Furnace Technology

Product Portfolio, Technology & References

Economical and environ-
ment-friendly furnace
technology from the
system supplier
SMS group is able to deliver nearly all thermal same time more difficult. With SMS as a technolo-
processing equipment which is required to pro- gy partner the complete know-how for heating and
duce modern steel and aluminum products. SMS cooling throughout the complete process chain can
designs, erects and commissions furnaces for the be supplied from one source and high material qua-
different production steps of carbon steel, electrical lity can be ensured.
silicon-steel, stainless steel, and aluminum. This
In this brochure you‘ll find comprehensive informa-
includes furnaces for heat treatment of strip and
tion about our products, technologies, services and
hot-formed materials like heavy plates, tubes and
references of furnace technology.
bars as well as reheating furnaces. Common to all
furnaces is high cost-effectiveness that results from
constant improvement, quality consciousness, and
a focus on saving resources. Drawing on the com-
bined strength of SMS group, the furnaces can be
supplied from one single source.

Key factor furnace

technology
Furnace technology is considered to be the core
process for the production of modern materials,
since it determines the material properties and the
quality of the final product. Controlled heating or
cooling is the only way for the manufactures to pro-
duce high-quality, marketable finals goods. Often,
cooling is more important than heating but at the
CONTENTS
General
Introduction 2
Highlights 4
Processes 6
Product Portfolio 8
System Supplier 10
SMS-FLAME® 12
Effective Lining Solutions 14
TM
SMS-Prometheus 16
DFC-Model (Dynamic Furnace Control) 18
Service 20
Workshop 22

Heat Treatment of Strip 24

Carbon Steel Annealing & Galvanizing 26
I-Furnace 30
Batch Annealing 36
Continuous Tinplate Annealing 38
Electrical Silicon Steel Strip Processing 40
Stainless Steel Strip Annealing 46
Color Coating 52
Aluminum Heat Treatment 56

Furnaces for Slabs, Bars and Tubes 58

Roller Hearth Furnaces 60
CSP®-Roller Hearth Tunnel Furnaces 62
Chamber Furnaces 64
Walking Beam Furnaces 66
Walking Hearth Furnaces 70
Pusher Furnaces 72
Fields of Application
Long Products 73
Flat Products 74
Pipes and Tubes 76
Forged Products 80

Heat Treatment of Hot-Formed Material 82

Heavy Plates 84
Roller and Platen Quench 86
MultiFlex-Quench® 88
Tubes and Pipes 92
SMS-Quench® 96
Bright Tubes 100
Bars 102

3
Numerous
References
Since 2000, SMS group has attracted orders for more than
150 furnaces for carbon steel silicon steel, stainless steel
and aluminum to produce high quality strips, plates, bars or
tubes including all important types of furnaces and cooling
technologies.

Steel and NF-metal producers

using furnaces from SMS (examples)

Acroni Outokumpu
Amag Rolling Panzhihua Iron & Steel
AM/NS Calvert POSCO
Angang Steel Company PRO-TEC Coating Company
Aperam Salzgitter Flachstahl
ArcelorMittal Severstal
ASAŞ Alüminyum Shagang Group
Baosteel Shandong Nanshan
Baoxin Shougang Jingtang
Bengang Shougang Corporation
Big River Steel SSAB
China Steel Corporation Steel Dynamics Incorporated
Deutsche Edelstahlwerke Stefana
Handan Iron & Steel Taigang
Henan Zhongfu TKAS Terni
Hyundai Steel ThyssenKrupp Steel
Ilva Tianjin Tiantie
Jisco Tianjin Zhongwang
Ma‘aden-Alcoa Joint Venture Timken
Maanshan Iron & Steel TMK Artrom
MMK Toscelik
NAS North American Stainl. US Steel
NLMK Voestalpine
Nucor Steel Wuhan Iron & Steel

4
Market leadership
The majority of market leading steel and NF-metal producers rely on SMS group's technology.

High product quality

Significant to all furnaces is the high quality of the final product. Thus, the furnaces are
especially designed to ensure flawless surfaces and homogenous material characteristics.

Flexible production
Flexible production conditions allow a quick reaction to changing market demands with
the greatest economic efficiency. SMS group has developed several furnace solutions for
highest flexibility.

System supply
SMS group is capable to deliver almost all furnaces completely from one single source.
This means, you get everything you need out of one hand and without any interface
problems.

Production know-how
SMS group offers process support for all materials and qualities. This covers both metal-
lurgical and design actvities as well as support during commissioning, operation, quality
control and certification.

Ecoplants
All furnaces are designed to keep resource consumptions as low as possible. All technol-
ogies and processes are continuously evaluated in order to improve their eco-friendliness.

Project Management
A professional project management aligned with latest knowledge and international
standards ensures in combination with modern design methods, a consistent and
reliable fulfillment.

Manufacturing
The set-up includes several modern and well equipped manufacturing locations worldwide
to ensure a high level of quality control and proximity to the customers.

Modernizations
SMS possesses rich experience and offers comprehensive services for refittings and
upgrades. Starting from the exchange of a single parts up to major modernizations of
complete furnaces with several measures.

Industry 4.0
The furnaces use production and process models which are deeply
integrated in the automation system and linked with other systems.

5
Furnace technology
based on thermal processes
Furnace technology is driven by thermal processes cesses of the steel and NE-metal production route.
to change material characteristics and enhance the Depending on the different materials requirements
material quality – and therewith the value of the and material developments, SMS offers special solu-
material – step by step. SMS group has extensive tions to fulfill highest demands.
know-how and understanding of all thermal pro-

Energy Source
Combustion gas Electrical energy

Furnace Atmosphere
Open atmosphere with exhaust gas Closed atmosphere with shielding gas

6
 Heating processes
Convection Radiation Induction

cooling agents
Gas Water Mist

7
Product Portfolio-Furnace
Technology: Overview

Heat treatment of strip

Carbon Steel
Annealing
and Galvanizing

See pages 26-35

Stainless Steel
Strip Annealing

See pages 46-51

Furnaces for slabs, bars & tubes

Roller hearth
furnace

See pages 60-61

Walking Beam
Furnace

See pages 66-69

Heat treatment for

Hot-formed material

Heavvy Plates

See pages 84-93

8
 Electrical silicon
Batch Annealing Tinplate Annealing steel strip
processing

See pages 36-37 See pages 38-39 See pages 40-45

Aluminum Heat
Color coating
treatment

See pages 52-55 See pages 56-57

CSP®-Roller Hearth
Chamber Furnace
Tunnel Furnace

See pages 62-63 See pages 64-65

Walking Hearth
Pusher Furnace
Furnace

See pages 70-71 See pages 72-73

Besides those main furnace types and

heat treatment processes, SMS group
Tubes Bars offers various other concepts or vari-
ations of processes depending on the
individual customer requirements.
See pages 94-101 See pages 102-103
Modernizations – from small improve-
ments to vast revamps – are also a
part from SMS group's product port-
folio

9
System Supplier

SMS group is the only company worldwide capable

of delivering nearly all furnaces and heat treatment
systems for steel and NF-metal production route as a
full system supplier. That’s because all products and
services are available within the SMS group.

auxiliaries Heating System Cooling

Handling
 equipment Radiant
 tube furnaces Gas
 cooling
Roller
 tables Direct fired furnaces Water
 spray coo
Charging/discharging
 machines Floatation furnaces Roller/platen qu


Guiding
 systems Catenary furnaces Mist
 cooling
Water
 treatment plants Reheating furnaces Laminar cooling


Hydraulic
 systems Inductive heating Air
 cooling

10
 Advantages due to
complete system supply:

Perfect match of all components

Clear responsibility

Electrical and
g System Special Services
Automation system
Level
 1 to level 3 Production
 know-how
oling Process
 and production models Startup
 assistance
uenches Quality
 monitoring systems Continuous
 production assist-
ance and process optimization
Measuring
 systems
Qualification
 assistance
Plug
 & Work integrations tests
Certification
 support
Operation
 and visualization

11
SMS-FLAME®
High-efficiency burners for varied application.
A new concept in burner development

SMS applies a new concept in burner design and

development and is capable for offering a full line
of advanced SMS-Flame® burners. These are availa-
ble in a wide range of power sizes and in different
models suitable for varied application:

SMS-ZERO Flame®, the new frontier of natural gas-

flameless combustion. Extra-Low NOx emissions at
any rating and combustion air temperature

SMS-ECO Flame®, a reliable unit combining low NOx

capability and high efficiency, available for any gas or
liquid fuel – also available in radiant configuration for
roof installation

SMS-DUAL Flame®, capable of dual fuel utilization,

gaseous fuel and oil

EFFICIENT BY DESIGN
A strong synergic approach between research and
experience in furnace realization allows designing
burners suitable for any kind of furnace.

“Flexibility” is the keyword of the research approach,

based on field tests, performed in combustion labora-
tory, and Computational Fluid Dynamics (CFD).

Before manufacturing and testing the prototypes in

the laboratory, SMS identities the most promising
design using detailed CFD-based modelling. Prediction
of flame reaction zone profile, temperature gradients
and pollutants generation are only some of the
aspects that are modelled and optimized with CFD
software before starting the test campaign on a real
burner.

12
VERSATILE BURNERS FOR OPTIMISED
COMBUSTION
Different products require different temperature profiles. With SMS-
FLAME® burners, plant engineers can flexibly adapt the combustion
parameters to diverse process conditions.

The shape and temperature control of

the flame outline helps to contain the
overall emissions: when firing in flame-
less mode, the SMS-ZERO Flame®
burners not only dramatically decrease
the NOx formation, (<70 mg/Nm3 at
3% O2 DFG), but also improve the
temperature homogeneity inside the
furnace chamber.

Measured NOx emission with SMS-ZERO Flame® burners,

in flame and in flameless mode.

Burners are studied and developed by

means of most advanced techniques:
the first phase foresees CFD modell-
ing, often followed by 3D printer
proto-typing.

Later the burners need to go through

extensive laboratory tests, in order to
assess their genuine capability to
steadily meet the emission parameters
foreseen by the software simulations.

13
EFFECTIVE LINING SOLUTIONS
Tailored to the particular properties of each plant

SMS group pays great attention to design and com-

ponent features that allow for the lowest possible
energy consumption. The furnace specialists continu-
ously test new materials, components and concepts.
The results are self explaining: energy requirements
below 260 kcal of heat input per kilogram of steel
reheated from 20 to 1,200 °C minimise energy costs
in long product rolling mills. Another example is a
total fuel energy consumption of less than 280 kcal
per kilogram required in a quench and temper cycle,
where the workpieces are heated from ambient tem-
perature to 900 °C for hardening then, having been
quenched, reheated again to over 500 °C to com-
plete the tempering process.
ADVANCED LINING
Refractories play a key role in containing energy
dissipation and in improving the efficiency of old
furnaces. In extensive field tests SMS examined
different lining materials and their impact on energy
efficiency. Based on the test results, the furnace spe-
cialists select the best material for each furnace.
FORM FOLLOWS FUNCTION
When designing a new reheating furnace or a
heat treatment plant, the experienced SMS en-
gineers use both their know-how and advanced
computational modelling tools. With state-of-the-
art CAD and FEM software they create smooth,
fast and precise mechanical designs for any heat-
ing task.
3D modelling is also an invaluable benefit for the
field engineers and erection crews on site, as all
details can be clearly understood at a glance. One
example is pipe routing detail engineering with
3D CAD programs: it simplifies and speeds up
the erection works so costs are reduced and the
plants can be commissioned earlier.
The digital modelling of a walking beam frame
is an efficient tool in removing interferences and
quota errors from the design. Loads and forces
are calculated rapidly with no risk of errors.

14
OPTIMIzED RESISTANCE
Improvements in material quality, durability and safety
allow for the utilisation of modern light-weight fibre
insulations for applications traditionally reserved for
castable and plastic refractories. Low thermal inertia
and optimised resistance to repeated thermal cycles
make this class of lining materials especially
beneficial for heat treatment furnaces. The modern
fibres are characterised by an enhanced resistance
to higher temperature conditions and by a certified
absence of hazardous compounds, compared to
similar linings available in the past.
15
SMS-PROMETHEUSTM
Combustion optimization for tailored steel quality and
reduced fuel consumption

With SMS-PrometheusTM, plant operators are able tors, although even highly experienced staff benefit
to boost their furnace’s overall performance. The ad- substantially from the mathematical model guidance
vanced combustion optimisation system improves during transitory events.
those parameters that can make the difference in
EFFICIENCY INDEX
special steel quality production. SMS-PrometheusTM
SMS-PrometheusTM tracks the consumption and the
allows for targeted improvements of the metallurgi-
other efficiency related parameters and stores the
cal properties, for example increased temperature
trends over time in order to allow prompt monitoring.
uniformity or minimised negative effects such as
steel decarburisation or high scale formation.
Heat flow charts and consumption trend bars help
FUEL – ONLY AS MUCH AS YOU NEED
to control furnace efficiency.
SMS-PrometheusTM helps to reduce fuel consumpti-
on by adopting those heating strategies that minimise
the temperature set points and yet guarantee the
required final stock target temperature. The core of
the program is a sophisticated mathematical model
capable of simulating the heating curves inside the
furnace for each stock loaded. The system shows
the overall furnace efficiency by visualising heating
balance diagrams. It also provides consumption and
emission trends that can be correlated to actual pro-
duction data.

