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Product program for efficient secondary metallurgy
SMS SIEMAG
SECONDARY METALLURGY
SMS Mevac
32
SECONDARY METALLURGY –ADDING VALUE TO YOUR STEEL
Technologies and ApplicationsSMS MEVAC
Content
ADVANCED STEEL QUALITY .............................................................................................................................. 4Preferred technologies ................................................................................................................................................................... 4
ATMOSPHERIC PROCESS TECHNOLOGIES ....................................................................................... 6HMP Hot metal pretreatment stations .................................................................................................................................. 7LTS Ladle treatment stations ..................................................................................................................................................... 7CHS Chemical heating stations ................................................................................................................................................. 8LF Ladle furnaces ............................................................................................................................................................................ 8
VACUUM PROCESS TECHNOLOGIES ........................................................................................................ 10RH and RH-TOP Recirculation degassers ............................................................................................................................. 11RH-TOP Lances ................................................................................................................................................................................ 11RH-RockerType® ................................................................................................................................................................................ 12VD and VD-OB Tank degassers, VOD Vacuum oxygen decarburization units ........................................................ 14Vacuum pumps ................................................................................................................................................................................. 16
AUTOMATION SYSTEMS ........................................................................................................................................ 18Plant and process control systems .......................................................................................................................................... 19
SERVICE SPECTRUM .................................................................................................................................................... 20Lifecycle maintenance ................................................................................................................................................................... 21
ADVANCED STEEL QUALITY ............................................................................................................................... 22 Process routes .................................................................................................................................................................................. 23
FIVE DIMENSIONS OF EXPERTISE
FOR YOUR SUCCESS
SMS Mevac’s product program covers the entirerange of technologies and services for effectivesolutions in secondary metallurgy. We combinefive dimensions of expertise in an holistic approach. In each performance area we deliver outstandingresults:
Advanced steel qualityPerformance and productivityLifecycle maintenance Safety, health, and environmentROI and TCO-driven perspectives
X-eed is the brand name of the overall SMS Mevacportfolio, expressing our continuous striving fordevelopment of enhanced technologies for thebenefit of our worldwide customers.
ADDING VALUE TO YOUR STEEL
Our secondary metallurgy program adds value toyour steel. It meets the requirements of all steelproducers worldwide. We are pleased to supportyou in creating the most efficient processes andprocess routes – tailored to your plant’s needs.
ROI +
TC
O
Ori
enta
tio
n
and Environment
Safety, Health, M
aint
enan
ce
Life
cycl
e
Advanced
Steel Q
uality Performance +
Productivity
Technologies and ApplicationsSMS MEVAC
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A PACKAGE OF SUPERIOR
SOLUTIONS
SMS Mevac’s program covers the complete range of technologies and services for advancedsteel quality. This package of secondary metallurgy solutions is an important factor in helping to continuously deliver products with superior benefits to the final customer.
These true assets in the value chain give you maximum flexibility in constantly supporting leading industries with the most appropriateadvanced steel quality. Seize the many opportunities to satisfy growing demand for quality steels in future-oriented markets.
ENGINEERING SUPREMACY
We individually tune and adjust each component of your secondary metallurgy plant. Our total commitment to technologies and services helps to create extraordinarily efficient performance, giving unique competitiveness in economy and ecology.
