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The leading choice for advertising within the international steel industry

M e d i a i n f o r M at i o n 2 0 1 3

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Message from the editor

Editorial statement:Steel Times International shows a total commitment to its editorial integrity by:tnever accepting editorial in return for advertisingtnever printing marketing as editorialtalways editing submitted articles in accordance with its basic principle of impartiality and objectivity

Steel Times International is committed to bringing its readers the latest technological, market & company developments in the steel industry via feature articles including:tSteel-focused articles from industry and academiat in-house authored articles based on contacts with & visits to the leading companies in the fieldtarticles on iron & steel manufacturing processes, company news statistics & conference reports

To subscribe to Steel Times International, please contact:tel: +44 (0)1737 855028 | email: [email protected] | Web: www.steeltimesint.com/subscriptionsUK £155 • Overseas £222 • €269 • US$342 • Single issue £35

Emphasis is placed on iron and steel making issues from all around the world.


Steel times international is an english language journal. it contains a digest of global news, events and statistics, as well as more detailed technical articles, company and country profiles, conference reports and regular regional briefings covering USa, China, Japan, Latin america and india.

edited by dr tim Smith, a metallurgist with over 40 years of experience in the ferrous and non-ferrous industries, Steel Times International publishes eight times a year. It can trace its pedigree back to 1866 when it published as ‘The Iron and Coal Trades Review’ and subsequently as ‘Steel & Coal’ before merging with its sister publication ‘Steel Times’ in 2001.

the target readership are managers and Ceos in the steel industry, but it is also widely read by stockholders, members of research organisations, technical consultants, business consultants, economists and financiers.

in addition to its regular eight issues a year it publishes technical supplements and foreign language supplements in Chinese, russian, and Spanish for distribution in the appropriate regions, the latter in Latin america.

the Chinese language issue is translated by industrial and academic personnel in China familiar with the steel industry. it is circulated by the Metallurgical Council of China, Council for the Promotion of international trade (MC-CCPit) and is also taken to various exhibitions within China.

the russian language edition is published to coincide with distribution at the two major shows in Moscow, Litmash and Metal expo, as well as being distributed by our agent in Moscow. translation is by personnel familiar with the steel industry.

in addition, the Steel times international website at www.steeltimesint.com provides news and events updated on a regular basis and a selection of technical articles as well as details about the magazine as a downloadable media pack. for paid subscribers, a pdf version of the magazine is available on application.

For a specimen sample visit www.steeltimesint.com and click on ‘Sample Copy’ at the top of the page.

Dr Tim Smitheditor – Steel times [email protected]

6000 copies of each issue are circulated worldwide to a combination of subscribers and targeted readers of which:59% are primary iron & Steel manufacturers9% are secondary iron & Steel processors9% are Plant & equipment suppliers6% are Stockists and traders4% are non-ferrous metal manufacturers4% are end-users of steel, and7% are ‘Others’ eg financial, consultants, universities and R&D

The Geographic distribution is:45% europe24% north america17% asia6% Latin & South america8% rest of World.

Editorial Features List

Foreign Language Issues

Month Features DatesKey Events For Distribution

January/ February

Handling & Scheduling Ladle & slab carriers; cranes; identification; bundling & strapping; fork lifts; scheduling software Analysis & Testing Mechanical testing; non-destructive testing; spectrographic analysis; infra-red imaging; sample preparation; Sample tracking and reporting Conference reportsMetal expo MoscowSteel Success Strategies (europe)

editorial copy date: 16/11/2012 advertising copy date: 19/12/2012

CrU World Steel

March Continuous CastingSlab, billet & thin slab casters; metal level control; electromagnetic stirrers & brakes; mould powders; water spray cooling; bearings; caster maintenance; cut off machines; shearsFurnacesreheat; heat treatment; continuous annealing; furnace control; burners; emissionsConference reportsJSi Paris; adam Smith CiS Summit,


eurocoke Summit

April Electric Steelmakingelectric arc furnaces, scrap, dri & pig charging; burners; control; electrodes; refractories; gunning; flue gas analysis; water panels; power supply; transformersEnvironmentenergy use; Co2 emissions; dust collection; analysis; recycling; water treatmentConference/Expo reportsCrU World Steel; arab iron & Steel Union


aiStech Pittsburgh

May/June Steel Marketsautomotive, Heavy transport, Construction, Packaging, domestic appliancess, Yellow goods (JCBs etc), Shipbuilding, energy (power plant & wind turbines)AutomationLevel 0 – 4 control; PLCs; scheduling; software models; hardware