SMS-PrometheusTM constantly monitors the heating

history parameters of each single workpiece. The
system works predictively, meaning it makes con-
sistent projections to estimate the development of
the heating path. On this basis, SMS-PrometheusTM
continuously chooses and modifies the temperature
set points. When coupled with SMS-Digiburn®, the
system also optimises the digital firing pattern.
ADVANCED FEATURES – ROUGHING
MILL PYROMETER FEEDBACK
This function adapts the mathematical model accord-
ing to the roughing mill pyrometer measurements.
The temperature of the piece measured by the pyro-
meter is compared to the expected one and adapts
the model accordingly.

ENERGY SAVINGS – EVEN DURING

NONPRODUCTIVE TIME
SMS-PrometheusTM is highly efficient in optimising
the combustion parameters during events like sud-
den stoppages, furnace heating-up time or changes
to the product campaign. This tool ensures proper
heating repeatability, even with inexperienced opera-

16
ADVANCED FEATURES – SKID
MARKS EFFECT prediction
This function allows to monitor the “skid marks
effect” by means of a specific algorithm which simu-
lates cold spot effect generated by water cooled
skids, managing different parameters of the auto-
mation and combustion system according to the
process requirements.
FROM DETAILED INFORMATION
TO COMPREHENSIVE OVERVIEW
The overview screen shows the furnace loading
pattern and provides the main data relevant to the
temperature set points of the different heating
zones.

ADVANCED FEATURES – PACING

MODEL
The model forecasts the time in which each piece
inside the furnace will be ready to be discharged to
fulfill the minimum heating/soaking time requirement
of each piece inside the furnace and get the maxi- By selecting a specific billet, the engineer obtains
mum productivity. the real-time heating status of any single workpiece.

17
DyNaMiC Furnace Control
Energy savings and higher
production with a CSP® furnace
The Dynamic Furnace Control (DFC) level 2 process
automation system is an integral part of SMS group's
energy saving and high production strategy. Integrated
in a CSP® Furnace it ensures heating of the slab to
the required target temperature with good uniformity
and without energy wastage. It allows the application
of different strategies to heat-up and accerlerate the
slab, which offers several operational advantages.
Therefore, the DFC system calculates the 3D tem-
perature distribution for each slab and the buffer
time. Furthermore, the model provides an effective
emptying of the furnaces after roller change by defin-
ing the sequence of the slabs for rolling. The system
continuously communicates with CSP® Furnaces
Level 1, Level 3, CSP® Caster Level 2 and CSP® Mill
Level 2. It generates several reports and diagrams to
support monitoring and furnace control.
Temperature calculation and
control
As mentioned above the DFC-system simulates the
temperature of the slabs while going through the
Caster speed, slab
dimensions and temp.
Caster
Level 2 Buffer time
Zone temp. setpoints
Setpoints for logistics
Caster
Level 1
18
CSP® Furnace in three dimensions. It calculates the
set-point temperature for the furnace zones which
depends on the entry temperature of the slab and
the set-point exit temperature for the slab. During
commissioning, the model for the slab temperature
is adapted to fit the real slab temperature.
The tracking module synchronizes the position of the
slabs in the furnace.The control parameters of the logi-
stics (acceleration point and ferry usage) are comput-
ed. This is of particular interest after mill idle when the
furnace is relatively full and needs to return to statio-
nary position. Moreover, the buffer time is determined
which enables the operator to judge if a roll change in
the mill is possible without scrap cutting.
Furthermore, the DFC calculates the theoretical gas
consumption of the furnace adapted during the com-
missioning of the furnace. If this value differs con-
sistently from the actual gas consumption, it is time
for maintenance. The model can be further used to
identify the part of the furnace that needs to be
checked (for instance rolls or the recuperator). The
heat balance includes walls, rollers, waste gas and
pre-heated air and is calculated for each zone.
Level 3
Slab ID, target temp. for slab
Slab temp. info
Furnace
Level 2 Mill
Slab request Level 2
(DFC)
Actual values for temp.
logistics and energy.
Furnace Mill
Level 1 Level 1
Communication with other CSP® components.
 Main advantages of DYNamic Furnace Control (DFC)

 Energy saving due to reduced set-point tempera-
tures for the furnaces zones
Reduced wear on rollers and slabs by shifting
the setpoint for the acceleration roll
Higher yield due to avoidance of slab cutting by
early accerleration of the slabs
Effective emptying of the furnace after roller
change by defining the sequence of the slabs
for rolling
Automatic communication with other automation
levels and moduls (Industry 4.0)
Automatic generation of reports and diagrams

3D calculation and visualization of the slab temperature.

Each heat-up process for every slab is efficiently calculated and controlled.

19
SERVICE
Taking care of everything

Whether you want spare parts, modernizations, that our employees provide the services you require –
tailor-made maintenance procedures, or customized on schedule, within budget, and in the right quality.
training programs, the Technical Service Division of
That means you can rely on the quality of our ser-
SMS group is ready at 50 locations around the world
vices as well as our global presence to reduce down-
to offer you service packages geared to your require-
times, increase productivity, and ensure the lasting
ments along the entire metallurgical process chain.
value of your machinery and plants.
It’s due to the know-how of the entire SMS group

Spare Parts & Logistics Upgrades & Modernization

OEM spare parts Mechanical & hydraulic
Spare parts management Electric & automation
Warehousing Value added components

Maintenance & Repairs Consulting & Training

Emergency support Fact finding
Inspection, repairs, servicing Maintenance audits
Maintenance tools Feasibility studies
Long term maintenance services TECademy

THE RIGHT PARTS IN THE RIGHT

PLACE AT THE RIGHT TIME
The right spare parts have to be available at all times
so that production doesn‘t come to a standstill. At
the same time, capital tie-up and storage costs have
to be kept low. That is why SMS group delivers
spare and wear parts for all machines quickly and
reliably.

A web-based, machine-specific parts catalogue

makes the ordering process even easier. On request,
SMS group also takes care of the whole spare part
and stock management. The differing parts stocking
concepts are always geared to the customers‘
individual needs.
Water-cooled furnace rolls with fireproof insulation made
of aluminum silicate wool allow higher temperatures and at
the same time low energy losses in a CSP ® Furnace.

20
CONTINUOUS HIGH PERFORMANCE
Whether one-off fact-finding, continuous monitoring
via remote service or regular plant inspections. The
SMS group Service experts analyse and service the
plants. Not only this, the complete maintenance can
be taken over by SMS on request. Plant owners thus
ensure maximum plant availability and optimum pro-
duction results.
ALWAYS UP-TO-DATE
Plant owners are engaged in dynamic markets. The
demands on profitability, product quality and produc-
tivity have risen steadily for plant owners in recent
years. New technologies and plants arrive on the
market in ever shorter innovation cycles. Tailored
and customised modernisation concepts from SMS
group ensure that the plants run for decades and that
with reduced operating costs, higher productivity and
improved product quality.
FIELD SERVICE
Even in emergencies, customers can rely on SMS
group Service. The Service technicians help with
troubleshooting and the necessary repairs. With
short reaction times and high availability, they ensure
that the plant is up and running again as quickly as
possible.
CORPORATE SUCCESS due TO
TECHNICAL KNOW-HOW
Whether individual or standardised trainings – our
experts plan individually tailored training programmes
and implement these together with the customer.
The plant operators gain valuable know-how through
time-tested formats and special e-learning offerings
for more operational reliability and more efficient
processes.
HIGHER PROFITABILITY due TO THE
RIGHT ADVICE
More efficient processes, optimised technology and
more effective use of resources – those are the
goals of our consulting concepts. SMS group carries
out feasibility studies to establish a sound basis for
management decisions, or develops strategies and
concepts for the optimisation of existing plants and
processes.
Examples of service parts
CSP® Rolls
- Dry rolls
- Water cooled rolls with fiber insulation
Furnace rolls for strip processing lines
Isolation materials
Energy saving concepts
Consulting for optimal integration of the
furnace operation into the overall process
21
WORKSHOP
R&D testing, equipment pre-assembly and
inspection under one roof

SMS group runs a fully equipped workshop for the
assembly and testing of key components in Tarcento,
Italy. Prototypes, special equipment and machines
which require extremely accurate tolerances are
assembled here. The workshop operates in close
conjunction with the R&D and technical departments.
A constant and precise exchange of information and
ideas is the basis for the continuous further develop-
ment of all components.
PREASSEMBLY FOR FASTER
COMMISSIONING
Most machines are completely preassembled –
including hydraulics, lubrication and cooling water
units. The engineers pay great attention to the
details, especially to the electrical pre-wiring of the
sensors and components to the terminal boxes.
Before being disassembled and shipped, each com-
ponent and module is marked for fast and error-free
reassembly at the business partner’s site.
FUNCTIONALITY TESTS ENSURE
MAXIMUM RELIABILITY
The workshop is equipped with testing motors,
switchboards and Programmable Logic Controllers
(PLCs) so the SMS group engineers can simulate
production conditions for factory dynamic tests. All
the hydraulic equipment is checked during cold test
runs with hydraulic units and benches.

22
 PREASSEMBLY SAVES TIME
AND MONEY
SMS preassembles and tests even large compo-
nents so its business partners save commission-
ing time and labour costs at the erection site.

OPEN FACTORY POLICY

SMS business partners are invited to visit the
Tarcento workshop. They can assure themselves of
the strict quality assurance standards and take a
close look at the machines during all assembly phases
according to inspection schedules.

23
24
HEAT TREATMENT
OF STRIP
Furnace technology is considered to be the core process for
the production of high-quality strip materials, since it deter-
mines the material properties and quality. Often, cooling
is more important than heating but at the same time more
difficult. SMS offers proven heating and cooling systems for
all strip processing lines.

Carbon Steel Annealing & Galvanizing page 24

Batch Annealing page 36

Continuous Tinplate Annealing page 38

Electrical Silicon Steel Strip Processing page 38

Stainless Steel Strip Annealing page 46

Color Coating page 52

Aluminum Heat Treatment page 56

25
Carbon Steel Annealing &
Galvanizing

Excellent quality, high effi- It has been proven that SMS has the competence
ciency and enormous capacity to design, engineer, erect and put into operation
During heat treatment in annealing and galvanizing furnaces for all kinds of modern annealing and galva-
lines, microstructure is precisely adjusted to meet nizing lines.
requirements strength and formability. Annealing
and galvanizing furnaces by SMS are characterized
in particular by the excellent quality of the end pro-
duct, high efficiency and economy, as well as – if
demanded – enormous capacities. In recent years
various improvements and new technical solutions
have been developed, particularly regarding furnace
concepts, furnace efficiency and cooling technology.
Special efforts were also made to adapt the galva-
nizing furnace to the new challenges which came
up with modern and sometimes high-alloyed steel
grades.
High-quality end-products, which are often determined
by the furnace technology, are crucial for the economical
success of a cold strip processing line.

SMS group‘s strip processing lines feature large vertical

furnaces which ensure a high strip speed in the furnace
26 also for big cross-sections in order to achieve high capac-
ities.
Production of automotive
grades
Steel continues to be the most important construc-
tion material for the automotive industry, whereby
particularly the share of high-strength steels in cut-
throat competition with other materials is constantly
increasing. As manufacturers are required to build
light and fuel-efficient vehicles, many new steel
grades with optimized combinations of properties
have been developed. Multi-phase steels, which are
high-strength and very ductile, are increasingly being
used for car components. These high-strength yet
easily deformable steels must meet the highest
quality requirements for use in automobiles, where-
by not only the material properties, but also the
surface quality must be of a high standard.
Hence, furnaces for the production of high-quality
steel strips for use in interior and exterior compo-
nents (usually annealing or galvanizing furnaces)
must be set up to produce high material strengths
and flawless surfaces. A crucial part for flawless sur-
faces is a surface-friendly annealing process, which
for example keeps the surfaces clean and controls
or prevents oxidations processes. In order to
achieve an outstanding material strength, advances
annealing and cooling strategies are implemented.

In automotive construction, a growing number of steel grades

with higher strength and good forming properties are used.

27
Carbon Steel Annealing &
Galvanizing: Concepts

ConTInuous Annealing

The Full-radiant tube furnace is the biggest part of a cess and gives the material the desired mechanical
continuous annealing line. The annealing and cooling properties. In the overaging section carbides are re-
process reduces strain hardening from the rolling pro- moved from the material to minimize the risk of aging.

Hot-dip Galvanizing

In a vertical hot-dip galvanizing line, which is often material has to be annealed to restore drawability
used to produce unexposed and exposed automotive and adjust the mechanical properties. Secondly, the
parts, the furnace has two main tasks. Firstly, the material has to be prepared for galvanizing.

Horizontal Hot-dip Galvanizing

Horizontal galvanizing lines are intended mainly also in part for automotive applications. The furnace
for the production of material for the construction, again has the task to adjust mechanical properties
household appliances and furniture industries, but and to prepare the material for galvanizing.

28
Universal Annealing with Gas
and Water Cooling

This universal furnace concept offers two cooling the current market conditions. In this way, it is pos-
options: gas and water cooling. On this line, different sible to produce the most valuable products every
products can be produced very flexibly according to time.

Universal Annealing and

Galvanizing

The universal annealing and galvanizing line features fully equipped continuous annealing line or as a hot-
a furnace with both: a hot-dip galvanizing section and dip galvanizing line and it is possible to switch be-
an overaging section. Thus, this line can be used as a tween annealed or galvanized material very flexibly.

