ANDRITZ METALS FURNACE TECHNOLOGIES FOR ... - …seaisi.org/file/S8A-2 SEAISI_ANDRITZ Metals_Furnace...

ANDRITZ METALS

25-28 JUNE 2018

SEAISI Conference & Exhibition

FURNACE TECHNOLOGIES FOR

LATEST GENERATION OF AHSS

01 MARKET EVOLUTION

02 AUTOMOTIVE STEEL REQUIREMENTS

03 CHALLENGES FOR FURNACE DESIGN

CHAPTER OVERVIEW

SEAISI - JUNE 20182

AUTOMOTIVE INDUSTRY REQUIREMENTS

MARKET EVOLUTION IN HOT DIP GALVANIZING

SEAISI - JUNE 20183

Development of new grades of AHSS providing lighter and

stronger car body for:

• Improved vehicle crash resistance

• Improved fuel efficiency

• Reduced greenhouse gas emissions

• By 2020, CO2 emissions in Europe must be reduced to 95 grammes per km

• By 2025, fuel efficiency in USA must roughly double at 54.5 miles per gallon

AHSS : WEIGHT REDUCTION


SEAISI - JUNE 20184

Comparison of global CO2 regulations for new passenger

cars (source ICCT, june 2016)

CO2 emission regulation targets are <95 g/km in 2025

20% body weight reduction is required

AHSS: THE MOST COMPETITIVE CHOICE


SEAISI - JUNE 20185

AHSS : HIGHER STRENGHT & INCREASED FORMABILITY


SEAISI - JUNE 20186

Press hardened steels (PHS)

• Chemistry

• Coating

3rd generation of Advanced High Strength Steels

• Quench & Partitionning (Q&P)

• Carbide Free Bainite (CFB)


SEAISI - JUNE 20187

ASEAN CAR DENSITY FORECAST 2013-2021

SEAISI - JUNE 20188

GROWTH OF AHSS WILL OUTPERFORM THE

OVERALL MARKET

SEAISI - JUNE 20189

EVOLUTION OF NORTH AMERICAN MARKET

40% INCREASE OF AHSS BY 2025

SEAISI - JUNE 201810

"NEW" AUTOMOTIVE STEELS REQUIREMENTS


RTSAc1

Ac3

CONVENTIONAL

ANNEALING CYCLE

For 3rd gen. AHSS,

austenitic annealing is

required

Optional slow cooling (~5-10°C/s)

to control ferrite fraction and

austenite Carbon enrichment

Flexible Cooling rate depending

on metallurgy and target product :

20°C/s to >150°C/s

Precise end of cooling temperature

for Q&P and CFB products

Controlled overaging

T° and time

High DFF exit T°

may be needed Rapid heating sections

working on partially

austenitic steels

CHALLENGES FOR FURNACE DESIGN


1

2

3

4 5

• FLEXIBILITY

1. Annealing temperature

flexibility

2. High soaking temperature

3. High speed cooling

4. Flexible overaging /

partitionning

5. Steel coatability

RTSAc1

Ac3



• FLEXIBILITY


flexibility




partitionning


1

2

3

4 5

RTSAc1

Ac3

1. ANNEALING TEMPERATURE FLEXIBILITY

ANDRITZ DFF


• Ability to heat the strip up to

750°C in 2 passes

1

2

3

4

1. ANDRITZ DIRECT FIRED FURNACE (DFF)

SEAISI - JUNE 2018

Preheating :

Radiative waste gas

DN Burners :

Radiative flame

KB Burners :

Radiative flame

15



• FLEXIBILITY


flexibility




partitionning


1

2

3

4 5

RTSAc1

Ac3

• Radiant tubes commonly used in carbon steels production :

• Max tube temperature : ~1000°C

• Working tube temperature : ~930-950°C

• Risk of increasing tube temperature : lifetime decrease, creep

• Max strip temperature : ~850°C

• Other radiant tubes technologies :

• Fe-Cr-Al, SiC material tubes

• Max temperature : up to 1250°C

• Working temperature : ~1100°C

• Max Strip temperature : ~950°C

• Special care : exhaust gas temperature, environment (cladding,

refractories)

2. HIGH ANNEALING TEMPERATURE

RADIANT TUBES


• Electrical radiant tubes:

• I shape

• Limited power (40 kW/tube)

• Max tube temperature : 850°C

• Less performance than gas radiant tubes

• Wire or strip resistances:

• Ni-Cr Wire : 1250°C

• Molybdenum wire : 1400°C

• Special care : Surrounding equipment (cladding, refractory)

• Strip temperature up to 1100°C in Silicon steel furnace


ELECTRICAL RESISTANCES


• Used as pre-heating for increase capacity when no space availableRef.: TKS FBA8, Dortmund, Germany –Strip temperature ~160 to 300°C

• Used when end-heating temperature cannot be achieved with existing radiant tubes section: Flux Transverse induction technology

