Werkstattbroschüre DIN A4

Furnaces
Arc
Submerged
SAF
BULLETIN 2013
The SMS group: Superior in Submerged-Arc
Furnaces and Electric Smelter Technology
Metix and Paul Wurth join the SMS group | Our complete product portfolio for
SAF technology | Technological highlights | Introduction of furnace applications
| Ferro alloys and Si-metal | Non-ferrous metals | Special applications | Waste
recycling and pig iron | Energy recovery systems | Waste recycling concepts |
Research and development | Services at a glance | Seminars and training | Information materials and publications
Passion for metals
Contents
Contents
Model cross section
of Si-metal furnace.
Si-metal tapping with
movable tapping platform.
Introduction
4
Rotary hearth furnace technology
35
SMS group at a glance
8
Environmental technologies
37
Refining and converter technology
42
General application ferro alloys
44
- FeNi
45
- FeCr, SiCr
50
- FeMn, SiMn
56
- Si-metal, FeSi and FeSiAl
58
Departments for submerged arc
furnaces and electric smelters
14
Paul Wurth as part of the SMS group
22
Product portfolio – overview
and technological highlights
24
Sinter plants
33
Auxiliaries
34
General application
2
SAF Bulletin 2013
non-ferrous metals
62
View to charging
tubes and electrode
column on roof top.
Electrode Column,
suspended design.
General application
Quality assurance and safety
89
Service and spareparts
90
- TiO2 (AC and DC)
68
- CaC2
70
- Minerals
73
Turnkey solutions
92
Application waste recycling
74
Seminars and trainings
94
Plant revamps
76
Publications
95
R+D and latest innovations
77
Evaluation services
96
Metallurgical competence
82
Economic success
97
Electrics und automation
84
Summary
98
Project execution
88
SAF Bulletin 2013
3
Introduction
A full-liner for metallurgical processes
How can SMS promote success?
Introduction by Dr. Guido Kleinschmidt,
Dr. Rolf Degel and Dr. Christian Fröhling
Currently, the prospects of the metal market are
looking up. The prices of most metals are stable
and ferroalloy prices are being driven by constant
growth in the steel industry. The long-term development of the non-ferrous market is predicted to be
stable.
Dr. Degel, Dr. Fröhling.
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SAF Bulletin 2013
Recent years have been exciting for the industry. That goes especially for the
smelter department of the SMS group. Many highly interesting and challenging
furnace projects are being implemented, including the world’s largest FeNi
furnaces ever built, the first large-scale FeCr production line based on DC-technology, Si-metal furnaces, FeSiAl furnaces, copper slag cleaning furnaces,
melters for the production of fused magnesia, as well as large-scale calcium
carbide furnaces.
The SMS group reacted to growing market demand for our smelter technology
Ferro-silicon furnace.
and increased the capacity of our submerged-arc furnace department in Düsseldorf/Germany.
We significantly enlarged the SMS Siemag team in Düsseldorf to enable it to rise
to future challenges.
SMS Siemag proudly presents Metix – the leading engineering company on the
southern African market – as a new member of the SMS Group.
Slag tapping.
For the southern African market, Metix is the top equipment supplier for ferroalloy submerged-arc furnaces as well as for sinter plant technology. This cooperation with Metix will strengthen our overall position in Africa significantly, and
represents a big step toward our aim to expand our business in Africa.
Furthermore, Paul Wurth, a global leader in technology for blast furnaces and
coke making, joined the SMS Group at the end of 2012. Paul Wurth offers
superior auxiliary equipment for submerged-arc furnaces.
What does this mean for you? You can continue to rely on the top quality our
FeNi furnace.
SAF department has supplied for more than 100 years, now combined with
enhanced upstream and downstream equipment and processes for full-line
solutions.
Today’s increasing energy costs and fluctuating raw material quality make our
reliable submerged-arc furnace and electric smelter technologies even more
attractive to current and future customers. Due to their excellent design and high
efficiency, our plants ensure consistent, dependable, and reliable production at
low energy consumption.
FeSi/Si-metal.
SAF Bulletin 2013
5
Introduction
When it comes to electric smelters, globally increasing energy costs as well
as environment-protection requirements place our energy recovery systems in
the spotlight. Depending on the process in the furnace, the stable, uninterrupted
production as well as the higher chemical and sensible energy content in the
off-gas enable a recovery of more than 20 % of the input energy.
The SMS group is proud to be participating in many of the new projects and
expansions currently being implemented.
FeNi furnace.
During the last decade, the SMS group responded to all demands in this area
with innovative smelter technology such as:
■ Large-capacity units that reduce specific operation costs
(applied in the production of FeNi, FeCr, CaC2)
■ AC and DC technology capable of directly processing ore fines and
lower-grade ore (applied in FeCr and TiO2 production)
■ Innovative metal refining technologies for top-quality ferroalloys
(applied for M.C. and L.C. FeMn, M.C. and L.C. FeCr, FeNi and Si-metal)
■ Rectangular slag cleaning furnaces for optimum recovery rates of valuable
metals (Cu, Co, Pt, etc.)
■ A new ferroalloy product (FeSiAl) for the steel industry made from
coalmine reverts
■ A new type of MgO melter
■ Efficient energy recovery systems that improve overall plant efficiency
and reduce CO2 emissions.
Slag tapping.
All these recent innovations and improved processes were only achieved
through constant, intensive cooperation with our customers, as well as in-house
research and development.
Our customers’ enthusiasm for innovative products like these has resulted in a
significant order intake for our department.
Due to worldwide purchasing and excellent, longstanding relations with our suppliers, we are able to keep our overall prices low. Most price fluctuations originate
with our suppliers. You can rest assured that we always pass any savings on to
you.
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SAF Bulletin 2013
For SMS, innovation has always been the key to future success. We believe in
building tomorrow’s furnaces today. That’s why the SMS Managing Board decided
to significantly increase R&D funds for the submerged-arc furnace product group.
Right now, two larger R&D projects are approaching completion:
First, at the IME in Aachen, a 1-MVA multipurpose furnace will be used to test a
range of processes and directly compare AC to DC technology.
Second, in Hamburg, we will commission a new type of slag-cleaning furnace that
works with a DC field and a magnetic field to maximize the metal recovery rate.
The SMS group is the globally leading supplier of steel refining technology such
Dr. Kleinschmidt, Dr. Degel.
as converters, ladle furnaces, chemical heating stations, injection stations, and
vacuum treatments. We also apply this extraordinary know-how to optimize
refining process for the ferroalloy industry. This results in intelligent and efficient
refining solutions for FeNi, FeCr, FeMn, and Si-metal suppliers.
During recent years, SMS has focused on green technologies including de-dusting
systems, water treatment plants, and in particular energy recovery systems. We
have significantly strengthened our expertise and expanded our workforce in this
field. Today, the SMS group supplies efficient energy recovery systems based on
boiler technology. To better promote this innovative field, we have implemented
a new department.
Finally, we would like to thank you for your loyalty in choosing SMS group technology. We are confident our equipment will continue to contribute to your sustained
success.
Dr. Guido Kleinschmidt
Dr. Rolf Degel
Dr. Christian Fröhling
SAF Bulletin 2013
7
Introduction
Introduction
of the SMS group
A reliable partner. Business Area SMS
Siemag generates some 60 % of total
sales. Its product range covers the process
chain from steelmaking, continuous casting, and rolling mill technology to processing lines for hot and cold strip, including
the electrics and automation, as well as
the associated services. Business Area
Under the roof of SMS Holding GmbH, the
SMS Meer produces tube plants, section
SMS group unites various global suppliers
mills, hydraulic presses, copper and alu-
of plants and machinery for processing
minum plants, as well as closed-die forging
steel and non-ferrous metals. The group
plants, ring-rolling mills, and the associated
consists of the Business Areas SMS Siemag,
thermal technology.
SMS Meer, and industrial participations.
In 2012, some 13,000 employees worldwide
The SMS group also holds industrial partic-
generated sales of around EUR 3.5 billion
ipations, with a majority share of 59.1 % in
for the SMS group.
Paul Wurth SA of Luxembourg and more
than 90 % of the shares in Elexis AG, Germany. Paul Wurth is a global leader in the
construction of blast furnaces, coking
plants, and environment technology for
metalworks. The elexis Group with its subsidiaries is a technology leader in production automation, drive technology, and
quality assurance.
Covering everything from advice to implementation and commissioning, right
through to plant services, the SMS group
employees support their customers with
extensive know-how. Working together,
they develop innovative solutions that give
their customers measurable advantages
on their markets. This is proven by many
references.
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SAF Bulletin 2013
High tech – made by SMS
Modern manufacturing. Over recent
years, the SMS group has modernized and
expanded its production locations in
Hilchenbach
(SMS
Siemag)
and
Mönchengladbach (SMS Meer). This is
where the core components responsible
for quality are produced. Simultaneously,
the group is increasing its presence on
important markets such as China and India.
Plug & Work test field.
For instance, in 2012, SMS Siemag
opened a new workshop in Zhangjiagang
duction costs, top final-product quality, and
The result is short paths due to direct con-
near Shanghai. It has also set up new ser-
efficient use of raw materials. Unique to
nection of the rolling mill to the steelmak-
the group is its Plug-&-Work concept. This
ing plant. Unlike previous plants, this sys-
involves setting up all the hardware and
tem doesn’t need a heating furnace.
Innovations. When it comes to techno-
software components of the electrics and
Instead, the steel is rolled directly from the
logical developments, the SMS group
automation in the SMS Siemag test center,
casting heat, which saves up to EUR 11
ranks among the world leaders in plant
where it undergoes integration tests. SMS
per t.
construction. The company focuses on
Meer has optimized the minimill concept
customer requirements such as lower pro-
with CMT (Continuous Mill Technology).
vice branches in Turkey, Brazil, and India.
View of the
workshop,
Hilchenbach,
Germany.
SAF Bulletin 2013
9
Introduction
Sustainability. SMS Meer and SMS Siemag engineers have long
been working on resource-efficient technologies. The objectives
are a significant reduction in raw material input, emissions, energy, and operating materials, plus a substantial improvement in
the recycling rate. To make the economy and ecology of these
new developments transparent and recognizable, the company
created the Ecoplants brand.
Ecoplants solutions are available in all fields. Included here are
the new ARCCESS® steady EAF for steelmaking from SMS
Siemag, which achieves 30 % higher productivity using less energy, and the X-Pact® energy management system Energy Advisor, which makes energy consumption transparent and enables
operators to systematically cut costs.
ARCCESS® steady EAF with integrated energy
recovery system.
SMS Siemag Düsseldorf,
Germany.
10
SAF Bulletin 2013
Over 140 years of experience
Milestones
True to tradition. The roots of the SMS group lie in Siegerland,
■ 1871 Carl Eberhard Weiss founds a forging company
traditional iron country. It was there that Carl Eberhard Weiss
■ 1918 Merger of mechanical engineering companies
founded a forge in 1871. This was the start of a family-owned
company that, through mergers, acquisitions, and its own growth,
has today evolved into a leading global player in metallurgical
machine and plant construction. The sole owner of the SMS group
is Siemag Weiss GmbH & Co. KG, the holding of the Weiss entrepreneurial family. Today, the group is family owned in the fourth
generation, with Dr. Heinrich Weiss at its helm. The main shareholder, he has acted since 1974 as Chairman of the SMS group,
and in 2007 brought the company back into the sole ownership of
the family.
Oechelhäuser, Hoffmann, and Weiss to create
“Siegener Maschinenbau AG”
■ 1973 Merger to create Schloemann-Siemag AG involves
half of the shares going to the MAN group
■ 1990 Foundation of SMS AG as holding in charge of
operations
■ 1999 Merger of SMS Schloemann-Siemag AG with
Mannesmann Demag Metallurgie to form SMS Demag AG
■ 2007 Acquisition of the other externally-owned shares –
the Weiss family becomes sole owner of the SMS group
■ 2009 SMS Demag AG renamed SMS Siemag AG
■ 2011 Takeover of Metix (Pty) Ltd.
■ 2011 Majority of shares in Elexis AG
■ 2012 Majority of shares in Paul Wurth S.A./Luxembourg
SMS Siemag workshops,
Hilchenbach, Germany.
SAF Bulletin 2013
11
Introduction
Introduction
to the SAF expertise
of the SMS group
The SMS group offers a
broad product portfolio for
end users in the areas of ferroalloys, platinum, NF metals, iron, and steel. Over the
past 100 years, SMS Siemag
and Metix have developed
various processes for manufacturing more than 60 different kinds of metals and
slags (with over 750 references).
The SMS Group is a strong
global player, supplying all
smelter components, equipment, and plant solutions.
Our successive integration
of major names in the indusHistorical draft of SAF tapping.
try (such as Demag, Krupp,
Schloemann, Concast, MANGHH) has helped make us
the world leader in metallurgical plant and machine
technology.
Air cooled gas hood with doors.
12
SAF Bulletin 2013
Our mission
SMS is dedicated to designing and building complete, innovative
SMS supplies furnaces to various industries. This involves a wide
submerged-arc furnaces and electric smelters, as well as inte-
variety of applications and related processes and often requires tai-
grated plants and components that manufacture products of the
lor-made individual solutions. Our equipment copes with all
highest quality, consistency and reliability. We design and build our
extreme process conditions such as high temperatures and
plants to ensure fast ramp-up and safe, long-lasting operation.
aggressive slag compositions. The solutions we develop are imple-
Equally important, they combine eco-friendliness with cost-effec-
mented in innovative as well as conventional furnace design. This
tiveness. Teaming up with you, we reliably achieve your project
is one major reason why SMS furnaces are considered the most
goals. Even after the completion of the job, we remain in close
reliable on the market.
contact.
The furnaces we have supplied so far are spread around the globe.
As a result, SMS is very experienced in dealing with all possible
local conditions such as climate, culture, political environment,
etc.
Illustration of Si-metal plant.
Tapping of Si-metal.
SAF Bulletin 2013
13
Introduction
The SAF team in Düsseldorf/
Germany and Johannesburg/
South Africa
Dedicated to supplying excellent SAF products, SMS Siemag
in Düsseldorf and Metix in Johannesburg share their technology to your benefit. We team up with you to provide the best
available solution. You can rely on a corporate culture based
on traditional family values, with support whenever you
require it.
Our team in Düsseldorf/
Germany and core competencies
The team in Düsseldorf covers all electric
smelter and submerged-arc furnace projects worldwide, except those in southern
Africa.