All-Purpose

The furnace in an all-purpose cold strip processing gether four completely different process routes, this
line offers two cooling options and the possibility to is the most flexible concept for cold strip production.
produce annealed or galvanized material. With alto-

29
Carbon Steel Annealing &
Galvanizing: Technology

I-Furnace predict material characteristics (e.g. tensile strength)

The Intelligent Furnace by SMS is a smart furnace depending on annealing and cooling temperatures as
process and production optimization model. The well as treatment curves. Furthermore, the model
combination of various tools leads to an optimized can be used offline to lay-out the furnace exactly
heat treatment and production process. It smartly according to the process requirements and limits.
combines a mathematical/physical model to control
the furnace and to optimize production with EMGs-
IMPOC system for online strength measurement
and a newly developed annealing microstructure
model to predict material properties after the heat
treatment. This intelligent combination of efficient
tools is a great step forward towards an autonomous
working furnace.

Special sophisticated grades can be produced more

easily and homogenous material characteristics over
the whole coil length can be achieved. A capacity
increase up to 15 percent is possible due to a better
utilization of the furnace capacity as well as an efficient
production planning and transition behavior. Also ener-
gy savings can be realized due to a better temperature
control close to its lower limit (in average -10 K).

The annealing microstructure model in combination

with the data collected by the other tools can be
used offline to develop new materials. It’s possible to
Automatic furnace and line speed control by furnace mathe-
matical/physical model.

30
Only Measurement of Material
Properties
The IMPOC measuring system of EMG Automation
GmbH – integrated in cold strip processing lines
continually checks the material’s tensile strength
and yield strength during production. That allows the
operator to immediately adjust process parameters
whenever necessary. Non-destructive magnetic
measurement shows that homogeneous material
properties over the whole coil length are achieved
even at high tensile strengths.
Since today many automotive manufacturers use this
system for checking materials, the material require-
ments of the automotive industry are increasing
and forcing the steelmakers to check the quality
within their lines. The IMPOC system is perfect for
automatic, non-destructive, online testing of ferro-
magnetic steel strips with thicknesses from 0.15 to 6
millimeters. This system is based on two identically
constructed sensors, which are arranged on the
upper and underside of the strip. Each sensor con-
sists of a magnetizing coil and a magnetic
field probe for recording the remanent magnetic
induction.

Pre-Oxidation Chamber
Some modern high-strength steel grades contain
high silicon and/or manganese contents. These alloy-
ing elements migrate to the surface during annealing
and create wettability problems which can lead to
bare spots. With a controlled infusion of humid air
into the pre-oxidation chamber the dew point gets
altered. This creates a closed iron-oxide layer on the
surface and suppresses the migration of silicon and
manganese to the surface. At the end of the furnace
a reduction of the iron-oxide layer takes place and
the resulting surface has the required wettability.

As a result, with this technology it is possible to gal-

vanize also high-alloyed high-strength steel grades
which leads to an extension of the product range of
every line. Another economic benefit is the substitu-
tion of expensive alloying elements with silicon.

31
Carbon Steel Annealing &
Galvanizing: Technology
Rapid Cooling with Gas
The ultra-fast cooling System (UFC) allows to realize
uniform cooling rates of up to 150 Kelvin per second
and millimeter of strip thickness in radianttube fur-
naces of galvanizing lines or annealing lines. The
results are excellent strip geometry and optimal sur-
faces. Thus, it is possible to obtain high-strength
multi-phase steel grades such as DP and TRIP having
tensile strengths of up to 1,000 megapascals. Further-
more, some steel grades can be produced using less
alloying elements due to the higher possible cooling
rates. This implies greater product diversity at lower
operating costs.
Higher cooling rates are obtained by adding pure
hydrogen to the cooling chamber without increasing
the total hydrogen consumption of the line. The gas
pressure may be reduced, and the consumption of
electrical power decreases by an amount up to 40
percent. The cooling system takes advantage of the
properties of hydrogen (low density and high thermal
conductivity) to enhance the cooling capacity. A spe-
cial feature of the patented ultra-fast cooling system
The ultra-fast cooling system (right) serves for the produc-
tion of high-strength steel grades with cooling rates of up to
150 Kelvin per second per millimeter.
32
is the addition of pure hydrogen directly into the
cooling chamber. The hydrogen content there is up
to 50 percent, thus permitting the high cooling per-
formance. A complicated separation of the cooling
zone from its neighboring sections is not needed
owing to the natural diffusion of the gas to the other
areas. Neither does the system normally requires
more hydrogen than the conventional furnace mode
with the inert gas containing a hydrogen share of five
percent. In customary radiant tube furnaces, the inert
gas is mixed automatically and fed into the furnace at
various places.
The cooling gas is applied to the strip via nozzles
with transverse slots to ensure uniform cooling
over the full strip width, thickness, and length. The
distance between strip and nozzles can be infinitely
varied between 40 and 120 millimeters. Despite the
high flow rate, the cooling chamber, thanks to its
special design, safeguards great strip stability with a
minimum of vibrations.
Quenching and ParTITIoning
SMS offers also furnace concepts for quenching and
partitioning of steel grades to produce for example
martensitic steel grades with enhanced levels of
retained austenite. The furnace comprises high-
speed cooling systems and subsequent high-
frequency induction heating modules. Within this
two-step thermal treatment the material is cooled
down with high cooling rates and afterwards heated
up via induction.
Intensive Cooling with Water
The water-spray cooling system is specifically de-
signed to produce ultra high-strength steel strips
for internal parts of a vehicle. The system is able to
attain tensile strengths of partly more than 1,700
MPa. These high strength dual phase and complex
phase as well as martensitic grades are mainly used
to produce crashproof core components in the pas-
senger compartment such as the A-pillar and B-pillar,
door beams and roof bows. That's the way steel
products improve the safety of modern automobiles
and, at the same time, reduce their weight.
The water-spray system is able to achieve cooling
rates that are distinctly above those attainable by gas
cooling sections. Due to the high specific heat capac-
ity of water, a large amount of heat energy can be
dissipated through spraying within a very short time.
The cooling rates thus achieved are above 1,000 Kel-
vin per second and millimeter.
In the water-spray section, the strip immerses in
demineralized water and both sides are sprayed with
water by special nozzles. This continuous spraying
Comparison of different cooling curves for the production of
modern high-strength steel grades.
Water-spray cooling for producing steel grades with tensile
strengths of up to 1,700 megapascal with cooling rates of
more than 1,000 Kelvin per second per millimeter.
action under high pressure creates turbulences that
ensure fast dissipation of the heat energy. In the
nozzle chambers cooling by more than 600 Kelvin is
achieved for example within less than half a second.
During this short period the steel strip microstructure
is completely transformed as a result of dimensional
changes. In co-action with a strip shape control, the
special nozzle configuration ensures a uniform coo-
ling result over the entire strip width, preventing the
formation of distortions or flatness defects.
Flexible Annealing Curves
A comparison of typical annealing curves for different
high-strength steels shows that cold strip processing
furnaces must offer considerable flexibility with
regard to heat treatment. Equipped with various coo-
ling systems the processing furnaces of SMS group
are capable to produce the latest high-strength steel
grades for the automotive industry. That allows for
lighter and fuel-saving vehicles.
Precise Following of the
Heating Curves
The precise and speed control with the mathematical/
physical control model enables the furnace to follow
the specified annealing curve exactly. Thus, every steel
grade gets just the heat treatment which is demanded
for the required material characteristics. This also
applies to the transitions area around the weld seam
when the material properties or geometry changes.
33
 Carbon Steel Annealing &
Galvanizing: References

MMK Magnitogorsk Iron and Steel Works, Russia

Hot-dip galvanizing line and complete with Plug-and-Work integration tests. Both
universal annealing and plants went on stream in summer 2012. As early as
galvanizing line the end of November, MMK issued the final approval
The two cold strip lines in the MMK plant in for the lines after an effective start-up phase.
Magnitogorsk, Russia, together produce more than
one million tons of high-quality steel strips, especially
for automotive outer and interior parts. This is where
SMS erected a pure hot-dip galvanizing line and a
universal annealing and hot-dip galvanizing line. It is
a plant array that covers a very wide range of top-
quality materials – from mild to high strength grades
– and produces two different product groups
(annealed and galvanized) as required.

Everything for the lines was supplied from one source:

mechanical equipment and hydraulics, air knives,
posttreatment and of course the powerful full-radiant
tube furnaces. Furthermore, SMS was responsible
for the entire electrical and automation systems
Bypass around the zinc pot for annealing mode.

Two powerful furnaces serve for the production of more

than one million tons of high-quality steel strip, particu-
larly for the automotive industry.

34
 Since in the PRO-TEC line two options for fast cooling
of the material are available, different cooling strategies
can be applied which leads to a drastically increased
product spectrum.

PRO-TEC Coating Company, USA

Continuous annealing line Among other sophisticated technologies, the line fea-
with rapid gas cooling and tures a high-capacity furnace with an integrated ultra
water spray cooling system fast cooling system and a water-spray cooling system
PRO-TEC Coating Company (PRO-TEC), USA, suc- for particularly high cooling rates, which allow the
cessfully commissioned a new continuous anneal- manufacturing of fully martensitic grades and ultra-
ing line for the production of cold-rolled ultra-high high-strength multi-phase steels.
strength steel coils. The line was completely supplied
by SMS group and is located in Leipsic, Ohio. In
February 2013, the first sellable prime coil was
produced. Besides the design and production of
the mechanical equipment as well as the furnace
and process technology, the complete electrics and
automation package was part of the supply scope of
SMS group.

Each year, 500,000 short tons of steel strips for auto-

motive structural components for cars, trucks and
sport utility vehicles can be produced, with a view
to both improve the safety of vehicles and reduce
their weight. The annealing process and special high
cooling rates, along with tempering, reduce the strain
hardening in the material caused by the rolling pro-
cess and enable the high-grade metallurgical proper-
ties to be attained.

The full radiant tube furnace ensures an economical produc-

tion of high-strength and ultra-high-strength materials.

35
Batch Annealing
Discontinuous Annealing of
Cold strip
After cold rolling the steel strip is hard and brittle. It
has to pass a recrystallization annealing process to
achieve the necessary ductility for the later cold
forming process.
Batch annealing furnaces (also called bell type
furnaces) serve to anneal and cool the cold rolled
and already cleaned material in the batch mode.
Depending on the required capacity numerous anneal-
ing bases with several heating and cooling hoods are
installed in a production plant. The heat treatment
process for each hood takes between one and three
days depending on the batch size and material grade.
Each hood can process several coils at once. The
coils are stacked one on the other using intermediate
convector plates for strip edge protection and to
increase the heat transfer. The coil stack is covered
with an inner cover to ensure an oxygen-free protec-
tive atmosphere. A heating or cooling bell is put over
the inner cover depending on the current process
phase.
In the annealing base an impeller and a diffuser ensure a
high circulation rate of the protective gas.
36
SMS uses modern batch annealing technology which
is based on the use of 100 percent hydrogen atmo-
sphere to increase the heat transfer and prevent the
strip surfaces from oxidation. The heating bell serves
for the heat-up of the annealing furnace up to recry-
stallization temperatures which differ for each mate-
rial. For the cooling process special cooling bells are
used with a combined air/water cooling technology.
Batch annealing furnaces offer the highest flexibili-
ty when it comes to different material grades with
different strip dimensions. This is because every
anneal-ing base works independently. The size of the
whole plant – i.e. the number of the annealing bases
is always adapted to the required production rate. Of
course, it is easily possible to add some bases to an
existing plant when necessary.
The inner covers are being put over the coil stack to have an
atmosphere containing 100 percent hydrogen around the coils.
Reference: Big River Steel, USA
Latest Batch Annealing
Furnaces
Besides an annealing and hot-dip galvanizing line,
SMS group will establish batch annealing furnaces
for cold strip treatment at Big River Steel’s new mill
complex in Osceola, in the state of Arkansas, USA.
These furnaces serve to anneal and cool cold strip
coils in the batch mode. They are able to process
For a high heating and cooling result the gas has to flow
through the convector plates.
The gas flow inside the inner cover is optimized with CFD
simulation (computational fluid dynamics).
several coils simultaneously with a maximum batch
height of 6.4 meters, a maximum batch weight of
140 tons and a maximum coil outer diameter of
2,000 millimeters. The treatment takes between
42 and 55 hours. In total, 24 bases with 13 heating
hoods and 11 cooling hoods will be installed to
achieve a throughput capacity of 413,000 tons of
steel per annum.
Batch annealing furnaces serve to anneal and cool cold strip
coils in the batch mode and are able to process several coil
simultaneously. For cooling and heating different bells are
used, while the coils remain in the inner cover under 100%
hydrogen atmosphere.
37
ConTInuous Tinplate
Annealing

Fast processing of thin strips

The full radiant tube furnace is the heart of the
Tinplate annealing line. During the annealing process,
the strip is treated in the individual furnace sections
according to defined annealing curves. This serves
to remove strain hardening. First, the strip is heated
up to about 750 °C. After the soaking section, in
which this temperature is held for a certain time, the
material is cooled down fast to some 100 °C, which
sets the desired microstructure of the material. In
the following overaging zone carbides are eliminated
from the steel which minimizes the risk of aging.
Finally, cooling units lower the temperature of the
strip to about 40 °C. A protective gas atmosphere
with hydrogen content of 5 percent or less prevents
oxidation on the strip surface in the heating zones. A
constant slight overpressure in the furnace prevents The material is annealed in a very environment friendly
air ingress into the furnace. The product range com- way in a full radiant tube furnace with atmosphere con-
prises all grades and also contains the qualities T2.5, trol and special designed rolls.

T5 and DR 10, which cannot be produced by batch

annealing.

Highlights
Low resource consumption

Precise following of the heating curve

Mathematical model with speed control

Experience in heating very thin strips up to 750 °C

High process speed (up to 750 m/min)

Special roll profile design

The precise furnace and speed control with a mathematical
Rapid cooling with temperature transversal control model enables the furnace to follow the specified annealing
(edge damper) curve for the different grades exactly.

