EBNER Journal for Progress in Industrial Furnace Technology

EBNER Journal for Progress in Industrial Furnace Technology
Volume 23
www.EBNER.cc
Issue 2, September 2014
3
Editorial
CON TENT S
Editorial
4
Alu m in u m
Success means taking on responsibility
Can by can
6
R e port
HICON® pusher-type furnace for aluminum ingots
Novelis / Brazil
Time for a change
12
A lu m in u m
From molten metal to hydrogen quenches
Tons of tin plate
Always in good hands
Report
14
Between Asia and Europe
S te e l
HICON® pusher-type furnace for aluminum ingots
Shandong Weiqiao Aluminium & Electricity Co., Ltd. / China
After Sales Department
Report / Austria
16
HICON/H2® vertical bright annealing line for steel strip
POSCO ASSAN TST / Turkey
18
Steel
Reaching for the stars
HICON/H2® bell annealer facility for steel strip
Starcore / Thailand
20
S t ee l
Non-stop precision
22
R ep o r t
HICON/H2® vertical bright annealing line for steel strip
POSCO AST Co. Ltd. / South Korea
CIELFFA
International Association of cold-rolling experts
INTERNET
Success means taking on
responsibility
Ladies and gentlemen,
Esteemed readers of the HICON Journal,
Friends and colleagues,
In this current edition of our HICON customer journal, you will read about the latest facilities EBNER
has installed at our customers‘ plants around the world.
A technical report on hydrogen quenching outlines the latest discoveries and options for hardening
and tempering steel strip.
This is hot topic at the moment, yet again proving that investing in research and development, as
we have done for decades, is essential for a technology leader like EBNER.
This is the only way we can ensure that soon-to-be-implemented limitations are already technologically possible while maximizing economic advantages.
Lead-free premium steel strip made possible for the first time thanks to HICON/H2Q® technology is
setting new, future-oriented standards in environmental responsibility and many other areas.
Enjoy reading this issue of the HICON Journal.
Yours
Robert Ebner
CEO
www.EBNER.cc
The articles can also be found on our website. Download the latest issues under NEWS & PRESS / HICON ® Journal.
2
3
Novelis / Brazil
Aluminum
C a n B Y C AN
Senior Sales Manager Carl-August Preimesberger tells us
about the synergies between the two facilities with a 15 year
age difference, and how EBNER solved other challenges in this
project.
A new facility in Brazil from EBNER, representing a massive
increase in capacity. Is Brazil so thirsty?
It almost looks that way! In this case, we are talking about a 6 zone
gas-fired HICON® pusher-type furnace facility with the complete
ingot handling system, power and control systems and a higher level
process control system. The facility heats 30 cast aluminum ingots
at a time up to rolling temperature, representing a maximum net
charge of 750 tons (826 USt). A major long-term increase in capacity,
especially when you consider that the facility we installed in 1999 is
still operating to Novelis‘s fullest satisfaction.
For what kinds of products is this aluminum destined?
Novelis produces sheets mainly used to manufacture beverage cans
but also for special applications. The newly-installed facility is intended to cover the surge in demand due to major sporting events,
such as the upcoming 2016 Olympic summer games and the World
Cup that took place in Brazil this summer, in addition to generally
strong South American market growth.
For South American beverage producers and breweries, cans are
the primary packaging choice. Major events such as this summer‘s
soccer World Cup and the coming Olympic games create a spike
in beverage can demand, giving the market leader Novelis South
America a record-breaking amount of orders.
2m10s
to read
There is quite a distance between the pusher-type furnace and
the rolling mill roller table - how did EBNER‘s engineers solve this
issue?
It‘s not just the distance that led us to consider an alternative to a
roller table. We also had to make sure we did not interrupt or make
huge detours for service and maintenance access paths to other
facilities. The solution: a charging car which accepts the aluminum
ingots after they have been downended and transports them along a
fixed rail before transferring to the rolling mill roller table via a hydraulically lowered beam. This solution worked so well that the existing
pusher-type furnace is now also being served by the transport car.
The facility achieves shortest annealing times despite high temperature uniformity and very high throughputs. Novelis is extremely ambitious with respect to environmental responsibility and careful use
of resources. This makes the HICON® pusher-type furnace with its
especially low energy consumption particularly attractive.