Dr. Thomas Germershausen
Executive Vice President
Metallurgical Plants
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SAF Bulletin 2013
Dr. Rolf Degel
Vice President Special
Metallurgical Plants
Phone: +49 211 881 6372
[email protected]
Dr. Christian Fröhling
General Manager Technical Sales SAF,
Gas Cleaning
Phone: +49 211 881 5288
[email protected]
Martin Köneke
Deputy General Manager
Technical Sales SAF
Phone: +49 211 881 6584
[email protected]
Hans-Erich Lembgen
Senior Project Manager
Phone: +49 211 881 6180
[email protected]
Bertram Muffert
Senior Project Manager
Phone: +49 211 881 6174
bertram.muffert
@sms-siemag.com
Dr. Stephan Geimer
Manager Technical Sales SAF
Phone: +49 211 881 4182
stephan.geimer
@sms-siemag.com
Christian Zimmermann
Manager Technical Sales SAF
Phone: +49 211 881 5285
christian.zimmermann
@sms-siemag.com
Detlef Strieder
Manager Project Planning
SAF
Stefanie Frohn
Manager Project Planning
SAF
Patrick Henke
Manager Project Planning
SAF
Harmen Oterdoom
Deputy General Manager
Metallurgy & Commissioning
Roland König
Deputy General Manager
Product Development SAF
Mircea Ionita
Deputy General Manager Sales
Electrical and Automation
Systems
Jan Bader
General Manager
Metallurgical Plants,
Steelmaking
Frank Dörmann
Ralf Nörthemann
Project Director
General Manager
Metallurgical Plant Division
Design Melting Units
Phone: +49 211 881 6622
[email protected]
SAF Bulletin 2013
15
Introduction
Our team in
Johannesburg/South Africa
and core competencies
Metix is responsible for all submerged-arc
furnace and electric smelter projects in
southern Africa. Additionally, the company
is responsible for pellet and sinter plants
worldwide.
Phone: +27 11 676 2300
www.metix.co.za
Metix Office.
16
SAF Bulletin 2013
Reinier Meyjes
Managing Director,
45 years of experience in building
plants for the ferroalloy industry
[email protected]
Andrew van Niekerk
Engineering Director,
experienced in metallurgical
processes and project contracts,
costing and execution
[email protected]
Frank Gunther
Financial Director,
experienced in company financials,
contract administration and
management
Wynand Moolman
Projects Director,
experienced in project management, has successfully executed
big EPC/EPCM contracts
Pat Davies
Marketing Director,
45 years experience in building
plants for the ferroalloy industry
Klaus Schmale
Deputy. Director Sales,
Delegate from SMS Siemag to
support Metix
Ivan Hall
Technology Equipment Manager,
experienced in industrial plant
maintenance, equipment sales
and development
Marco van Niekerk
Mechanical Engineering Manager,
experienced in mechanical and
piping engineering systems, design,
execution and specifications
Bradley Nqumba
Acting E&I manager,
experienced in E&I engineering
systems, design, execution and
specifications
Goerge Farmer
Lead Process Engineer,
experienced in various processes
for the ferroalloy and non-ferrous
industry
Cor Brink
Project Manager,
experienced in plant operation
and maintenance, project
management
SAF Bulletin 2013
17
Introduction
Essen
Hilden
Hilchenbach
Düsseldorf
Mönchengladbach
Braunau
Zürich
Bilbao
Tarcento
Milan
Furthermore, the SMS Group is well represented
by company offices and branches.
Moscow
Pittsburgh
New Delhi
Dubai
Sao Paulo
Johannesburg
The above contact details do not indicate the full network of SMS Siemag representatives.
If you would like to know who your representative is, please contact us at [email protected].
18
SAF Bulletin 2013
Major branches:
Brazil and
China
South America
SMS Siemag Technology
SMS Siemag Equipamentos
(Beijing) Co. Ltd.
e Servicos Ltda.
18th Floor, Juanshitiandi Tower A
Avenida 2, 230
Jia No. 50-1,
Distrido Industrial Parque Norte
Wangjing Xilu, Chaoyang District,
33.200-000-Vespasiano, Minas
Beijing 100102
Gerais, Brazil
P.R. China
Phone: + 55 31 2125 -1160
Contact:
Fax: + 55 31 2125 - 1408
Zhiqiang Li
Beijing
Phone: + 86(0) 10 59 07 71 67
Fax: +86(0) 10 59 07 71 45
North America
Shanghai
Wuhan
SMS Siemag LLC
India
100 Sandusky Street
Pittsburgh, PA 15212-5852, USA
SMS India Pvt. Ltd.
Contact:
387, Udyog Vihar, Phase II
Kevin Cotchen
Gurgaon 122 016, India
Phone: +1 412 237 - 8910
Contact:
Fax: +1 412 237 - 3995
Ramesh Ayya
Internet: www.sms-siemag.us
Phone: +91 (0) 124 435-1541
Fax: +91 (0) 124 435-1603
Russia and
Eastern Countries
Gulf States
SMS Siemag AG –
SMS Gulf FZE
Liaison Office Moscow
Dubai Airport Free Zone
Hotel Renaissance
Building 4E, Block A, Office G16
Office 4095
PO Box 54795
Olympijski Prospekt 18/1
Contact:
129110 Moskau
Ulrich Breuer
Russia
Phone: +971 4 204 50 10
Phone: +7 (0) 495 931-9823
Fax: +971 4 204 50 17
Fax: +7 (0) 495 931-9824
SAF Bulletin 2013
19
Interview
Interview with the
Metix management team
Q: Dr. Kleinschmidt, what was the major
driving force behind the acquisition of
Metix in South Africa?
Interview with Dr. Guido Kleinschmidt,
Kleinschmidt: We were aware of a
Dr. Rolf Degel, Reinier Meyjes, Andrew
strong and sustained demand for sub-
van Niekerk and Pat Davies during board
merged-arc furnace equipment. Over the
meeting in Johannesburg 2013.
last few decades it had become difficult
for SMS Siemag to supply the southern
African market from Germany. Although
SMS Siemag is the leading supplier of this
technology worldwide, we faced a bottleneck in this particular region. That’s why it
made sense to merge with the No. 1 in
Africa.
Q: Mr. Meyjes, how does Metix feel
about this development?
Meyjes: Our customers and staff reacted very positively to the merger. We’re
very proud to be a member of the SMS
Group. It gives us a much wider range of
products. What’s more, joining forces with
a financially very strong partner also opens
up excellent opportunities, especially for
larger projects.
Degel: We were also amazed at the positive response of our African customers.
It looks like the market was waiting for this
collaboration with Metix. After the merger,
in November 2011, we immediately organized three seminars in Rustenburg, Middleburg, and Johannesburg attended by
more than 100 participants. At the work-
Metix office, South Africa.
shops, we presented and discussed the
joint product program of Metix and SMS.
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SAF Bulletin 2013
As a first step in our joint collaboration, we
passed on our rectangular furnace technology know-how to Metix. This resulted
in a significant order from First Quantum in
Zambia.
Van Niekerk: Everybody at Metix is
excited about the project. We’re talking
here about the world’s largest copper slag
cleaning furnace (6-inline electrode rectangular furnace). A project like this wouldn’t
SMS management during Metix board meeting in Johannesburg.
have been possible without the know-how
transfer from Düsseldorf. It clearly demonstrates how quickly both companies have
based on their professionalism and our
Kleinschmidt: Metix is very similar
grown together. We worked as a team
additional products.
to SMS Siemag in that it is a premium
equipment supplier. Some of their solu-
during the sales phase and we can also
rely on strong support during the execu-
Q: What additional products?
tions, for instance the lower part of the
electrode column, are also very interest-
tion and commissioning phases.
Davies: We see a good market for our
ing for us. Right now, we’re evaluating the
Davies: As part of a joint understanding,
DC technology in South Africa, in particu-
various technological solutions with a view
SMS Siemag and Metix have already car-
larly in the FeCr industry, where SMS
to further improving both SMS Siemag and
ried out lots of internal workshops in Düs-
Siemag has a remarkable track record.
Metix equipment. Then there’s the exten-
seldorf and Johannesburg, where we
Another plus is the company’s range of
sive Metix expertise in ore agglomeration
exchanged ideas and evaluated the tech-
green technology products, including ener-
technology such as pelletizing and sinter-
nological solutions from both sides. There
gy recovery systems and efficient
ing. The track record is impressive.
was a very positive atmosphere at these
dedusters. Some of our new dedusting
meetings, with constructive discussions
systems, such as hybrid electrostatic pre-
Q: Mr. Meyjes, do you have any final
and mutual respect.
cipitators, can be retrofitted in commonly
remarks?
used wet scrubbers, reducing the dust
Degel: What also clinched the decision
content in the clean gas to less than 10
Meyjes: It’s true to say this is a merg-
was the fact that Metix has been doing
mg. SMS Siemag energy recovery sys-
er between the No. 1 in the world, SMS
great business here for the past 10 years.
tems recover more than 20 % of the elec-
Siemag, and southern Africa’s No. 1,
The company is very healthy and highly
trical power used, depending on the met-
Metix. We’re excited about this collabora-
successful on a market we had limited
allurgical process.
tion that will strengthen our good relations
with all our current and future clients.
access to. SMS Siemag was especially
impressed by the references realized over
Q: Dr. Kleinschmidt, does Metix also have
the past 10 years. We’re confident Metix
technology you can include in your world-
will grow on the southern African market,
wide marketing strategy?
Q: Thank you very much for this interview.
SAF Bulletin 2013
21
Paul Wurth, Luxemburg
Paul Wurth
joins the SMS group
With 1,500 employees working in 26 companies worldwide, Paul Wurth Luxembourg
is a market leader in the design and supply
of complete solutions for blast furnaces,
coke oven plants, and environment protection systems for the iron & steel industry.
When it comes to submerged-arc furnaces
and electric smelters, the Paul Wurth Group
supplies state-of-the-art equipment, such
as TMT clay guns and drilling machines.
Paul Wurth’s portfolio also includes slag
and metal granulation systems, pig casting
machines, and advanced automation systems for metallurgical plants.
There is an impressive range of waste treatment and direct
reduction technologies, mainly comprising the direct reduction
processes RedSmeltTM, RedIronTM, Primus®, i-Meltor®, and PLD
deoiling. These innovative solutions can also be applied upstream
of electric smelters. Especially efficient, the rotary hearth furnace (RHF) can be used to produce prereduced hot iron-bearing
material, which cuts the smelters’ power consumption to slash
overall manufacturing costs. The RHF can also be used to recycle steelmaking residues and for hot metal production.
Moreover, Paul Wurth supplies modern lining concepts for SMS
furnaces, covering the hearth area, side walls, and roof. Our customers benefit from the addition of Paul Wurth to the SMS group
through synergies that result from our complementary programs
for almost all pyro-metallurgical process lines.
Paul Wurth – world
leader in ironmaking
technologies.
22
SAF Bulletin 2013
Blast furnace N°1, Hyundai Steel, South Korea.
Castfloor of blast furnace “H”, Tata Steel, India.
Mudgun and drilling machine (TMT).
Ingot casting at Primus® plant.
SAF Bulletin 2013
23
Product portfolio
Individual tailor-made solutions for best
process performance
Application fields – General SAF
technology product portfolio
SMS supplies a wide range of submerged-arc furnaces
and electric smelters for the ferroalloy, non-ferrous metals,
chemicals, and electronics industries.
AC-based technology
Over 99 % of smelting systems use AC
furnaces, either with three or six inline electrode systems for rectangular furnaces, or
with three electrodes for circular furnaces.
This will remain the dominant smelting
technology over the coming decades. Furnaces are already installed with a power
rating of up to 140 MVA. Well-known benefits of AC furnaces are their reliable and
efficient operation.
Illustration of a rectangular FeNi furnace.
Slipping devices.
24
SAF Bulletin 2013
Furnace roof of a ferro alloy smelter.
DC-based technology
DC technology is normally used in certain
niche areas (FeCr fines, TiO2 slag production, UG2 smelting, copper, cobalt, platinum, and recycling technology). Over
recent years, we have developed a nextgeneration DC-smelter and aim to be the
leading supplier in this field.
Model of a conductive
bottom for DC operation.
Illustration of DC SAF for ilmenite smelting.
Illustration of a DC-furnace for FeCr production.
SAF Bulletin 2013
25
Product portfolio
Individual product portfolio
for best electrical smelter solutions
During recent decades, numerous smelter solutions have been
developed to cope with the individual conditions dictated by
the process. For an overview of the options, see the following
figure.
Overview product portfolio SAF and electric smelter
Basic system
■ AC based rectangular
(3 or 6 electrode in-line)
■ AC-based circular furnaces
■ DC-based circular furnaces
Charging systems
■ Hot/cold charging
■ Hollow electrode charging system
■ Liquid charging (launder system)
■ Choke/batch feeding principle
■ Automatic/manual feeding
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SAF Bulletin 2013
Process type
■ Open design
■ Semi-closed design
■ Closed design
Furnace shell types
■ Flat/dished bottom
■ Cylindrical/conical
■ Stationary/rotating
■ Changeable/tiltable
■ Various sidewall cooling systems
Furnace roof types
■ Water cooled multi-sectional roofs
■ Water cooled roof (spray cooling)
■ Suspended brick roof/cast roof
■ Flat/arched shape
■ Air cooled brick roof
■ Water cooled copper roof
Electrode systems
■ Pre-baked/graphite electrodes
■ Self baking electrodes
■ Extrusion electrodes
■ Hollow electrode systems
■ Suspended/supported
E-column design
■ Compound electrode
Technological highlights
The wide range of products available from
SMS means we supply all the equipment
for complete processing lines. This starts
from the raw material charging and ends
with the dispatch of the finished products
for the metals industry.
Basic design principles
Smelters are usually designed as open or
closed furnaces.
The right choice depends on the raw materials, the process, and local environment
protection regulations. Operators use rec-
Tapping of „washed“ Cu-slag.
tangular or circular furnaces according to
their process and capacity.
FeSi plant prior to start up.
SAF Bulletin 2013
27
Product portfolio
Electrode columns
SMS electrode columns have long been
Depending on the process, nine different
known for their reliable and efficient perfor-
lower electrode-column parts are used.
mance in all submerged-arc furnace appli-
SMS also supplies copper pressure rings,
cations. We have constantly optimized
which save energy by reducing electricity
them over the decades. Now, our new
losses.
electrode column generation ensures safe,
maintenance-friendly operation with mini-
SMS has developed an innovative copper
mized energy consumption, and repre-
pressure ring for the lower part of the elec-
sents the most modern electrode system
trode. It allows very fast access to the con-
on the market.
tact clamps. Today, these copper pressure
rings are installed in furnaces all over the
New here is the slipping device that pro-
world.
vides very accurate operation, avoiding
electrode breakages. The lower system is
exposed to the harsh environment of the
furnace.
Inside view of electrode column, contact clamps.
28
SAF Bulletin 2013
Slipping device at manufacturing.
Sidewall cooling systems
Choosing the right sidewall cooling sys-
■ Cu-plate cooling
Included among the key features are:
tem for some processes significantly
■ Tailor-made cooling elements (fingers)
■ Cooling outside the shell (no water
extends the plant lifetime. Our systems
are inherently safe solutions that work
for locally stressed areas
■ Water-cooled tap-holes
within the refractory lining)
■ Optimized thermal conductivity right
from the start, resulting in outstand-
with a minimum of heat extraction (saving energy).
Especially when the process requires
The following options are available:
is ideal. In terms of safety, heat removal
higher cooling rates, SMS copper cooling
■ Rinse cooling/water film cooling
rate, commissioning, and energy con-
■ Spray cooling
sumption, this system is by far superior
■ Chamber cooling
to the copper cooling systems supplied
■ Channel cooling
by other manufacturers.
ing service life
■ Minimized wear on the refractory lining due to formation of a freeze line
■ Cooling elements as an integral part
of the refractory lining, so no connection with the vessel wall
■ Heat extraction of up to 250 kW/m2
Side wall copper
cooling system.