July/August Steel ProcessingService Centre equipment eg slitters; cut-to-length; pickling; levellers; toll servicesOxygen SteelmakingBasic oxygen steelmaking plant, on-line analysis; ferro alloys, scrap; secondary metallurgy, pretreatments eg de Sulphurisation & Phosphorus removalConference reportaiStech


September Rollingflat and long rolling: mills; shape control; rollsSpecial & Stainless Steelstool, high alloy; wear resistant; stainless steel; powder met; ferro-alloysConference reportSteel Success Strategies (new York)iaBr (Brasil) & MB & duluth ore Conference


CrU north american steel Chicago

World Steel assn

October IronmakingBlast furnace; direct reduction shaft; dr rotary; direct smelting; control; charge; sinter lines; emission control; energy; tuyere injectantsSafety & TrainingSafety equipment – protective clothing, gas monitors; ear & eye protectors; safety training programmes; on-job training; simulation


November/ December

Minimillseaf based long and thin slab caster mills; continuous casting; rolling; scrap, dri & pig charging; controlCoatingContinuous strip coating; galvanising; priming; painting; strip weldingConference reportCrU north americaIndex for 2013


JSi Paris

Issue Month Advertising copy deadline Key Events For DistributionChinese april 7 february 2013 CiSa & MC-CCPit shows

Chinese august 21 June 2013 CiSa & MC-CCPit showsRussian May 29 January 2013 adam Smith CiS

LitmashRussian September 15 May 2013 Metal expo Spanish october 15 July 2013 alacero (ex iLafa)

Annual Buyers’ Guide & Directory 2013 21 february 2013

Readership and circulation

Geographical breakdown of circulationteurope 45% tnorth america 24%tSouth east asia 17%tLatin america 6%tafrica 2%tMiddle east 1% toceana 1%tCaribbean 1%Average net circulation: 6,000 Average readership: 30,000

Readership breakdowntCeo 17% tdirector 43%texecutive 9%tManager 29%tSpecialist 2%

PLUS additional circulation of the foreign language editions:Chinese issue 5,000russian issue 6,000Spanish issue 1,50045%

24%

17%

6%

2%

1%

1%

1%

tTraditional or online the ability to maintain the traditional route to market through the printed issue or the option to utilise a number of online opportunities

tBonus distribution Bonus distribution at key industry events ensures your advertising message is exposed to even more potential prospects.

tDecision makers exposure to a large number of decision makers across the industry

tRespected in the market respected editorial and industry-leading contributors mean articles will be read alongside your advertisements

tFocused advertising Controlled advertising means that Steel times international is not deluged with vast numbers of advertisements. readers take a keener interest in the focused adverts we present to them

Reasons to advertiseFor advertisers, the Steel Times International portfolio offers an attractive mix of print and online options:

58 – May/June 2011 – Steel Times International

Furnaces

CSM as the first step towards a regenerative

flameless solution. The TRG burner is

equipped with an internal honeycomb regener-

ator which can preheat the combustion air up to

1000°C due to both its high thermal capacity

and large specific surface area.

TRG burners work in pairs with typical cycle

times of 30-40 seconds and are controlled by

automatic valves installed in the combustion air

and the flue gas ducts. Operation is:

– the first burner intakes hot flue gases

(T=1300°C) from the combustion chamber

through the cold ceramic honeycomb which

raises the honeycomb to 1200°C. Flue gases

are exhausted at 150-200°C. The gas valve

and combustion air valve are shut off.

– The second burner pair is fed with cold com-

bustion air which passes through its regener-

ator heated in the previous cycle, which rais-

es the air temperature to 1000°C. Flue gases

valves are shut off.

TRG burners are characterised by relative

high NOx emissions (~70ppm) due to the high

combustion air temperature. Some reference

data of this burner are given in Table 1 for the

combustion of natural gas.

In a furnace equipped with regenerative

burners there is no need to have a centralised

device for preheating combustion air as this is

performed by means of the regenerators

installed internally or externally on each burner.

A key component of the burner is the regener-

ator.