38

Reference: Shagang Group, China
Tinplate production plants
Shagang Group, China, has successfully commis-
sioned its new annealing line and the electrolytic
tinning line both supplied by SMS group in 2014.
Being a systems provider, SMS supplied all compo-
nents including electrical and automation equipment.
The annealing line with a yearly capacity of 418,000
tons provides the strip with the required material and
surface properties by annealing and subsequent re-
Furnace in the continuous annealing line for tinplate pro-
duction which was erected completely by SMS for the
Shagang Group.
duction plus surface treatment. In a powerful
radiant tube furnace, the strip is processed according
to an exactly defined annealing curve with a process-
speed of up to 720 meters per minute. The width of
the strips treated here may vary between 700 and
1,250 millimeters, and it is possible to process strip
gauges of 0.18 to 0.55 millimeters.
In a tinplate annealing line the full radiant tube furnace is
the biggest and most quality-decisive part. Annealing and
cooling reduces strain hardening from the rolling process
and adjusts the desired mechanical properties. Carbides
are removed in the overaging section to avoid subsequent
aging.
39
Electrical Silicon Steel
Strip Processing

Processing furnaces to ensure the required

electromagnetic properties

SMS group supplies processing furnaces for the pro-
duction of electrical silicon steel strips from non-grain
oriented grades to high-permeable grain oriented
grades. The demand for electrical steel strip is grow-
ing steadily due to its electromagnetic properties
that lead to a significant increase in energy efficiency
when this strip is used in electric applications such
as power transformations. Manufacturing electrical
strip requires a highly complex production route
including sophisticated strip treatment strategies.
The main material properties are set through the heat
treatment of cold strip. Thus, furnace technology and
thermal processing are the crucial parts in producing
high-quality materials.

Non-Grain Oriented and Grain

Oriented Electrical Steel

There are two groups of electrical steel steel: non-

grain oriented (NGO), and grain oriented (GO). In
NGO electrical strip, the iron grains are distributed
in a non-ordered way so that the material has largely
the same, so called isotropic magnetic properties
in all directions. That is why NGO electrical strip is
mainly used in rotating machines such as electric
motors and generators with alternating field orienta-
tion.

Grain oriented electrical strip is used in energy-

efficient transformers. ( ©Dieter Schütz/PIXELIO).

In GO electrical strip, the microstructure (grains) are

arranged in the direction of cold rolling, resulting after
special heat treatments in what is called cube-on-
edge texture. Because of the uniform orientation of
the grains, the electrical strip has a preferred direc-
tion in which the magnetization can occur relatively
easily. Due to the high permeability and lower losses
in this preferred direction, GO electrical strip is typi-
cally used in static machines such as transformers.

Non-grain oriented electrical strip is used in wind turbines for

electricity generation. ( ©Thorsten Wengert/PIXELIO).

40
Process Know-How
Support for all grades and
production routes
In cooperation with MET/Con, SMS group offers
process support for all grades and production routes.
This covers both metallurgical and design activities as
well as support during commissioning and operation.
The experts involved look back on long production
experience and offer full parameter sets from
steelmaking to final processing. This ensures safe
production also of difficult and high-quality grades.
Furthermore, operational costs can be minimized,
for example through greatly reduced use of alloying
All furnaces and processing lines feature special
elements. equipment tailor-made to the particular requirements
of silicon steel strip.

Smooth strip running is enshured by heating of the coils as

well as the strip edges to avoid strip breaks.

41
Non-Grain Oriented
Electrical Silicon Steel Strip

Furnaces for annealing and

coating lines
The most important processing line for fully-finished
non-grain oriented (NGO) material is the annealing
and coating line. One highlight is the recrystalliza-
tion furnace with a hydrogen content of up to 100
percent. For contactless drying of the coating, a
floatation furnace with a high specific heat transfer is
installed.

Furnace in an annealing and coating line.

Thermal simulation of the heating process in an NGO- NGO electrical strip is mainly used in rotating machines
furnace. such as electric motors and generators with alternating
field orientation.

42

Reference: ArcelorMittal, France
New furnace for an annealing
anD coating line
In its new annealing and coating line, ArcelorMittal
St-Chély d`Apcher, France, processed the first coil in
March 2013. Thanks to good preparation by all
participants, the commissioning was done quickly
within a few weeks. Already one month after the
furnace had dried out, the production reached the
nominal rate.
With the new line, ArcelorMittal St-Chély d`Apcher is
drastically increasing its production capacity of high-
grade non-grain oriented electrical steel strips (NGO).
Among other products, the furnace processes the
newly developed iCAReTM material by ArcelorMittal
which helps automakers to offer environmentally
friendly mobility solutions for a greener world.
In the annealing and coating line, the internal micro-
structure of the electrical steel strip is adjusted
during the annealing process. The material is then
The horizontal furnace in the new annealing and coating
line for ArcelorMittal St-Chély d`Apcher.
coated with an insulating layer. The strip is heated
up to 1,100 °C by means of inductors and electrical
heating elements in the horizontal annealing furnace.
The atmosphere in the furnace comprises a nitrogen/
hydrogen mix whereby the furnace can be opera-
ted with hydrogen content up to 100 percent. This
reducing atmosphere helps to achieve a particularly
oxide-free and clean strip surface, which is important
for a high-quality material grade. Furthermore, the
careful and slow cooling of the material is important
for the microstructure. For this reason, the strip is
first cooled down at a very accurate cooling rate in
the slow-cooling section and then in the rapid cool-
ing section. Due to the high annealing temperatures
and the very high hydrogen content in the furnace,
ArcelorMittal achieved very good material properties
right from the start. Especially the core losses are
already at the level of those attained by the best pro-
ducers in the world.
43
 Grain Oriented Electrical
Silicon Steel Strip
Setting the main material
properties
The focus in the production of grain oriented silicon-
grades is on the heat treatment of the cold strip, as
the main material properties are set in this stage.
The first heat treatment in the annealing and pickling
line is to recrystallize the steel and to obtain the
appropriate quality and size or inhibitor precipitates.
The furnace is composed of a direct flame furnace,
followed by a radiant tube furnace. The strip is
annealed at a maximum temperature of 1,170 °C.
The strip is then cooled to 900 °C and soaked for a
minute. A cooling air and/or water is used to cool the
strip to the exit temperature. In case of production
of HiB grades, the cooling gradient should be higher
than 35 K/s between 900 °C and 400 °C.
During decarburized annealing, the carbon content
in the steel making process is high in order to avoid
abnormal grain growth in the slab. This carbon has to
be removed at this stage to avoid aging. The heating
is achieved due to radiant tubes. The annealing tem-
perature is between 830 and 900 °C. The cooling is
divided in two stages: slow-cooling at the beginning
and fast-cooling when the strip temperature is less
44
than 600 °C. In the soaking section, the atmosphere
is humidified to adjust the carbon content. After
annealing, strip is coated with a magnesia solution
and dried.
In batch annealing, the second recrystallization takes
place and the steel is purified from the inhibitor
elements. The strip is annealed at a temperature of
maximum 1,200 °C by a heating hood.
In the flattening and coating line, the goal is to dry
the tension active solution coated just before the
furnace and to improve the strip flatness. The first
section, in which the tension active coating is dried,
is of the catenary type and heated by direct flame
burners. Radiant tubes heat the second section of
the furnace. The annealing temperature is about
870 °C. A pair of flattening rolls is installed when this
temperature is reached. A slow-cooling and a fast-
cooling follow this section when the strip tempera-
ture is below 600 °C. The final cooling is achieved
with air-cooling. The control of the annealing curve
and the furnace atmosphere as well as the strip
tension, which could cause negative impact on final
magnetic properties, and the improvement of the flat-
ness are the most important issues in this stage.
Furnace in an annealing and coating line.
 Catenary furnace for contact-free drying of the
insulation layer.

Reference: Wisco, China

Two furnaces for flattening
and coating lines
SMS supplied two furnaces for Wisco’s new two
flattening and coating lines in China. These two lines
are used to enhance the production of HGO grades
around 180,000 tons. Both furnaces were successful-
ly commissioned in 2012. Without a stop for the first
five months after start-up, both furnaces have been
operating and produced, among other grades, HGO
materials in the low-temperature mode. The furnaces
feature new technologies for thermal flattening as
well as for cooling, which improve surface quality
and process control.

Strip entering the drying and sintering furnace, which is

divided into a radiant tube and a direct-fired section.

45
Stainless Steel Strip
Annealing

Powerful furnaces for stain-

less steel strips
SMS group offers perfect concepts for all thermal
process stages of stainless steel strip which are
characterized by their efficiency, sophisticated pro-
duction models and powerful environmental technol-
ogy. All this leads to low production costs, high
energy efficiency and outstanding environmental
compatibility. The scope comprises of all significant
furnaces for stainless steel strip treatment. Besides
furnaces for annealing of hot strip and cold strip SMS
also delivers furnaces for bright annealing lines.

Hot strip Annealing and

Pickling Lines

Horizontal furnace in a stainless steel hot strip annealing line.

Cold strip Annealing and

Pickling Lines

Horizontal furnace which is capable to anneal stainless steel

cold strip.

46
In hot strip as well as in cold strip annealing and pickling
lines the furnace plays a major part when It comes to mate-
rial quality, operational costs and environment friendliness.

47
Stainless Steel Strip
Annealing – Technology

The furnaces are designed to optimize energy utili-

zation and environmental compatibility. The strip is
preheated in a radiation zone which operates with
the exhaust gases from the downstream heating
furnaces. To increase the thermal efficiency, a special
heat recovery system is used. The process para-
meters are set and controlled by a mathematical
model over the entire annealing cycle, which is also
combined with the pickling model to match up and
optimize both processes. More than 25 SMS fur-
naces for stainless steel strip processing have been
ordered since the year 2000 worldwide.

The support rolls in the furnace are designed as easy-to-

maintain "carrousel rolls" and can be changed within 15
minutes without disturbing operation.

Heat recovery system

Thanks to an intelligent heat recovery system, the
furnace achieves excellent thermal efficiency. The
strip is heated up in two zones by means of direct
firing. The hot waste gases are then led through the
preheating zone in the opposite direction to strip-
travel and heat up the strip. Finally, the gases are
extracted at the furnace front end and, with the aid
of a recuperator, are used for preheating the combu-
stion air. Thus, the exhaust gases of the furnace are
used to preheat the combustion air as well as the
strip in the first parts of the furnace.

48
Water cooling for hot strip
In hot strip processing, a special water cooling
technology ensures a better strip quality due to
faster cooling and a better control of the last heat-
ing zone. The efficient system results in a shorter
cooling section and massive electrical savings.
Furthermore, the impact on the environment is mini-
mized because there are no dust emissions and no
vibrations or noise.

Mist cooling for cold strip

The mist cooling technology reduces the length of
the energy consuming air-cooling section and elimi-
nates the final cooling performed by water, since this
can generate cooling buckles. In total, 17 annealing
and pickling lines have been equipped with mist
cooling sections. Due to reduced blower motor
power and exhaust motor power, electrical energy is
saved. Moreover, water consumption can be re-
duced drastically. This adds up to annual operational
savings which significantly reduce production costs.

49
Stainless Steel Strip
annealing – References

North American Stainless (NAS), USA

High-performance furnace for
the production of bright-
annealed stainless steel strip
North American Stainless (NAS), USA, a subsidiary
of the Spanish Acerinox Group, has contracted SMS
group for the supply of a complete bright annealing
line. NAS is erecting a modern, high-performance
production facility for bright-annealed stainless
steel strip in Ghent, in the U.S. state of Kentucky.
The in-stalled plants will be characterized by high
efficiency, flexibility and product quality. The output
capacity of the plant will be 95,000 tons per year.
Commissioning will take place in early 2017.
The new line will manufacture both austenitic and fer-
ritic grades (AISI 300 and 400 series). The end ma-
terial will be between 600 and 1,350 millimeters wide,
and between 0.15 and 1.5 millimeters thick. In addition
to the supply of the mechanical, process, furnace, elec-
trical and automation equipment, also the supervision
of installation, commissioning support and training of
the operating personnel belong to the contract scope.
The bright annealing line will be the highest-perfor-
mance line of its kind in the USA. Here the material
will be annealed with a speed of 50 meters per
minute in an oxygen-free, inert atmosphere with high
hydrogen content, creating a high-grade, reflective
strip surface.
The technological highlight of the bright annealing line
is the entirely electrically powered vertical furnace.
Thanks to the furnace’s high operating efficiency, the
energy consumption, at approx. 220 kilowatt hours per
ton, is 60 percent lower than in a conventional design
with a muffle furnace. Furthermore, the shorter hea-
ting section enables the bay height to be reduced by
50 percent. The high efficiency is achieved by means
of direct heating via electrical heating elements and
dynamic annealing at up to 1,250 °C. The annealing
process takes place in a pressurized inert atmosphere
(up to 90 percent hydrogen). This ensures a low dew
point and produces an immaculately reflective surface.
A special strip stabilization system allows contactless
positioning of the strip, preventing surface damage.
The total furnace construc tion is made gas tight.
Special sealing elements at the entry and exit mini-
mize losses. In order to keep the hydrogen require-
ment low, a recycling unit will be integrated to conditi-
on the used hydrogen and return it to the process. For
strip cooling, the furnace will be fitted with two inert
gas recirculation units.
The technological
highlight of the
new NAS line is the
entirely electrically
powered vertical
furnace with a pres-
surized inert atmo-
sphere (up to 90
percent hydrogen).