SAF Bulletin 2013
29
Product portfolio
Roof/hood cooling
SMS supplies various roof cooling options.
The right choice strongly depends on the
Hernic F4 78 MVA roof.
maximum temperatures that occur as well
as the process type.
■ Water-cooled steel roof with channel
cooling
■ Water-cooled roof with copper panels
■ Air-cooled roof
The copper roof is specially designed for
furnaces with extreme temperatures in
the free board of the furnace (> 1,000 °C)
and extreme off-gas composition conditions.
Metalloys M14-furnace
during construction.
Recently, SMS designed an air-cooled roof
for a moderate heat stress in this area,
which has been in operation successfully
for years.
Model of gas hood with doors, electrode columns, charging and transformators.
30
SAF Bulletin 2013
Reliable failsafe hydraulic
system
Failsafe hydraulic systems provide smooth
and reliable furnace operation and allow
quick movements of even heavy electrode
columns. All hydraulically operated components, i.e. electrode columns, furnace
doors, charging chute gates, stack closures,
etc., are supplied by one central hydraulic
pressure-generating unit. That means
Hydraulic valve
stand for electrode.
the system is failsafe and maintenancefriendly.
Hydraulic piston accumulator station.
Hydraulic pump station.
SAF Bulletin 2013
31
Product portfolio
Clay guns and drilling
machines
Paul Wurth recommends and uses the
world-class tapping technology from its
affiliated company TMT – Tapping Measuring Technology, a joint venture between
Dango & Dienenthal and Paul Wurth.
Strengthened by the know-how and references of its parent companies, TMT has
successfully extended its market position
over the last 10 years.
These machines are applied in nearly all
modern electric smelters for opening and
closing the metal and/or slag tapholes as
well as in a majority of blast furnaces.
Due to their high performance, the
machines enable safe and quick taphole
maintenance for a long lifetime.
Also included in the TMT product range
are machines with special functions, such
as rodding devices and cleaning or lancing
equipment that are useful in certain furnace operations.
TMT tapping machine.
32
SAF Bulletin 2013
Sinter plants
Metix has supplied the last five sinter plants in South Africa
in cooperation with Outotec. The most recent was completed
at the end of 2012 as part of the Xstrata-Merafe Tswelopele
project.
The Tswelopele project included a 600,000 tpa pelletizing and
sintering plant that was executed on an EPC basis. The plant produced its first sintered pellets in the first week of October 2012,
and passed the contractual performance tests within two months
of operation. Then it achieved a total of 1,750,000 accident-free
construction hours. Merafe announced that the project was completed on time and within budget; making it another successful
project for the largest FeCr producer in SA. The plant is currently
producing record tonnages.
Tswelopele FeCr plant in production.
Chrome ore sinter plant.
SAF Bulletin 2013
33
Product portfolio
Downstream equipment
and auxiliaries
SMS supplies a wide product range downstream of the SAF. Innovative equipment
for solidification, refining and metal /matte/slag handling is available.
■ Slag granulation (static or dynamic)
■ Metal granulation systems
■ Hot metal charging systems to EAF
Tests in Vaccuum AOD for M.C. FeCr production.
and converter
■ Pig casting machines
■ Casting wheels
■ Metal/alloy handling equipment
■ Metal refining equipment
- Ladle refining equipment
- Ladle arc reheating stations
- Tilting stations
- Skimming stations
- Injection stations
- Top blown converters
- AOD converters
- Deslagging stations
- Chemical heating furnaces
Tapping of Vaccuum AOD.
■ Cooling water plants
■ Heat recovery systems
TBRC converter for copper production.
34
SAF Bulletin 2013
Rotary hearth furnaces
Rotary hearth furnaces (RHF) are used in
many pyrometallurgical processes to preheat, chemically prereduce, or calcine the
feed going into the electric smelters. This
pretreatment has the major advantage of
significantly cutting operation costs, in particular by reducing the electrical energy
required. Furthermore, the unit can remove
undesired components such as lead and
zinc, which may enter the smelting stage
RedIron™ Plant, Lucchini Piombino, Italy.
and negatively impact on the process.
Depending on the application, this coalbased direct reduction process in a rotary
hearth furnace is an attractive method of
producing pig iron and ferroalloys.
The RHF is suitable for many metal-bearing
materials, from iron ore to steel mill
residues, nickel, and chrome ore that can
utilize several carbon-bearing reductants
ranging from coal to coke breeze.
Extensive research and testing was carried out to investigate and optimize this
technology for processing a wide range of
metal-bearing residues and ores.
RHF, RedIron™ Plant, Lucchini Piombino, Italy.
SAF Bulletin 2013
35
Product portfolio
Slag and metal granulation
Paul Wurth is the leading supplier of slag
granulation systems.
Right now, a dry slag granulation system is
under development for recovering substantial quantities of energy contained in
the slag while maintaining the physical
properties of the granulated slag. This highly innovative process is currently implemented in an industrial pilot plant under
construction in Germany.
The equipment for the granulation of metal, particularly for the FeNi and FeCr production lines, is also part of Paul Wurth’s
extensive product portfolio. The systems
provide the physical properties and shapes
INBA® Pb-slag granulation.
defined by the customer.
Pig casting machines
Pig casting machines are commonly used
for the solidification of hot metal produced
in blast furnaces. Converting ferroalloys
into pigs is usually done in similar units.
The pigs are shaped to our customers’
specifications. To meet environment protection regulations, the systems are
equipped with an appropriate dedusting
system.
Pig casting machine.
36
SAF Bulletin 2013
Environment protection
SMS supplies a complete range of energy
and environmental technologies. Included
here are innovations in energy recovery,
water treatment, air pollution control, byproducts & recycling, as well as energy
management services. ecoplants is the
label for SMS solutions which combine
ecologic and economic benefits.
www.sms-ecoplants.com
Water treatment
SMS Siemag’s water supply and treatment
systems draw on more than 100 years of
experience in metallurgical plant and rolling
mill engineering.
As experts in water supply and treatment
systems, we provide services ranging from
planning and design to supply and commissioning. You can rely on high quality,
efficient project handling in all stages of
production of your systems.
This know-how ensures the optimized, reliable integration of water supply and treatment systems into a production process
that saves both energy and water.
Tailor-made and cost efficiently solutions.
SAF Bulletin 2013
37
Product portfolio
Dedusting technologies
Air pollution control
Our dedusting department is committed
to making our plants eco-friendly and keeping your workplaces clean.
Dedusting plant for a Si-metal plant in Kazakhstan.
SMS has in-depth experience in the entire
So far we have been involved in the con-
■ Efficient secondary dedusting con-
field, including dedusting and gas clean-
struction of more than 35 dedusting plants
cept for a cleaner working environ-
ing systems for submerged-arc furnaces,
for submerged-arc furnaces.
mentand overall reduction in plant
pollution
electric-arc furnaces, BOF, and other equipment used in the steel industry.
■ Innovative primary dedusting systems
■ Energy recovery system for power
(based on bag house, electric filter,
generation or steam production
We supply dry and wet cleaning systems
and wet systems such as disintegra-
as well as electrostatic precipator (ESP)
tors and scrubbers)
■ Process gas recovery
stations for primary dedusting.
General overview: components for SAF off-gas cleaning
Innovation
safety feature:
Controlled
combustion
Open furnaces and closed furnaces with post combustion
gas cooling
■
■
■
■
■
Hairpin cooler
Forced-draft cooler
Dilution air
Water cooled duct
Boiler system
gas cleaning
■ Pulse-jet bag filter
■ Reverse air bag filter
■ ESP (with conditioning)
gas recovery
■ Waste Heat Boiler
system
Closed furnaces without post combustion
gas cooling
■
■
■
■
38
SAF Bulletin 2013
Goose neck
Water cooled duct
Quench
Gas conditioning tower
gas cleaning
■ Venturi scrubber
■ ESP (dry, wet)
gas recovery
■ Gas collecting
(gas holder) flares,
gas handling
■ Boiler system
(co-generation)
Dedusting technologies
There is growing environmental awareness worldwide. This is why we provide
overall primary and secondary dedusting
solutions that protect the environment and
keep workplaces clean. We supply:
■ Dry cleaning systems
■ Wet cleaning solutions
■ Electrostatic precipitators
In particular, SMS applies its detailed
know-how in the primary and secondary
de-dusting of sinter plants.
Primary dedusting system of a FeNi plant in Brazil.
Principles of dust separation
■ Bag filter
- pulse-jet or reverse air
- suction- or pressure-type
■ ESP
- dry or wet system
■ Wet scrubber
- venturi (one- or two-stage)
- desintegrator
SAF Bulletin 2013
39
Product portfolio
Energy saving options
Especially in ferroalloy, Si-metal and non
■ Minimized furnace heat losses with
ferrous metal production such as copper
balanced cooling/refractory systems
Global warming, stricter restrictions of CO2
and PGM, electric smelters form an essen-
emissions, and rising energy and raw-
tial part of production technology. Howev-
elimination of agglomeration)
material prices all make green, energy-effi-
er, most electric furnaces are extremely
■ Process optimization (resulting in
cient production processes a must.
energy-intensive.
■ Fewer process steps (such as
higher metal yields) and higher recov-
Statutory limits affecting energy consump-
The high level of electrical power required
tion and emission behavior will increasing-
is mainly determined by the process. SMS
ery rates
■ Greater furnace capacity for lower
heat losses
ly impact on the technical layout of pro-
Siemag has developed several ways of
jects.
reducing the overall electricity consump-
■ Maximized power-on time
Plant owners recognize that environment
tion of these production lines.
■ Optimized calcine and pre-reduction
stages (for example, for FeNi
protection is no longer just a social responsibility, but that green technologies are a
In particular, the following improvements
sustainably profitable investment – new
make a huge difference:
technology pays off. SMS Siemag as the
■ Better electrical efficiency with intelli-
market leader offers innovative solutions
gent design and application of compo-
for all relevant processes.
nents
smelters)
Types of SAF processes for potential energy recovery systems
Open furnace design
AC type
Closed furnace design
■ No post combustion
AC type
■ Low off gas volume
■ Combustible gases included
(CO, H2, CH4, etc.)
■ High dust load
■ higher dust load
(80-200 g/Nm³)
(70-100 g/Nm³)
■ high temperatures
■ variable temperatures
(up to 1,800 °C)
(300 -1,000 °C)
DC type
■
■
■
■
40
full combustion
high off gas volume
low dust content (8-12 g/Nm³)
Off-gas temperature appr. 600 °C
Sensible heat
Sensible heat / Chemical heat
SMS Siemag
Waste Heat Boiler
SMS Siemag
Process Gas Boiler
SAF Bulletin 2013
Model of section of energy recovery system.
Energy recovery systems
for open furnaces
for closed furnaces
■ Fully combustion in open type electric smelters
■ Continuous SAF process allows the generation of
superheated steam in the Waste Heat Boiler
■ New furnace door design allow to control the inlet air
flow and thus the off-gas temperature (average 600 °C)
■ Currently energy recovery systems for two FeCr-SAF
of ETI KROM in Turkey are under construction, up to
11% of input energy is recovered
■ In some Si-metal and FeSi processes up to 20% of the
input electric power can be recovered
■ No post-combustion in closed type electric smelters:
generation of combustible process gas
■ Process gas can be used after treatment
(e.g. Theisen Scrubber) in a Process Gas Boiler to
generate superheated steam
■ A part of the sensible heat can be used to heat up e.g.
feedwater
■ Use of superheated steam to generate electrical energy
or as process steam for different applications
■ Possibility to sell electrical energy or process steam
Furnace doors for off-gas temperature control.
Process gas boiler.
SAF Bulletin 2013
41
Product portfolio
SMS refining capabilities
Refining technology
for FeNi
for FeCr and FeMn
SMS also supplies technology for ferroal-
The product portfolio includes chemical
SMS can look back on a long history of
loy refining, mainly FeNi. References for
heating stations, slag rakes, ladle furnaces,
converter technology. Reference lists spec-
FeNi refining are Pacific Metals, Falcon-
and ladle cars with electromagnetic stir-
ify more than 200 converters supplied over
bridge Dominicana, Cerro Matoso, and
ring.
the last 60 years. SMS constantly
Koniambo. These are all ladle furnace solu-
improves the process and the technolo-
tions with auxiliary equipment (slag rake,
Another option is refining the FeNi in a
gy. Today, state-of-the-art design by SMS
oxygen blowing).
conventional converter like the one we
covers converters with fluid flow models
supplied to Larco in Greece.
optimized by CFD (computational fluid
dynamics), as well as detailed parameter
Tap
Transp
(Deslag)
CH-deC/P
Oxidising Refining
Multi stage FeNi-refining process.
42
SAF Bulletin 2013
Desl
Heat/de-S
Deslag
Reducing Refining
de-Al
Trim/transp.
Granulation
studies covering vessel geometry, stirring
rate, plus the number and diameter of
pouring plugs.
Our range of converters includes
■ Conventional BOF converters for FeNi
■ AOD converters for the production of
MCFeMn and MCFeCr
■ AOD vacuum converters
Most recently, we developed and proved in
industrial-scale application CO2-blowing
technology in an AOD vacuum converter
for MCFeCr < 1.0 %C. This technology sig-
Illustration of a vacuum AOD process.
nificantly cuts operation costs and the need
for expensive cooling materials. The Cr
yield achieved is above 95.5 %.
SMS refining capabilities
for non-ferrous metals
Another of our strengths is secondary metallurgical treatment for the nonferrous
industry. Our group supplies all types of
chemical heating stations and refining
based on converter technology, for example Kaldo (TBRC).
Illustration of an AOD converter.
SAF Bulletin 2013
43
Application areas
General application areas
We distinguish between four major appli-
tration shows the major reference num-
cation areas for electric smelters and sub-
bers. Submerged-arc furnaces and electric
merged-arc furnaces. The following illus-
smelters – product portfolio
Ferroalloy and silicon metal industry
■ Ferrosilicon, silicon metal and FeSiAl
■ Ferronickel, ferromanganese, and silicomanganese (L.C.,
M.C., H.C.), ferrochrome (L.C., M.C., H.C.) and silicochrome
■ Special alloys such as FeNb, FeV
■ CaSi
since 1970: 79
Non-ferrous metals industry
■ Slag cleaning furnaces for Cu, Ni, Pb
■ Copper matte and nickel matte
■ Platinum
since 1970: 61
Special applications and pilot / test furnaces
■ Titanium oxide slag
■ Refractories and minerals
■ Calcium carbide
■ Tailor-made test and pilot furnaces
■ Phosphor
since 1970: 28
Waste recycling furnaces
■ Steel mill waste
■ Catalysts and batteries
■ Ni-plant waste
■ Power and waste incinerator plants
for flue dust and ash
■ Pig iron
since 1970: 4
44
SAF Bulletin 2013
FeNi-production
Superior technology
for FeNi production
Ferroalloy and Si-metal type furnaces
account for approx. 70 % of the smelter
business of the SMS Group. Most of these
furnaces are based on principles developed
early in the last century.
Ferro-nickel is produced in submerged-arc furnaces by the reduction of nickel ores. The aim is to transfer most of the nickel into the
metal phase and the iron into the slag phase. Good carbon distribution and specific slag metallurgy are important for a high yield.