Author: Carl-August Preimesberger
Pindamonhagaba - known as Pinda to the locals - is a city in the São
Paulo province, halfway between the economic metropolis São Paulo and the
party destination Rio de Janeiro. In the 1950s, agriculture was still the main pillar of
the economy for the city, but in the 70s, a wave of industrial companies including
Alcan Aluminio do Brasil (which later became Novelis South America) discovered
southern Brazil. Today Novelis, a member of the Aditya Birla Group, is South
America‘s leading company in the manufacture of material for aluminum beverage
cans, including the can body and end. The plant was opened in 1977. Novelis is the
world‘s market leader for aluminum rolled products and recycling, distinguishing
itself from the competition by its goal of processing 80% recycled material.
EBNER received an order to expand heat treatment capacity with a HICON® pushertype furnace facility. The facility is already running at full capacity, homogenizing 30
ingots at a time with a max. weight of 25 t (27.5 USt) each and dimensions of up to
7000 x 2000 x 660 mm (23‘ x 6‘7“ x 2‘2“) at a max. furnace temperature of
680° C (1256 °F).
The facility is operating in parallel with another HICON® pusher-type furnace which
was installed in 1999.
How long has the facility been in operation?
Commissioning was completed and production started in summer
2013. Can by can, Novelis says,
"Yes, Novelis CAN!"
Special can
commemorating
the 2014 soccer world cup
4
HICON® J o u r n a l
HICON® Jou r n al
5
Hardening and tempering steel strip
Technical Article
TImE FOR
A CHANGE
OTHER APPLICATIONS INCLUDE:
Annealing cycles for multi-phase steels with quenching gradients of >200 K/s.mm and
subsequent transformation to produce DP, CP, TRIP and Q+P steels for automotive applications.
Normalizing anneals with limited cooling gradients < 25 K/s to produce „earing-free“ material
(such as battery sleeve strip).
Recrystallization anneals
overaging.
From molten metal quenches to
hydrogen quenching technology
Author: Sascha Eppensteiner
of material such as LC steels with quenching and subsequent
Well-designed and flexible facility concepts allow several technologies to be combined in a single facility.
This ensures highly-economical facility utilization.
3m50s
to read
FACILITY DESIGN WITH HICON/H2Q® HYDROGEN QUENCHING TECHNOLOGY
Unalloyed and low alloy carbon steel strips require very high quenching speeds, which used to only be possible in a molten metal quench.
The experience gained from the many molten metal quenches we have supplied which incorporate innovative 2-stage hardening, has been seamlessly transferred to gas quench technology during several years‘
development work. The new process has been successfully launched as HICON/H2Q® Technology (= High
Convection / H2 Hydrogen Quench).
HARDENING AND TEMPERING STEEL STRIP
Hardened and tempered steel strip is used in a broad spectrum of applications, ranging from everyday items
to high-performance tools and safety components.
The product requirements are complex, encompassing special microstructure, highest possible homogenity,
precise tensile strength tolerances, extreme flatness and geometry characteristics as well as special surface
properties.
Schematic diagram of a martensite bright H&T line with HICON/H2Q® quenching technology.
TECHNOLOGY
Continuous in-line hardening and tempering of unalloyed and low-alloy carbon steel as well as martensitic
Cr steel strip using hydrogen quench systems or molten metal quench technology is a process that has won
worldwide acceptance.
In a continuous steel strip hardening and tempering line, unalloyed and low alloy carbon steel strips can be
transformed with the following technologies:
Martensite (martempering) with hardening, leveling and tempering to produce material for hand saws, band
saws, head saws, circular saws, springs, flapper valves, tools, etc.
Bainite (austempering) with isothermal transformation in the austempering duct and following furnace units,
to produce material with good bending and punching qualities for products such as blanking knives, cutting
and minting lines, precision components for the automotive industry, etc.
Pearlite (patenting) with isothermal transformation in the patenting section, to produce material for safety belt
springs for the automotive industry, cable drum springs, high-strength spiral springs, etc.
tension stand
1.
2.
inlet seal with integrated safety system
3.
austenitizing furnace
4.HICON/H2Q® hydrogen quenching unit
5.
outlet seal with integrated safety system
6.
martensite cooler
7.
leveling furnace
8.HICON® tempering furnace
9.HICON® process atmosphere jet cooler
Stainless steel strip (chromium martensite) is martempered to produce material for leaf springs for
compressors and cooling units, tools, cutlery, etc.
