EMG emass - the leading electro MAgnetic Strip Stabilisation

Transcription

1 The time is ripe: EMG emass - the leading electro MAgnetic Strip Stabilisation White paper 1

2 Content The time is ripe: the current zinc price, a compelling argument for EMG emass strip stabilisation 3 Application scenarios and their potentials 4 Reducing over coating - saving zinc with EMG emass 4 Production of thin layers - massive zinc savings with EMG emass 6 The integrated solution EMG emass + DUMA-BANDZINK JETPRO 7 A special class: Coating thickness control in combination with EMG emass 8 On the way to a successful EMG emass project 10 2

3 The time is ripe: the current zinc price, a compelling argument for EMG emass strip stabilisation Is the hike in zinc prices affecting your profitability? Are you over-coating zinc just to be on safer side of your sales contract? Do you face challenges to attain uniform zinc coating? Are you planning a new hot dip galvanising line in near future? If the answer to any of the questions above is yes, please read this white paper on EMG emass strip stabilisation system! Currently there is one factor that puts all other value-adding factors into the background, namely the zinc price. The zinc price which was at around 1560 USD/t at the end of 2015 is rising rapidly and is around 3473 USD/t in the middle of January 2018 as per recent LME commodity price report. The bad news is that this trend is not expected to change in near future given that 30 % fall in zinc inventory levels at London Metal Exchange and about 60 % for Shanghai! You could say grey is all theory and we agree with you in principle. In this sense, you will find in the following articles of this newsletter examples of EMG emass customer applications in which the aforementioned order of magnitude has at least been reached, but often significantly exceeded. The figures quoted there have generally been published by EMG emass users at international conferences in recent years and thus provide a solid picture of the user experience. Which emass solution is the best for your plant can of course only be estimated after taking a close look at the situation on site and knowing the actual production data. We are also happy to provide you with the corresponding calculation aids and advise you in detail. Please feel free to contact our sales organisation or our product department at any time. Mr. Steffen Dombrowski steffen.dombrowski@emg-automation.com Phone: A rough calculation may illustrate the potential of an investment in a technology that helps to reduce zinc consumption. Take a hot-dip galvanising line with a focus on the automotive industry with an annual production of 450,000 tons of flat steel and an average material thickness of 0.8 mm of coils produced as an example. Let s assume that the aim of an investment in the strip stabilisation EMG emass is to save an average of only 1 g/m 2 zinc per side by avoiding unnecessary over-coating. If you want, just take the produced coil surface as a basis and calculate: Right, the annual savings from zinc savings alone in this scenario is about 140 tons of zinc or about 451 TUSD (or 379 T )! 3

4 Application scenarios and their potentials There are various process improvements that lead to significant savings in zinc and aluminium by using EMG emass electromagnetic strip stabilisation, as well as quality improvements in hot-dip galvanising or hotdip aluminising lines. Roughly speaking, the respective implementation scenarios can be divided into three groups: Reduction of the zinc over coating at existing or new hot-dip galvanising lines Achievement of thin coating layers and thus massive savings on existing hot-dip galvanising lines Narrow nozzle spacing at the air knife and extra homogeneous layers for new or existing hot-dip galvanising lines with a focus on e.g. the automotive industry Of course, users of EMG emass strip stabilisation solutions are carefully and cautiously publishing figures on the actual savings achieved, but in the last 10 years they have presented results at conferences and trade fairs, which we have taken up here and put into the context of the above-mentioned application scenarios. Let s start with the reduction of the zinc over coating at existing or new hot-dip galvanising lines. Reducing overcoating - saving zinc with EMG emass In a narrower sense, this scenario only applies to existing plants that are already in production. In new plants, EMG emass is used from the very beginning to avoid over-galvanising as far as possible. A before/after comparison is neither sensible nor possible with regard to costs. Let us therefore concentrate on the upgrading of existing plants. In 2007, thyssenkrupp Steel was already able to demonstrate at the EMG emass pilot plant that it is possible to reduce the standard deviation in the zinc coating from 4.4 g/m 2 to 1.8 g/m 2 for a single-sided layer of 160 g/m 2. A reduction of the over coating by g/m 2 seemed to be within reach. Results from continuous operation of EMG emass were then provided by ArcelorMittal Columbus, USA, at the Galvanizers Conference 2010: Immediately after commissioning, the coating target of the plant could be reduced by 1 g/m 2 /side. These results were topped by GalvTech in 2012, also on the occasion of the Galvanizers Conference. The total coating could be reduced by an average of 3.3 g/m 2 (or 1.65 g/m 2 /side) and in terms of production volume in 2011, GalvTech reported a zinc saving of 202 tons/year. This was at that time equivalent to 359,000 and would now be worth over 520,000! 4