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INDUSTRIES
Appliance Industry
Appliance Industry
Automotive
Automotive
Automotive
Automotive
Chemical Industry
Building, Architecture
Building, Architecture
Decoration
Electrical Industry
Energy
Energy
Mechanical engineering
Mechanical engineering
Transportation
Transportation
SELECTED FINAL PRODUCTS
Refrigerators
Washing machine drums
Antifriction bearings
Automotive panels, car bodies
Crankshafts
Valve springs, valve cones
Tubes
Facades
Steel bars
Cuttlery
Sheets
Rotor blades for wind turbines
Gas pipes
Punching tools, screw taps, screws
Tin plates
Railroad wheels
Rails
TECHNOLOGIES
VOD, LF, LTS
VOD, LF, LTS
LF, VD, (RH)
(RH), RH-TOP, CHS
LF, VD, (RH)
LF
VOD, LF, LTS
VOD, LF, LTS
LF, LTS
VOD, LF, LTS
(RH), RH-TOP, CHS
VD, LF, (RH)
VD, LF, (RH)
LF, LTS, VD
LF, LTS
LF, VD, (RH)
LF, VD, (RH)
ADVANCED STEEL QUALITIES
Precise analysis adjustment, precise temperature control
Low carbon content, precise analysis adjustment, high steel purity
High steel purity, precise temperature control, precise analysis adjustment, slag management
Low carbon content
High steel purity, precise analysis adjustment, sulphide inclusion modification
High steel purity, oxide inclusion modification
Low carbon content, precise analysis adjustment,precise temperature control
Precise analysis adjustment, precise temperature control
Slag management, high steel purity, oxide inclusion modification
Precise analysis adjustment
Lowest carbon contents, precise analysis adjustment, precise temperature control
High steel purity, precise analysis adjustment
Sulphide inclusion modification, low contents of sulphur and hydrogen
Precise analysis adjustment
High steel purity, precise analysis adjustment
High steel purity, precise analysis adjustment, slag management
Oxide inclusion modification, slag management, precise analysis adjustment
BENEFITS FOR THE FINAL CUSTOMER
Surface quality, clean edges
High resistance to washing solutions
Long service life, low noise
Perfect surface quality, high formability, low weight
Long service life
Long service life, low material consumption
High resistance to corrosion
Perfect surface quality
Long service life, high stability
High resistance to corrosion
Low energy losses
High strength, high wear resistance, long service life
Not sensitive to low temperatures
Low wear, high precision
High strength, low weight
High operating reliability, long service life
High wear resistance
Advanced steel quality
PREFERRED TECHNOLOGIES
ATMOSPHERIC PROCESSTECHNOLOGIES
Atmospheric process technologies
HMP, LTS, CHS, LF
Technologies and ApplicationsSMS MEVAC
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HOT METAL PRETREATMENT
STATIONS
SMS Mevac’s HMP stations are installed in manysteelmaking plants in order to economically removedetrimental elements from hot metal. Heat sizescover a range up to 350 t. Mono or co-injectionunits for desulphurization agents are available.Our latest Twinjection® technology allows fastreagent delivery without compromising efficiency.
Metallurgical functionsPretreatment of hot metal and adjustment of compositionDesulphurization by powder injectionDephosphorizationDesiliconizationDeslaggingHomogenization of hot metal quality and temperature
KANBARA REACTOR (KR)
As an alternative technology the Kanbara reactorcan be applied in HMP stations to thoroughly disperse the desulphurization reagent.
Metallurgical functionsDesulphurization by a mechanical stirring process Deslagging
LADLE TREATMENT STATIONS
SMS Mevac’s LTS units are installed in EAF andBOF steelmaking plants between the melting andcontinuous casting facilities. Ladle treatmentstations carry out an important set of secondarymetallurgical processes without using large-scale,capital intensive equipment.
Metallurgical functionsDesulphurization by addition of synthetic slag or by powder blowingDeoxidation by addition of aluminum or micro alloysAdjustment of the chemical composition by wire feeding and alloy additionHomogenization of liquid steel by bottom purging or lance stirringAlloying and fine trimmingImprovement of castabilityTemperature adjustment by addition of cooling agentsLiquid steel storage buffer prior to casting
Atmospheric process technologies
HMP, LTS, CHS, LF
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Technologies and ApplicationsSMS MEVAC
CHEMICAL HEATING STATIONS
CHS by SMS Mevac are incorporated into EAFand BOF steelmaking routes to attain clean steelwith precise chemical composition. A bell or ringis used as the main component, partly immersedinto the liquid steel bath. CHS serve heat sizes ofup to 400 t.
Metallurgical functionsChemical heating by oxidation of aluminum or siliconDesulphurization by metal-slag reactionAlloying and fine trimmingHomogenization of steel quality and temperatureImprovement of castability
LADLE FURNACES
SMS Mevac’s LFs provide electrical heating toadjust accurate steel temperatures to the continuous caster. The LF can also be used tolower the BOF/EAF tapping temperature to compensate for losses due to secondary metallurgical processes like degassing or desulphurization. The power conducting arms aremade of copper or aluminum plates. In addition to
fixed-roof installations, slewing versions are available in order to serve two treatment positionsor two ladle transfer cars for increased productivity.Inert gas roofs for special applications are available.LFs are installed in steelmaking plants with heatsizes of up to 400 t.
Metallurgical functionsElectrical heatingDesulphurization by metal-slag reactionAlloying and fine trimmingSlag managementImprovement of castability Homogenization of ladle contentsBuffer function between melting and continuous casting units to ensure security of sequence casting
VACUUM PROCESSTECHNOLOGIES
Vacuum process technologies
RH, RH-TOP
RH AND RH-TOP RECIRCULATION
DEGASSERS
RH and RH-TOP units are installed in steelmakingplants with heat sizes of up to 400 t.