The bright annealing line operated by an electrical furnace

convinces through highly efficient production of stainless
steel strips with extremely high-grade surfaces.

50

Outokumpu Stainless, USA
Annealing and pickling lines
for cold and hot strip
The annealing and pickling line for hot and cold stain-
less steel strip is an integral part of a new cold rolling
mill for stainless steel in Alabama, USA, owned by
Outokumpu Stainless Steel USA. The line is able to
produce flexible hot and cold strip as well as very
With a length of almost 140 meters the furnace is capable
to heat the strip up to 1,150 °C.
The furnace serves for the production of 140 tons of
hot strip per hour or 90 tons of cold strip per hour.
thick material (up to 10 millimeters). The yearly
capacity is 750,000 tons including AISI 200, 300 and
400 grades. The line went on stream in 2011 with
excellent results so far. The thermal treatment of the
strip takes place in a modern horizontal furnace with
various innovative features.
The intelligent heat recovery system ensures a high-thermal
efficiency.
51
Color CoaTIng

Efficient drying furnaces for

steel and aluminum strips
Color coating lines apply a high-quality coating to the
strip so that it can be used directly for processing
into end products. This saves costly process stages.
SMS group delivers color coating lines for various
applications of aluminum and steel strip. The lines
differ depending on the final use of the material.
The lines are delivered completely from a single
source and feature several outstanding processes.
The highlight of the lines is the compact coating pro-
cess. Chemical strip pretreatment, subsequent color
coating and drying oven are ideally synchronized.
This way it is possible to attain a high product quality
at low consumption of resources and energy. The
high-performance floatation or catenary ovens to dry
the solvents stand out for even heating and cooling
performance as well as exceptionally high efficiency
and eco-friendliness. All this requires ideal setting
and control of the process parameters, ensured with
a mathematical model. The air is heated by burners
that work with reheated combustion air, yet require a
very low energy input.

Contact-free strip travel

Nozzles in the floatation oven ensure the strip tra-
vels contact-free through the oven and air cooler in
a sinus shape. This is possible because, throughout
the oven length, hot-air nozzles heat the strip evenly
and keep it afloat on an air cushion. With interaction
of the mechanical drive, a fault-free strip transport
is generated. The ovens are designed with several
modular heating and curing zones for best process-
ing and strip quality.
In a floatation oven the strip travels on air cushions without
any mechanical contact.

52
Regenerative Thermal Oxidizer
(RTO)
The flue gases of the oven are burned in a regene-
rative thermal oxidizer system (RTO) with a thermal
efficiency of 98 percent. Depending on the solvent A regenerative thermal oxidizer system burns the solvent-
containing exhaust air and regains the energy produced.
content in the exhaust air, the after burning system
and even the oven itself can be operated without
additional energy input (autothermal mode).In color
coating lines, solvents are evaporated so as to cross-
link the varnish molecules and to cure the varnish.
The type of heating of the ovens is specified on the
basis of the product portfolio and the product mix as
well as an energy balance and economic calculation.
Thus, concepts with autothermic operating practice
of the ovens have already been realized over of a
wide product range. The exhaust gases are extracted
and combusted via a regenerative thermal oxidizing
system (RTO) with a high thermic operating efficiency.
Depending on the solvent content of the exhaust air,
the post combustion system and, if an energy
recovery system is employed, also the ovens them-
selves can be operated without additional energy
supply.
For products, where the energy demand is in balance with
the generated energy of the solvents by the heat recovery
system, the curing oven operates with autothermal mode.

In a color coating lines – here for aluminum can-end stock

material – a floatation oven is used to evaporate the sol-
vents without contacting the material to make the color
layer curing on the strip.

53
Color CoaTIng: References

Severstal, Russia
Two color coating lines for
carbon steel strip
Severstal's new color coating line in Cherepovets,
Russia, was successfully put into operation at the
end of 2011 and production quickly increased in
the following months. The new plant is of identical
design to the SMS color coating line that went into
operation at Severstal at the end of 2005.

Besides the very high process speed, the highlights

of the line are the roll coaters and the high-perform-
ance drying ovens. In the future, a further 200,000
tons per year of hot-dip or electrolytically galvanized
cold strip will be color coated in western Russia.
The strips are mainly used in the construction and
household appliances industries.

A backup roll coater is used to apply a primer on

the surface, which is dried in low-emission catenary
curing oven. Subsequently the strip can be coated
with a finish coat in two back-up roll coaters and Two highly efficient ovens are integrated in each color
hardened in another horizontal catenary curing oven. coating line to dry the primer coating and the finish coating.

Oven from the operator side. Drive side of the finish oven.

54
Shandong Nanshan, China
Color coating line for alumi-
num can material
SMS is supplying a color coating line to the Chinese
aluminum producer Shandong Nanshan. The line will
be designed for an annual production of 50,000 tons
of coated aluminum strip. The line is designed for
strips with a thickness of 0.15 to 0.5 millimeters and
widths ranging from 950 to 2,000 millimeters. The
material is intended to be used predominantly for the
production of beverage cans.
The highlight of the plant design is the compact coat-
ing and curing process. The chemical pretreatment
section, the subsequent strip coating process and the
drying oven are perfectly harmonized.This ensures
high product quality and low consumption of resources
and energy.
The solvents will be evaporated without any contact
in a floatation oven, with the strip surface curing in
the process. Along the entire furnace length, the
strip will be uniformly heated by hot-air nozzles while
being carried by an air cushion in a floating position.
The fact that there is no mechanical contact between
the strip and any part of the furnace guarantees an
impeccable surface quality.
The evaporated solvents will be combusted in a high-
ly efficient thermal process in a regenerative thermal
oxidizer (RTO). This solution makes it possible to
heat-treat a wide range of products without any
external energy input (autothermal operation).

The new color coating line of Shandong

Nanshan features a powerful floatation oven to
dry-out the color coating which is combined with an
integrated regenerative thermal oxidizer system, that makes
it possible to heat-treat a wide range of products in an auto-
thermal operation mode (i.e. without any external energy
input).

55
Aluminum Heat Treatment
Aluminum as light weight construction material for the
automotive industry
The use of aluminum as a light weight construction
material in automobiles continues to be on the rise.
Subsequent to the cold rolling process, the aluminum
sheets have to under go a heat treatment to regain
formability as well as the required material strengths.
Especially the heat treatment and the cooling of the
strip play a major role. This happens in combined
heat and chemical treatment lines or in single heat
treatment lines.
The furnace and cooling technology is the heart of
the process. The strip enters a floatation furnace
56
where it is guided sinusoidal in a contactless floating
mode. It is heated up and kept at the required strip
temperatures in time, so the aluminum-alloy obtains
their structure. Especially 6xxx automotive-alloys as
well as 2xxx and 7xxx aerospace-alloys require high
cooling rates up to approx. 400 Kelvin per second.
The cooling process is executed as a combination of
water and air cooling.
A special feature of the furnace is the eco-friendly
process control. Operation is controlled by a physical
process under consideration of the mechanical prop-
erties model and a production planning model with
physical transient state calculation.
Water cooling with a pre-
defined cross-bow
In the aluminum heat treatment furnace a water-
quench ensures at the same time high cooling rates
and good strip shape. Thus, high qualities are
achieved. Controlled and stable cooling is ensured
by a predefined cross-bow. A special sealing unit
prevents premature cooling.

Reference: Ma‘aden-Alcoa JV, Saudi-Arabia
Heat and Chemical Treatment Line for
Automotive and Aviation Grades
For a new continuous heat and chemical treatment
line at Ma’aden-Alcoa, all plant components including
electrical and automation systems were supplied by
SMS from a single source. SMS was responsible for
the design, manufacture, erection supervision and
commissioning of the line in the Ras al Khair plant in
Saudi Arabia.
During cold rolling, the aluminum strip solidifies and
must be annealed to regain its formability for further
processing. These lines also homogenize and solution-
anneal alloys that can solidify due to special inter-
metallic precipitates. To achieve the microstructure
The heart of the new heat and chemical treatment line
for Ma’aden-Alcoa JV is the powerful floatation furnace
with water-quench unit.
One of the technical highlights of the line is the strip
floatation furnace.The equipment paves the way for
Ma’aden-Alcoa to enter the market for aluminum
car body sheets. The line is able to produce 60,000
tons of annealed,cleaned and chemically treated strip
material. In March 2015 the first aluminum coil was
successfully heated and chemically treated in the
new line.
necessary for thedesired mechanical properties, the
material is heated to approx. 560 °C, then rapidly
cooled in a controlled way. It is imperative that the
sensitive surfaces are not supported by rolls during
heating, which is where convection strip floatation
furnaces come in. Furthermore,in a combined heat
and chemical treatment line, (which is shown here)
the strip receives a chemical treatment that prepares
the surfaces for subsequent painting.
57
58
furnaces for
slabs, bars
and tubes
Every rolling mill is different and the same should apply to
every furnace. The SMS furnace experts offer tailored solu-
tions for any process and layout. The design capability inclu-
des in general the following furnaces.

Roller Hearth Furnaces page 58

CSP®-Roller Hearth Tunnel Furnaces page 62

Chamber Furnaces page 64

Walking Beam Furnaces page 66

Walking Hearth Furnaces page 70

Pusher Furnaces page 72

59
Roller Hearth Furnaces
Efficient heating of heavy
plates
The roller hearth furnace is often used in a contin-
uous heat treatment process for heavy plate. Its
strengths are, on the one hand, different speeds for
the individual heat treatment of plates and, on the
other, a high maximum speed, which is important,
in the first place, when it comes to transporting the
plates to the quench.
The furnace housing of a roller hearth furnace has
the shape of a long tunnel. The hearth itself consists
of rollers arranged transversely to the direction of
transport. The distance between the rollers must not
exceed a maximum dimension, as otherwise there
would be a risk of the plates “diving” below one of
the rollers. This maximum dimension is thus deter-
mined by the bending behavior of the thinnest plate
at the highest possible temperature. The roller hearth
divides the furnace into a top and a bottom section
which provides the possibility of heating from both
sides.
The hearth usually consists of high-alloy centrifugal
cast rollers and which is the core component. On the
Roller hearth furnace for normalizing and tempering
60
one hand, the rollers are a decisive factor as regards
the costs of such a furnace system, which again
depend to a large extent on the price fluctuations,
especially for the main constituents of Cr and Ni. On
the other hand, the rollers may also impose restricti-
ons on the system design. A sufficient lifetime of the
rollers can only be guaranteed if the hearthload as a
combination of temperature, plate load per roller and
bearing center distance (which again is directly linked
to the plate width) does not exceed certain limits.
Heating is accomplished either by open or indirect
firing through radiant tube burners with the furnace
chamber being rendered inert by flushing with nitro-
gen. The indirect heating method results in less
scale on the plates, but requires considerably higher
investment and operating costs. The radiant tubes of
indirectly heated furnaces are equipped with recupe-
rator burners.
For open fired furnaces, however, it is recommended
to use high speed burners with a central recuperator
for preheating the air.
Cross-section of a roller hearth furnace with radiant
tube heating.
Reference: Acroni, Slovenia
Two roller hearth furnaces for special grades
SMS delivers two roller hearth furnaces for the The roller hearth furnace for hardening and solution
Slovenian steelmaker Acroni, which are integrated annealing will be equipped with two chambers, in
into heat treatment lines for heavy plates. The fur- which the plates will be annealed in a nitrogen-based
naces will be designed for 4 to 13 meter plates inert gas atmosphere. Heating to up to 1,100 °C will
with thicknesses ranging from 3 to 100 millimeters be carried out indirectly using radiant heating tubes
and a width ranging from 700 to 2,560 millimeters. with recuperator burners. The total furnace length is
The maximum weight of the plates is 16 tons. The 33.6 meters.
range of materials includes high-strength carbon
The roller hearth furnace for tempering is only
steels, stainless and tool steels as well as a range
slightly shorter with a length of 32.3 meters. In this
of special grades.
open fired furnaces, however heating takes place
SMS supplies a roller hearth furnace for hardening, via high-speed burners which heat the furnace up
normalizing and solution annealing and another roller to 800 °C. The achieved plate temperature lies
hearth furnace for tempering, as well as a quench- between 400 °C and 780 °C.
ing system and all auxiliary facilities. These will
include the complete plate conveying equipment, all
systems for the water supply and water treatment
as well as the automation of the systems.

Roller hearth furnace for hardening and normalizing.

61
CSP®-RolleR HeaRth TuNNel
FuRNaCes

EFFICIENT HEATING AND SLAB TRANSPORT WITH SPECIAL COOLING ROLLS

In the CSP® plant, the roller hearth furnace is the The downstream homogenizing zone keeps the tem-
logistical and technological link between continuous perature at a constant level and harmonizes it over
caster and rolling mill. The first zone of the more the cross-section and length of the slab to achieve a
than 1,100 °C hot furnace serves to set the thin slab homogenous temperature distribution. This is neces-
temperature required for the rolling process. This is sary for an optimized rolling process and makes sure
achieved by using environmental friendly ultra-low the finished product is of high quality.
NOx burners. In order to save energy, the combustion
To transport the thin slabs through the furnace, spe-
air is preheated by waste heat from the furnace via
cial water-cooled rollers are used. They ensure little
recuperators.
heat is dissipated and thus increase the energy effici-
ency of the furnace. To satisfy the high demands on
the final product surface quality, a newly developed
calculation module minimizes the contact pressure
between roller support rings and slab.

A special Dynamic Furnace Control (DFC) level 2 pro-

cess automation system is used in a CSP®-furnace
to ensure heating of the slab to the required target
temperature with good uniformity and without ener-
gy wastage (see page 18).