Two types of regenerators are mainly used on

the burners for the steel industry:

– Honeycomb regenerators; and

– Ceramic ball regenerators.

The differences of these two are not only

related to the shape of the regenerator media,

but also to the chemical composition of the

material and to the requirements for use.

It is necessary to select the best solution of

the form of the regenerator according to the

type of furnace, the type of fuel, the furnace

atmosphere, etc. For this reason Tenova uses

both types for its regenerative burners.

FlexyTech Flameless Regenerative

burnersThe TRGX burner was realised in 2006 when

Tenova decided to integrate flameless technolo-

gy with regenerative combustion to obtain a

burner which is able to guarantee reduction of

both emissions and energy consumption.

The TRGX FlexyTech Flameless

Regenerative burners represent the latest gen-

eration of regenerative burners; they can work

both in flame mode (for cold ignition) and

flameless mode (for best performance in term

of lowering NOx emissions). Thanks to cou-

pled gas and air staging, when working in

flameless mode, NOx emissions are brought

down to 35-40ppm.

Honeycomb regenerators allow a very high

preheating efficiency due to both their high

thermal capacity and high specific surface area

while keeping a very compact geometry. In con-

trast, ball regenerators use alumina balls which

provide better access and easier cleaning of the

regenerative media. Therefore the ball solution

is more suitable when the furnace atmosphere

is particularly dirty which would obstruct the

honeycomb channels after a short period of

operation. But the option using balls makes for

a much bulkier and heavier regenerator than

the honeycomb.As with all regenerative burners, the TRGX

burners work in pairs: when one is firing and

ture of 450°C. The TSN burner capability

includes both a cold start up function (ie with

pilot flame) and low NOx operation (with high

impulse jet). Its geometry was developed in a

way to delay as long as possible the mixing of

fuel and air. In this way the products of com-

bustion can dilute the O2 available in the com-

bustion air, reducing the temperature peak gen-

erated in traditional burners. The experience

obtained with TSN allowed Tenova to start the

new and more ambitious TSX project in 2004

with the aim of developing a natural gas side

burner with the following characteristics:

– NOx emissions below 40ppm at 3% O2 in

dry flue gases;

– Ultra-low CO emissions (below 5ppm);

– No valves on hot air for air staging;

– Least excess air operation for maximum fuel

efficiency;– NOx emissions not affected by air tempera-

ture;– NOx emissions independent of turn-down;

– Air preheating up to 550°C.

Flameless technology was the basis of TSX

burner development and it has been successful-

ly employed in association with highly preheat-

ed combustion air while maintaining low NOx

values, adding exceptional heat transfer unifor-

mity as well as relevant improvements in the

uniformity of the charge temperature.

All of the TSX project goals were reached

through extensive CFD modelling and industri-

al tests. Several thousand Tenova FlexyTech

flameless burners are now installed on reheat-

ing and heat treatment furnaces across the

world.

Regenerative burners

The development of the TRG regenerative

burner was started in 1999 in cooperation with

Fig 2 (Left) Roadmap for Tenova FlexyTech combustion technologyFig 3 Development timeline for Tenova FlexyTech® burners

Fig 5 A pair of TRGX burner prototypes (1.5MW each) working in

flame (left) and flameless mode (right)

Fig 4 Velocity fields in the FlexyTech TRGX CFD model

TS TSN TSX TRX TLX

TRGX

TRG

Flame

RegenerativeFlame

RegenerativeFlame & Flameless

Dilutedflame

Flame &Flameless

Flame &Flameless

20022003

2006

2004-2005 2005-2006

Flame &Flameless

OngoingR&D

Projects

OngoingR&D

Projects

129122116110103979084777164585245393226191360

TENOVA FLEX2_Layout 1 5/23/11 12:38 PM Page 2


Company profile

MMK invited Steel Times International tovisit its works in Magnitogorsk to see theresults of its $5bn investment over thepast five years which includes a 5m wideplate mill, a new caster, a cold mill com-plex including galvanising and colourcoating line and improved environmentalprotection. An additional $2.1bn hasbeen invested in a new mill in Turkey tosupply the Middle East market and$0.5bn in the Belon coal mine. By Alex Gurov*