First, pre-heated and pre-reduced ores are hot-charged (at temperatures of up to 900 °C) into the furnace. Then, final nickel reduction takes place in the submerged-arc furnace. Ferro-nickel furnaces are semi-open stationary-type furnaces. Usually, round
furnaces are used for smaller and medium quantities, whereas
large capacities are produced in rectangular furnaces.
Ferro-nickel specification:
FeNi 15 – 35% Ni
Rectangular furnaces:
Superior smelters for large-capacity
FeNi-production
Ferro Alloy References
1970 – today: 118
Most ferroalloys are produced by pyrometallurgical smelting in
submerged-arc furnaces. Advanced high-power smelting units
have made submerged-arc furnaces highly competitive for ferroalloys. Over the last decade, SMS has introduced a series of
improvements ensuring efficient and safe operation of large-scale
FeNi furnaces.
Related developments followed, such as various sidewall cooling methods as well as AC thyristor controls for better operational
control, higher and more efficient power input, and less overall
maintenance.
Ferro Nickel slag tapping
SAF Bulletin 2013
45
FeNi References
The market also demands smelters with maximum capacity. Yet
SLN Eramet, New Caledonia
rectangular smelter technology comes with even more advantages:
In 2006, SMS commissioned the first 99-MVA FeNi furnace for
■ The most effective dedusting solutions at lower specific
investment
SLN Eramet in New Caledonia (Furnace No. 10), followed later by
a second 99-MVA FeNi furnace (Furnace No. 9).
■ Higher energy efficiency
■ Safer and cleaner working conditions
Owing to the success of this revamp, our customer decided to
■ Fewer spare parts and less wear on critical parts
modify Furnace No. 9 in the same way. Modernization of the fur-
■ Less maintenance, therefore higher furnace availability
nace – originally installed by SMS in 1971 – will more than double
(up to > 98 %)
its capacity. This remarkable increase is due to a special sidewall
■ Less manpower
cooling system and a higher transformer rating. Eramet was the
■ Generally much lower production and investment costs
first customer to benefit from implementation of the slab copper
■ Compliance with high environmental standards
cooling principle. With a length of some 35 m and six series-connected electrodes, the rectangular furnace is designed to pro-
During recent years, SMS has focused on different ways of improv-
duce up to 35,000 t of nickel per year.
ing the efficiency of its smelter portfolio. Due to high global metal prices, one of the most important factors driving plant efficiency is the level of recovery rates at high plant availability.
This type of “furnace tuning” is particularly interesting for customers in the ferroalloy sector who want to significantly increase
their furnace capacities without having to carry out extensive mod-
Our plants feature:
ifications to associated facilities such as buildings and foundations.
■ Higher recovery rates with rectangular furnace technology
The side wall cooling system does not feature any water passages
■ Higher specific power input with advanced sidewall cooling
inside the lining, so it is considered safer than other systems avail-
systems
able on the market.
■ Process optimization as a result of
intensive FEM modeling
■ Advanced process simulation tools for
improved training options
■ New process for faster settling of
finely dispersed matte/metal particles
SMS smelters are charged with either lateritic-based calcine as applied, for example, for POSCO SNNC/Korea, Eramet/New
Caledonia, Barro Alto/Brazil, or MOP/Brazil,
or with limonitic-based calcine as, for example, at Feni Industries in Macedonia and
Larco in Greece.
FeNi plant of SLN Eramet.
46
SAF Bulletin 2013
Larco, Greece
Various FeNi furnaces
Posco SNNC, Korea
135 MVA FeNi
FENI Industries, Macedonia
2 x 84 MVA FeNi
Minera Loma de Niquel,
Venezuela
2 x 45 MVA FeNi
Barro Alto (Anglo American)
2 x 114 MVA FeNi
MOP
2 x 120 MVA FeNi
Votorantim
63 MVA FeNi
Eramet SLN, New Caledonia
3 x 47.5 MVA + 2 x 99 MVA FeNi
(modified)
MOP, Brazil
with the high silica rates contained in the
Votorantim, Brazil
slag, the furnace cooling system comprisThese furnaces represent the world’s
es our unique SMS copper cooling side-
Votorantim Metais Niquel awarded SMS
largest ever built in terms of both dimen-
wall system in the slag zone, similar to the
a contract for a 63-MVA furnace for its
sions and transformer rating. In 2006, SMS
one used at Eramet in New Caledonia. It is
Tocantins project. Engineering activities
attracted a contract to supply 2 rectangu-
also possible to monitor each individual
started in May 2007, and commissioning
lar furnaces with 6 in-line electrodes of 120
feeding pile in order to optimize the melt-
was due in late 2008, followed by han-
MVA capacity each.
ing conditions and increase the melting
dover to the customer by mid-February
capacity.
A special feature of the furnaces is the
2009. The equipment was shipped to site
and the furnaces have been partly erected.
application of so-called gradators. These
The Onca Puma project enables Vale to
However, the project was put on hold after
improve the shielded arc operation in order
produce high-quality FeNi. The two fur-
the collapse of the Ni price.
to enhance the production rate. To cope
naces were commissioned in 2010.
Top view of the MOP plant in Brazil.
Model cross section of round furnace
with suspended brick type roof.
SAF Bulletin 2013
47
FeNi References
Barro Alto, Brazil
SMS delivered two FeNi furnaces to AngloAmerican do Brazil for their Barro Alto project. The two furnaces of 114 MVA each
will supply more than 50,000 tpa of contained nickel.
In principle, the furnace dimensions and
features are similar to the furnaces being
installed at MOP.
SMS in Düsseldorf and São Paulo were
responsible for engineering and procurement of the equipment. On-site erection
activities started in March 2008 with the
welding of the furnace base frames that
support the furnace shells. The furnaces
were commissioned in 2011 and reached
Furnace building of the Barro Alto plant in Brazil.
nominal capacity.
Larco, Greece
Larco is steadily upgrading its older Krupp
furnaces for FeNi production. Since 1999,
SMS has carried out numerous improvements to the columns, high-current supply system, hydraulic plant, etc. The modifications to furnaces Nos. 2 & 5 were
completed in 2006, and to furnace No. 3 in
2007.
Larco in Greece is one of Europe’s key ferronickel producers.
Slipping devices at manufacturing.
48
SAF Bulletin 2013
POSCO SNNC, Korea
New on the books in December 2012 was
an order for SMS Siemag from POSCO
SNNC, a global leader in FeNi production,
for the world’s largest submerged-arc furnace intended to produce FeNi. POSCO
SNNC is a joint venture between Korean
company POSCO and mining company
Illustration of the 135 MVA furnace for POSCO SNNC.
SMSP, which is based in New Caledonia.
The Ni ore from SMSP’s mine NMC is
the patented sidewall copper cooling sys-
operation and maximum production. What
shipped to the plant in Gwangyang, where
tem for the slag line level. The cooling rate
makes the gradators so special is that they
it is converted to FeNi.
will be improved compared to the old sys-
prevent rapid movements of the electrode
This is how POSCO SNNC aims to boost its
tems. The overall cooling rate required is
column and minimize the mechanical
annual capacity to approx. 54,000 tons of Ni.
moderate, ensuring better thermal efficien-
stresses on the equipment and the
The expansion at POSCO SNNC includes
cy and productivity of the furnace.
hydraulic unit.
the capacity increase of the New Caledon-
The binding system used here is the best
The supply scope covers engineering and
ian mine as well as an expansion of the
mechanical system for the controlled
supervision services as well as complete
FeNi plant. This requires other units plus
expansion of the furnace lining. It works
furnaces with the required features, includ-
an additional kiln for the production of cal-
with tie rods in the longitudinal direction
ing the electrics and automation.
cine, and a second submerged-arc furnace.
and with a balcony-shaped sidewall system
Our customer plans to commission the
The power rating of the rectangular FeNi
in the transversal direction.
plant in the final quarter of 2014. The pho-
smelter is 135 MVA, resulting in a total
SMS Siemag is well known for the high-
to shows the contract signing on December
nominal power input of approx. 100 MW.
quality electrode columns it developed par-
17, 2012 at the Gwanyang site together
To provide this enormous capacity, the fur-
ticularly for 6-inline rectangular FeNi fur-
with POSCO SNNC, Tong-il Boiler, and
nace requires impressive dimensions of
naces. The columns are energy efficient
SMS Siemag. This contract underlines SMS
approx. 40 x 15 m, making it the world’s
and operate at the highest availability level.
Siemag’s superior position in FeNi smelters.
largest electric smelter.
Furthermore, the furnaces are equipped
During recent years, all large scale FeNi
SMS Siemag is proud to work on this pro-
with gradators, allowing flexible furnace
smelters were supplied by SMS Siemag.
ject with such a renowned partner. POSCO
SNNC is well known for its excellent expertise in FeNi production. Designed with SMS
Siemag’s in-depth know-how and experience in ferroalloy furnaces, the new furnace will represent a milestone in largescale FeNi production. The local share of
production is carried out with Tong-il Boiler
as a consortium partner of SMS Siemag.
The company contributes its experience in
the manufacturing of this type of furnace
and was also involved in the first stage of
POSCO SNNC’s smelter project.
A whole string of innovations is incorporated in the smelter design. SMS Siemag will
use a modern air cooling system for the
lower shell. There will also be an upgrade of
Contract signing on December 17, 2012.
SAF Bulletin 2013
49
FeCr References
Introduction
to competencies in FeCr
High-carbon ferrochrome with carbon
contents of 4 - 8 % is usually used in
AOD converters for the production
of alloy steel grades. Due to environmental restrictions, ferrochrome is
commonly produced in closed stationary furnaces. Medium-carbon chrome
alloys (0.5 - 2 %C) and low-carbon FeCr
(<0.5 %C) are produced in combined
process stages. Both products require
View inside round furnace.
special slag metallurgy to attain high
chrome yields.
References
Ferrochromium specifications
of SMS Siemag regarding FeCr
H.C. FeCr
4 - 8 %C
M.C. FeCr
1 - 2 %C
L.C. FeCr
< 0.5 %C
SiCr
20 - 45 %Si
■ Market leader in SAF technology for ferro
alloy and circular smelters
(>100 references during the last 40 years)
■ 27 references for FeCr smelters
■ >90 references on DC-furnaces
■ >16 references (including conductive
hearth) for special smelters
■ Extensive track record on turnkey disciplines
■ New plant for Etikrom/Turkey including
energy recovery system
■ 4 x 72 MW furnaces for Kazchrome/
Kazakhstan
DC-furnace for FeCr production.
50
SAF Bulletin 2013
Kazchrome, Kazakhstan
4 x 70 MVA DC FeCr
Tulcea, Rumania
2 x 33 MVA FeMn, 43 MVA FeCr
2 x 55 MVA FeSi
Jindal Stainless, India
2 x 60 MVA FeCr
Etikrom, Turkey
2 x 30 MVA FeCr
Xstrata Lion, South Africa
63 MVA FeCr
Innovative DC technology
for metal production
SMS is the top-quality supplier of DC furnaces for metal production. To date, more than 80 steel furnaces and eight smelting furnaces have been installed by the company.
SMS holds patents for all bottom-anode systems (such as conductive hearth, billet-type, and pin-type systems). Even further
advanced, the furnaces of the next generation utilize a conventional electrode column system (also patented by SMS) that enables
the operator to control and slip the electrode under full power.
This significantly increases production levels. Furthermore, an inhouse design tool provides minimized arc deflection, which increases the lifetime of the lining.
DC technology is applicable in certain niche areas such as FeCr,
Co, TiO2, and waste recycling.
Illustration of a slipping device for DC-furnaces.
Included among the benefits of DC furnaces are:
■ Unique in-house know-how to minimize arc deflection
(busbar routing and electrode column)
■ Optimized energy consumption due to combined electrode
movement regulator with thyristor ignition controller and
high electrode speed
■ Patented reliable long-life electrode column system that
allows slipping and nipping under full power (providing
maximized power-on time)
■ Quick-change centerpiece device essential for maximum
operating time
■ Intelligent feeding arrangement to maximize throughput
and refractory lifetime
Lining procedure of a round furnace.
SAF Bulletin 2013
51
FeCr References
Reference Kazchrome
In September 2011, SMS Siemag received an order from
Kazchrome JSC for the engineering and supply of a FeCr plant. The
complex is currently under construction at the existing FeCr plant
in Aktobe/Kazachstan.
SMS is supplying four DC-based smelters with a power input of
72 MW for each furnace. The annual production of the plant (melt
shop No. 4) will be approx. 440,000 t of H.C. ferrochrome.
Kazchrome also placed an order for basic engineering of an AOD
converter for the production of approx. 50,000 tons of medium-carbon FeCr per year. The converter will be installed in the main
complex of melt shop No. 4. The process chosen ensures costeffective production of the grades FC 100, FC 200, and FC 400.
DC-furnace at Kazchrome during erection.
One of the world’s leading FeCr-producers, Kazchrome is part of
the ENRC group and already operates FeCr plants in the north-west
and central regions of Kazakhstan.
General application of FeCr –
AC-technology
Working together with Metix, SMS Siemag played a significant role
in supplying new FeCr furnaces as well as in revamping a large
number of furnaces worldwide. Most of the recent installations
were realized in South Africa, which is the country with the richest reserves of chrome ore minerals.
Tapping of a FeCr furnace.
Jindal Stainless, India
In 2006, Jindal Strips Ltd awarded SMS a contract for two semi-
SMS was responsible for the basic and detail engineering as well
closed 60 MVA submerged-arc furnaces for high-carbon fer-
as the supply of the key equipment. Included in the scope was raw
rochrome. The raw materials are chromite ore, mainly in the
material handling, two submerged arc furnaces with dedusting
form of briquettes, quartzite, and reductants such as nut coke and
plant, and engineering for the plant auxiliaries (prepared for the
Indian coal. The plant is designed for an annual production of
installation of an energy recovery system).
150,000 t.
Today, both furnaces operate above their nominal capacity.
52
SAF Bulletin 2013
ETI KROM
This contract comprised the revamp of the
two existing FeCr furnaces of ETI KROM
Tapped FeCr slag.
in Elazig, Turkey. The new furnaces were
connected to a 30 MVA-transformer.
has been delivered to site and erection is
Our scope of supply included the engineer-
basic and detailed engineering as well as
In 2011, Zimasco awarded SMS a contract
ing, the furnaces themselves, the hydraulic
the delivery of the mechanical and electrical
to revamp its existing FeCr furnace in Zim-
system, the water-cooled hood, and the
core components for the gas cleaning plant
babwe. This will increase the overall capac-
electrode columns. The two furnaces are
and the energy recovery system.
ity from 18 MVA to 30 MVA. SMS has
Zimasco
in progress. Included in the job were the
expected to produce approx. 90,000 tons
delivered the core equipment, such as the
of H.C. FeCr per annum. The smelters
A prime example of green technology, the
charging system, electrode column, fur-
were commissioned in 2011 and operate
energy recovery system utilizes the sensi-
nace roof, lining, as well as the trans-
reliably.
ble energy of the off-gas and converts it to
former. SMS is also responsible for the
super-heated steam. This steam then dri-
electrics and automation. Construction is
Additionally, ETI KROM placed an order with
ves a power generator. SMS calculates
ongoing and commissioning is expected
SMS Siemag for the installation of an ener-
that approx. 5 MW will be recovered as
to commence in the near future.
gy recovery system connected to the two
electrical power. Our customer has pro-
recently installed furnaces and the two refur-
jected an amortization period of less than
bished furnaces. Meanwhile, the equipment
4 years.