5 At the JSI-ESTAD Conference 2014 in Paris, Arcelor- Mittal added: In Cleveland [ArcelorMittal, USA] the over coating could be reduced by 1 to 1.5 g/m² with this solution [EMG emass ]. The info chart below shows the range of achieved and published results. And of course, the added value that can be achieved by using EMG emass is not limited to zinc savings. In addition, there is the significantly more homogeneous coating in the cross profile as an important requirement of demanding end customers (e. g. in the automotive or packaging sector) as well as a possible increase in line speed without any loss of quality. Just to make it clear: this applies to modern systems that already produce high-quality surfaces even with low coating weights. Conclusion: Based on this and supported by internal information from various customer projects, we can now say that upgrading an existing modern type of hot-dip galvanising line with an EMG emass strip stabilisation system can lead in regular operation to a reduction in the over coating of at least 1 g/m 2 /side or more. This has been proven and published by the world s leading steel manufacturers! 5

6 Production of thin layers - massive zinc savings with EMG emass Often, EMG emass application scenarios are not primarily concerned with saving the last gram of zinc, but primarily with the ability to produce thin coatings at all. This is the case wherever either older nozzle systems are used or air knives in which the main focus was not initially on low coating weights for reasons of investment costs or target market orientation. With EMG emass, however, precisely such air knife arrangements can be upgraded to produce thin layers with high quality. The following graph illustrates the technical challenge and solution. at Hao Sen in Vietnam in EMG emass alone enabled Hao Sen to meet the high quality standards and the required production volume with a very moderate investment in the air knife technology for this new hot-dip galvanising line. A plausible strategy that has until today been confirmed by 6 further orders for EMG emass from the emerging steel centres in Vietnam, Malaysia and Thailand. The zinc savings to be achieved depend on the specific plant situation on site. Even with initially smaller nozzle distances compared to the example above, relevant savings can be achieved (see also previous article). With EMG emass switched off, the minimum nozzle distance in this example is 40 mm. After switching on the strip stabiliser, the minimum nozzle distance can be reduced to 20 mm. In this application example, this means that, for the first time, layers of 100 g/m 2 can be achieved without having to live with a massive overcoating. Fantastic, yes, but not unrealistic. The above values reflect the result of an air knife revamp with installation of EMG emass at a European manufacturer of hotdip galvanised sheet material for architectural applications in We will gladly leave it to you to estimate the Return of Invest period for this project. If you land well under 12 months, you are not wrong. In the figurative sense, such results have also been reported by manufacturers who have opted from the beginning on to combine a cheaper air knife technology with EMG emass. A good example of this is the use of the emass system at the hot-dip galvanising line 6 Conclusion: Are you wondering whether it is possible to reduce the coating weights and/or increase production throughput while maintaining or improving quality in your line with the existing air knife technology? Or whether you are investing in an air knife combined with an EMG emass strip stabilisation system? Do not hesitate to contact EMG or your EMG sales or service partner. It could be worth more than you think! This applies both in view of the possibly massively reduced zinc consumption and the opening up of new customer market segments.

7 The integrated solution EMG emass + DUMA-BANDZINK JETPRO The integrated solution means a complete integration of an electromagnetic strip stabilisation into an air knife design. We have already reported on the integrated solution in detail in the following previous articles: An ideal symbiosis: EMG emass strip stabilization and the DUMA-BANDZINK nozzle as an integrated system EMG emass and DUMA-BANDZINK: the first integrated solution for strip stabilization successfully commissioned at voestalpine Stahl GmbH This solution is only available in combination with the DUMA-BANDZINK air knife technology JetPro and is used especially in high-end automotive lines for new investments or complex retrofitting of the complete coating arrangement. The integrated solution rounds off the portfolio of the available EMG emass system categories and is characterised by a particularly small distance between the electromagnets and the air knife nozzle level (approx. 900 mm). Achieved results so far Amplitude 1.4 mm Amplitude 1.6 mm Amplitude doubled When the magnets are on the amplitude of vibration of the left strip side is 1.4 mm to 1.6 mm on the right side. When EMG emass is off those amplitudes are more than doubled with a very pronounced crossbow! The actual reduction is about 70 %! Results of coating gauge measurement: Crossbow heavily pronounced! In addition, this system category has the special feature of individually movable magnetic actuators, which enables an even better coverage over the strip surface for all widths and lateral strip positions. Conclusion: Better surface quality (coating uniformity +/- 2 % across strip) Higher exposed throughput (increased O5 (automotive car body) line speed m/ min.) Reduced investment costs (compared to conventional settings) Operational savings (compared to conventional settings) A very uniform top and bottom side can be seen as well as nearly overlapping measurements when EMG emass is switched on. The illustration shows the variation of the zinc coating over the strip width, with different nozzle lip to strip distances. The perfect uniformity of the zinc coating with a nozzle distance of only 4.9 mm is to be highlighted. 7