The slabs are transported through the furnace via cooled

and wear resistant rollers.

Newly developed rolls with fireproof aluminum silicate wool.

62
Reference: Big River Steel, USA
CSP®-roller hearth tunnel furnace
steel plant
For the new steelworks of Big River Steel, SMS
group will supply all thermal processing equipment.
Thus, the complete know-how for heating and cool-
ing throughout the whole processing chain is supplied
from one source and ensures high material quality is
attained. In the first stage, the new complex of Big
River Steel in Osceola, in the state of Arkansas, USA,
will produce 1.5 million tons of hot strip. Part thereof
will be refined in-house to produce high-strength cold
strip for automotive applications.
The CSP® plant is capable of producing strips with
thickness ranging between 1.55 - 25.4 millimeters.
Equally impressive is the strip width of up to 1,930
millimeters, which means Big River Steel owns the
world's widest CSP® plant. The CSP®-roller hearth
furnace features a newly developed calculation mo-
dule to minimize the contact pressure between roll
carrier rings and slab for high surface quality of the
in a new integrated
end product. Already in place are plans for producing
sophisicated products that cater to the demands of
the growing market-products such as pipe grades for
pipelines, AHSS grades, and especially silicon steels
for electrical sheet. That's why the CSP®-Furnace is
designed from the start for slab temperatures of up
to 1,220 °C.
This includes water-cooled furnace rollers with fire-
proof insulation made of aluminum silicate wool.
Thus, higher temperatures are possible at low energy
losses via the cooling water. Still to come is an
expansion stage that will substitute the final section
of the tunnel furnace with a muliple module induction
heating system. Carrying out this conversion means
it will be possible to increase the slab temperature
from 1,220 °C to the level of 1,320 °C, required for
the most difficult-to-produce steels.
63
Chamber Furnaces

Batch operated furnaces with

a fixed hearth
Chamber furnaces are batch-operated furnaces with furnace and discharged from the furnace by means
a fixed hearth. These furnaces are characterized by of a machine. For plate transfer to the furnace and
their high degree of flexibility and are thus typically away from the furnace, a conventional roller table is
used in the case of low capacity requirements and installed along the longitudinal side of the furnace.
frequently changing batches. Depending on the case
The chamber furnace is often used for normalizing
of application, the hearth can be subdivided such that
or solution annealing at elevated temperatures in
heating of the plate bottoms can be implemented at
the case of high plate loads and large plate widths.
least in parts of the furnace. On the longitudinal side,
Concerning the combination of plate load and tempe-
the furnaces are equipped with a large door. Through
rature, this furnace has almost no restrictions.
this door, the plates are introduced into batch type

With the help of loading machines all plates are introduced

separately into the batch type furnaces.

The large doors on the longitudinal side of the furnace

opens and a glowing plate is discharged out of the furnace.

64

Reference: Outokumpu, Sweden
Two chamber furnaces which
can be connected
As part of a complete heat treatment line, SMS deli-
vered two chamber furnaces to Outokumpu Stainless
in Degerfors, Sweden. The two batch-type were deli-
vered completely with charging machines and con-
necting roller tables as well as all the accompanying
electrical and automation equipment.
The new furnaces are used for heavy plates and high
heat-treatment temperatures, as well as for small
batch sizes of niche products. The loading machine
introduces a stainless steel plate into the furnace.
The furnace plant consists of two batch type fur-
naces, both of which have two doors. The reason for
this is that every furnace can be further divided into
two chambers using a special separation gate. In this
way, Outokumpu can occupy a furnace with either
one long plate or two short plates. If two plates are
in the furnace, then these can be heat-treated indi-
vidually using differing annealing temperatures
Solution annealing takes place via high-speed burners in the
open fired batch furnace at Outokumpu.
times, provided that the separation gate is closed.
This offers a high degree of flexibility and thus
optimal hearth utilization at all times, which guaran-
tees energy-efficient plant operation. In this way,
Outokumpu can occupy a furnace with either one
long plate or two short plates.
The batch type furnaces can heat plates to more than
1,200 °C. With such high temperatures, Outokumpu
is capable of manufacturing sophisticated steels such
as high-alloy grades for special applications.The
furnaces meet the high environmental protection
requirements and are equipped with a modern heat-
recovery system. A further special feature is the pro-
cessing of very thin plates. The plate lengths range
from 3,000 to 16,000 millimeters and the widths
from 400 to 3,500 millimeters. The loading and un-
loading machine conveys at approximately 2 meters
per second.
65
WALKING BEAM FURNACES
High productivity combined with operational flexibility
Walking beam furnaces, both top and bottom-fired,
allow for high production rates and top quality steel
grades. Billets, heavy blooms, slabs and beam blanks
can be charged. Walking beam furnaces feature
many cooled elements as well as special alloy parts
which endure high temperatures and mechanical
stresses. SMS group continuously works on the
development and integration of new designs and
materials. Thanks to the advanced combustion sys-
tem, all SMS walking beam furnaces are highly flexi-
ble in operation.
66
FAST AND RELIABLE MATERIAL
HANDLING MACHINES
SMS sturdy discharging machines avoid any misalign-
ment in the discharging area, even when handling
workpieces of very different sizes and shapes. They
virtually eliminate vibrations and positioning errors.
The possibility of reverse movement in emergency
situations as well as the choice of manual handling
are further key advantages. SMS group offers a wide
range of kick-in and kick-off machines, both electro-
mechanically and hydraulically operated – so even
the most challenging demands are met.
RAPID DISCHARGE RATE
The record-setting machine delivers one billet every
24 seconds. It is installed in the high-capacity walk-
ing beam furnace at KSC Nizhneserginsky Metizno-
Metallurgichesky Zavod – ZAO “NSMMZ”.

BENCHMARK EFFICIENCY
The 180/220 tons per hour walking beam furnace
at United Steel Company, Bahrain, is equipped with
ultra-low NOx burners. It sets benchmarks in
efficiency and low emissions.

67
68
HIGH QUALITY MEETS LOW
ENERGY CONSUMPTION
ArcelorMittal Ruhrort operates one of the world's
most modern wire rod mills. The plant was supplied
by SMS group and produces a wide range of special
steel grades for the premium market, primarily the
automotive sector. The walking beam furnace
adequately supports the slender billets with the fixed
and movable skid. The result: 110 tons of billets with
a thickness of 155 millimeters and a length of 16.5
meters are optimally heated every hour, meaning
ArcelorMittal can reliably deliver premium quality pro-
ducts. The double-stage recuperative system allows
for benchmark efficiency and minimum emissions: a
specific natural gas consumption of 250 kcal/kg and
less has been achieved very early after lighting of the
furnace. The waste gas evacuation system is equip-
ped with special filter units which effectively reduce
the release of particulate matter.The walking beam
geometry guarantees perfect overall heating quality:
Faster reheating ensures better control of decarbu-
risation, vital for high-quality rods.
The temperature homogeneity is enhanced by a
large battery of low-NOx radiant burners in the
heating and soaking top roof, and by the digitally
controlled long-flame burners installed in the bot-
tom soaking zone.
69
WALKING HEARTH FURNACES
Minimum specific consumption figures

Walking hearth furnaces are the optimum choice for
many long products mills with production rates of up
to 140 tons per hour. Due to the layout with top heat-
ing only, these are recommended for products with
a maximum thickness of 160 millimeters. A major
advantage of this furnace type is that it allows for
very low specific consumption figures, achieved
thanks to the absence of water-cooled elements
inside the furnace.

70
RECORD-BREAKING PERFORMANCE:
16 M SLENDER BILLETS UNDER A RADIANT ROOF
Stefana S.p.A. set up a 700,000 ton per year bar mill burners guarantees optimum temperature homo-
under a project entitled “Dream Steel”, located in geneity of the reheated workpieces.
Ospitaletto, Italy. The furnace specialists designed
The heat maintenance zone, a series of small burners
a furnace capable of reheating billets with a length
that retain the furnace temperature during weekend
of 16 meters, with the result that Stefana can profit
stoppages and prolonged mill downtimes, helps
from the market demand for large coils with a weight
Stefana to reduce energy costs. The reheating fur-
of more than three tons, as well as from the overall
nace is able to supply the mill with a continuous out-
benefits of improved yield. This target was achieved
put of 120 tons per hour starting with cold billets, or
by constructing a walking hearth furnace with a sus-
140 tons per hour when hot charged.
pended 16.8 meter wide roof. A battery of 90 radiant

71
PUSHER FURNACES
Low investment costs combined
with robust design

When it comes to heavy duty and straight forward

design furnaces for billet reheating, the pusher type
furnace is often the perfect choice. Pusher furnaces
are typically suitable for low-production mills for
common steel grades, for example rebar mills.

ADAPTABLE TO VARIOUS NEEDS

Top-fired pusher type furnaces combine the benefits
of a sturdy construction and simplicity in design with
low consumption. Top and bottom-fired pusher type
furnaces are capable of high production rates. Pusher
type furnaces are an inexpensive alternative to more
sophisticated walking hearth furnaces or walking
beam furnaces for the production of simple products.

72
FIELD OF APPLICATION:
LONG PRODUCTS
Larger furnaces for greater profit

SMS group has decades of experience in the design even longer billets – the engineers can deliver what-
and construction of rolling mills for bars, sections ever their business partners need to improve their
and wire rod. The same goes for reheating furnaces. competitiveness.
Over the years the furnace experts have developed
The demands in terms of heavy section mills and rail
many benchmark solutions to meet the increasing
mills are similar: by using starting blooms longer than
demands of the long products market.
the traditional 12 meters, the plant owners profit
One example is the ability to produce coils which from increased metal yield by reducing crop ends.
have a weight of 3 tons and more and a higher market
value per ton. For this purpose, billets much longer
than the traditional 12 meters are used as starting
stock. Billets above 12 meters in length are the mar-
ket standard today. SMS group offers furnaces for

73
FIELD OF APPLICATION:
FLAT PRODUCTS
Reheating furnaces for optimum slab quality

SMS group offers highly productive walking beam

QUICK COMISSIONING, SHORT
furnaces for slab reheating with capacities of up to
CYCLE TIME
400 tons per hour. They are equipped with a set of
The enormous kick-off machine for a 30 ton
fixed and movable water-cooled skid beams. In order
slab treatment furnace at Outokumpu in
to minimise skid marks both fixed and movable skids
Degerfors, Sweden, was preassembled in the
are staggered between the heating and the soaking
SMS group workshop
area. Heat losses through the cooling water are mini-
to ensure a minimum
mised using composite double-layer insulation for the
commissioning time.
complete skid system.
Cycle times are short
too: the machine can HIGH QUALITY THROUGH OPTIMISED
unload one slab every TEMPERATURE DISTRIBUTION
20 seconds. A set of special alloy skid riders is placed on top of
the fixed and movable skids over the entire length of
the furnace chamber. The furnace engineers calcu-
late the height of the riders precisely so the slabs are
at a sufficient distance from the water-cooled skid.
The results: skid marks and dark spots on the slab
are minimised as the temperature of the skid’s
contact spot is very close to the temperature
of the heated slab.

74
WIDE RANGE OF COMBUSTION SYSTEMS
SMS group equips all walking beam furnaces with highly efficient,
digitally controlled combustion systems and conventional, hybrid or
fully regenerative burners that work using all widely available fuels.

SMALL IN CAPACITY BUT GREAT ON

FLEXIBILITY
SMS group also offers special walking hearth furnaces for small
slabs. These compact solutions are characterised by smart loading
diagrams which allow high loading flexibility. They process a wide
range of slab sizes and thicknesses.

75
FIELD OF APPLICATION:
PIPES AND TUBES
Fully integrated furnaces for any process
Tube rolling is one of SMS group core competencies.
The know-how accumulated by the heating technol-
ogy experts is extensive: they know every detail of
the production process and can handle even critical
reheating profiles.
SPECIALISTS IN TUBE ROLLING,
REHEATING AND HEAT TREATMENT
SMS combines the benchmark-setting Premium
Quality Finishing (PQF®) mills for producing seamless
tubes with high-end furnaces. Advanced combustion
systems guarantee complete temperature uniformity
and minimum energy consumption. The rotary hearth
furnaces as well as the shell reheating furnaces are
fully integrated into the rolling process. SMS individu-
76
ally adapts the technically sophisticated systems to
the specifics of every single mill, such that even spe-
cific process requirements are optimally met. Plant
operators benefit from a smooth production process
and optimum tube quality.
SMS has designed and constructed some of the
most advanced and largest rotary hearth furnaces in
the world. They combine high capacities with special
materials and components for maximum temperature
endurance. That’s why for decades SMS furnaces
have been able to withstand the high temperatures
typical for this process – and plant operators have
been able to minimise maintenance costs.
SHELL PIPES WITHIN A 5 °C
TEMPERATURE RANGE
SMS walking beam furnaces bring shell pipes
to the required temperature with maximum
precision before final sizing. Thanks to advanced
combustion control systems, the furnaces
achieve a temperature tolerance deviation of
only ±5 °C, more than sufficient for overall
mill process control and thereby ensuring the
final tube quality.

77
 INTELLIGENT ENERGY RECOVERY
Whenever SMS engineers design a plant, they con-
sider the whole production process and combine
the individual process stages to produce the best
results for their business partners. One example is
the further utilisation of the heat energy that exits
the rotary hearth furnace, which is by far the most
energy-demanding unit in a seamless pipe mill. Using
a completely automated fume recirculation system,
SMS rotary hearth furnaces satisfy all the energy
requirements of the mandrel reheating furnace. Plant
operators save all energy costs for mandrel reheating
and reduce emissions here to zero.