100% of the scrap needs of the Group).Minerals complete the picture with Belon (a4.2Mt/y coal mine), Prioskolsky GOK (workinga 2bnt iron ore deposit over the next 50 years tomeet MMK’s steel production needs) andMMK has a long-term agreement with iron oresupplier ENRC of Kazakhstan to cover 70% ofits needs until 2017. The MMK Group's revenue in 2010 totalledUS$7.719bn, EBITDA was $1.606bn, and theprofit for the period $232M. Investments in 2010MMK’s dynamic growth stems from the contin-uing modernisation of the its production assets,adoption of its technology, implementation ofmany promising projects and integration intothe global economy.MKK’s investment strategy is for a ‘high-return from high-quality projects’ and it usesequipment from world leading engineeringcompanies, including SMS Siemag, Danieli,Fata Hunter, Fives Stein and others. MMK’slong-term modernisation programme is aimedat satisfying the growing demand and require-ments of Russian customers and raising thelevel of production of value added products.About $5bn of investment has been spent onthis over the past five years at the Magnitogorsksite plus $2.1bn at a new mill in Turkey and$0.5bn to upgrade the Belon coal mine.

Wide PlatePlate Mill 5000 and Continuous Caster No6are currently the key investment projects to

grow the company’s presence in the domesticmarket. A contract for the supply of equipmentwas signed with SMS Siemag in November2006 and the Mill was put on stream in July2009. The mill is designed to produce heavy-gaugeplate of strength class up to X120 and up to4800mm wide for oil and gas pipelines andshipbuilding and bridge building. Mill 5000 produces about 1.5Mt/y, including0.3Mt/y of heat treated plate. In 2010 the millreached full capacity and currently runs at100% utilisation rate. Plate is supplied toChelyabinsk (ChTPZ), Volzhsky (TMK) andVyksa (OMK) pipe plants with about equal vol-umes of 110kt per month to make large diame-ter line-pipe for such applications as Gazprom’soil and gas pipeline projects. MMK’s plates account for about 43% of totalRussia needs for large diameter pipe producerswhich is currently about 50kt per month.Another large-scale investment project near-ing finalisation is a new cold rolling complex(Mill 2000) supplied by SMS Siemag as aturnkey project.

This 2Mt/y facility will turn out high-strengthsteels for manufacturing exposed and internalautomobile parts, household appliances andconstruction materials. The rolling mill and pickling line will be com-missioned in July 2011, while full-cycle produc-tion at the facility will be commissioned by mid-2012. The old Hot Strip Mill 2500 is also beingrevamped.

THE birth of the MMK Works took place on 1of February 1932 when the first tap of pig ironfrom blast furnace N1 was carried out. Twoyears later rolling mill ‘500’ started up – a500mm wide blooming/plate mill which workeduntil 2006 during which time it rolled 54Mt ofproduct – giving rise to the legendary integrat-ed Russian steel works ‘Magnitka’ and, along-side it the city of Magnitogorsk grew. Today, mill500 has gone to the SMS museum in Germanywhile two stands from mills 300 and 250replaced in 2005 by wider modern mills fromDanieli stand as industrial sculptures in the cityof Magnitogorsk.

Russian steel leaderMagnitogorsk Iron and Steel Works today ranksamong the world’s largest steelmakers.Producing 11.4Mt of crude steel in 2010,MMK is one of Russia’s largest fully integratedsteel producers occupying about 120km2 ofland. At Q1 2011 MMK produced 17.7% of thesteel products sold on the Russian market. In2010 MMK’s share of this market averaged17.3%, with the next closest Russian steel com-panies, Severstal and NLMK taking 17% and15%, respectively.MMK is the number one producer in thedomestic market of hot rolled steel (37%), gal-vanized flat products (27%) and tin plate(100%). It ranks second for rolled sections(47%) and third for cold-rolled strip (22%) andcolour coated flat products (25%).Historically, the bulk of MMK’s productshave been sold to customers in the Urals (37%)and the Volga Regions (30%) which todayaccount for two thirds of MMK’s sales. MMK’skey domestic customers have traditionally beenpipe makers (37% of all domestic sales in2010), machine builders (13%), construction(11%) and metalware producers (10%).MKK’s success largely became possiblethanks to the adoption of many high-marginproducts to meet domestic demand, includingthose which replaced imports. The share ofvalue-added products in 2010 was 38% (up 7%on 2009).