8 A special class: Coating thickness control in combination with EMG emass In hot-dip galvanising lines, the winding of the strip around the pot roll results in flatness defects, which are most often referred to as crossbow. These deviations influence the zinc layer distribution by varying the nozzle distance across the strip width and require a significant increase in the coating target if an undercoating of parts of the strip is to be prevented. Automatic coating control systems can compensate for the skew of the strip between the nozzle lips, but they cannot rule out coating defects due to crossbow errors. ArcelorMittal Florange, France, reported for the first time at METEC & 2nd ESTAD 2015 on a technique in which the online coating measurement (cold measurement) was used to determine the cross profile of the coating between the air knife lips and to achieve an absolutely flat strip between the nozzle lips by overcompensation of the strip shape between the EMG emass magnets. The basic principle is based on dividing for each scan of the coating measurement (approx. 120 m after the coating process) the coating cross section profile of the top and bottom side of the strip into two linear and non-linear components. The linear component is used to correct the skew error by re-aligning the nozzle with respect to the strip while the non-linear component is used to deliberately deform the strip in the area of EMG emass so that the strip is held flat further down between the air knife nozzles. The coupling of EMG emass with the jet machine requires robust coating control to avoid interference between the three control loops: air jet pressure, nozzle position and electromagnetic strip stabilisation. The result is shown in the following illustration: 8

9 And the result? In the project described by ArcelorMittal, the crossbow was reduced from 8.2 mm to 4.7 mm for the Alusi coating and from 3.1 mm to 0.6 mm for zinc. So again a drastic improvement between 50 and 80 % of already very good values! [Reference: Cross-strip coating weight control at the hot dip galvanizing line of ArcelorMittal Florange, N. Guelton et. al., METEC & 2nd ESTAD, 2015] The solution described here is particularly suitable for very modern, technologically advanced automobile lines such as ArcelorMittal Florange. The results are then comparable to the possibilities offered by an integrated EMG emass / DUMA-BANDZINK solution. Please note: The closer the strip stabilisation can be brought to the level of the nozzle lips, the smaller the need for a theoretically possible overcompensation. Conclusion: These results underline the fact that excellent results can be achieved by combining EMG emass with intelligent control approaches using information from online coating layer measurement. This requires close cooperation between the line operator and the automation suppliers at the line in question. EMG provides in all cases the necessary data from the strip stabilisation for the corresponding interfaces. 9

10 On the way to a successful EMG emass project - Achieving optimum process results with a project effort as low as possible In the chapter Application scenarios and their potentials, we have dealt intensively with the question of which methods and scenarios can be used to achieve optimum results when using the EMG emass electromagnetic strip stabilisation. Once the basic decision to invest in strip stabilisation has been made, the second question is how to plan the installation in the line, commissioning and use of the system in production in such a way that, on the one hand, the project effort is kept as low as possible and, on the other hand, optimum process results can be achieved without unduly hindering the operation of the coating line. Achieving these goals is possible with a high degree of certainty, provided that the following six points are observed: 1. Target definition First of all, it must be clarified what exactly are the goals associated with the planned use of EMG emass. Is it the further saving of zinc for a system that has already been optimised to a large extent? Is it the achievement of thinner layers, which can only be obtained if the strip runs more stable? Or is it a new investment or a fundamental optimisation of the coating line, in which not only the strip stabilisation system but also the combination of strip stabilisation and air knife system as an integrated solution (EMG emass / DUMA-BAND- ZINK JetPro ) comes into consideration? 2. Mechanical integration The second important point is the clarification of mechanical integration possibilities. On the one hand, care should be taken to ensure that the EMG emass strip stabiliser can be placed as close as possible to the air knife nozzle level, and on the other hand that the operation of the coating line can continue unhindered even with regard to manual nozzle cleaning. If an integrated solution is not possible, the strip stabilisation system should be mounted on a separate frame in almost all cases. EMG emass can then be driven out of the line independently of the air knive. Maintenance work on the jet arrangement is thus possible without hindrance and considerably increases the acceptance of the operating personnel with regard to the continuous use of the system. 3. Electrical integration and automation A third important point to be clarified is the integration of data and control technology into plant automation. The depth of this integration is related to the objectives defined in point 1 and the mechanical coupling between the air 10