Ref.: AM Kessales CAL, Belgium – Strip temperature ~ 820 to 900°C• Used when end-cooling and overaging temperatures are below the zinc bath temperature (Al-killed, TRIP, Dual-

Phase with high austenite content steels)Ref.: VoestAlpine CGL#4, Austria – Before zinc bath – strip with up 40% austenite ~ 340 to 480°CRef.: AM Gent CGL#3, Belgium – Inductors at different locations

after cooling: strip with up 50% austenite ~ 150 to 480°Cbefore zinc bath: strip with up 40% austenite ~ 350 to 480°C

strip with up 10% austenite ~ 250 to 480°CRef.: Tangshan CGL#6, China – Before zinc bath ~ 270 to 460°CRef.: Yieh Phui CGL, China – Before zinc bath ~ 270 to 460°CRef.: Tangshan CGL#6, China – Before zinc bath ~ 270 to 460°CRef.: Baosteel CGL, China – Before zinc bath ~ 270 to 460°CRef.: VoestAlpine CAL, Austria – Overaging ~ 270 to 350°C

Uniform, high yield rapid heating even on low thickness and high austenite content


INDUCTION HEATING


Induction coil outside the

atmosphere chamber is an

ANDRITZ SELAS patent

Un seal



• FLEXIBILITY


flexibility




partitionning


1

2

3

4 5

RTSAc1

Ac3

3. ANDRITZ COOLING TECHNOLOGIES


2 to 10 °C/s

5 to 30 °C/s(*)

0 to 40 °C/s(*)

15 to 70 °C/s(*)

40 to 120 °C/s(*)

80 to 200 °C/s

▪ Radiant cooling (air cooled tubes)

▪ Slow jet cooling (HNx tubes)

▪ Flexible Chamber (Cooling +

soaking)

▪ Rapid Jet Coolers (HNx nozzles)

▪ Differential Rapid Jet Cooling

➢highest cooling rates by

homogeneous temperature

distribution

➢Higher H2-concentration for

further increase of heat

transfer

➢Modular design for different

operating modes(*) : 5% H2, 1,0 mm, 750°C->500°C

Differential Rapid

Jet Cooling : up to

100°C/s at 5% H2

ANDRITZ SELAS

PATENTED DRJC

Use of variable H2

content :

up to 170°C/s

Strip temperature

control accross

width.

HOMOGENEOUS STRIP

TEMPERATURE

3. HIGH SPEED COOLING


3. HIGH SPEED COOLING

DIFFERENTIAL RAPID JET COOLING (DRJC)


By optimized nozzle designMaximize heat exchange

By homogeneous temperature profile along strip with optimized

evacuation backflowAvoid flatness defects

By minimum strip distance (40 mm) with automatic controlIncrease heat transfer

By cooler modularization & controlHorizontal & vertical flexibility

More than 20 installations in productionProven technology

3. DRJC DESIGN


Temperature

scanner

1 2 33 2

1 2 33 2

1 2 33 2

Strip

travel

• Adjustable flow rate over strip width and strip length

1

2

3

• Optimized nozzle profile

• Optimized return flow

• Adjustable nozzle to strip

distance during operation

3. DRJC DESIGN


CENTER CENTER

TEMPERATURE PROFILE CONTROL

3. DRJC DESIGN


CENTER CENTER

INNER INNER

INNER INNER


3. DRJC DESIGN


CENTER CENTER

INNER INNER

INNER INNER

OUTER OUTER

OUTER OUTER


3. DRJC DESIGN


Temperature

scanner

1 2 33 2

1 2 33 2

1 2 33 2

1

2

3

TEMPERATURE PROFILE CONTROL – SCANNER ACROSS STRIP WIDTH

• ± 3°C across strip width

3. DRJC DESIGN


Speed variation of all fansClose loop control with scanner (center)

Adjustment across the strip width (pressure) Close loop control with scanner

3 directionsModularity

Mod.1

Mod.2

Mod.3

Mod.4

TEMPERATURE PROFILE CONTROL – FAN & PRESSURE CONTROL

3. DRJC : EXAMPLES OF LINE RESULTS


Design Results

3. DRJC : EXAMPLES OF LINE RESULTS


At 5% H2



• FLEXIBILITY


flexibility




partitionning


1

2

3

4 5

RTSAc1

Ac3

5. STEEL COATABILITY


MnO MnOSiO2MnSiO3

FeFe

FeFe

Zn Zn Zn Zn Zn

Preferential oxidation of Mn and Si - Non wettable oxides in Zn bath

Bare spots after coating

In H

eati

ng

Zo

ne

Aft

er

Co

ati

ng

5. PREOXIDATION IN DFF ALLOWS COATING OF

HIGH Mn/Si STEELS


Fe

FeO

Fe

Fe

Zn

Fe

Operation Where

Heating AHSS

strip up to 750°C

Preheat

+ DFFRTH1

Ultra rapid

Oxidation

Last

Zone of

DFF

Preoxidation

chamber

Reduction of

FeORTH + RTS

Defectless Zinc

CoatingZn bath

5. PREOXIDATION IN DFF


• Radiant cup burners:

Homogeneous O2 at the burners

• Multiple burners:

Homogeneous O2 across strip width

• Air/gas premix + Trimming:

Identical air/gas ratio for all burners +

Trimming for narrow strip

Comb.