ETI KROM plant.
Open-type FeCr-furnace.
SAF Bulletin 2013
53
FeCr References
International Ferro Metals
Xstrata
(IFM)
Currently, a new Lion 2 plant is being built
We upgraded two 66 MVA FeCr furnaces,
featuring two 75 MVA FeCr furnaces
including new water-cooled copper delta
based on Xstrata’s PREMUS technology
sections for the furnace roof, additional
for pre-reduction. Here, Metix is supply-
charging chutes equipped with solid cop-
ing and installing complete sets of 1600
per feed chute tips, and modifications to
mm diameter electrode columns. The first
the four gas cleaning plants.
furnace is scheduled for start-up toward
the end of 2013.
This is just one in a series of projects covering jobs such as replacing the entire bot-
Previous projects on Lion 1 included the
tom electrodes with Metix equipment.
replacement of the electrode columns for
the two 63 MVA FeCr furnaces along with
associated secondary power factor correction. This enabled an increase in the power input to the furnace.
Poxer factor corrector Xstrata Lion 2.
IFM 3D illustration.
Xstrata Lion 2 project during construction.
54
SAF Bulletin 2013
Hernic Ferrochrome
Hernic F4 78 MVA roof.
One of the first major projects for Metix
consisted of supplying the overall EPCM
services for HFC’s F4PS2 project. The project involved a 350 000 tpa sinter plant and
a 78 MVA closed FeCr furnace with preheating. Work was completed in 2005,
simultaneously marking the launch of
Metix equipment onto the SAF market
with the supply of full electrodes (1750
mm diameter) to the biggest FeCr furnace
in the world.
Metix also modified two existing open
FeCr furnaces into closed furnaces by supplying new electrode columns, busbar systems, and closed roofs with copper roof
deltas. Also part of the supply and service
Hernic plant at night.
package were a new gas cleaning plant
and water treatment. The plant was recommissioned in 2010.
Tata Steel
Metix was the EPCM contractor for Tata
Steel’s FeCr plant in Richards Bay, with a
300,000 tpa briquetting plant and two 37
MVA furnaces commissioned in 2006.
FeCr plant of Tata Steel KZN.
SAF Bulletin 2013
55
FeMn and SiMn application
General application
FeMn and SiMn
Ferro-manganese is usually available on the
market as high-carbon (6 - 8 %C), mediumcarbon (1 - 4 %C), and low-carbon (< 0.4 %C)
ferro-manganese products. Alloys with high
Si contents (15 - 20 %) are known as silicomanganese. High-carbon ferro-manganese
and silico-manganese are produced in open
or closed furnaces with a stationary shell.
Ferro-manganese specifications
H.C. FeMn
6-8%C
M.C. FeMn
0.5 - 2 % C
L.C. FeMn
< 0.5 % C
M.C. SiMn
15 - 25 % Si, 0.5 - 2 % C
L.C. SiMn
25 - 35 % Si, < 0.5 % C
Illustration of a Closedtype FeMn furnace.
56
SAF Bulletin 2013
Mogale Alloys
in Krugersdorp
Upgrading of two SiMn furnaces with new
electrode columns, air-cooled roofs, gas
off takes, bus tubes and flexible cables.
Mogale air cooled roof.
Yunnan Metallurgical Group
Co Ltd in China
Metix completed the basic engineering for
a closed 67.5 MVA SiMn furnace, the
largest in China, as well as the detail engineering of the core equipment. This included the supply of the electrode column
(1750 mm diameter), copper delta roof,
and refractory freeze lining. The plant started up in 2011.
Forged copper delta roof.
SAF Bulletin 2013
57
FeMn and SiMn application
General application
Si-metal, FeSi and FeSiAl
Always aware of customer requirements,
The ferrosilicon grades produced in a submerged-arc furnace fea-
SMS has optimized its Si-metal-based
ture Si contents of 43 - 96 %. Grades with more than 96 %Si are
furnaces. The process requires a rotating
known as silicon metal. Due to the high energy concentration and
gear and ideally a 25 - 40 MVA trans-
the process gas formation involved, these applications make
former. Paramount for safe and reliable
extreme demands on the design and material. The furnaces are
operation are the proper design and quality
characterized by encapsulated electrode columns with hydraulic
of the rotating gear, furnace hood, hood
control, contact clamp tightening operation, and short and low
curtain/hood doors, the furnace itself, and
inductive electrical feeders. Silicon metal production units gener-
the electrode column.
ally utilize prebaked electrodes. SMS Siemag also provides special extrusion electrode systems for Si-metal production to reduce
Key advantages, confirmed by our
operating costs.
customers, are:
■ The only Si-metal plants with a heat
recovery system
Si-, FeSi- and FeSiAl-metal specifications:
■ More than 90 references for large-scale
Si-metal
> 99,9 % Si
FeSi
40 - 50 % Si FeSi45
■ SMS has a solid and sound reputation
FeSi
72 - 78 % Si FeSi75
which attracts customers and project
FeSi
85 - 96 % Si FeSi90
financing => best reputation for
FeSiAl
(depends on raw material
Si-metal furnaces worldwide
specification)
Si-metal and FeSi furnaces since 1970
■ Widespread network with furnace
operators, off-takers, and consultants
provides additional in-depth know-how
■ Overall intelligent logistics ensure
smooth operation without bottlenecks
=> proven in many plants all over the
world
SMS also participates in developments
for the production of solar silicon, supplying equipment to one of our European
customers. This company will utilize a
DC furnace currently under construction
to produce solar silicon. Our department
is supplying the core equipment for the
furnace and the DC electrode column,
Illustration of an Si-metal plant.
which will result in maximum power-on
time for top productivity.
58
SAF Bulletin 2013
Becancour Silicon, Canada
1 x 47 MVA FeSi, 2 x 20 MVA Si-metal
IMC, USA
1 x 67 MVA FeSi
RW silicium, Germany
24 MVA Si-metal
Bjölvefossen, Norway
1 x 36 MVA FeSi, 1 x 24 MVA FeSi, 1 x 13 MVA FeSi
Zunyi, China
2 x 50 MVA FeSi, 1 x 30 MVA FeMn
Evonik, Germany
Solar silicon pilot furnace
Bluestar, China
4 x 30 MVA Si-metal
Airco Alloys, USA
1 x 60 MVA FeSi +
1 x 36 MVA FeSi
Northwest, China
2 x 25 MVA FeSi
Asia Cement
2 x 37.5 MVA Si-metal
Tulcea, Rumania
2 x 33 MVA FeMn,
43 MVA FeCr 2 x 55 MVA FeSi
Dow Corning/CBCC, Brazil
2 x 30 MVA FeSi +
1 x 19 MVA Si-matal
Kyrgyz Ferroalloy Plant, Kazakhstan
2 x 45 MVA FeSiAl
CCM, Brazil
4 x 18 MVA Si-metal
Basco, Kazakhstan
2 x 30 MVA
Liasa, Brazil
2 x 18 MVA Si-metal
POSCO
2 x 31.5 MVA FeSi/Si-metal
IFC, Iran
52 MVA FeSi
IFC, Iran
39 MVA FeSi
Gulf Ferro Alloys Comp. Saudi Arabia
4 x 27 MVA SiMn, FeMn, FeSi, Si-metal
BAP Billiton Metallurgy Ltd., South Africa
81 MVA FeMn
Simcoa, Pty, Australia
2 x 27 MVA Si-metal
RW silicium/Germany
Modernization of the SAF at RW silicium successfully
Re-commissioning took place in 2009. The SMS scope of supply
completed
and services covered the layout of the air injection and cooling
RW silicium GmbH of Pocking, Germany, re-started its silicon
water system, the planning, design, and supply of three electrode
SAF after a successful revamp. The aim of the modernization was
lines, the water-cooled gas hood with moving chain curtain, and
to equip the furnace for higher production.
the high-voltage system. RW silicium GmbH is a German manufacturer of metallurgical silicon.
Furnace at
RW silicium.
SAF Bulletin 2013
59
FeMn and SiMn application
POSCO/South Korea
In July 2011, SMS attracted an order from Posco in South Korea
for two 37.5 MVA FeSi furnaces for high-purity (HP) FeSi. The furnaces are equipped with a rotating gear so our customer can also
use them to produce Si metal at a later stage. We are supplying the
furnace itself, the main electrical supply systems, the automation
system, and the hydraulic unit. According to the customer’s time
schedule, the furnaces will be commissioned in 2013. A special feature here is a suspended electrode column, making for a very precise and compact design. This minimizes electrode breaks, while
also reducing building costs. The plant is under construction at the
POSCO site in Pohang in South Korea.
FeSi furnace prior to start up.
Basco, Kazakhstan
According to the customer, the innovative Si metal production
This project comprises the turnkey supply of two 21-MW fur-
line will be commissioned sometime in 2009.
naces for Si metal production. Not only the furnaces themselves,
Based on our experience from supplying over 30 furnaces in the
but the entire plant from delivery of the raw material to packing of
last few years, we can say that the furnace capacity of 21 MW cho-
the final product (Si metal lumps) is in SMS hands. Also party to
sen here is the best size for large-scale Si metal furnaces.
the contract alongside SMS is Thyssen Krupp Mannex (TKM).
The plant is designed to operate under extreme weather condi-
The end customer is Vassili Import in Almaty, Kazakhstan.
tions, ranging from 45 °C in summer to minus 40 °C in winter.
Basco plant.
60
SAF Bulletin 2013
Asia Cement
Furthermore, Asia Cement of South Korea contracted SMS Siemag
to supply two 31.5 MVA Si metal furnaces. Due to favorable local
conditions, Asia Cement decided to install the Si metal plant in
Malaysia. The scope of the project is similar to the POSCO order
and commissioning is scheduled for 2014.
Kyrghys Ferro Alloys/
Kirgizstan
Closely cooperating with Kyrgiz Ferroalloys in Kazakhstan, SMS
Siemag is developing a new process for the production of FeSiAl.
High current lines.
The most significant innovation is a special process that uses
reverts from the coal processing industry as the major raw mate-
Dongbu Metal
rial for the production of this special alloy. The furnace type is
similar to Si metal furnaces. In the first phase, SMS Siemag is
At the beginning of 2013, Dongbu Metal placed an order with SMS
supplying the raw material handling system, the furnace, the tap-
to install a comparable unit in the same location in Sarawak/Malaysia.
ping equipment, the product handling system, and the dedust-
The scope of supply for the two 33 MVA Si metal furnaces includes
ing unit. The reason our customer decided to build the plant in Kir-
the electrode column with high-current supply system, the hydraulic
gizstan is the very low cost of electricity there. FeSiAl is used as
unit, the water-cooled roof, and the rotating gear. Commissioning
an alloy and desoxidation agent in the steel industry.
of the first furnace is scheduled for 2015.
Manufacturing of
a gas hood.
SAF Bulletin 2013
61
Non ferrous metals
General application
non-ferrous metals
Most smelters supplied
to the non-ferrous metals
industry feature slag-based
processes, recovering the
maximum amount of valuable metals from the slag.
The principles behind these
processes emerged in the
1950s.
Slag cleaning furnace.
Solidified Cu-slag.
62
SAF Bulletin 2013
Nickel matte
and copper matte
There is a broad similarity between the ferronickel process and the production of copper matte and nickel matte from primary
smelters and converter slags in electric
furnaces. Both use closed, stationary-type
furnaces. Usually, round furnaces are used
for smaller to medium-size quantities,
while large quantities are produced in rectangular furnaces.
Slag cleaning furnaces
We supply several submerged-arc furnace
units for slag cleaning. This is where we
Two-line solution for slag cleaning.
draw on our know-how from more than
30 references to date. The slag is either
liquid-charged into the furnace or coldcharged in solid form via conventional feeding systems. These furnaces are used for
various applications such as copper (for
example from a Teniente converter, Pierce
Smith converter, Outokumpu flash
smelter, Noranda converter, reverts).
■ nickel
■ cobalt
■ lead (for example, from Kivcet
process) and secondary lead
■ zinc
■ tin and secondary tin
■ platinum
■ palladium
Cleaning system of a Cu-slag cleaning furnace.
SAF Bulletin 2013
63
Non ferrous metals
Lead and zinc
Zinc exits the submerged-arc furnace with
the gas phase. Residual metals and slag
are tapped separately. Other applications of
submerged-arc furnaces are recycling flue
dust from the steel industry (for example,
EAF dust) and recycling slag containing
Pb/Zn from BF-based zinc/lead production
plants.
Cu slag cleaning
Slag cleaning furnaces are commonly connected to copper smelting units such as
the Teniente and Noranda converters, Outokumpu flash smelter and Isasmelt/AusTapping area of a rectangular slag cleaning furnace.
melt-type furnaces. The main function of
electric furnaces is to reduce the copper
level in the slag. SMS furnaces reduce the
level from 1 - 8 % to 0.6 - 0.9 %.
Rectangular furnace design
for slag cleaning
A renowned supplier in this field, SMS has
supplied more than 25 slag cleaning units
in the past 40 years. Depending on the
process, the slag is either liquid-charged
into the furnace via launders or coldcharged in solid form via conventional feeding systems. The application range is very
wide, with units operating in copper, nickel, cobalt, lead, tin, zinc, and precious metals (platinum/palladium) production.
Top view of a rectangular slag cleaning furnace.
64
SAF Bulletin 2013
Aurubis, Germany
1 x 9 MVA Copper slag-, 1 x 8 MVA Cu/
Pb-slag cleaning Kaldoconverter 20 t
Kazzinc, Kazakhstan
1 x 11 MVA Copper slag cleaning
Atlantic Copper, Spain
1 x 11 MVA Copper Slag
Codelco, Chile
1 x 9.5 MVA Copper Slag
1 x 14 MVA
Thai Copper, Thailand
1 x 10,5 MVA Copper slag
Birla Copper, India
1 x 8 MVA Copper slag
FQM, Zambia
1 x 22 MVA copper slag cleaning
Enami Paipote, Chile
1 x 11 MVA Copper slag
Mopani Copper Mines, Zambia
1 x 12 MVA copper slag cleaning
Today we can identify a trend toward rectangular slag cleaning units.
Lonmin, South Africa
1 x 9 MVA Platinum slag
■ Expansion of bottom refractory
controlled in both directions by frame
design => no bulging
Increasingly, semi-continuous operation is
■ Easier arrangement of channel cool-
used for primary smelters (such as ISAS-
ing or copper cooling system for the
MELT or Ausmelt) as well as for slag cleaning furnaces. Rectangular SAFs are more
suitable here because of their superior
geometry.
sidewalls
■ Easy installation of channel cooling
for bottom part of the furnace
■ Easy arrangement of metal/slag
tapping equipment
SMS calculates that the recovery rate of a
rectangular furnace in continuous operation can be 0.1 - 0.4 % higher than that of
conventional SAFs (depending on the specific parameters).
The advantages of rectangular as against
circular furnaces can be summed up as
follows:
■ Optimum settling conditions in largecapacity units (>20 MW)
■ Smaller furnace cross-section due to
more effective furnace volume
■ Three or six electrodes in-line provide
even power distribution
■ Compared to round furnaces, no dead
areas between the electrodes
■ Smaller transformer connecting load
due to smaller furnace cross-section
Cu-slag granulation system.