The company’s products are sold to 60 coun-tries worldwide. In 2010 exports were 3.2Mt or31.2% of total shipments of which hot rolledsteel accounted for 79%. MMK’s traditional keymarkets are the Middle East (about 15% of totalproduction), Asia (6%) and Europe (but exportsto Europe incur $50-60/t in transport costs.The MMK Group includes the MMK Iron &Steelworks, MMK-Atakas (Turkey), MMKMetiz (a hardware producer making 450kt in2010), Intercos-IV (a metals service centre in StPetersburg) and Profit (a company supplying

MMK – The revival of a legendary Russian works in Magnitogorsk

*Steel Times International, Moscow

Magnitogorsk Iron and Steel Works ranks among the world's largest steel producers

producing 11.4Mt of crude steel in 2010

MMK Group production figures in 2010– Crude steel reached 11.419Mt, 19% higher y-o-y. – Finished steel products amounted to 10.4Mt (+18%). – The share of higher value-added products (HVA) of the MMK Group grew to 38% (compared to

31% in 2009) and in Q4 2010 it reached an historical level of 42%. – Production of iron ore for its own needs amounted to 4.680Mt (+18%).

MMK_Layout 1 5/10/11 2:33 PM Page 1


Ironmaking

Coal based DRI quality and raw materials:

Experiences at Bhushan Steel

reductant at its works in the state of Orissa,

India. The plant and machinery has been sup-

plied by the former Lurgi company of Germany

(this SLRN technology now being owned by

Outotec of Finland). Similar to other coal

based DRI plants, Bhushan controls its process

performance and product quality by controlling

the input materials. This paper summarises

observations regarding the dependence of DRI

quality on the physical characteristics of the

input materials.The monthly plant data was analysed to see

the influence of ore and coal quality parameters

on the quality of DRI produced.

Raw Materials The raw materials required for coal based DRI

production are iron ore and non-coking coal

and dolomite for sulphur capture.

Iron OreThe DR process involves the removal of oxygen

in the solid state thus concentrating any impu-

rities in the oxide (ore) feed. DRI containing a

high level of gangue has adverse effects during

subsequent melting in electric furnaces by

affecting flux power and increasing refractory

consumption during steelmaking. High gangue

in the DRI also results in increased slag vol-

umes, poses handling problem and adversely

affects furnace productivity. Hence the gangue

content of ore should be minimal and the iron

content as high as possible. The process

requires adequate reducibility and resistance to

degradation during reduction. Hence the pre-

ferred iron ore is haematite with a Fe content of

62-66% and having low gangue and decrepitat-

ing characteristics. Size is an important charac-

teristic as this determines the retention time for

complete reduction of a particular ore feed.

During the early days of operations at

Bhushan the iron ore was washed in a scrubber

and sized to 5-20mm for use. Presently thanks

to a better understanding of the process, it has

become standard practice to use +5 to

+18mm ore size as feed and the scrubbing to

wash the ore has been suspended.

CoalNon-coking coal is used both as reductant and

BHUSHAN Steel is operating eight DRI kilns

using coal as the reductant to feed its EAF, IF

and Conarc units on site. The plant has made

remarkable improvements as regards to DRI

quality since its start-up in 2006. The perform-

ance of the kilns has been improved by optimis-

ing the ore and coal size feed. The dependence of conventional blast fur-

nace ironmaking on metallurgical coke and

scarce availability of the required grade of coal

for coke production in India makes it necessary

to search for alternative ironmaking technolo-

gies. Thus direct reduction has increasingly

become an important means of iron production

in the world with over 60Mt produced in 2010

or 6.6% of output of world iron. In this process, reduction is carried out below

the melting point of the iron and gangue mate-

rials using gas or coal as the reducing agent. The

products from such processes are called Direct

Reduced Iron (DRI) or sponge iron after its

porous appearance. The DRI retains the origi-

nal external shape of the lump ore or pellet

charged. Reduction decreases the weight by approxi-

mately 30% due to the removal of oxygen and

the apparent density of the sponge is in the

order of 4.4g/cc compared with 7.8gm/cc for

solid iron. The pores occupy about 54% of the

volume. Coal produced DRI contains up to

about 90% metallic iron, typically 1-4% carbon

along with any gangue from the ore consisting

mainly of alumina and silica. Bhushan Steel is operating eight DRI rotat-

ing kilns each of 500t/day capacity using coal as

The particle size of the ore and coal are

the most important parameters in the

quality of DRI produced in a coal fired

DRI kiln although the LOI is also impor-

tant as this loss improves the reducibility

of the ore by making it more porous. The

iron content of the ore is less important

although a high gangue content or high

ash content of the coal is undesirable

because of the additional energy penalty

is causes in both DRI production and

subsequent melting to produce steel.

