, we are able to identify critical parts and hence ensure efficient spare parts management with parts availability in the minimum of time. EquIPment CHecks With our equipment checks for furnaces, we identify weaknesses in the plants and optimisation potentials through thorough machine inspections using the latest measurement technologies. These standardised and thorough checks help to avoid unforeseen machine standstills. EquIPment AuDIts for PLAnt oPtImIsAtIon The equipment audits provides holistic, systematic analyses of the plant engineering, processes, maintenance and organisation. The findings from the audit allow more efficient processes and new process technologies to be integrated. At the same time, the results can also be used for well-founded investment decisions. MAIntenAnce mAnAGement What maintenance concept is the right concept for the individual customers requirements? Our experts draw up a customised maintenance concept and make a major contribution to ensuring maximum plant availability on economiErection of 200 sh tons per hour walking beam furnace at SDI.
In summArY, we cAn ensure: The right configuration based on the customers requirements, determined by SMS Meer in close cooperation with customers staff. Reliable technical solutions: long life time of the installed plants. Trouble-free installation: SMS Meer commissioning experts are able to assist the customer during all the erection steps, supervising the whole manufacturing process. On-site training: through the guidance of SMS Meer technical staff, the customers engineers are quickly led to complete their learning curve and to run the furnace by themselves. Spare parts and after sale assistance through SMS Meer Service organization.
3-D modeling of discharging area.
In concrete terms, service from SMS Meer means for our customers: Increased productivity Increased availability Improved product quality Reduced operating costs Safeguarding of the plant value Your contAct PArtner worLDwIDe Our furnaces are in operation around the world, and our organisational structure for service is oriented to this global presence: International teams for immediate proximity to the customer, high flexibility for quick reactions and bundled competence for comprehensive support. Thanks to the close links and coordination at SMS Meer, the customer thus receives the full range of services from a single source. ErectIon AnD commIssIonInG The aim of a new or modernised plant is: Optimum production start-up with high added value. We handle all the steps necessary for this: From the site management and OEM commissioning through the installation of the mechanical,
SDI is a primary beam producer in the US. At the new medium section mill in Columbia City, Indiana, the 200 sh tons per hour walking beam furnace reheats blooms and beam blanks to feed the 15 stand continuous rolling mill. SMS Meer supplied the equipment for the entire mill.
cally attractive terms. Our spectrum ranges from the consultation through to the outsourcing of the maintenance. MoDernIsAtIon Our furnaces are designed for decades of operation. But technology does not stand still. With specially tailored modernisation concepts, our experts ensure a longer plant service life and hence an improved investment efficiency. TrAInInG ProGrAmmes In international competition, the latest know-how of the plant operators is just as important as innovative plant technologies. We offer comprehensive knowledge transfer here. Whether on site or in the SMS Meer training centre, we instruct the customers experts in, for example, maintenance questions.
ServIce over tHe wHoLe LIfe cYcLe As manufacturers we know every detail and every single component of our furnaces. Our service experts know exactly how the reliable and productive operation can be assured over the whole life cycle of the plant. Thanks to our service, both the furnaces and the know-how of the plant operators are constantly kept in step with the latest market demands.
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Via De Marini 1 16149 Genoa, Italy Tel.: +39 010 2359301 Fax: +39 010 2359304 info@sms-meer.it www.sms-meer.com
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