ZERO EMISSIONS AND ZERO

ENERGY CONSUMPTION
The energy required for the mandrel reheat-
ing furnace is fully obtained by exploiting the
excess heat from the rotary hearth furnace
exhausts.

78
79
FIELD OF APPLICATION:
FORGED PRODUCTS
Furnaces as versatile as the product mix

SMS group has set new standards in forged product

THE FORGE MILL FURNACE AT
reheating, in terms of both operational flexibility
TOSCELIK
and reheating efficiency. The furnace experts trans-
The furnace for heavy blooms and ingots at
ferred and optimised the comprehensive experience
Toscelik, Montenegro: a single motorised
gained to high-productivity rotary hearth furnaces for
machine, swivelling on a 25° arc, handles both
pipe mills. On this basis, they developed advanced
charging and discharging.
dedicated reheating solutions for forging plants. With
SMS group furnaces, forging plant operators gain a
competitive edge due to increased productivity and a
wide product mix combined with reduced energy and
maintenance costs.

FLEXIBLE, EFFICIENT AND COST-

EFFECTIVE
An impressive example of the SMS approach is the
new type of rotary hearth furnace: it is charged and
discharged through two separate doors by a single
elevated-type swivelling machine. This design, com-
bined with state-of-the-art combustion and control
systems, allows for the perfect combination of high

80
energy efficiency and proper operational flexibility.
At the same time, plant operators benefit from low
investment and maintenance costs.
ONE FURNACE, MULTIPLE
TEMPERATURE ZONES
SMS group developed a special furnace design for
forging plants with small to medium capacity and a
wide product range: multi-chamber furnaces which
allow for simultaneous heating of different products
at different temperatures. In these highly flexible
furnaces every product is heated precisely according
to its specific requirements. The temperature zones
are regulated by a digitally controlled single combus-
tion system. Regenerative burners guarantee high
efficiency,

MULTI-CHAMBER FURNACE
One control system, multi-stage heating:
the capability of three separate furnaces
combined into one.

81
82
HEAT TREATMENT
OF HOT-FORMED
MATERIAL
Highly demanding applications require exceptional qualities
guaranteed for every single plate, tube or bar. SMS’s heat
treatment specialists design and construct benchmark
setting heat treatment solutions combining the sophisticated
heating technology with advanced and proven cooling
systems.

Heavy Plates page 82

Tubes and Pipes page 92

Bright Tubes page 100

Bars page 102

83
Heavy Plate Heat
Treatment Lines
Different process routes for
heat treatment of hot-rolled
heavy plates
SMS group has been focusing on heat treatment
technology for heavy plates and hot strip to make
production processes more efficient and flexible. The
development of new materials and changing market
environments caused a demand for flexible plant
solutions concentrating on material quality. The
solutions permit a wide range of heat treatment strat-
egies for a great variety of materials.
To produce plates with ever higher strength and
toughness, plant technology must undergo con-
tinuous advancement. New rolling and cooling tech-
nologies often allow the mechanical properties to be
set within the rolling line, but extremely challenging
materials, however, require a final heat treatment in a
special heat treatment line.
The type of furnace normally used in a continuous
heat treatment process for normalizing and temper-
ing is the roller hearth furnace. Its strengths are on
the one hand different speeds for individual heat
treatment of plates and on the other hand a high
maximum speed to transport plates to the quench.
For the heat treatment of stainless and special
steels, double walking beam and chamber furnaces
are also frequently used.
In the face of changing energy costs and rising
environmental requirements, SMS attaches great
importance to high energy efficiency in the rating
and design of the furnaces. For each project, SMS
develops a tailor-made optimum solution in coope-
ration with the customer, taking into consideration
upstream plant areas.
84
The result of the quenching process is a significant
increase in hardness due to the formation of mar-
tensite. Plate fixing during the quenching process
ensures good flatness even at high cooling rates.
Whereas a continuous quench cools the plates on
their way through the line, a platen quench or a
discontinuous roller type quench cools in batches
plate by plate. Due to their lower throughput, they
are economic solutions especially for low production
volumes. A new type of quench is the newly devel-
oped MultiFlex-Quench® which is no longer rigidly
subdivided into a high-pressure and a low-pressure
section. Instead, the entire range of cooling rates is
available over the full length.
Electrical and automation
systems
For the effective setting of mechanical properties in
heat treatment, SMS integrates its X-Pact® electrical
and automation systems also in these plants. To
describe the complex and, in part, highly dynamic
processes, mathematical models are used and com-
bined to a holistic approach. The essential target
values for plant control are mechanical properties
(respectively the microstructure), energy efficiency
and plate flatness. Calculation of the cooling rates
which determine the material properties is made on
the basis of SMS’s material data base which is the
foundation of all SMS group process models. For all
steel grades it provides the most important physical
and mechanical properties depending on their chemi-
cal composition and temperature.
 Furnaces for
Heavy Plate
Heat Treatment

Discontinuous Continuous
Operation Operation

Double Walking
Chamber Furnace Roller Hearth Beam Furnace
Furnace (Normalizing)

Open Protective
SMS offers different heating Atmosphere Atmosphere
solutions for heavy plate
heat treatment lines.

SMS is able to deliver complete heat treatment lines systems for heavy plates with different furnaces and quench types as well as
all auxiliary equipment (incl. electrics and automation, water treatment plant, handling and transport systems, cooling beds, levelers).

85
Heavy Plate Heat Treatment
Lines – Roller and platen
quench
Quenching of heavy plates
Plates can be quenched in two different types of
quenching units. One of them is the batch-operated
so called platen quench. If this quenching station
is used, the plates are stopped after their rapid dis-
charge from the furnace and clamped by means of
clamping jaws. After clamping, water is applied by
means of nozzle pipes, which are arranged above
and below the plate.
For continuous operation so called roller quenches
are used. In this case, the plates pass through the
plant without being stopped. The major advantage
of the continuous roller quench as compared to the
platen quench is the possibility of using individual
stages with different cooling rates and the associated
implementation of a short section with a higher
86
cooling intensity. Furthermore, as soon as water is
applied in the case of a platen quench, differences in
temperature will occur between plate head and tail
ends that due to the plant‘s discontinuous operation
cannot be entirely avoided.
For both types of quenching machines, the actual
quenching process is characterized by very high
dynamics. In doing so, extreme cooling rates are
implemented by means of enormous amounts of
water and special nozzle systems. Monitored and
controlled by the plant automation systems, cool-
ing must take place homogeneously across the
entire length and width of the plate, since even the
smallest variations in the cooling conditions may
result in flatness deviations and warped plates.
In a roller quench the heavy plates are cooled down with
water while achieving high cooling rates.
Reference: MKK, Russia
Roller pressure quench
system for austenitizing lines
The roller pressure quench has been delivered
to Magnitogorsk Iron and Steel Works (MMK).
Commissioning of this system took place in 2010.
Reference: Acroni, Slovenia
New quench for larger
product spectrum
In January 2013, Slovenian steelmaker Acroni com-
missioned a new multimedia roller quench supplied
by SMS. To be able to extend the product range,
especially for thin and wide plates and to improve
plate quality, Acroni invested in a new 2.6-meter
heavy plate mill stand and a new multimedia roller
quench. The supply scope concerning the quench
consisted of the supply and the installation of the
new quenching device, a new pump station, the
interconnected piping, as well as a new electrics and
automation system. The new quench is designed for
plates up to a width of 2,560 millimeters and a thick-
ness between 8 and 130 millimeters.
The roller pressure quench provided by SMS helps
MMK to excel in the areas of cooling speed and
flatness while using less energy than the previous
systems. Thanks to the use of lower pressures in the
high intensity section, the quench system attains the
required cooling performance while consuming less
energy than conventional installations. This provides
substantial savings in operation costs. Improved rol-
ler design ensures better uniformity over the width
of the strip. In the spray lines situated above the
metal, an edge masking system limits water con-
sumption to the quantity strictly necessary for the
width of plate concerned.
The quench for MMK treats plates with a thickness
between 8 and 60 millimeters and a width of 1,500
to 4,650 millimeters. The plates with a length of 6 to
20 meters are mainly used in the construction or ship
building industry.
Due to higher cooling rates, the new quench opens
up new possibilities for the extension of the product
scope (e.g. in the range of Duplex grades). To avoid
different temperatures between the top and bottom
side of the plate, the quench is equipped with spe-
cial cooling headers, which control the water flow to
ensure homogeneous cooling. At the same time they
prevent the formation of flatness deviations on thin
plates. In addition to the high cooling rates by water
cooling, the quench is also able to slowly cool down
grades like tool steel by air. Here, plates are cooled
down by air until a critical temperature is reached,
and then the faster water cooling starts.
87
Heavy Plate Heat Treatment
Lines – MultiFlex Quench®

New technology for more
flexibility
SMS developed a new type of quench, the MultiFlex-
Quench®. Contrary to conventional continuous
quenches, this type is no longer rigidly subdivided
into a high-pressure and a low-pressure section.
Instead, the entire range of cooling rates is available
over the full length. All cooling patterns from slow
cooling to abrupt quenching can thus be realized to
achieve an even wider product portfolio. By install-
ing different nozzle systems and control valves, the
MultiFlex-Quench® can be individually designed to
suit the customer’s product mix.
SMS also assists customers in determining the opti-
mum heat treatment parameters to new high-quality
plate products on the MultiFlex-Quench®. Material
properties such as time-temperature transformation
characteristics or mechanical core values after dif-
ferent heat treatment steps are integrated into the
automation systems to optimize the process param-
eters. Based on this know-how, it will be possible
to set the mechanical properties achievable by the
heat treatment more precisely, minimize the use of
alloying elements, shorten process times, increase
the output and hence contribute to environment pro-
tection.
Exact control of the cooling
process via proven level 2
model
Precise setting of the mechanical properties
Minimized use of alloying elements
Short process time
Increased output
Environment friendly production

The MultiFlex-Quench® offers the highest flexibility for heavy plates with variable pressure
sections and an optimized plate flatness due to active hydraulic clamping via pinch rolls.

88
 Plate data (level 2)
Online temperature data
Physical reference values

SMS cooling model

Process parameters

The process parameters are calculated automatically which

ensures an exact control of the cooling process.

Accelerated cooling (ACC)

Quenching (DQ)
Temperature

Quenching/
self tempering (Q+SA)

Core Temp. Sensitive cooling/

Surface Temp. accelerated cooling (SQ)
Martensite Start Temp.

Time

The newly developed solution offers a wide process

window which allows all cooling patterns from slow
cooling to abrupt quenching.

89
Heavy Plate Heat
Treatment Lines:
References

Reference: Outokumpu, Sweden

Heat treatment line for flexi- treated simultaneously in the quench. The automation
ble and efficient stainless system for the entire heat-treatment line was also
steel plates implemented by SMS. This includes all material-
SMS group delivered a heat treatment line for stain- tracking in the individual plant components and on
less steel plates to Outokumpu Stainless in Degerfors, the roller tables, as well as the furnace recipes and
Sweden. This expansion allowed Outokumpu to the quench's cooling strategies which are coordinated
boost its production of heat treated plates and im- with them. This ensures that all plant components
prove the product quality. are harmoniously coordinated with each other when
it comes to the heat treatment processes.
As an addition to the existing line, which consists of
a rolling mill, a roller-hearth furnace and a quench-
ing device, SMS has erected a new line for heat
treatment in parallel. The line essentially consists
of two batch type chamber furnaces with charging
machines, a roller quench, the connecting roller
tables, the water supply and treatment system and
all the accompanying electrical and automation equip-
ment. As regards process engineering, the new line
has been integrated with the cooling bed and the
cold plate leveler, also supplied by SMS. As the line
is directly connected to the rolling mill, it is possible
to feed the plates into the furnace or the quench
at rolling temperature, by way of hot charging. The
plate length ranges from 3,000 to 16,000 millimeters
The plates are heated up discontinuously in two chamber
and the widths from 400 to 3,500 millimeters. furnaces.

The batch-type furnaces can heat plates to more than

1,200 °C. With such high temperatures, Outokumpu is
capable of manufacturing sophisticated steels such as
high-alloy grades for special applications. The furnaces
meet the high environmental protection requirements
and are equipped with a modern heat-recovery system.

In the quench, the plate is guided between the

rollers positioned above and below. The upper and
lower spraying headers use water to quench the
whole width of the plate at a precisely defined cool-
ing rate. Oscillation of the plate makes for an optimal
and uniform cooling process. Two plates can be

Subsequent cooling takes place in a roller quench unit.

90
 The MultiFlex-Quench® ensures a high
degree of flexibility when it comes to
different cooling strategies for heavy plates.