By U S Yadav,* Ajay Jha** and

A K Verma***

*Asst Vice President, **Deputy General Manager, ***Chief Operating Officer, Bhushan Steel Ltd Angul, Orissa, India

Bhushan Steel is operating eight coal fired DRI kilns each of 500t/day capacity

Met

allis

atio

n,

%

Met

allis

atio

n,

%

FeO

,%

Fig 1 Inter relation between FeO content in

DRI and metallisation

Fig 3 Influence of iron content on FeO

content of DRIFig 2 Influence of iron content in ore on

metallisation

yadi coal_Layout 1 5/24/11 9:48 AM Page 1


USA Update

Sales of plate are rising rapidly in USAlargely due to increased demand fromrail car manufacturers following a growing number of rail freightmovements as the US pulls further out of recession. By Manik Mehta, New York

of steel plate rose to as high as $1080 per shortton at one point. Contrary to the expectations of some indus-try pundits, who had thought that the risingcurve in prices of steel plate would halt andthen decline, demand in the railcar industry hastriggered a sharp rise in prices which would alsokeep the order books of suppliers full, at least,in the short term.

The latest report by the Association ofAmerican Railroads, the trade organisation of

THE economic recovery combined with risingdomestic shipments of all kinds of productsthrough the rail mode of transportation, is pos-itively impacting demand for certain steel sup-plies. As demand for freight railcars grows, theneed for steel to manufacture railcars alsogrows. Experts say between 18 and 20 tons ofsteel, mostly plate, are required for each railcar.Industry analysts maintain that the freightrailcar market has buoyed the US plate demandbut has also led to price increases. Indeed, therailcar industry is emerging as one of the majorsteel plate consuming industry segments. Prices

the US freight railway industry, reported thatthere was a 7.9% increase in freight carload vol-ume – this excluded grain and coal – to 4.6 mil-lion rail cars in the first quarter of the year,compared to the previous-year period. This isan extension of the rise in demand that startedin the final quarter of last year and continuedinto 2011. This trend also marks a reversal of the rail-road industry’s fortunes. The 2010 fiscal yearbrought in change for the railroad industry after

Steel industry to benefit fromdemand for freight railcars

A 7.9% increase in freight carload volume is buoying US plate demand for new railcars

USA copy_Layout 1 5/10/11 10:19 AM Page 1


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SPECIAL POSITIONS front CoVer SPonSorSHiP £4,000 inSide front CoVer £3,804

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Web AdvertisingThe Steel Times International website is an invaluable resource for visitors and offers a range of flexible advertising options to match a range of budgets and to help advertisers achieve their desired level of exposure within the market.ta simple but dynamic method of generating new sales enquiriestreach more than 24,000 visitors*tMeasureable results that enable you to analyse the success of your campaigns* Source: Google Analytics, September 2011 - September 2012

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Weekly newsletterthe newsletter contains a round-up of the top news stories posted on our website that week. it is widely read by steel professionals across the globe.

Reprintsreprints of editorial articles and features are a cost-effective form of product marketing and can be used in direct mailand at trade exhibitions, they can be tailored to your precise requirements at no additional cost.For more information contact: Esme Horn, Tel: +44 1737 855136, Email: [email protected]

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Contact UsSalesPaul Rossage international Sales Manager +44 (0) 1737 855116 [email protected] Anne Considine area Sales Manager +44 (0) 1737 855139 [email protected] Ken Clark Group Sales director +44 (0) 1737 855117 [email protected]

EditorialTim Smith PhD editor, Ceng, MiM +44 (0) 1737 855154 [email protected] Annie Baker Production executive +44 (0) 1737 855130 [email protected] Martin Lawrence advertisement Production +44 (0) 1737 855042 [email protected]

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The leading choice for advertising within the international steel … · for advertising within the international steel industry ... from all around the world. ... 6% are Stockists