6
HICON® J o u r n a l
HICON® Jou r n al
7
Hardening and tempering steel strip
Technical Article
This technology has already given many facility operators
numerous new opportunities, allowing them to process
their existing product range with improved surface
quality, expand their range with additional sophisticated
materials, and to supply new industries.
The lead/bismuth
eliminated.
quenchant
alloy
is
completely
This makes it possible to offer a completely new premium
product - "lead-free hardened and tempered steel
strip" - for the food industry, automotive industry, etc.
Environmental guidelines and customers with special
requirements of even lower lead residue levels are no
longer an issue.
Hardening and tempering with hydrogen carries lower
operating costs than the molten metal method, since far
fewer wear parts are necessary.
The hydrogen is blown symmetrically onto the strip from
above and below by a gas-tight high-capacity circulation
blower. Special adjustable nozzles with infinitely variable
covers ensure an extremely high and uniform cooling rate
allowing the temperature of the strip to be rapidly reduced
and controlled at the desired level.
Special processes in the quenching system and
supplementary equipment also permit isothermal
transformations such as austempering and patenting.
View of a HICON/H2Q® quench
in a horizontal bright H&T line for
martempering unalloyed and low
alloy carbon steel strip as well as
martensitic chromium steels
Another technological advantage over the molten-metal
quench is the significantly shorter distance from the exit
of the hardening furnace through the jet system (first
cooling stage), and on to the martensite transformation
section (second cooling stage).
This second cooling stage can be carried out with the
revolutionary FLEXFLAT® system. This special leveling
system uses a cooling plate with an infinitely variable
shape to directly influence strip geometry during
martensite transformation. Perfect flatness can be easily
reproduced.
The quick reaction time of the HICON/H2Q® quench and
the use of the shapeable cooling plate technology
(FLEXFLAT® system) make a combination with a
flatness measuring system possible. This enables quick
modifications to the flatness parameters and soon,
automatic optimization of strip flatness.
View of a martensite cooling section
including a FLEXFLAT® leveling
system for martempering unalloyed
and low alloy carbon steel strip
The combination of the two technologies sets new
standards in terms of achievable surface quality, flatness
and productivity.
The gas is cooled in a heat exchanger and recirculated,
requiring very little fresh gas.
The inlet and outlet seals are designed as safety seals
and integrated into the higher level safety system.
Process steps such as grinding or polishing, which are
currently necessary to remove lead residue, become
unneeded and the nice cold-rolled surface finish is
preserved. If a ground or polished surface finish is
desired, it can be produced with significantly less effort.
Horizontal bright hardening and
tempering line with HICON/H2Q®
quench for martempering unalloyed
and low alloy carbon steel strip as
well as martensitic chromium steels
Strip can move through the quench either horizontally or
vertically, without needing to be deflected. The chance
of a strip break approaches zero and facility uptime
increases.
The time it takes a HICON/H2Q® quench to change
process parameters is many times faster than a sluggish
molten-metal quench. This minimizes the scrap length
following the weld seam, which in turn increases yield.
8
HICON® J o u r n a l
HICON® Jou r n al
9
Hardening and tempering steel strip
Technical Article
MODERNIZATION OF EXISTING FACILITIES
Comparison of productivity and operating costs of HICON/H2Q® technology vs. molten metal quench
technology at a mid-sized facility (type BVHg 65/25/1100 M).
Type of quenching technology
The HICON/H2Q® hydrogen quench can also be integrated into existing facilities to replace a molten metal quench. This technology
can also be integrated into non-EBNER facilities, with careful consideration of each individual case.
Molten Metal Quenching
(MMQ)
HICON/H2Q®
Hydrogen Quenching
ADVANTAGES /
DISADVANTAGES
HICON/H2Q® vs MMQ
7,000
7,500
500
Comparision of productivity
Average operating hours per year [h/a]
Upgrading to hydrogen quenching technology involves the following modifications:
•
•
•
•
•
•
•
•
new inlet seal with integrated safety systems
various new parts for the austenitizing furnace
new gas-tight HICON/H2Q® quench unit
new gas-tight high-performance cooling blower with heat exchanger
new outlet seal with integrated safety systems
new valve stand for hydrogen/nitrogen/cooling water/emergency water supply distribution
new pressure control system for hydrogen / nitrogen
associated electrical control center with safety functions
While modernization this part of the facility, other optimizations could also be considered. Some options include:
Average throughput capacity
Average yield factor
Average net output per year
[kg/h]
[%]
[t/a]
800
•
new roller support system for the austenitizing furnace to improve strip surface results.