SAF Bulletin 2013
65
Non ferrous metals
Mopani Copper Mines/Zambia
The rectangular furnace at Mufulira in Zambia is now primarily
used for copper slag cleaning. It is installed downstream of an
IsaSmelt furnace for cleaning copper slag. SMS envisages
improved metal/matte recovery as well as higher energy efficiency and process flexibility.
The first matte and slag were tapped in September 2006. The
results for the recovery rate confirm the optimal depleting conditions of this type of furnace.
Mopani plant during construction.
Kazzinc, Kazakhstan
In December 2006, SMS received an order from Engineering
Dobersek for a rectangular slag cleaning furnace, again placed
downstream of an ISASMELT smelter. Engineering Dobersek
was the general contractor on behalf of Kazzinc in Kazakhstan. Following its completion, the entire plant, including the depleting
furnaces, was commissioned in 2011.
After Mufulira, this is yet another project that proves the plant
configuration is gaining acceptance as a viable and efficient concept for copper production.
The advantage of the method is that the electric furnace becomes
a key unit in the overall copper smelter configuration, acting as a
buffer for the copper matte. This in turn results in flatter operation
peaks for both the primary smelter and the converters.
66
SAF Bulletin 2013
Kazzinc plant during construction.
Lonmin
Acting as part of an owner’s team, Metix
supplied the 6 electrode columns and performed the EPCM services for a 6-in-line
platinum matte furnace.
First Quantum
The most recent order for slag cleaning
Lonmin slipping
devices.
furnaces came from Kanshanshi Mining
Plc. in Zambia, a company owned by First
Quantum Minerals.
The project started in March 2012 and the
engineering is now completed. We expect
the first slag to be charged into the furnace in 2014.
Designed for a production of 200 tons of
matte and slag per year, the ISASMELT
smelter requires a large slag cleaning unit.
That is why SMS will first install a 6-inline
rectangular slag cleaning furnace with a
transformer rating of 24 MVA. The supply
package includes the furnace, the charging
system and tapping system, the electrode
columns with the hydraulic unit electrics
and automation, the tapping equipment,
the hydraulic unit, and the transformer with
the high-current line system.
This project represents a new milestone in
copper slag cleaning technology.
First Quantum plant
during erection.
SAF Bulletin 2013
67
TiO2-smelters
General application
TiO2-smelters
What makes electric smelters
for special applications
challenging is the fact that
they are usually tailor made
for unique requirements.
This demands especially
in-depth know-how of the
development of such units.
Titanium slag furnaces produce TiO2-rich
slag and pig iron as a valuable “by-product”. The ilmentite ore can be processed
either in DC or AC furnaces.
It is not necessary to pre-treat the ore
before directly smelting ore fines in DC
furnaces. Usually the specific electrical
power consumption is higher due to the
Model of DC TiO2 Slag furnace.
lower thermal efficiency of the furnace. In
South Africa, most smelters are DC-based.
References since 1990: 6
Other companies produce TiO2 slag in ACbased smelting units, using either circular
Titanium oxide slag
or rectangular furnaces.
■ The market for TiO2 products shows
a strong demand
■ Numerous large scale projects are
currently under discussion mainly in
South Africa, Australia, Middle East
and North America
■ Major product is rutile rich slag
68
SAF Bulletin 2013
■ Pig iron as a valuable “by-product”
■ New trend in DC based technology
■ AC technology still dominating in
the market
■ For AC solutions, SMS Siemag
proposes closed type rectangular
and circular type furnaces
Yunnan XinLi, China
This project involved the supply of a DC furnace for titanium slag
production. Besides the engineering, SMS is also supplying proprietary equipment such as the high-voltage system, furnace shell,
and water-cooled roof.
This last installed reference means that SMS has supplied the
major equipment for almost all DC-based titanium slag furnaces.
The furnace in XinLi was commissioned in 2010.
Roof of a DC-furnace for titanium slag production.
Titanium slag production plant in South Africa.
SAF Bulletin 2013
69
CaC2-production
General application
calcium carbide
Calcium carbide (CaC2) is used as the
■ Calcium carbide (CaC2) is used for:
starting material in the production of
- PVC
acetylene and calcium cyanamide. Initial-
- Acetylene
ly, acetylene was produced for lightning
- Calcium cyanamid
purposes, then its market was extended
through welding acetylene to the manufacture of organic products from acetylene. In organic and plastics chemistry,
- Desulfurization agent
■ Growing demand due to higher oil
prices
■ China as world largest CaC2 producer
calcium carbide is in strong competition
intends replacing 30 % of smaller
with the various processes for the pro-
units with large furnaces
duction of acetylene from hydrocarbons.
Today, calcium carbide is mainly used in
the chemical industry and as a desulfur-
References
ization agent in the steel industry.
since 1960: 27
Calcium carbide – Example: Guodian Younglight and Junzheng Energy
■ Project goal: Fulfilling the Chinese market demands for
environmentally friendly and efficient large scale CaC2production line
■ SMS Siemag developed efficient large scale 81 MVA units
with HES (hollow electrode system) allowing the direct use
of fines
■ Currently three projects are under execution in the inner
Mongolia: Guodian Younglight (6 furnaces for 750,000 tpy)
and Junzheng Energy (4 furnaces for 500,000 tpy)
■ The produced high quality Calcium Carbide will be further
processed in the companies internal chemical plant for the
production of PVC etc.
70
SAF Bulletin 2013
Cyanamid, Canada
1 x 108 MVA CaC2
Alzchem, Germany
1 x 43.5 MVA + 1 x 70 MVA CaC2
VEB, Germany
1 x 40 MVA CaC2
U.P. Carbide, India
1 x 12 MVA CaC2
Carbudo del Cinca, Spain
1 x 25 MVA CaC2
M.P. Carbide, India
1 x 12 MVA CaC2
Guodia Younglight, China
6 x 81 MVA CaC2
Donau Chemie, Austria
1 x 24 MVA CaC2
Carbide Fox, Rumania
1 x 40 MVA CaC2
Metaloides, Mexico
1 x12 MVA CaC2
Junzheng Group, China
4 x 81 MVA CaC2
MCB Industries, Malaysia
12 MVA CaC2
White Martins, Brazil
49.5 MVA CaC2
Electrona Carbide, Tasmania
1 x 15 MVA CaC2
HECI, South Africa
1 x 57 MVA CaC2
Illustration of calcium carbide furnaces.
Goudian Younglight/China
In 2010 and 2011, SMS Siemag was contracted by 2 major CaC2 producers in China for the engineering and supply of the
world’s largest CaC2 furnaces.
Featuring a power rating of 81 MVA, they
achieve an annual production of over
120,000 t each.
The 6 furnaces ordered by Guodian Ningxia Younglight are located in Ningxia
province while the 4 furnaces of Junzheng
energy operate in the province of Inner
Goudian Younglight furnace during construction.
Mongolia.
SAF Bulletin 2013
71
CaC2-production
All furnaces are equipped with a hollow electrode system (HES)
unique in the PR China. This system enables operators to also
charge fine material.
Besides the basic engineering and detail engineering of the entire
furnace plant, SMS is supplying the proprietary equipment such
as electrode columns, high-current lines, and hydraulic plant. Further, SMS is responsible for the automation system.
Most of the high-quality CaC2 produced in the new 46.5 MW furnaces is directly converted into acetylene gas on site.
Acetylene gas is a chemical base material for the downstream
production of a wide variety of chemical products such as PVC and
other plastics.
By producing CaC2, companies in the provinces in northern China
can make use of their rich resources of coal and limestone, the sole
raw materials for CaC2 production.
The first furnace was commissioned by Junzheng Energy in 2012.
Calcium carbide
furnace during
tapping.
72
SAF Bulletin 2013
3D-model of the Hollow-Electrode-System (HES).
General minerals
General application
minerals
General minerals
The SAF principle makes it possible to melt minerals with high
fusion temperatures. That’s why our furnaces are also applied
in various fields for refractory and mineral production. The following products can be produced with SAFs:
■ corundum (Al2O3)
■ fused magnesia
■ fused minerals
■ mineral and slag wool
■ refractory fusion furnaces
Illustration of a fused
magnesia production
furnace.
Magnezit Group,
Satka/Russia
The Magnezit Group, which is based in
Satka/Russia, awarded SMS a contract for
the engineering and supply of 10 smelting furnaces for the production of fused
magnesia. The plant in Satka will receive 5
furnaces and 5 more will go to the plant in
Rasdolinsk. Each furnace has a transformer
capacity of 8.8 MVA and produces approx.
10.000 t/y of fused MgO.
We are supplying the engineering and the
complete furnaces as well as the electrics
and automation.
According to schedule, the first furnaces
will be commissioned in 2014.
Illustration of a fused magnesia smelting plant.
SAF Bulletin 2013
73
Waste treatment
Zero-waste metal production
philosophy – waste recycling
with SAF technology
Steel mill waste treatment
Overview of waste sources of
various industries
Today’s increased landfill costs for steel mill
waste residues, stricter environment regula-
Steel mill wastes
tions, and increasing public resistance to
EAF-, LF-dust, sludges (dewatered) from cooling
waste dumping are driving the iron and
water, mill scale, oily sludges, grinding swarf
steel industry to adopt greener solutions on
site. This is where SMS offers a wide range
Automotive Industry
of technologies for the treatment of almost
Spent catalysts, diesel engine filters
all accumulated steel mill waste without
affecting quality or plant productivity, while
Battery Industry
minimizing overall steel plant emissions.
NiCd/ZnMn-Batteries
FeNi Industry
Flue dust
Power plant flue dust
Flue dust recycling to non-leachable slag
Dry dusts
Slag former
Mill scales & sludges Reductants (e.g. coal)
Drying and grinding
Daybins
Air preheater
Mixer
Bagfilter
Submerged Arc Furnace
Pig Iron
(Cr, Ni, Mo-rich)
Slag
74
SAF Bulletin 2013
Zn-Pb rich dust
Single level treatment
for waste recycling.
Here are some of the products SMS
supplies in the field of waste recycling:
■ Better material yields and energy
able slag can be sold to the zinc/lead,
utilization
cement, or road construction industries.
■ Single smelters on AC basis
■ Single smelters on DC basis
■ Rotary hearth furnaces (RHF) –
There is plenty of scope for improvement
The metal and metal oxide components
here, because steel mill waste products
from the waste material are almost fully
submerged-arc furnaces (RedSmelt
are generated in almost all process lines,
transferred into the metal phase. Taking
process)
starting with iron-making units (including
typical steel mill waste from the stainless
raw material transport and preparation)
steel industry, the smelter produces an
through to finishing lines such as cold
alloy with up to 6 % Ni and 15 % Cr.
■ Fine charging using the hollow electrode system
rolling and pickling lines.
All the above technologies meet zero-
Furthermore, the smelter produces an inert
waste steelmaking requirements:
What zero-waste steelmaking technology
slag which is a good base product for the
■ Treatment of all residues from iron
does is convert the majority of these
cement and road construction industry.
reverts into non-hazardous, saleable prod-
The majority of the zinc and lead is collect-
ucts and re-introduce them into iron and
ed as an oxide in the flue dust. This mate-
steelmaking processing lines. Other prod-
rial also finds its consumers in the lead and
ucts such as crude zinc oxide or non-leach-
zinc-producing industry.
and steelmaking operations
■ No effect of waste recycling on steel
quality and productivity
■ No increase in overall emissions to
the atmosphere
Raw material preparation
Iron bearing
material
(ores or residues ...)
Heating and
chemical reduction
Grinder
Mixer
Green
pellets
Final chemical reduction
and smelting
Submerged
Arc
Furnace
Rotary
Hearth
Furnace
Hot
metal
DRI
Reductant
(coal, pet coke ...)
Slag
Pelletizer
Binders and fluxes
(bentonite,
lime, chemicals)
Electricity
Steam
Dust/Waste
Dust/Waste
Power
co-generation
Steam
Flow sheet of the
RedSmelt process.
SAF Bulletin 2013
75
Plant revamps
Plant revamps
and production increases
Over the last 35 years, SMS has modified
more than 80 submerged-arc furnaces.
Revamping plants is challenging because
of the nature of brownfield design.
It requires the lowest possible downtime
Electrode column
lower part.
as well as adaptation of the existing plant
environment.
To meet these challenges, we design our intelligent solutions so
There is no better demonstration of the capacity expansion that
they achieve higher production levels while retaining the approx-
can be achieved with a newly-developed copper cooling sys-
imate dimensions of both the furnace and the plant. It is also pos-
tem than the rectangular submerged-arc furnace we installed
sible to boost production with intelligent logistical improvements
in New Caledonia. The application of AC thyristor control systems
and charging patterns.
can boost the production of conventional FeNi furnaces by up to
10 %. Furthermore, the system smoothes the regulation of the
You can choose from the following options for optimizing plant
electrode columns.
efficiency:
■ Electrode column modification
In applications where the furnaces run on high current (> 80
■ Sidewall cooling systems
kA), it is possible to save electrical energy by using material that
■ Thyristor control systems (mainly for FeNi application)
minimizes the electrical losses caused by induced magnetic
■ Charging systems/infrastructure optimization
fields. Often, the use of antimagnetic material pays off in less
■ Furnace enlargement
than a year.
■ Transformer capacity enlargement
Revamp of a FeNi furnace.
76
SAF Bulletin 2013
Modified FeCr plant.
Innovations
R+D and
latest innovations
A key factor in the global leadership of SMS in electric
smelters is the creative spirit of our engineers. Their
inspired thinking enables them to develop new application
areas for smelters, and optimize existing designs. Our teams
cooperate with our customers as well as reputed institutes
and universities to develop groundbreaking innovations.
Constant interaction with third parties gives us new impulses and new insights.
See below for a list of just
Major R+D activities for
some of our partners:
SAF technology
■ Institute for Process Metallurgy and
Strategic developments
Metal Recycling (IME) in Aachen/
■ Intensive DC-based slag cleaning unit
Germany
■ Large scale Si-metal furnaces (40 MW)
■ Institute of Ferrous Metallurgy in
Aachen/Germany
■ Technical University Dortmund/
Germany
■ University Duisburg-Essen/Germany
Test furnace at the University in Aachen/Germany.
■ Two-furnace concept for L.C. FeCr
production
■ New process lines with pilot smelter
at IME/University in Aachen/Germany
■ New waste recycling concept
■ Slag-Institute Rheinhausen/Germany
■ University in Delft/Netherlands
Fundamental research activities
■ SGA in Othfresen/Germany
■ Fundamental R+D for new process
■ Universidad de Chile in Santiago/Chile
lines AC vs. DC
■ Mintek in Jo-burg/South Africa
■ Modeling of various processes
Basically, our company differentiates
Operational research activities
between strategic, fundamental, and
■ Thyristor control system of the next
operational developments. The table
below shows the major topics we tackle
FEM simulation regarding the gas flow pattern in
submerged arc furnaces.
generation
■ Development of new cooling concepts
here.