11 knife system and the strip stabilisation in point 2. From the beginning on, a clear interface definition and task distribution between EMG, the automation partner and the end user is required. As with mechanical integration, EMG can draw on a rich portfolio of solutions and experience in this area. 4. Project plan and distribution of tasks A closely coordinated project plan and an intelligent distribution of tasks are further prerequisites for a successful project. In many cases, mechanical and electrical integration tasks can be carried out directly by the customer or local service providers. This generally allows a very cost-efficient solution for the use of an EMG emass system to be implemented. 5. Mentoring and training Last but not least, the intensive support and training of service and plant personnel at the end customer by EMG s experts is an important precondition for a successful project. This means that the end user is brought into the driver s seat as quickly as possible in order to ensure the successful use of an electromagnetic strip stabilisation system. 6. Production usage and continuous optimisation The system is in full production usage and will be optimised in an iterative process with respect to changing or modified production scenarios (e.g. special coatings, new gauges, different production speeds). This process is either carried out by the trained user himself or supported by consulting services of EMG engineers. Your optimum EMG emass system Conclusion Based on more than ten years of experience with EMG emass electromagnetic stabilisation in almost 50 applications worldwide, a successful project with very low risk for the end user can be realised in cooperation with EMG, taking into account the above mentioned factors. The customer is then able to implement the added value anticipated in his investment decision very quickly in reality. A mutually agreed and accepted definition of goals is in this context the decisive success factor! 11

12 Almost 50 successful EMG emass solutions throughout the world References (as at January 2018) Customer Country Plant/Line Delivery year Baoshan Iron & Steel, Shanghai China 1550 CGL 08/2007 ThyssenKrupp Steel, Duisburg Germany CGL#1 08/2007 Dongbu Steel, Incheon Korea CGL#2 10/2007 ArcelorMittal, Columbus USA CGL 11/2007 ThyssenKrupp Steel, Dortmund Germany CGL#8 12/2007 ArcelorMittal, Eurogal Belgium CGL 03/2008 Hysco, Dangjin Korea CGL 05/2008 Hysco, Suncheon Korea CGL#1 05/2008 Union Steel Korea CGL#3 06/2008 ArcelorMittal, Florange France CGL 07/2008 Posco Korea Mexico CGL 12/2008 ArcelorMittal Aviles SP Aviles Galva2 11/2008 Union Steel Korea CGL#5 11/2008 ArcelorMittal, Gent (Sidgal) Belgium CGL#1 07/2008 Corus Myriad France CGL#2 12/2008 ArcelorMittal Cleveland USA CGL 11/2008 ArcelorMittal, La Magona Italy CGL#4 04/2010 Handan China CGL#1 09/2009 Shougang Jingtang China CGL#3 01/2010 Shougang Jingtang China CGL#4 01/2010 Arcelor Mittal Sagunto Spain CGL 08/2010 Posco India CGL 02/2011 SEAH Steel Korea CGL 02/2011 Arcelor Mittal Krakow Poland CGL 03/2011 Shandong Guanzhou Steel China CGL 06/2011 Bhushan Steel Orissa India CGL 08/2011 GalvTech USA CGL 08/2011 N.N. Mexico * 02/2012 N.N. Thailand * 06/2012 Yieh Phui China CGL2 08/2012 Yieh Phui Taiwan CGL3 08/2012 ThyssenKrupp Steel, Galmed Spain CGL #9 08/2012 N.N. Japan * 01/2014 Hoa Sen Group Vietnam CGL 05/2014 JSW Bellary Vijayanagar India CRM#2 CGL 08/2014 Pangang Chongqing China CGL 08/2014 Yieh Phui China CGL 03/2015 Than Phuoc Khanh (TPK) Vietnam CGL 1 06/

13 Customer Country Plant/Line Delivery year Angang Group Int. China CGL3 06/2015 N.N. Indonesia GAPL 03/2016 NamKim Vietnam CGL1 02/2016 NamKim Vietnam CGL2 02/2016 Federal Iron Works Malaysia CGL6 03/2016 Southern Steel Sheet Co. Vietnam CGL 02/2016 voestalpine* Austria FVZ2 08/2016 ThyssenKrupp Steel, Bochum* Germany CGL#7 10/2016 SSAB Hämeenlinna* Finland CGL 3 09/2017 ThyssenKrupp Steel* Germany FBA 3 06/2018 ThyssenKrupp Steel* Spain CGL Galmed 09/2018 AITC-Angang China CGL#5 04/2018 *Integrated Solution Have you become curious? You want to know more about EMG emass and the effort for a successful project? Which emass solution is the best for your plant can of course only be estimated after taking a close look at the situation on site and knowing the actual production data. We are also happy to provide you with the corresponding calculation aids and advise you in detail. Take a look at our website ( quality-assurance-systems/emg-emass-electromagnetic-strip-stabilisation/) and please feel free to contact our sales organisation or our product department at any time. Mr. Steffen Dombrowski steffen.dombrowski@emg-automation.com Phone:

14 Automation GmbH Industriestraße Wenden Germany Phone: Fax: automation@emg-automation.com Group.moving ahead. EMG / P-A / emass -White paper / EN / Revision 00 / / Printed in Germany / Subject to modifiation 14