Fixed vessel installations use ladle lifting systems,while movable vessel installations employ vessellifting systems. Fast vessel exchange systemsincrease the plant’s general performance andduplex vessel installations enable furtherincreased output.
The RH process is characterized by short treatment periods, minimal temperature lossesand extremely favorable results for decarburizationand degassing. No special slag measures, extraladle freeboard or porous plugs are required.
RH-TOP LANCES
A short lance design is used to blow from a longdistance, allowing installations in plants withrestricted headroom. Oxygen blowing, powderblowing and gas burner functions may be combined in a single multi-function lance. Videocamera installations can also be incorporated toprovide constant visual monitoring.
Metallurgical functionsDecarburization to lowest levelsHydrogen removalAlloying and fine trimming with high accuracyFast homogenization of the ladle content, even when large quantities of alloys are introducedVacuum carbon deoxidation
With RH-TOP lanceForced decarburizationAdjustment of C:O ratioDesulphurizationAdjustment of steel temperature by chemical heatingSkull removalHeating of vessel by means of integrated gas burner function
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Technologies and ApplicationsSMS MEVAC
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Technologies and ApplicationsSMS MEVAC
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Vacuum process technologies
RH, RH-TOP
RH-ROCKERTYPE® – A BOOST
FOR SAFETY
The RH-RockerType® unit has been engineered to significantly increase the performance parametersof RH processes. This well proven yet future-oriented solution gives safe, reliable RH operation.
The origin of RH-RockerType® technology from SMS Mevac goes back to the 1950s. Its main purpose then was to safely lower the vacuumvessel system and immerse the snorkels into theliquid steel in a simple and reliable way. The systemstands out because of its user friendly operationand maintenance.
Recently, RH-RockerType® technology has been further improved. It now smoothly lifts and lowersthe ladle instead of the vacuum vessel system.Many useful features were added.
INCREASED EFFICIENCY
To speed up your intra logistic processes in theRH plant, the ladle lifting RH-RockerType® canuse two ladle cars. One of them brings the ladleto the RH station for treatment. After treatment,another car takes it to the caster area whilst thefirst ladle car brings the next ladle.
This design supports flexible processes, as the firstladle car can be recharged while the ladle is beingtreated. Depending on the layout of the steel shop,this greatly improves your ladle transportationlogistics. The resulting advantages can be implemented both in single treatment stationsas well as in our fast vessel exchange units.
As the alloy system and the vacuum pump arefixed directly to the vacuum vessel system, nospecial conveyors or moving vacuum ductwork are required.
A KEY TO LASTING RELIABILITY
Two hydraulic cylinders are installed to operatethe lifting and lowering processes of the ladle. For normal operations, they are mechanically synchronized. In the case of an electric power failure, the ladle is lowered safely onto the ladlecar in a controlled way by gravity. Maintenance ofthe complete hydraulic system is simple andstraightforward. The RH-RockerType® unit is verywell protected against liquid steel splashes andliquid steel from a ladle break-out.
In comparison to vacuum vessel lifting installations,there is much better access to the vacuum vesselplatform. Similarly the automatic sampler andother auxiliary equipment are easily accessed.
For safety and efficiency reasons RH-RockerType®
technology will play an important role in futureRH secondary metallurgical infrastructure.
RH Ladlerocker (3D)
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Vacuum process technologies
VD, VD-OB, VOD
VD AND VD-OB TANK DEGASSERS
SMS Mevac’s tank degassers support EAF andBOF plants, permitting heat sizes of up to 340 tor more. Inert gas is introduced into the bottom ofthe ladle by means of porous plugs. The process ischaracterized by slag-free tapping at the meltingunit. The plant requires an efficient vacuum pumpsystem to meet the specific requirements of thedesired metallurgical process.
Standard tank installations are fixed above orbelow the shop floor. Movable tank installationsor twin tank installations substantially increaseperformance.
Metallurgical functionsHydrogen and nitrogen removalDecarburization to lowest levelsDesulphurization by metal and slag reactionEfficient alloying and fine trimming with high accuracySlag managementImprovement of castabilityHomogenization of ladle contents
Additional applications using VD-OB lance systems:Oxygen blowing for forced decarburization from high initial carbon levels, e.g. for the production of ultra-low carbon steel gradesOxygen blowing for chemical heating by aluminum oxidation
VACUUM OXYGEN
DECARBURIZATION UNITS
FOR STAINLESS STEEL
SMS Mevac has supplied VOD units with heatsizes of up to 200 t, mainly for the production ofstainless steel.
Similar to VD, the VOD units are designed tomeet the specific requirements of the plant layout as well as the individual processes of our customers.