SAF Bulletin 2013
77
Innovations
New testing options
at RWTH Aachen
SMS has developed a pilot electric smelter
furnace and donated it to the IME (Institute for Metallurgical Processes and Metal Recycling) at RWTH University of
Applied Sciences in Aachen/Germany.
This multi-purpose furnace makes it possible to run metallurgical smelting processes such as ferroalloys, non-ferrous metals, mineral wool, slag cleaning, steel mill
waste recycling, waste recycling of nonferrous and ferroalloy residues, and steel
production on a semi-industrial scale. Usually, the data gained is sufficient for upscaling new processes.
Ferro alloy pilot furnace at the IME in Aachen/Germany.
The heart of the 1-MVA furnace is an intelligent power connection, and the following
modes are available:
Implemented here is a unique multiple■ 3-electrode DC-operation mode with
section design for testing sidewall cooling
AC-mode simulation
systems such as spray cooling, channel
■ 2-electrode AC-mode
cooling, and intensive copper cooling.
■ 1 - 3-electrode DC mode
What makes the furnace so valuable is
that it is large enough to provide impor-
Central to the furnace is a conductive
tant information for up-scaling new
hearth. The charge can be fed either via
processes.
charging tubes or hollow electrodes to
evaluate optimized feeding patterns.
Designed for direct comparison of the
effects of DC and AC operation, the furnace is the first of its type.
The test unit will be available sometime in
2013.
Illustration of pilot furnace for RWTH Aachen.
78
SAF Bulletin 2013
Slag washing machine
SMS is working hard on an innovative,
intensive slag cleaning stage arranged
downstream of conventional slag cleaning
furnaces. This new development overcomes the problem of finely dispersed
Slag cleaning pilot furnace at Aurubis.
smaller precious metal droplets that do not
gravitationally settle into the matte/metal
phase of the furnace.
This has always led to a considerable portion of precious metals remaining in the
slag phase. The new invention is a very
attractive solution, especially for the copper
and platinum metals industry.
In copper slag cleaning, the copper content of the slag can be further reduced by
0.2 - 0.5 percentage points.
We have already demonstrated the recovery of copper inclusions. Currently, we are
in talks with the platinum and palladium-
Top view of slag cleaning pilot furnace.
producing industry, above all in southern
the
University
of
Chile
(UDC)
in
Africa. According to test results, the recov-
In the first zone of the furnace, the slag is
ery of 50 % of the matte containing plat-
electromagnetically stirred, causing partial
Santiago/Chile. Recently the process was
inum inclusions is feasible at a unitary elec-
coagulation of the smaller metal droplets.
demonstrated in a large-scale demonstration plant in Europe.
tricity consumption of 50 - 70 kWh/t of
slag.
Then, in the second zone, the droplets are
forced by capillary motion towards the
This plant achieved reductions in copper con-
metal/matte phase, and additional elec-
tent in the slag of up to < 0.4 % (depending
nace are simple. The small channel-type
trolytic effects increase the metal recov-
on the original slag copper content).
unit has a permanent DC field combined
ery rate. This unit/process is patented for
with a magnetic field.
all metals.
The principles behind the channel-type fur-
There is a huge economic potential of the
“slag-washing machine” for certain appli-
The principles of the new slag cleaning
cations, with amortization periods of less
stage were jointly developed by SMS and
than 6 months possible.
SAF Bulletin 2013
79
Innovations
Development
of a two-stage L.C. FeCr process
Also under development at SMS is an innovative, two-stage subTwo stage process
for the production of
L.C. FeCr
merged-arc furnace process. New here is that SiCr is produced in
As a result, SMS is negotiating with a num-
the first stage, which is then charged together with Cr-ore and
ber of companies in the copper and PGM
lime into the second unit. This process combination allows C-con-
industry with a view to installing the first
tents of < 0.05 % in the FeCr. The main benefits are lower ener-
industrial-scale plant.
gy costs at an improved yield.
The advantages of the unit are obvious:
Development
of large scale Si-metal furnaces
■ High recovery of precious metals
■ Extremely low investment because of
simple principle
■ No control of the electrode necessary
=> easy operation
■ Minimum graphite anode consumption due to coke layer principle
■ Bypass option does not affect daily
operation and minimizes project risks
■ Small compact unit fits in almost all
downstream locations of the primary
smelting unit
This unit is patented for all kinds of metal,
slag and matte in batch and continuous
operation modes.
Currently, a pilot plant is being installed at
a European copper producer (see photo of
the unit during manufacturing).
Rotary hearth furnace/submerged
arc furnace combination for FeCr
production.
80
SAF Bulletin 2013
There is a strong demand in the Si-metal industry for larger units.
This is because the power input of the smelters is limited by the
electrode design. We are working on numerous concepts designed
to boost future furnaces to power levels of > 40 MW.
Pre-reduction
Development
of ore in rotary hearth furnaces
of slag energy recovery systems
SMS is examining the potential of using rotary hearth furnaces as
So far, recovering the sensible heat from the slag has been an elu-
a pre-reduction step for FeNi and FeCr. The results of tests con-
sive goal. Achieving this would make a big difference in furnaces,
ducted in two demonstration plants look promising, and depend-
which generate large amounts of slag. Now SMS is investigating
ing on the location, the RHF-SAF process combination may
a new dry slag granulation option which promises a breakthrough.
become a competitive alternative to conventional process combi-
Smaller-scale pilot tests have already demonstrated the technical
nations on the market today.
feasibility of the method. The encouraging results convinced a
leading German steel producer to install a large-scale demonstra-
In particular, SMS sees potential benefits from using RHFs to
tion unit. The first results will be available in 2013.
pre-reduce fines from Ni-calcination kilns.
Steam
14 bar abs.
320°C
Crushing,
Liberating
Hot conv
eyor
Stack
Fan Heat Recovery
Steam Generator
Cyclone
Steel sphere
injection
Impact Cone
Slag
Slag Caster
Buffer
Heat
Exchanger
Cold conveyor
Feeding device
Feed water
Magnetic
sepatator
Extraction
device
Rotary
valve
Fan
Slag
Flow sheet of a slag energy recovery system.
SAF Bulletin 2013
81
Metallurgical department
Our Metallurgical department –
expertise in submerged-arc furnaces
Both process definition and furnace dimenDuring the last decade, around 60 different
sions are determined hand-in-hand with
products were processed with SAF technolo-
the Metallurgical department. To ensure
gy for the ferroalloy, non-ferrous metals, iron-
your furnace features the optimum dimen-
making, and special applications industries.
sions, we analyze all your process and met-
Each individual process requires extensive
allurgical requirements. Intelligent dimen-
and detailed process know-how.
sioning maximizes yield, while keeping
energy consumption down.
The expertise of our Metallurgical department is the basis for efficient
design as well as safe and reliable operation of each application.
Our professional support during the commissioning phase helps operators progres-
We also cooperate very closely with a large number of plant oper-
sively ramp up their plant. You can choose
ators as well as with reputed institutes worldwide. The result of
classroom training, on-the-job training,
our decades of work was a metallurgical model based on practical
work situation evaluations and, when
and scientific data. Using our in-house software for complex metal-
required, external experts for a certain
lurgical evaluation, our experienced staff provide you with reliable and
product. SMS not only gets your plant up
achievable figures.
and running, but also makes sure your
operators understand how it works.
Plant data: from data
to information
Larger furnaces and higher loads mean
that both equipment and processes
become more complex to monitor. Collecting and processing enough data without swamping operators with irrelevant
information is a constant focus of SMS
Siemag.
When the right instrumentation is provided from the start and the data is displayed
and collected in a structured way, both
operators and managers can use this information to their advantage.
82
SAF Bulletin 2013
SMS Siemag is committed to optimizing
the whole chain from data collection to
display. This is only possible when experts
Submerged carbon
electrode.
from both sides work together at an early
stage to design the optimal solution. SMS
Siemag applies its experience to convert
raw data into the information required to
upgrade your system and ensure it runs
smoothly.
Data acquisition &
evaluation
SMS Siemag collects data using a highresolution system. Then the data can be
processed in a common program such as
Excel. Your own staff can do this on site,
if necessary with the support of SMS
Metal tap.
Siemag personnel.
Another option SMS Siemag offers is
online support. With temporary access to
the data, SMS Siemag can evaluate the
situation from our head office in Germany
and propose solutions.
Data archive
Naturally, supplying furnaces for over a
century has given us a lot of experience.
SMS Siemag maintains databases on operations, furnaces, experience, and raw
materials. While respecting client confidentiality, SMS Siemag’s extensive knowledge is at your disposal to benefit new
projects.
Data archive system.
SAF Bulletin 2013
83
Electrical and automation systems
Introduction to the Electrical and
Automation Systems department
Holistic system competence
X-PACT® electrics and
automation
Electrics and automation
Modern metallurgical plants from SMS fea-
for submerged-arc furnaces
ture high availability and meet today’s ever-
SMS electrics and automation systems
& electric smelters
increasing end-product quality require-
are known collectively under the brand
ments. That’s because we supply the
name X-Pact®. It covers all process levels.
harmonized system components necessary. SMS is the ideal main contractor,
Modular in structure, X-Pact® can be adapt-
offering you the complete package of engi-
ed or expanded flexibly to meet your
neering, construction, and commissioning
requirements. X-Pact® integrates the dif-
from a single source.
ferent levels of electrics and automation.
Included here are not only technological
controls and process models, but also all
tasks of modern plant automation from drive technology and sensors (Level 0) right
Production planning
systems
Technological process models
Material tracking & data servants
Reporting
Technological controls
Sequence controls
Drive controls
up to production planning (Level 3).
SMS supplies professionally integrated
hardware for the electrical and automation
requirements of all product sectors. Our
solutions cover the engineering and implementation of all automation systems, plus
safety engineering. You can rely on a complete package for the whole plant, includ-
Energy distribution
Drives
ing the planning of switchgear rooms and
operating pulpits as well as cable routes.
To ensure successful production, you
require effective strategies for production
monitoring and operation. With these solutions in place, all the information on the
production process comes together on the
operating pulpit at your plant. Our modern
user interfaces provide operators with the
84
SAF Bulletin 2013
quality and production data they need at
all times. The pulpits and their control elements are ergonomically designed to create a comfortable working environment.
When designing the desks and user interfaces, we focus on the requirements of
the operators to ensure they have a direct
view of the entire production line.
You benefit because the technology,
mechanics, hydraulics, electrics & automation form an effective unit.
Energy distribution
and drive systems
When designing the mains supply and dis-
Control room.
tribution systems in the plant, we look at
the public power grids and the infrastructure available on site. Essential here is considering all the possible interactions. SMS
Siemag carries out power supply studies in
close cooperation with you. These form
the basis of reliable plant power supply
and the foundation for calculation of the
interference that may affect the public
power grid.
Also part of the SMS supply scope is
dimensioning, engineering, and supply of
the entire process power equipment for
AC and DC furnaces and their required
power factor compensation.
Power distribution room.
SAF Bulletin 2013
85
Electrical and automation systems
Automation highlights
SAF-HD monitoring
SMS has developed a high-definition
points (approx. every 0.5 to 1.0 m per opti-
tem delivers the information, in specially
cal fiber around the furnace circumfer-
prepared form, that is decisive for prof-
ence).
refractory lining monitoring system for all
submerged-arc furnaces.
The monitoring model works on the basis
forecasts in spite of fluctuating raw mateSAF process monitoring
of temperature measurements and delivers reliable information on the refractory
itable operation. As a result, you can optimize procurement via material requirement
rials prices. Fresh supplies and logistics
can be structured more efficiently. Natural-
Today’s SAF operators face multiple chal-
ly, the reporting system also provides valu-
lining condition. To do this, it takes account
lenges. They include worldwide demands
able information on process evaluation and
of the type of lining and the material
for CO2 reductions, energy savings, errat-
optimization.
charge, and can determine fine structures
ic raw materials prices, and the entry of
such as the current thickness of the frozen
new countries onto the market and into
slag layer of the freeze lining design.
The SAF reporting system is seamlessly
global competition. It is no longer enough
integrated into the overall automation sys-
to rely solely on empirical values for SAF
tem, with interfaces to the laboratory sys-
The measurement data is sent online to
operation. What counts today are precise
tem, the basic automation (Level 1), and
the HD monitoring system from a temper-
knowledge and transparency of the SAF
the production planning system (Level 3).
ature monitoring unit via modern fiber-
processes and interrelations.
optics technology. Unlike traditional ther-
It records material, energy, and utility con-
mocouples, optical fibers allow the
This knowledge forms the basis of our
sumption. That includes: numbers of
implementation of many more measuring
retrofitted SAF reporting system. The sys-
heats, production times, metal and slag
weights, metal and slag analyses, final
temperature after tapping, and more.
You choose how you want the automatically generated reports to be issued (for
example, per heat or per production period). The reports can be made available
directly on the HMI stations or sent to other computers or mobile devices via webbased, user-authorized solutions.
Your benefits at a glance:
■ Reliable information for profitable SAF
operation
■ Automatically prepared reports
■ Reports issued via HMI or web-based
and mobile solutions
Typical lining temperature measurement.
86
SAF Bulletin 2013
■ Upgrades for economical retrofitting
Safety strategy
machine controls. This strategy also com-
tions, using a simulation model that maps
plies with all safety laws and regulations.
the entire mechanics, drive technology,
Worldwide, the importance of machine
And it reduces the time and cost of testing,
and process. It’s an added advantage that
and plant safety is growing. Not just plant
documentation, and commissioning.
SMS Siemag employees train your future
owners themselves, but also current laws
operators on the original control panels.
and standards demand personal and envi-
This involves virtual production where your
ronmental protection.
Faster commissioning with
personnel gets to know the functions of
Plug & Work
the plant and how to use it in realistic oper-
Essential for safe operation of our prod-
ation situations. As a result, Plug & Work
ucts is a coordinated approach during plan-
Here is what you get within the frame-
ning and design. Our engineering and
work of Plug & Work– a program that
electrics engineers work together on the
starts early on, even before commission-
main elements of our safety strategy. That
ing: Our Electrics and Automation Division
includes danger zone layout, risk assess-
carries out extensive integration tests on
ensures a rapid runup of your plant.
After sales service
ment, the “Safety” electronic-mechanical
your system, and also instructs your per-
In particular, we provide a wide range of
function, and the Emergency Stop plan.
sonnel on how to operate it. Next in line
after sales services:
are careful checks in the SMS test fields –
■ Service entry point with 24/7 service
Closely cooperating with you, we devise a
long before installation at your facility.
practical solution with safety control func-
There, the automation system is tested
■ Tele service
tions that operate independently from the
and optimized under near-reality condi-
■ Job assignments locally
hotline
■ Updates / upgrades
■ Spare parts service
Specifically for X-Pact® electrics and
automation, the SP/1 service portal from
SMS Siemag offers the option of rapid support in troubleshooting. Even during commissioning, we set up a service portal for
optimal plant support. Via this portal, the
SMS Siemag experts access your plant’s
automation system to give you immediate support in the form of remote diagnosis and maintenance – worldwide.
Typical HMI screen shot.
SAF Bulletin 2013
87
Project execution department
Professional project
execution at SMS
The SMS Project Execution
department
Essential for successful pro-
Smooth and on-time project execution is guaranteed by our
jects is professional manage-
highly qualified project team, supervised by competent tech-
ment. SMS project manage-
nical and commercial project managers, each with extensive
ment guarantees the execution
experience. This team is responsible for the project from the
of your project complies with
day of contract signing until handover to you. That ensures
the demands of quality, time
continuity throughout the project execution.
and contractual conditions.
