News

eMASS Strip Stabilization

In January 2008 the EMG-team received a new order for an eMASS strip stabilization system from ArcelorMittal Asturias (Aviles), Spain. Together with this new order, ArcelorMittal has meanwhile ordered 6 eMASS-systems. One of these systems has been running in the USA for several months now and a second system will be used at Arcelor-Mittal Eurogal in the next weeks. Beside this, the biggest steel producer in the world ordered additional systems for its works in Florange, France; Gent, Belgium and Cleveland, USA.

In the meantime, one of our eMASS-systems has been working very successfully at the CGL #1 at ThyssenKrupp Steel, Duisburg, Germany since August 2007. Beside zinc saving, it is found out that the zinc coating is much more homogenous, a fact that attracts attention also directly to the end customers (especially in the automobile industry).
The success of the EMG-eMASS-sytem is also mirrored by the orders of the eMASS-systems. The following systems are already installed, are actually shipped to the customer or will be delivered in 2008:

Strip Centering for Welding and Joining Press Applications

In the entry section of continuous strip processing lines the strip ends are joined by welding or stitching machines. In the connecting of both strips it is extremely important that the strips are centred in reference to the centre axis and angularity. Problems in this alignment lead to strip tracking problems in all consequent process areas.

The EMG strip centering control works securely in both new facilities as well as in the modernising of existing facilities. All the different configurations in use worldwide are proof of the system’s reliability, flexibility and accuracy. One strip end is aligned to the second strip end in reference to the centre axis and angularity. This solution provides, especially when reconditioning existing paint or galvanizing lines, a very space and cost saving solution.

In close cooperation with DMS – one of the worldwide leading engineering firms with its headquarters located in Lille, France – EMG developed and installed strip guiding systems for an annealing and pickling line for Taiyuan Iron and Steel (Group) Co. Ltd. (TISCO) in China. TISCO which is located in Taiyuan, Shanxi province, is one of the largest in the stainless steel branch with a yearly production rate of 6,26 million tones.

The line finishes stainless steel strips with widths up to 2.100 mm and thicknesses up to 14 mm. The nominal strip tension for these strip formats is 400.000 N – maximum strip tensions are increased by a factor of 3. Maximum strip speed is 130m/min, line performance is 1.1 million tons p.a..

Planning of this project started in 2004, in November 2005 EMG received the order for the strip guiding systems, which were delivered on time at the end of 2006. The line was put into operation in the middle of 2007. After starting step-by-step with pilot strips, regular production began. Today reliable results coming from strips with maximum processing thickness are available, which show, that TISCO’s expectations regarding EMG’s strip guiding systems have been fulfilled.

eMASS-System bei Arcelor Mittal in Columbus

ArcelorMittal Columbus has already installed the EMG-eMASS-system at its Columbus plant, Ohio, USA. At this installation the EMG-eMASS-system is used directly below the galvannealing oven as an alternative for touch rolls. The installation was completed in December 2007 and was rapidly implemented without problems. Justification for the investment in the system was based on its expected ability to correct strip shape (especially crossbow) above the coating knives and also reduce strip vibration, both of which contribute to minimizing zinc consumption.

For Columbus Coatings, a line with 100 % production of lighter-coating GA products and with over 50 % critically exposed automotive parts, on the same level of importance as the zinc saving is the goal to avoid jet lines and other defects caused by poor strip shape, and furthermore lower the frequency of air knife changes when these defects occur during exposed production. As in the first installation at the ThyssenKrupp CGL # 1, Duisburg, Germany, positive results were evident immediately upon start-up: visually the segment of the strip between the system and the coating knives was more stable, and the crossbow shape was visibly reduced in the air knife zone. Of course the crossbow re-appeared above the eMASS-system, but has no influence on the coating at this position.

Coating weight profiles across the strip width, which are displayed by the HMI in-line coating weight gauge, were flatter, and values did indicate a lowering of triple spot zinc coating weight which will permit a reduction of target coating weight in the near future and thus lower the overcoating. Since its introduction eMASS has been ordered by ArcelorMittal 6 times world wide for different lines, underlining the strong need for a standardized strip stabilization solution for hot-dip galvanizing lines.

eMASS-system at Dongbu

In March 2007 Dongbu, Korea belonged to one of the first purchasers of the newly introduced EMG-eMASS-system. The installation followed in November 2007.

With it came special requirements for the operation of the system. The selectable operation of four air knives from two different manufacturers (Foen/Kohler) needed to be warranted, as the air cooled system was to be used in the galvanizing as well as the annealing (temperatures up to 680 °C) lines. A construction and technical challenge which EMG mastered.

During the final approval of the system it showed that the expectations as well as the performance of the system, as provided in the contract, were significantly over-fulfilled in part; the damping of the strip increased by up to 75 %. So Dongbu Steel’s expectations regarding zinc saving and homogeneity of the zinc layer have been surpassed. Furthermore, Dongbu Steel was convinced by the constructive and problem-free co-operation of EMG’s development centre in Wenden and the project monitoring on-site, executed by Yuwon Trading Co. Ltd. in Seoul, responsible for the EMG quality assurance systems division. The combination of exact technical preparation, technological excellence and closeness to the customer on-site guarantees smooth processing even with complex projects like this. The success of the first eMASS-project in Korea led to POSCO, Hysco and UNION Steel deciding for an eMASS-system as well. We will be reporting on the installations there in one of our following newsletters.