•
new modular martempering section with a cooling plate with an infinitely variable shape (FLEXFLAT® system) for improved flatness.
•
new directly electrically heated leveling furnace to improve temperature uniformity and flatness, as well as saving space, since the hot air heating duct from the austenitizing furnace to the leveling furnace is eliminated.
•
new roller support system for the tempering furnace to improve strip surface results and flatness.
•
new flatness measuring system implemented together with the flexible cooling plate (FLEXFLAT® system) for improved throughput and in-line quality assurance.
800
90.4
96.1
5,060
5,769
based on average coil
OD of 1500 mm (59“)
709
14.0%
Upgrade of the oil quench of an existing facility to HICON/H2Q®
quenching technology for martempering unalloyed and low alloyed
carbon steel strip.
Comparision of operating costs (1st year)
Cost of consumables per year [EUR/a]
per ton [EUR/t]
268,278
53.0
121,733
21.1
-146,546 €
Cost of media (NG, H2, N2, HN-mix, electric)
per year [EUR/a]
per ton [EUR/t]
258,557.7
51.1
339,476.3
58.9
80,919 €
SUMMARY
-65,627 €
10
HICON® J o u r n a l
An extensive package of facility concepts and modernization options are available in order to help our customers produce top
quality hardened and tempered strip steel.
Modular facility design allows several technologies to be combined in a single facility, covering a broad spectrum of products.
HICON® Jou r n al
11
Shandong Weiqiao Aluminium & Electricity Co., Ltd. / China
Aluminum
Tons of tin plate
2m30s
to read
If you follow the
industry reports on
growing capacity and
newly-built plants
in the Chinese aluminum industry, you
will notice that most
of these companies
supply the automotive and aerospace
industries.
Author: Günter Mascher
But in addition to this interesting and highly-competitive market,
the beverages industry is also booming with great demand for
high-quality aluminum strip. Shandong Weiqiao Aluminium &
12
Highest quality - best chances
The company philosophy prioritizes quality above all else. This was
an influential factor in the choice of EBNER as a supplier. The new
rolling mill was outfitted exclusively by western technology leaders.
Senior Product Manager Günter Mascher on the
new facility at Shandong Weiqiao:
What were the biggest challenges with this
mega-facility in Zouping?
EBNER supplies four pushers
Placing an order for four pusher-type furnaces at once, Shandong
Weiqiao is one of EBNER‘s largest aluminum industry customers. All
the furnaces in Zouping are served by a single shared ingot handling
system. Once again, EBNER proves that effective planning combined
with state-of-the-art engineering result in major savings at high
facility throughput. The technical challenge this solution represents
is underscored by the fact that the aluminum ingots (up to 32 t / 35
USt each) are heat treated in the EBNER HICON® furnace with the
temperature scatter of just +/- 3°C (ΔT 6°C/10.8°F). Each furnace
can handle a charge of 25 ingots with dimensions of 2200 x 620 x
8650 mm (7‘3“ x 2‘ x 28‘4“), representing a total charge weight of
max. 800 t (881 USt) and a throughput of 83 t (91 USt) per hour for
reheating. These parameters and dimensions can only be handled
by facilities of the latest generation. EBNER‘s overall concept won
the customer over, combining trusted, proven technology with the
specific requirements.
“When can we start with production?“
This is always the customer‘s most important question, and EBNER
heard it quite clearly during the quotation and planning phase. With
the support of Shandong Weiqiao, the whole project was completed
quickly and efficiently. The turn-key facility was installed and handed
over on schedule. Projects on such tight schedules demand perfect
coordination of EBNER‘s locations in China and Austria. The EBNER
specialists in Leonding took care of the planning and engineering,
while our colleagues in Taicang manufactured the steel components
and the electrical control center. The facility was installed by local
installation contractors under the supervision of our experts.
In addition to the overall size of the facility and the
very short delivery time, the shared ingot handling
system is definitely one of the highlights of this
facility. It should be mentioned that it is responsible not only for supplying ingots to the furnace,
but also manages the ingots going to the rolling
mill. EBNER excels at offering custom solutions
for these types of challenges which are sometimes
caused by the available space and sometimes due
to up and downstream processes.
What is the production throughput of the facility now?