Project handling is supported by special management tools,
quality gates, and guidelines. It is also monitored by several
automated reporting systems.
The high quality of SMS project execution is maintained by
constant further training and expansion of our personnel.
Execution team at work.
88
SAF Bulletin 2013
Quality management
Top quality –
quality assurance and
safety aspects
Excellent plant performance can only be
Quality assurance is performed by our
achieved with top-quality equipment. This
team in Düsseldorf and, if locally available,
is why SMS demands very high standards
also supported by on-site specialists.
of its subcontractors. Especially components such as electrode columns, electrode
SMS uses a quality management system
glands, and all water-cooled parts in direct
based on DIN EN ISO 9001.
contact with the harsh furnace environment
must be treated with special care.
There is an emphasis on high safety standards in our engineering and operating
manuals (in accordance with strict European standards). Safety aspects are
addressed as early as possible – during
the sales phase of a project – and are
always integrated in the design phase.
Electrode interieur – superior quality.
Workshop assembly of gas hood.
E-column (lower part).
SAF Bulletin 2013
89
Service and spare parts
Service and spare parts
To keep plants at this high level of opera-
WARE
HO
SERVIC USING
ES
tion, sophisticated and efficient spare parts
and components management as well as
SMS SIE
MAG
servicing are indispensable.
EXPERT
That’s where our team of specialists comes in – ready to offer customer support in all spare parts-related issues. Equally important
is our commitment to improving the performance of existing plant
units. Total Quality Management always forms an essential part
of our services.
When designing our components, SMS also considers its customers’ experience. Wear parts are repaired and manufactured in
our workshops worldwide, or sourced from our qualified suppliers.
Our specialists also assist locally when repair work is required.
Closeness to our customers requires permanent availability, and
this is guaranteed through our office in Düsseldorf / Germany and
our international locations. We are always at your service for all
your questions or any assistance you may require.
It goes without saying that we offer modern spare parts planning
to all our customers. This ensures smooth, safe, and long-term
operation with maximum plant availability and efficiency. Our team
will assist you with any request in connection with effective spare
parts management.
Service working
as a team.
90
SAF Bulletin 2013
KNOW
LEDGE
Custome
r Plants
Concrete long-term benefits:
■ High-quality spare parts
■ All features available
■ Complete spare parts planning
■ Worldwide presence
■ Maintenance planning
■ Round-the-clock online assistance
■ Quality assurance for the products
■ Teamwork
■ Special “older“ parts available
■ Extensive experience
Hydraulic equipment:
Various valves and fittings
Various cylinders
Various pumps
Various motors
Various hoses
Various switches
HFC fluids
Filter elements
Various seals
Electrical equipment:
HV circuit breakers
Capacitor units
Spare transformers
Transformer OLTC-contacts
Transformer oil circulation pumps
Transducers (power, voltage, current)
Transducers (electrode position)
Transducers (slipping length counter)
Thermocouples and transducers
Charging system:
Mouth pieces
Insulating parts
Slide gates
Plunger valves
Miscellaneous:
Crane systems
Ancillary equipment
Cooling water:
Various valves and fittings
Various pipes
Various hoses
Various couplings
Various pumps
Utilities:
Valves and fittings for nitrogen/
oxygen systems
Compressed air systems
Hoses
Couplings
Tapping:
Tapping machine spares
Tapping blocks
Copper tap holes
High current line:
Wall bushing
High-current lines
High-current flexibles
High-current rods
and cables
SAF Bulletin 2013
91
Turnkey services
Turnkey solutions
Turnkey solutions
made by SMS Siemag
The SMS turnkey department is known
are subsequently combined with other
for its high expertise in planning and sup-
units to make an optimally designed com-
plying complete plants of any size for fer-
plete plant.
delivery (for example, Barro
Alto/Brazil)
■ Business concept 2: Turnkey equip-
roalloys, nonferrous metals, and other
products all over the world.
■ Business concept 1: Core equipment
You can also benefit from our commercial
ment delivery (for example, BASCO/
services, include financing on an interna-
Kazakhstan)
■ Business concept 3: Business con-
As leading partners in consortiums or as
tional basis as well as commercial and
plant planning specialists, we offer compre-
organizational services. We coordinate all
hensive know-how and a wide spectrum
activities in each phase of project planning
procurement and construction by cus-
of services.
and order transaction to ensure depend-
tomer with SMS assistance
able performance of every contract.
cept 2 plus local engineering by SMS,
(Vale/Brazil, Kazchrome/ Kazakhstan)
■ Business concept 4: Business con-
SMS technical services range from the
planning and project phase to the handover
As an EPC/EPCM contractor, SMS has
cept 3 plus local civil engineering and
of the turnkey plant. We also provide engi-
implemented many projects based on the
construction engineering by SMS
neering for individual plant sections that
following business concepts:
(PNTZ/Russia)
Kazchrome plant during erection.
Raw material storage
area of Kazchrome
during erection.
92
SAF Bulletin 2013
Turnkey services
from Johannesburg
The expertise of the SMS Johannesburg
office regarding EPC-service contracts is
underlined by an impressive track record of
plants installed under the full budget and
time responsibility of Metix. In particular
in the FeCr-sinter plant (based on Outotec
Sinter plant during construction.
design and technology) and electric
smelter business, Metix has an excellent
reputation.
The most recent references are:
The services available from SMS
■ Hernic F4PS2
in Johannesburg include:
■ TATA Steel Richardsbay
■ Engineering, procurement, and
■ Bokamoso Sinter Plant
construction (EPC) – (LSTK)
■ MFC PSP3
■ ASA Sinter Plant
■ Mogale Furnace Rebuild
■ Tswelopele Sinter Plant
■ Engineering, procurement, and
supply (EPS)
■ Engineering, procurement, and
construction management (EPCM)
Sinter plant during construction.
SAF Bulletin 2013
93
Seminar
SMS-Seminars
and training options
Also available from SMS are seminars that
give you an update of recent SMS project
participations as well as an opportunity to
discuss our latest design solutions.
Take for example the highly successful seminars we held at
three different locations in South Africa in 2011.
It is important for us to conduct open discussions with our customers to seek future solutions and to share operational experiences.
Please contact us at any time if you and your team would like us
to organize a seminar at your location.
SAF-Seminars in
Düsseldorf and
Johannesburg.
94
SAF Bulletin 2013
G
ITORIN
D-MON
SAF-Hand Automation
Electrics
Publications
(can be ordered under
[email protected])
SAF R
EPORT
Electri
ING
cs and
Autom
ation
SYSTE
M
C
AR
S
D- D
GE AN TER
R
L
E
M CES ME
B
S
SU RNA RIC
FU ECT
EL
Brochures SAF
■
■
■
■
SAF technology: Passion for metals
Spare parts brochure
SAF-HD-Monitoring
SAF Reporting System
Publications
■ Degel, R.; Kunze, J.; Warczok, A.: Current status and trends in the
copper slag cleaning; Copper 2003 in Santiago/Chile
■ Degel, R.; Kunze, J.: Innovative submerged arc furnace technology
for non ferrous metals industries; EMC 2003 in Hannover/Germany
■ Degel, R.; Kunze, J.: New trends in submerged arc furnace technology; Infacon 2004, Capetown/South Africa
■ Degel, R.; Borgwardt, D.: New trends in submerged arc furnace
technology; Technical seminars at 100 years SMS in China; October
2004, Beijing/China
■ Degel, R.; Kummer, K.-H.; Kunze, J.: New trends in SAF technology;
EMC 2005 in Dresden/Germany
■ Degel, R.; Lembgen, H.-E.; Schmieden,. H.: SAF technology: Leadership with advanced solutions; 2nd Ferro Alloy Conference, Sept.
2005, Delhi/India
■ Degel. R., Kunze, J.: SAF technology, application highlights and
trends; 100 years SAF technology symposium 2006 in
Düsseldorf/Germany
■ Kempken, J.; Degel, R.: 100 Years SAF technology by SMS Demag;
Pyrometallurgical conference 2006 at the cradle of the human
kinds/South Africa
■ Degel, R.; Kempken, J., Warczok, A.; Schmieden, H.: Innovative
smelting technology for the platinum industry; Platinum 2007; Sun
City/South Africa
■ Degel, R.; Kempken, J., Kunze, J.: Innovative smelting technology
for the non-ferrous industry; EMC 2007; Düsseldorf/Germany
■ Degel, R.; Kempken, J.; Kunze, J.; König, R.; Kunze, J.; Oterdoom,
H.: Design of modern large capacity FeNi-smelting plants; Infacon
2007; Delhi/India
■ Degel, R.; Kempken, J., Warczok, A.; Schmieden, H.: Innovative
smelting technology for the platinum industry; Platinum 2007; Sun
City/South Africa
■ Degel, R.; Warzcok, A.; Riveros, G.; Marin, T.; Degel, R.; Kunze, J.;
Oterdoom, H.: Intensive electrodynamic slag cleaning; Copper 2007;
Toronto/Canada
■ Degel, R.; Kunze, J.; J., Warczok, A.; Latest development of the
intensive slag stirring reacor smelting technology for the platinum
industry; Platinum 2008; Sun City/South Africa
■ Degel, R.; Kalisch, M.; Oterdoom, H.; Kunze, J; Warczok. A.;
Köneke, M.: Latest results of the Intensive Slag Cleaning Reactor for
metal recovery on the basis of copper; EMC 2009; Innsbruck/Austria
■ Degel, R.; Schmale, K.; Kleinschmidt, G.; Oterdoom. H.: AC- and DCSmelter technology for ferrous metal production; Infacon 2010,
Helsinki/Finland
■ Degel, R.; Kunze, J.; Kalisch, M.; Oterdoom, H., Warczok, A;
Riveros, G.: Latest results of the intensive slag cleaning reactor for
metal recovery on the basis of copper; Copper 2010, Hamburg/Germany
■ Degel, R.; Schmale, K.; Köneke, M.; Schmieden, H.: Application
potentials of DC- smelter technology for the platinum industry in
South Africa, Platinum 2010; Sun City/South Africa
■ Degel, R.; Oterdoom, H.; Fröhling, C.: High efficient electric smelters
for ferro-alloy and non-ferrous metal production – SMS Siemag solutions for CO2-reduction; EMC 2011; DüsseldorfGermany
■ Schmieden, H.; Schmale, K.; Degel, R. Köneke, M.: Application
potential of SMS DC smelter technology for the pyrometallurgical
industry in Southern Africa, Pyro 2011, April 2011, Johannesburg,
South Africa
■ van Niekerk, A.; Degel, R.: Latest trends of Metix solutions for the
ferro alloy industry; SMS Symposium 2012 in Johannesburg/South
Africa
■ Degel, R.; Oterdoom, H.; van Niekerk, A.; Schmale, K.; Farmer, G.:
Highly efficient electric smelters for the platinum industry – SMS
solutions for energy saving; Platinum 2012; Sun City/South Africa
■ Degel, R.; Germershausen; T.; Nörthemann, R.; Köneke, M.; van
Niekerk, A.: Innovative electric smelter solution of the SMS group
for the ferro alloys and Si-metal industry; Infacon 2013, Almaty/Kazakhstan
■ Fröhling, C.; Nörthemann, R.; Degel, R.: Ecoplants Technologies –
ecologic and economic solutions for the ferro alloy industry; Infacon
2013, Almaty/Kazakhstan
■ Bader, J.; Thiedemann, U.; Degel, R.; Germershausen, T.: Advanced
refining option for the ferro alloy industry; Infacon 2013,
Almaty/Kazakhstan
SAF Bulletin 2013
95
Studies
Evaluation services by SMS:
– Studies
– Financing of Projects
Besides engineering, equipment, and plant
supply, we provide the following services:
■ De-bottlenecking studies, plant logistics, process modeling
■ Environmental studies
■ Development of measures for minimization of operating
costs
■ Planning and supply of complete plants
■ Technical feasibility studies for new process lines
■ Maintenance planning
■ Product optimization programs
■ Furnace dimensioning
■ Commissioning planning
■ Product change/enlargement of product portfolio
■ Consulting assignments
■ Financial and comparative studies
On request, SMS Siemag assists you with
tailor-made financing concepts.
Please feel free to contact us at any time for more information:
[email protected]
(Head of Financial Services Division)
96
SAF Bulletin 2013
Economic success
Satisfied customers confirm the reliability and high performance
of our plants. Our team assist the customers with all their requirements concerning the plant through the intensive care that we provide on-site during the planning, engineering, erection and commissioning phases. We take pride in the plants erected by us, which
guarantee long-lasting added value for our customers.
Faithfulness to deadlines goes without saying, but SMS Siemag
try to do even better: to achieve a rapidly increasing start-up curve
before the appointed date.
The nature and scope of our customers investment are crucial
for the success of the project. Quick start-up of production and reliable, flexible work sequences at low operating costs ensure that
their investment will be paid back within a very short time.
Low operation costs due to:
■ Very high overall plant availability
Inside view of a FeNi furnace.
■ Robust and solid equipment suitable for the harsh
furnace environment
■ Energy efficient process
■ Long furnace life time
■ Quick ramp-up
■ Low maintenance request (especially for E-column)
■ Low man power due to high level of automation
■ Maximum furnace size for the chosen location
Low investment due to:
■ The overall price level for the investment is moderate
due to international sourcing
■ Maximized local portion
Inside view of a FeNi furnace.
■ Compact furnace building design lower the costs
on the civil and building portion
■ Attractive financing options
SAF Bulletin 2013
97
At a glance
SAF and Electric Smelters
at a glance
The SMS group is your best partner for efficient and
reliable submerged-arc furnaces and electric smelter
technology. We supply the full range, starting with small
components and spare parts supplies, up to turnkey,
full-liner solutions.
Partnership
Time schedule
Summary
■ Our teams in Germany and Johan-
■ Our professional execution team
■ Complete range of products and
nesburg work hand-in-hand with
ensures compliance with the agreed
you
time schedule and provides secure
■ Superb track record
financial planning
■ Trailblazing innovations
■ The excellent company organization
services
provides services from our offices
■ Clear focus on service
all over the world
■ In-house manufacturing of core
■ Our goal is a sustainable, long-lasting, and professional business relationship based on trust
Technological excellence
■ We supply best-technology solutions based on experience
■ Economically efficient and safe
furnaces
■ Operation with low maintenance
■ Very reliable, high-quality design
based on existing plants
■ Superb safety record
■ Best available reference track
record (>700 furnaces)
Titanium slag plant.
98
SAF Bulletin 2013
components
■ Automation of all plant systems
Charging system.
CaC2-tapping.
SAF Bulletin 2013
99
Metallurgical Plants Division
Submerged-Arc Furnaces (SAF)
Eduard-Schloemann-Strasse 4
40237 Düsseldorf, Germany
Phone: +49 211 881-6372 or 6180 or 5288
Telefax: +49 211 881-6980
E-mail: [email protected]
Internet: www.sms-siemag.com
MEETING your EXPECTATIONS
H4/303E
1500/05/13 . Ky . Printed in Germany
SMS SIEMAG AG
“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.”