Air

Natural

Gas

HOMOGENEOUS OXIDATION

5. PREOXIDATION IN DFF


• Accurate thickness of the oxide layer (200-300 nm) through:

• Accurate setting of air/gas ratio

• Accurate control of O2 rate in the waste gas

• A too thin layer will give coating problems

• A too thick layer could lead to roll pickup and incomplete reduction Permanent WG

analysis

ACCURATE OXIDATION

Customer Works Line Country Start-up Product Coating Pre- oxidation

ArcelorMittal Cleveland CGL USA 1991-2010 Auto / AHSS GI/GA YES

Tata Steel Llanwern CGL UK 1991-2004 Auto / AHSS GI/GA YES

Voestalpine Linz CAL Austria 1998-2019 Auto / AHSS / GEN3 - -

ThyssenKrupp Dortmund CGL 8 Germany 2001-2006 Auto / AHSS GI YES

Voestalpine Linz CGL 4 Austria 2007 Auto / AHSS GI YES

Voestalpine Linz CGL 5 Austria 2010 Auto / AHSS GI/GA YES

Tagal Chongqing CGL China 2015 Auto / AHSS GI/GA/Al YES

Baosteel Shanghai CGL China 2015 Auto / AHSS GI/Al-Si YES

ArcelorMittal Kessales CAL Belgium 2016 Auto / GEN3 EG - JVD YES

ArcelorMittal Gent CGL 3 Belgium 2018 Auto / GEN3 GI YES

ArcelorMittal Florange CGL France 2019 Auto GI/Al-Si YES

ThyssenKrupp Dortmund CGL 10 Germany 2020 Auto / AHSS / GEN3 GI/Zn-Mg YES

HBIS Laoting CAL China 2020 Auto / AHSS / GEN3 - -

ANDRITZ REFERENCES

DEDICATED TO AHSS & 3RD GEN AHSS


THANK YOU !

• Ajoy CHAKRABARTISales Director

ANDRITZ Technologies Pvt. Ltd

Plot No. 22, 6th Floor, Block KB

“Bhakta Towers” Sector-II, Salt Lake City

Kolkata - 700 098, India

p: +91 (33) 46027958 / 59

m: +91 9831036615

[email protected]

YOUR CONTACTS


• Nadine BANLINSales Director

ANDRITZ Selas SAS

4, avenue Laurent Cely, Hall A, Tours d’Asnieres

92600 - Asnieres-sur-Seine, France

p: +33 1 40803404

m: +33 612136766

[email protected]

• Alain DETHIERDirector Technology

ANDRITZ Technologies Pvt. Ltd

Magnolia , Block B, Level 4

Manyata Embassy Business Park, Nagawara

Bangalore - 560045, India

p: +91 (80) 46669600

m: +91 9741473396

[email protected]

This presentation contains valuable, proprietary property belonging to ANDRITZ AG or its affiliates (“the ANDRITZ GROUP”), an d no licenses

or other intellectual property rights are granted herein, nor shall the contents of this presentation form part of any sales contracts which may be

concluded between the ANDRITZ GROUP companies and purchasers of any equipment and/or systems referenced herein. Please be awa re

that the ANDRITZ GROUP actively and aggressively enforces its intellectual property rights to the fullest extent of applicabl e law. Any

information contained herein (other than publically available information) shall not be disclosed or reproduced, in whole or in part, electronically

or in hard copy, to third parties. No information contained herein shall be used in any way either commercially or for any pu rpose other than

internal viewing, reading, or evaluation of its contents by recipient and the ANDRITZ GROUP disclaims all liability arising f rom recipient’s use or

reliance upon such information. Title in and to all intellectual property rights embodied in this presentation, and all infor mation contained therein,

is and shall remain with the ANDRITZ GROUP. None of the information contained herein shall be construed as legal, tax, or inv estment advice,

and private counsel, accountants, or other professional advisers should be consulted and relied upon for any such advice.

All copyrightable text and graphics, the selection, arrangement, and presentation of all materials, and the overall design of this presentation are

© ANDRITZ GROUP 2018. All rights reserved. No part of this information or materials may be reproduced, retransmitted, display ed, distributed,

or modified without the prior written approval of Owner. All trademarks and other names, logos, and icons identifying Owner’s goods and

services are proprietary marks belonging to the ANDRITZ GROUP. If recipient is in doubt whether permission is needed for any type of use

of the contents of this presentation, please contact the ANDRITZ GROUP at [email protected].

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