All four pusher-type furnaces are operating as
planned with increasing capacity. They are processing the amazing total of half a million tons of
aluminum per year. It is just another step forward
at Shandong Weiqiao as one of the world‘s largest
producers of primary aluminum.
Electricity Co., Ltd. saw this opportunity and decided to invest in
a new rolling mill complex at their Zouping location, in the eastern
Chinese province of Shandong.
HICON® J o u r n a l
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13
Report / Austria
After Sales Department
ALWAYS IN GOOD
HANDS
INFOBOX
New to the team
Jürgen Rubasch has been working in the After Sales team for the past year,
focusing on After Sales in the American market. Beginning his career at
EBNER as apprentice in 1992, Jürgen Rubasch is perfectly suited for this new
challenge thanks to his many years at the company. Being able to see the big
picture and knowledge of several facility generations are key qualities of an
EBNER After Sales specialist.
2m40s
to read
EBNER heat treatment furnace facilities guarantee high-quality and
economical products for a broad spectrum of materials and requirements
Customers who decide on “made by EBNER“ industrial furnace facilities
appreciate the advantages of being able to enter new market segments and
significantly increase capacity very quickly.
at customers around the world.
14
Three teams - a dozen specialists
Original spare parts
EBNER‘s After Sales team includes specialists who know
exactly what the customers need. The teams (Europe, Asia
and America) are made up of experts for all types of heat
treatment facilities as well as employees specializing in
maintenance queries.
The customer can choose between ordering spare parts via
a direct enquiry, utilizing an existing contact at EBNER such
as a commissioning or service specialist, or even working
with a preferred contact person (such as the Sales manager
or country representative).
In addition to modernizing existing facilities, supplying
quality spare parts is a major factor in ensuring smooth and
effective production. Having original spare parts is especially
important when it comes to key components continually
being refined by our engineering department: longer services
lives and maximum performance for your facility.
The EBNER spare parts CD for every type of facility makes
it quick and easy to find the required spares by component
groups and spare part numbers.
Good as new
The newest and latest
Because EBNER maintains long-term relationships with our
customers and facilities are often installed in several stages,
advances in technology and efficiency are immediately
noticeable when a new expansion phase is installed. The
customer can experience the advantages first hand and
compare different generations of facility. This tends to be
the basis and motivation to modernize an existing facility.
Another major advantage of EBNER: the production chain
is upgraded to state-of-the-art technology completely
seamlessly, securing the customer‘s market position. Thanks
to the close cooperation between the After Sales team, the
Service department and the installation specialists, there is
always someone available to consult the customer on every
facility generation.
The biggest possible technical advancement is undoubtedly
upgrading the electrical control system from S5 to the current
S7 generation. Features include a modern user interface and
control system as well as quality assurance documentation.
All relevant production parameters are collated at a
standardized interface, allowing easy integration into existing
process control systems. A fully digital visualization system
on site at the facility rounds out the upgrade package (see
HICON Journal 2014/1, “Visual Furnaces®“ special feature).
HICON® J o u r n a l
Looking to
the future
Jürgen Ranner: “In the future, we would like to be even more active
in providing our customers with relevant solutions, allowing them
to get the most use and efficiency out of existing facilities. We are
also planning on integrating modern process control systems in
the booming aluminum sector, as well as expanding our team of
specialists.“
HICON® Jou r n al
15
POSCO ASSAN TST / Turkey
Steel
BETWEEN
The 60 meter tower contains the bright annealing line
and adjacent looper
AsiA AND
EuropE
Author: Sascha Eppensteiner
2m50s
to read
In order to further optimize the operating costs, the
facility is fitted with a hydrogen recycling system.
Process atmosphere consumption is extremely low
without compromising product quality.
A new stainless steel cold rolling mill has opened in the Turkish province of Koceali, as a
cooperative effort between Pohang Iron and Steel Company (POSCO, the South Korean steel
manufacturer), KIBAR HOLDING of Turkey and DAEWOO INTERNATIONAL, also of South Korea.
Situated an hour south of Istanbul on the bay of Izmit with good
access to the industrial harbor, the new factory produces 200,000 t
(220,000 USt) of stainless steel strip per year.
The Korean steel giant‘s extensive expertise on the subject of cold
rolled stainless steel strip of the highest quality were seamlessly
transferred to the Turkish location. The Turkish plant is supplied
with hot-rolled strip directly from the main plant in Pohang.