Reference: Acroni, Slovenia

World’s first MultiFlex- annealed in a nitrogen-based inert gas atmosphere.
Quench® for heat treatment Heting to up to 1,100 °C will be carried out indirectly
of heavy plates using radiant heating tubes. The innovative MultiFlex-
The Slovenian steelmaker Acroni has placed an order Quench® is characterized by its exceptionally
with SMS, to deliver a heat treatment line. As part high degree of flexibility. It sets itself apart from
of the heat treatment line, SMS will for the first time other quenches by the extremely wide range of
install the newly developed MultiFlex-Quench®, which cooling rates, from abrupt water quenching right
offers an outstandingly high degree of flexibility and down to gentle cooling, achieved by a multiple nozzle
high cooling efficiencies in the heat treatment of systems. As a result, flexible cooling patterns are
heavy plate. possible for a wide range of different steel grades.
Squeezer rolls fix the plate in place and hence en-
The line will be designed for plates with thicknesses
sure good plate flatness, even at high cooling rates.
ranging from 3 to 100 millimeters; the range of
Following the MultiFlex-Quench®, the plates can be
materials includes high-strength carbon steels,
tempered in an open-heated roller hearth furnace at
stainless and tool steels as well as a range of spe-
temperatures between 400 °C and 800 °C.
cial grades. For the new line, SMS supplies a roller
hearth furnace for hardening and normalizing, a
quench of the MultiFlex design and a roller hearth
furnace for tempering, as well as all auxiliary facilities.
These will include the complete plate conveying
equipment, all systems for the water supply and
water treatment as well as the automation of the
systems. The hardening furnace will be equipped
with two chambers, in which the plates will be

91
HEAT TREATMENT of
Tubes and Pipes
Premium quality pipes that satisfy even the most
demanding requirements

Over recent years, the tube industry has enjoyed

a boost from the worldwide upturn in oil and gas
exploration. Deeper conventional wells and non-
conventional oil and gas exploration require a huge
number of quality tubes which are often exposed to
extreme conditions. In this field, the failure of one
single pipe can make the difference between a highly
profitable business and a considerable money loss.

To guarantee the high quality and desired mechanical

properties required for Oil Country Tubular Goods
(OCTG) applications, sophisti-cated heat treatment is
necessary. The pipes must be heated and cooled in
accordance with strictly controlled process cycles.

92
IN-DEPTH CONTROL FROM SINGLE TUBES TO PROCESS OVERVIEW
An intelligent tracking system ensures traceability of each tube through the line. It enables tracking of the
heat treatment performed on the single tube lots, in order to keep a record of the achieved results.

The production input mask Layout overview

Each lot or tube can be identified and assigned to a The operator can monitor the functionality of every
specific heat treatment recipe. single machine and control the position of any
workpiece inside the plant.

93
Century long experience in
seamless tubes production
SMS group has already more than 125 years of expe-
rience in the production of seamless tubes: Its roots
go back to 1885, when brothers Reinhard and Max
Mannesmann obtained the first patent for the manuf-
acture of seamless tubes – a pioneering invention. In
the past 50 years alone SMS group has implemented
over 2,000 seamless tube plant projects.
HEAT TREATMENT: THE COMPLETE
RANGE
The heat treatment specialists complement the
company’s tube rolling expertise with a wide range
of advanced heat treatment plants, from quenching
and tempering through normalising to annealing.
SMS group offers benchmark solutions like the SMS-
Quench® system, which enables pipe manufacturers
to achieve the desired quality and to enhance process
consistency from the billet to the pipe fit for sale.
94
DESIGN FEATURES FOR PREMIUM
TUBE QUALITY
SMS hardening and tempering furnaces guarantee
the tightest temperature tolerances. This is how
plant operators can ensure consistent properties over
the whole tube length. In most cases, the furnace
specialists install high-speed burners that generate
strong turbulence inside the furnace chamber. The
result is a consistent and homogeneous skin tem-
perature which leads to homogeneous mechanical
properties over the whole pipe length and cross-
section.
EFFICIENT HANDLING SYSTEMS FOR
A SMOOTH PROCESS
SMS individually designs the pipe handling equip-
ment for each heat treatment line. The fully integrat-
ed systems guarantee a proper material flow that
avoids any bottlenecks. Scratch-free pipe handling
machines help to prevent defective tubes.
PRECISE TEMPERATURE FOR INCREASED TUBE QUALITY

Combining a well-engineered fur-

nace with a fine-tuned combustion
system is the key to maximum pre-
cision: the discharge temperature
of a whole tube lot, measured by
pyrometer, demonstrates that the
surface temperature is kept con-
sistently within a narrow range of a
few degrees.

MINIMUM NOX EMISSIONS

Self-recuperative burners, available in both visible flame and
flameless configurations, minimise NOx emissions.

95
SMS-QUENCH®
When it comes to adding value to the pipe

To achieve the desired structure transformation developed by specialized SMS metallurgists, every
effectively during the quenching process, it is essen- tube manufacturer benefits from a tailor-made cool-
tial that the cooling down parameters are accurately ing system that fully covers the specific quenching
controlled. Especially when it comes to OCTG pipes, requirements of any tube size and steel grade in the
deviations from the demanding mechanical properties product portfolio.
dictated by the relevant norms cannot be tolerated.
Despite the fact that single tubes differ from each
The difference between a premium quality pipe and
other before heat treatment, SMS quenching
a failure often comes down to just a few seconds or
machines guarantee a predictable, properly controlled
degrees. With SMS-Quench®, tube manufacturers
and repeatable process that generates the targeted
can reliably control and monitor all quenching param-
quality precisely. This is especially important as even
eters and thus adjust every tube’s qualities with
the slightest difference in the chemical composition
maximum precision.
may lead to wide variations in the final properties.
TAILOR-MADE QUENCHING
ALWAYS RIGHT ON SPOT
SOLUTIONS
The quenching head is the core element of SMS-
SMS-Quench® is an integrated system individually
Quench®. It is one of the most effective solutions
designed for each tube plant. Based on bain curves

96
QUALITY GUARANTEED
The temperature-time-transformation function
for a martensitic structure guarantees that the
P110 grade, as stipulated in the API standard,
is reliably met.

97
OPTIMUM QUENCHING OF
THICK-WALLED TUBES and bars
The SMS quenching tank and the new-born SMS
quenching shell are fully automatic units, dedicated
to the treatment of heavy tubes and solid bars. The
SMS tank includes rollers to guide the tube and
special stainless steel clamps to firmly hold it in
position. The SMS shell is a synchronous quenching
system where the workpiece is constantly kept
spinning during the water spraying.

98
available for outside quenching and guarantees a
fail-proof process. The quenching head is a ring-type PRECISELY THE QUENCHING
device which allows for automatic regulation of the RESULTS YOU NEED
spray nozzles’ angle according to different pipe out- The quenching head is the heart of the SMS-
side diameters. It also automatically aligns the pipe Quench® system. It features over 1,100 stainless
pass line with the head axis. This ensures that the steel nozzles per module to ensure maximum
water streams strike the pipe in the direction of cooling uniformity. The ideal geometry and work-
travel. The SMS-Quench® system also accurately ing parameters for the desired quenching result
controls water pressure and flow and thus ensures are determined via CFD analysis.
the desired depth and uniformity of the martensitic
structure. A sophisticated automation system is
a key process feature: the quenching head set-up
parameters are managed automatically by the control
system of the upstream austenitising and hardening
furnace.

SMS-Quench® also features devices such as the

quenching lance for internal pipe quenching and the
quenching tank for treating heavy-walled pipes by
complete submersion.

HIGH PERCENTAGE OF MARTENSITE

EVEN IN LOW CARBON STEEL
When treating low carbon steel grades, which are
often used for welded tubes, a considerable and
well directed water flow is necessary from the very
first sprayer module. This is the only way to ensure
a fast transformation and thus a high percentage of
martensite. The results tube manufacturers achieve
with SMS Quenching Head speak for themselves:
the Grossmann quench severity factor, the so called
“H-factor”, is reliably above an index of 2.

99
Tube bright ANNealiNg LiNes

Tube annealing in a protecTive an exit tunnel and an exit purge. Further important
gas atmosphere components are atmosphere analyzing and control
Tube bright annealing lines are used to produce systems.
tubes made of stainless steel, nickel and titanium
In the heating and soaking section the tubes are
alloys (e.g. Inconel). In these lines annealing takes
heated up to more than 1,000 °C and soaked for
place in an oxygen-free, inert atmosphere with high
several minutes. The section consists of an electri-
hydrogen content. The tubes are characterized by
cally or gas heated muffle. A newly developed system
a shiny, reflective appearance and a high corrosion
improves the mesh belt transportation inside the
resistance. Typical areas of application are nuclear
muffle. This system uses ceramic rolls. It increases
and power plants, aerospace industry or chemical
the lifetime of the mesh belt, reduces furnace stops
processes and some other areas where, in addition
for maintenance and last but not least minimizes
to the characterisics of the material itself, high-grade,
surface defects during thermal processing. Especially
reflective surfaces and increased corrosion resist-
the last point is very sensitive to process final
ance are required.
Inconel 690 tubes for nuclear application.
The lines are designed for tubes in a length up to
The heat treatment process takes place in a protec-
30 meters and diameters up to 60 millimeters. Tube
tive atmosphere (pure hydrogen, hydrogen/nitrogen-
thickness is up to 6 millimeters. Three different types
mix or argon depending on the process). At both,
of furnaces can be integrated in these lines: mesh
entry and exit section of the furnace, two heaters
belt furnaces, multi muffle furnaces or roller hearth
are installed to ignite and burn the atmosphere gas
furnaces.
escaping from the tunnel. This is for safety reasons.
Since the mesh belt furnace offers several advan-
CONVECOOL system for high
tages, this type is normally integrated in lines built
speed cooling
by SMS. The main advantage of this furnace is the
The slow cooling section provides a buffer zone
minimal risk of tube defects. This is very important
between furnace and rapid cooling section to
because the tubes are often used for safety relevant
achieve stable pressure distribution. Furthermore, it
parts and subject to intensive quality checks where
is responsible for initial cooling of the belt and work
even minimal failure leads to rejections. Furthermore,
load by means of a water jacket so that the cooling
high and controlled cooling rates can be applied.
in the rapid cool section is alleviated.
Mesh belt furnace with im-
The function of the CONVECOOL rapid cooling sec-
proved mesh belt trans-
tion is to cool down the belt and tube load to their
portation system
final temperature to achieve required mechanical
The line consists of a charging table with fixed rollers
properies. It utilizes the principle of convection cool-
to carry the bundles (set of tubes) to the entry tunnel,
ing with recirculated atmosphere gas. High velocity
a heating, soaking and cooling section as well as
convection impingement allows the cooling down

Exit Purge Charging

Jet Cool Table
Heating Entry
Exit Tunnel Tunnel

100
of the tube temperature rapidly and uniformly from
annealing temperature to below 400 °C. The system
provides the best product quality while at the same
time using less space for cooling than conventional
systems (water jacket cooling).
The system is a single zone unit. The cooled atmo-
sphere gas is discharged at high velocity to impinge
on both top and bottom of the load through a pair of
slot type plenums. The returning gas will be cooled
down by the gas-water exchanger before entering to
the recirculating fan.

Several references worldwide

12 Tube Bright annealing lines delivered
SMS delivered altogether 12 tube bright annealing lines mostly with mesh belt furnaces, but also with roller
hearth furnaces. Most lines have been delivered to customers in Europe (France, Sweden, Germany, Czech
Republic) but there are also references on the Asian continent (China, Turkey). The last two lines were deliver-
ed in 2010 to Vallourec, France. These lines feature mesh belt furnaces, CONVECOOL cooling system and the
improved mesh belt transportation system. Vallourec became world's first supplier to hold NSQ-100 certification
(Nuclear Safety and Quality Management System), which is considered to be the strictest standard of its kind
worldwide.

For Baosteel, China, a tube bright annealing line with mesh The CONVECOOL cooling system reaches high cooling rates
melt furnace was erected in 2009. due to convection cooling with recirculated atmosphere gas.

For safety reasons the escaping atmosphere out of the A mesh melt furnace is the best choice for the production
furnace is burned at entry and exit section. of tubes where surface quality is crucial, which is mandatory
for most bright annealed tubes.

101
HEAT TREATMENT OF BARS

NOT ONLY TUBES REQUIRE HEAT

TREATMENT
Solid bars for numerous different applications need
to be hardened, quenched, tempered or annealed to
improve their mechanical properties. SMS offers a
full range of different heating solutions ranging from
bogie to tunnel furnaces to the more productive
walking beam furnaces, always coupling the com-
bustion expertise with a smooth design of the
complete process line.

102
TOP CUSTOMERS DESERVE
GROUNDBREAKING SOLUTIONS
Working together with the worldwide top players in
special steel production has always been a key to
SMS for being at the avantgarde of innovation.

SMS designed a new heat treatment directly con- controlled sequence, managed by the SMS Controlled
nected to the rolling line, enabling for the first time to Cooling Technology (CCT®) simulation model.
treat bars up to the range of 250 millimeters without
The core of the line is represented by a high-alloyed
stopping the process and saving a large proportion of
skids walking beam furnace, equipped with self-
the heating energy. Stainless, acid and heat resistant
recuperative burners to enhance the energy saving,
steel as well as high-grade structural or tool steel are
and by a tailor made Quenching Head.
produced, each deserving a heating/cooling precisely

103
SMS group GmbH Drever International SA
Processing Lines and Furnace Technology
Allée des Noisetiers 15
Eduard-Schloemann-Strasse 4 4031 Angleur (Liège)
40237 Düsseldorf Belgium
Germany
Phone: +32 4 366-62 62
Phone: +49 211 881-5100 Fax: +32 4 367-76 78

W 7- 320 E · Published on 24- 04-17 · Circulation 1.000 · Printed in Germany · KD

Fax: +49 211 881-4212 info@drever.be
furnace.technology@sms-group.com www.drever.be
www.sms-group.com

SMS group S.p.A. Ares Industrial Furnace (Tianjin) Co., Ltd

Via Udine 103 K1-5-301 Hi-Tech Green Industrial Base, No. 6 of Rd 6th
33017 Tarcento Hi-Tech Development Huayuan Industrial Park
Italy Tianjin 300384
China
Phone: +39 0432 799 253
Fax: +39 0432 792 058 Phone: +86 22 2378-7828
furnaces@sms-group.com Fax: +86 22 2378-3828
www.sms-group.com ares@ares-furnace.com
www.ares-furnace.com

The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics
as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obliga-
tion to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.