Metallurgical functions enhanced by our efficientoxygen lance are:Forced decarburization under vacuum for low chromium oxidationChemical heatingHomogenization of ladle contentsAlloying and fine trimming
Technologies and ApplicationsSMS MEVAC
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Vacuum process technologies
VACUUM PUMPS
Technologies and ApplicationsSMS MEVAC
EFFECTIVE VACUUM TREATMENT
High-performance vacuum pumps from SMSMevac are the heart of secondary metallurgicalvacuum processes. For both recirculation ortank degassing processes, our vacuum pump technologies are tuned to your specific steel conditions and to your individual plant and production requirements.
Our vacuum pump systems precisely controlthe rate of pressure reduction from atmosphericlevel to low vacuum pressure. During the varioustreatment steps the vacuum level is accuratelycontrolled to match the system’s metallurgicalneeds.
In order to deliver optimum results high suctioncapacity, low energy consumption and optimalreliability are essential elements of our design.
VACUUM PUMP TECHNOLOGY
FOR YOUR PROCESS
Three technologies form the cornerstones ofSMS Mevac’s vacuum systems:steam ejector vacuum pumpssteam ejectors with water ring pumpsdry mechanical pump systems.
The selection of a specific technology dependson the respective conditions in the secondarymetallurgical plant. Availability of utilities, metallurgical needs and the balance of operationaland investment costs are basic considerationsfor our individual, high performance concepts.
PIONEERING EXPERIENCE
SMS Mevac has decades of pioneering experiencein various vacuum pump technologies.
In 1956 SMS Mevac built its first steam ejectorvacuum pump for vacuum treatment processingof liquid steel. Since 1960, we also designedplants with mechanical vacuum pumps.
In 1985 our four stage steam ejectors replacedthe former five stage version for high coolingwater temperatures. For advanced splash control,our RH-SC® with variable steam nozzles waslaunched in 2000. And in 2006 we introduced ourTriple-S-technology for reduced consumption ofcooling water.
This set of advanced innovations has a provenrecord of success in many hundreds of applicationsall over the globe.
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AUTOMATION SYSTEMS Automation systems
PLANT AND PROCESS CONTROL SYSTEMSSMS MEVAC’S
AUTOMATION SYSTEMS
Advanced electrical systems, automation andinstrumentation bring together the balance of product quality, safety, energy and media consumption and reliable operations. SMS Mevac’sLevel 1 and Level 2 automation systems linkthese functions, giving highly efficient plantoperation.
MANAGEMENT SUPPORT AND
CONTINUOUS IMPROVEMENT
Secondary metallurgy automation is linked to thesteelwork’s Level 3 system, giving full information,providing reporting systems and supporting thescheduling of heats.
Metallurgical and thermal models, least cost calculations and process simulation assist yourspecialists to continuously improve yourprocesses.
OPERATOR SUPPORT
Ergonomic HMIs are supported by state-of theart technology. Operators obtain up-to-the-minute information to safely control secondarymetallurgical processes.
Maximum safety is provided by interlock indication on HMI, sequence control, equipmentand functional interlocks, pin pointing failuresand monitoring of critical processes such asmedia flow and possible leakage.
A WELL PROVEN BRAND
SMS Mevac and SMS Siemag express their greatpassion for steelmaking by sharing the unmatchedautomation brand X-Pact for their plant and processcontrol systems.
This gives additional assurance of highest qualityto our customers.
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Technologies and ApplicationsSMS MEVAC
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SERVICE SPECTRUM Service spectrum
LIFECYCLE MAINTENANCE
LIFECYCLE-ORIENTED CARE
Secondary metallurgical plants from SMS Mevacare highly reliable and maintenance friendly.Care for our customer’s plant starts even beforehanding over.
Our vast spectrum of consulting services beginswith the feasibility study – based on the individualstrategy of the customer. We discuss alternativesolutions with regard to technologies and economics. By using extended 3D simulationprograms we fine-tune the final layout of eachcomponent.
TRAINING PROGRAMS
Individual training packages provide soundknowledge and motivation to the prospectiveteams - from operation routines to automationdetails and safety measures.
A combination of initial off-site training coursesat the SMS Mevac headquarters or at suitablepartner plants plus continuous on-site workshopsprovide advanced know-how for successful long-term operations.
MAINTENANCE AND SPARE-PARTS
Monitoring of the plant’s performance by our specialists and preventive maintenance packageseffectively reduce costly down times needed forfault-finding and trouble-shooting activities. Ourafter sales service supplies the required OEMspare parts for our customer’s plants ensuringcontinuous high performance of the equipment.