The requirements of the bright-annealing line were clear from day
one: best product quality and high throughput at lowest operating
costs. Meeting the customer‘s needs required combining the
most advanced technology and large facility capacity. The result:
the world‘s largest operating HICON/H2® bright annealing line,
capable of processing over 100,000 t/a (110,000 USt/a) of a wide
spectrum of strip dimensions. Strip between 0.2 and 2.0 mm
(0.008“ - 0.08“) thick and up to 1600 mm (5‘3“) wide are perfectly
heat treated at high temperature in the 60 m (197‘) tall facility.
16
The material grade to be annealed is AISI 300 series
(austenite) and AISI 400 series (ferrite), which are
used in diverse applications such as exhaust ducts,
heat exchangers, washing machine drums, pots and
pans, and tanks for the foodstuff industry.
The advantage of experience and comprehensive
references
A superior, efficient facility layout, state-of-the-art technology and
EBNER‘s decades of experience were key factors in convincing
the customer, especially since POSCO is familiar with the
advantages and performance of other “made by EBNER“ heat
treatment facilities.
Senior Product Manager Sascha Eppensteiner tells us more:
Every component and assembly group: high tech
Korea meets Turkey: more than a cultural exchange?
The waterfront location: a competitive advantage?
The facility is designed with an inlet seal box and integrated
dancer roll for precise strip tension control. The furnace section
features a gas-tight welded muffle, allowing lowest dewpoints
(below -60°C/-76°F) and the use of pure hydrogen as process
atmosphere. Together with the latest generation of jets in the
HICON/H2® cooling zone, the facility achieves top performance
with best surface finish and strip geometry.
Much more! A combination of Asian-influenced corporate culture
and European business sense.
From the very beginning, Korean experts from the head office in Pohang were stationed in Izmit and helped with placing orders, planning, construction ad well as installation, commissioning and production. You can really feel the shared spirit between the Turkish and
Korean colleagues, despite their different backgrounds.
Of course the location on the Bay of Izmit with excellent connection to the industrial harbor is an advantage. Since POSCO ASSAN
TST receives its raw material directly from Pohang, the water route
is a very important supply path. This ensures consistent raw material
quality at a reasonable price.
The products are exported to Europe, the Arab region and Africa,
making this location equally perfect for transporting the coils to the
final customer.
HICON® J o u r n a l
HICON® Jou r n al
17
Steel
Starcore / Thailand
REACHING
FOR THE
STARS
A two-hour drive from Thailand‘s capital
of Bangkok takes us to the industrial area
of Rayong, which has become a soughtafter location in southwest Asia for many
European industries.
Senior Sales Manager Michael Meisczuk tells us more about this rising star:
First and second expansion phases within two years, next expansion phase already being discussed. Sounds like a fairytale!
We at EBNER certainly did not expect these lofty goals to be met in such a short time, either. But the Starcore team (which we very much
enjoyed working with) showed us they mean business! All intermediate goals were met easily and we are proud of having been a part of
Starcore‘s success from the very beginning, as well as continuing to be active in this rapidly growing market.
Author: Michael Meisczuk
2m05s
to read
With an impressive annual production volume of 200,000 t
(220,000 USt) of steel strip, the Thai company Starcore is already
one of EBNER‘s customers, despite having been founded only 6
years ago.
Starcore‘s parent company, Saeng Thai Metal Drum, manufactures
metal drums for a variety of uses, including lubricants, paints and
chemicals. Increasing internal demand for steel strip prompted the
foundation of Starcore and the erection of a new cold rolling mill to
supply the required capacity. The first phase in 2012 comprised 5
workbases with 3 heating and 3 cooling bells. Less than 2 years after
commissioning, the facility was expanded and the number of bases
and bells was doubled. Starcore‘s positive outlook and forward
thinking is reflected in the fact that space is provided for a total of 14
workbases.
A proven size was selected for the EBNER HICON/H2® bell annealers:
190 cm (6‘3“) in diameter and a charging height of more than 5 m
(16‘). The current expansion phase is an active step towards the
export market. It ensures a continuous manufacturing process and
high utilization.
18
Trusting in the #1 name in the industry
EBNER‘s good name is a guarantee for the quality heat treatment
facilities known globally. This is what convinced Starcore to work
with the market leader right away during their first steps into a new
market segment. The experiences gained in the first expansion
phase allowed the second expansion phase to be installed smoothly
and quickly. With the support of the EBNER India team, production
started ahead of schedule and the required quality was achieved
from day one.
HICON® J o u r n a l
HICON® Jou r n al
19
POSCO AST Co. Ltd. / South Korea
Steel
Proven design
Fast start of production, reasonable costs and sufficient reference
projects were the major factors that convinced the Koreans to place
the order with EBNER. A new building was constructed to house
the facility, allowing for optimal layout and placement of facility
components. There are many parameters to be optimized when a
new facility is installed, in order to guarantee consistently high quality.
Because the plant in Ansan City receives its raw material from the main
plant in Pohang, the raw material quality is very consistent, significantly
shortening the time until the start of production. Among the annealed
grades are AISI 304 austenitic steel and AISI 430 series ferritic strip.
The cooperative spirit of the entire POSCO AST team is highly
appreciated at EBNER. Many furnace components were manufactured
at EBNER Asia and shipped from Shanghai to Korea.
Great material flexibility
Five gas-fired heating zones and the high performance HICON/H2® jet
cooling system are able to anneal strip up to 1300 mm (4‘3“) wide
and 0.1 to 1.5 mm (0.4“-0.6“) thick with best continuity. The thinnest
0.1 mm thick strips are particularly challenging for the bright annealing
line to process. The dancer roll ahead of the tension control system and
the gas-tight welded muffle ensure low hydrogen process atmosphere
consumption.
Author: Franz Wiesinger
2m15s
to read
Senior Manager Sales Franz Wiesinger sat down
to talk to HICON Journal:
Western South Korea is home to a POSCO AST Co. Ltd. plant specializing in
stainless steel strip.
Formerly Taihan Electric Wire, the company had specialized in narrow precision stainless steel strip
(≤ 600 mm /24“ wide) until it was bought out by POSCO several years ago. Recently, the installation of a new,
modern HICON/H2® vertical bright annealing line from EBNER has set the course for a highly productive future
including wide precision stainless steel strip.
Long-term partnership
20
EBNER and POSCO have had a good partnership for years, was the
order for the Ansan City facility more or less a given?
Oh no. Not at all! We were confronted with competition from Japan,
this time, and it was our extensive experience with vertical strand
annealers and our many references that finally convinced POSCO to
place the order with EBNER again.
Has the customer given any feedback with regard to the facility?
POSCO is convinced that choosing EBNER was the right decision. The
customer has told us: EBNER is always held to the highest standard
- an honor!
POSCO‘s headquarters in Pohang are also home to an EBNER vertical strand annealer. Thanks to
this long-term partnership on the best of terms, the odds were in favor of receiving the order from
POSCO AST. In addition to the main facility, the alkaline degreaser and the entire strip handling
section were also supplied, resulting in the installation of a complete production line. Twin pay-off
reels for continuous operation and especially compact inlet and outlet loopers round out the facility.
HICON® J o u r n a l
HICON® Jou r n al
21
Conference / Austria
CIELFFA
CIELFFA Conference 2014
A tour of EBNER‘s workshop and R & D department
In mid June of this year, just as the soccer World Cup was starting
up, Linz hosted the annual meeting of CIELFFA (Comité International
d’Étude du Laminage à Froid du Feuillard d’Acier), the international
association of cold rolling experts. Nearly thirty guests from six
countries took part in the two-day conference. The exchange of
ideas and networking were rounded out with several lectures in both
the economical (voestalpine Stahl GmbH) and technical committees.
Peter Seemann of EBNER fascinated his audience with a very
informative presentation on the subject of „New Emissions Limits“.
Starting with the current regulations and limitations, the presentation
touched upon new approaches to reducing NOx emissions in the
1m10s
to read
Touring EBNER
22
heat treatment sector, before taking a critical look at the defined
limits and units. Undoubtedly, technology and research must take
not only economical aspects into consideration, but also ensure that
EU guidelines and limitations can be met.
A sociable evening was had together watching the Germany-Portugal
World Cup soccer game on the big screen. Another highlight of the
conference was a lunch at the EBNER guesthouse and a tour of
EBNER‘s workshops and the company museum, before the visitors
headed home again that evening, taking with them new information
and ideas about current industry issues and memories of two days
of Austrian hospitality.
Nearly 30 participants from 6 countries
Dr. Rolf Jansen presents a bouquet to Barbara Ebner
HICON® J o u r n a l
More of 65 years of company history, personal items and historical
documents are on display at the EBNER museum
Lunch at the EBNER guest house, the former home of Udo Ebner,
the company‘s founder
HICON® Jou r n al
23
LATEST NEW ORDERS
Customer
Country Type of facility
US
Trefilerias Quijano, S.A.