UPGRADING, MODERNIZATION,
AND REVAMPING
Depending on your plant’s lifecycle stage, a periodic up-date of special innovations andimprovements provides optimum return on yourinvestment. Our specialists’ recommendationsfocus on metallurgy, process technology, engineering and automation.
SMS Mevac is very experienced in careful planning to ensure minimum down times for therequired activities. Fast return on investment aftermodernization supports our customer’s economicand market targets.
For these reasons, our broad service spectrumprovides efficient lifecycle maintenance to ourcustomer’s secondary metallurgical operations.
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Technologies and ApplicationsSMS MEVAC
Technologies and ApplicationsSMS MEVAC
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Advanced steel quality
PROCESS ROUTES
INTEGRATED PROCESSES
A growing number of advanced steel qualitiesare based on sequential treatment in a series ofsecondary metallurgy stations. These processroutes combine complementary technologies toproduce steels at unique quality levels. Finishedproducts with high performance profiles originatefrom these high quality steels.
Consistent reproducibility makes them preferredqualities for high level industrial applications.The technology of the steelmaking process andthe required steel quality determine the mostsuitable process route. SMS Mevac’s full rangeof secondary metallurgy technology permits abroad spectrum of combinations. Integratedtechnologies for atmospheric and vacuumprocesses determine the choice of the mostappropriate routes.
LINE PIPE STEELS
Micro-alloyed line-pipe steels with high strengthand HIC-resistant profiles can be produced on BOFor EAF routes. Secondary metallurgy equipment
consists of SMS Mevac VD vacuum degassers andLF ladle furnaces for the EAF route, alternativelySMS Mevac LTS ladle treatment stations, RH-TOPrecirculation degassers, LF ladle furnaces and anHMP hot metal pretreatment station to serve theBOF route.
EXTRA DEEP DRAWING STEELS
The EAF route, for example for automotiveapplications uses SMS Mevac VD-OB vacuumdegassers and LF ladle furnaces. The BOF routecombines SMS Mevac HMP desulphurizationunits, LTS ladle treatment stations and VD-OBtank degassers or RH-TOP recirculationdegassers.
STAINLESS STEELS
The Duplex process route especially for the production of ferritic grades combines SMS MevacVOD vacuum oxygen decarburization technologyand LF ladle furnaces. The Triplex route is supportedby SMS Mevac HMP desulphurization units andVOD vacuum oxygen decarburization technology.
STEELMAKING PROCESS ROUTE – BOF
Micro-alloyed high-strength steels e.g. for line pipes or ship building
SMS Mevac LTS Ladle treatment station- Shape control, Ca-treatment
SMS Mevac RH-TOP Recirculation degasser- Degassing of H, N, final trimming, cleanliness
SMS Mevac LF Ladle furnace- Analysis, slag conditioning, temperature adjustment
BOF Basic oxygen furnace
SMS Mevac HMP Hot metal pretreatment station- Desulphurization
STAINLESS STEEL PROCESS ROUTE
Stainless steelsfor ferritic low carbon and low nitrogen grades
SMS Mevac LF Ladle furnace- Slag conditioning- Temperature adjustment- Shape control- Cleanliness
SMS Mevac VOD Vacuum oxygen decarburization unit- Decarburization- Desulphurization- Final trimming
EAF Electric arc furnace, deslagging unit
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ADVANCED STEEL QUALITY
STEELMAKING PROCESS ROUTE – EAF
Extra-deep drawing steels e.g. for automotive applications
SMS Mevac VD-OB Vacuum tank degasser- Decarburization- Deoxidation- Final trimming- Temperature adjustment
SMS Mevac LF Ladle furnace- Temperature adjustment
EAF Electric arc furnace, deslagging unit
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SMS MEVAC GMBH
Bamlerstr. 3a45141 Essen, Germany
Phone: +49(0) 201 6323-0Telefax: +49(0) 201 6323-200
E-Mail: mail@sms-mevac.comInternet:www.sms-mevac.com
H5/305E
1.500/05/2011 . MM .Printed in Germany
MEETING your EXPECTATIONS
The information provided in this brochure containsa general description of the performance characteristics of the products concerned. The actual products may not always have thesecharacteristics as described and, in particular,these may change as a result of further developments of the products. The provision ofthis information is not intended to have and will not have legal effect. An obligation to deliverproducts having particular characteristics shallonly exist if expressly agreed in the terms of thecontract.
RH-SC®, RH-RockerType® and Twinjection®
are registered trademarks of SMS Mevac.
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