ES
Belgo Bekaert Arames Ltda.
BR
C.S. Aluminium Corporation
TW
Outokumpu Nirosta GmbH
DE
ArcelorMittal Brasil S.A.
BR
Nanjing XingQiao Y-Tec Automobile Parts Co. Ltd. CN
Constellium France SAS
FR
Dongbu Special Steel Co., Ltd.
KR
Bhushan Power & Steel Ltd.
IN
Nisshin Steel Co. Ltd.
JP
Mubea Tailor Rolled Blanks GmbH
DE
WEMPCO - Western Metal Products Co. Ltd.
NG
Ferrous CAL, LLC
US
voestalpine Stahl GmbH
AT
Giebel Kaltwalzwerk GmbH
DE
Quiver Ventures LLC
HICON® floater-type furnace for aluminum strip coils
HICON/H2® bell annealer facility for steel wire coils
HICON/H2® bell annealer facility for steel wire coils
HICON® pusher-type furnace facility for aluminum ingots
HICON/H2® vertical bright annealing line for steel strip coils
HICON/H2® bell annealer facility for steel strip coils
HOTPHASE® roller-hearth furnace facility for steel press-hardening blanks
HICON® batch-type furnaces for aluminum strip coils
HICON/H2® bell annealer facility for steel wire coils
HICON/H2® bell annealer facility for steel strip coils
HICON/H2® bell annealer facility for steel strip coils
HICON/H2® bell annealer facility for steel strip coils
HICON/H2® bell annealer facility for steel strip coils
HICON/H2® roller-hearth furnace facility for steel strip coils
HICON/H2® bell annealer facility for steel strip coils
HICON/H2® bell annealer facility for steel strip coils
EBNER TRADE FAIR SCHEDULE 2014/15
24.09. - 27.09.2014
07.10. - 09.10.2014
21.10. - 25.10.2014
06.11. - 07.11.2014
31.03. - 03.04.2015
04.05. - 07.05.2015
12.05. - 15.05.2015
20.05. - 22.05.2015
16.06. - 20.06.2015
WIRE CHINA
Aluminium 2014
EUROBLECH
Jahrestagung Stahl 2014
M + M China 2015
AISTech 2015
Wire Russia
Made in Steel
Thermprocess
Shanghai / CN
Düsseldorf / DE
Hannover / DE
Düsseldorf / DE
Shanghai / CN
Cleveland / USA
Moscow / RU
Milan / IT
Düsseldorf / DE
EBNER
EBNER
EBNER
EBNER
Ebner-Platz 1
4060 Leonding / AUSTRIA
Tel.: (+43) 732 68 68
Fax: (+43) 732 68 68 1000
e-mail: [email protected]
224 Quadral Drive
Wadsworth, Ohio 44281 / USA
Tel.: (+1) 330 335 1600
Fax: (+1) 330 335 1605
e-mail: [email protected]
Beijing East Road 82
215400 Taicang, Jiangsu / CHINA
Tel.: (+86) 512 5357 6868
Fax: (+86) 512 5357 6867
e-mail: [email protected]
A /310 – 311 / Dynasty Business Park
J B Nagar / Andheri-Kurla Road
Andheri East / Mumbai– 400059 / India
Tel: (+91) 98 20010218
e-mail: [email protected]
EBNER Industrieofenbau GmbH
EBNER Furnaces, Inc.
EBNER Industrial Furnaces (Taicang) Co.,Ltd.
EBNER India Private Limited
I M P R I NT
HICON ®: The EBNER Customer Journal / Volume 23, Issue 2, September 2014. Copyright© EBNER Industrieofenbau GmbH, Ebner-Platz 1 / 4060 Leonding, Austria /
Tel.: (+43) 732 / 68 68 - 0 / Fax: ( +43) 732 / 68 68 - 1000 / E-Mail: [email protected]. Reproduction, in full or in part, is authorized only with the express written
permission of EBNER Industrieofenbau GmbH. / text: froschauer.com / translation: Sabine Schuster, Chen Lin, Irina Lomovtseva /
photography: EBNER Industrieofenbau GmbH. / graphic design: froschauer.com / editing: Sabine Schuster / published twice yearly
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www.ebner.cc