Process tuning, taking the rolling process to the next level

News

             In the beginning of 2007 Votorantim Siderurgia, S.A. and Stigelius, S.L. signed a contract for long term collaboration, including the following main tasks for Stigelius:

· Consultancy of Process Control Systems for New Rolling Mills to be installed in the group.

· Improvement of existing Process Control Systems in the group.

Votorantim Siderurgia, long term collaboration

First mill with Votorantim completed successfully

             Complete green field Mini Mill (Unidade Resende, RJ, Brazil - 2007 to 2009) for 1.000.000 tons per year, including layout for a Two Strand Wire Rod Mill for 1.000.000 tons per year.

             The first phase consisted of the installation of a One Strand Morgan Wire Rod Mill, with a capacity of 600.000 tons per year.

             During the project the main activities of Stigelius were:

· Consultancy for the write up of the Request For Quotation.

· Equalization Study for the different proposals from the Bidders.

· Follow up of Basic Engineering, including projects meetings.

· Follow up of Detailed Engineering, including projects meetings.

· Inspection of all manufacturing.

· Follow Up of FAT.

· Follow up of Project Time Schedule.

· Supervision of Electrical Installation.

· Supervision of  Cold Tests.

· Supervision of Hot Tests.

· Supervision of Production.

· Process Tuning.

· Supervision of Performance Tests.

· Training.

Stigelius introduces process tuning at RBM, Celsa Uk

             Process tuning means to optimize the process control system in such away that all different sizes, speeds and set ups will be rolled under optimal performance.

             We have seen that the best results is obtained by spending, as an average, One (1) Week on site per month doing modifications and in between the visits following up is done in close collaboration with Celsa UK maintenance personnel. The IBA, Process Data Acquisition System, is used for detail analyses of the modifications that have been implemented.

             The process tuning project has been active now for about Two (2) years and with excellent results.

             Stuart Thomas, Process Engineer at Celsa UK Rod and Bar Mill confirms: “We have really improved the overall performance of our Mill as a consequence of the Process Tuning done by Stephan and Eive Stigelius. Going into details some of the mayor improvements are:

· Increased yield for Cut Length Optimization System at the Bar Mill, especially for large sizes.

· Improved mill stability, having more control on the head and tail crop length

· Significant reduction in random cobbles, by modifications of the Control System Software.

We will continue the process tuning service as we know we can still improve our performance”

SITREL, next project with Votorantim Siderurgia

             A new Bar Mill, with the capacity of 400.000 tons per year, will be installed in Tres Lagoas, Mato Grosso do Sul, Brazil.

             For this project Stigelius will repeat the same tasks as for the Mini Mill in Unidade Resende, RJ.

Process tuning at Section Mill in Celsa Uk

             The “Process tuning” started on the RBM has been extended to the Section Mill. We are focus on improving the general performance of the mill, introducing new functions, solving existing problems and training.

Improving Unidade Paz del Rio, Votorantim Siderurgia

             Stigelius was contracted to supports the customer in the improvement of the control system for the two strand wire and rod mill.

             The performance was improved well over expectations and the project was selected and presented in the yearly VS Technology Seminar.

GUSA and Stigelius signed a three year contract

             Stigelius will supply technical and inspection services for the installation of a new Combination Mill, delivered by Siemens Industry Inc.

First and very successful assistance at Acindar

             Stigelius was contracted by ArcelorMittal Acindar to analyze the instability of the Main DC Drives in the SBQ Combination Mill. After adjusting the drives and solving problems on the control the instability was eliminated giving an important improvement of the performance.

Stigelius announce a new cooperation business agreement with AIC

             AIC and Stigelius S.L., at the close of AIKW conference last 7th of October, have announced the signing of an important business cooperation agreement.

Thanks to this agreement AIC will rely on technical competence and long-standing expertise of Stigelius company to implement new commercial strategies and to develop new business channels as well as to supply primarily a constant and qualified technical support to the customers all over the world.
This technical & commercial synergy will allow AIC to increase its presence on international markets, particularly the growth and development of AIC American Company, which was opened a few months ago. The remarkable technical expertise and interpersonal skills of the Stigelius consultants will certainly allow a quantum leap in the diffusion of AIC's products & solutions and of service level throughout North and South American market.

 

AIC  is an Italian company focused on industrial automation systems with 35 years of experience in the steel market, references in more than 40 countries all over the world and international sites.

Stigelius S.L. is a consulting company offering unique level of Know how for process control systems for long product Rolling Mills.

Stigelius doing Process Tuning at Acindar

             The first visit for Process Tuning at Acindar's SBQ Combination Mill have been successfully completed, improving the performance of the Wire Rod Outlet. Further visits are already scheduled for the near future.

Inspection Services for Votorantim Siderurgia

             Votorantim Siderurgia selected Stigelius for the Inspection and Follow Up services during themanufacturing of the new Cold Rolling Line to be installed at their plant in Resende, RJ, Brazil.

Stigelius followed the manufacturing at the installations of Eurolls in Italy and the equipment was shipped on time, as per project schedule.

Consultancy for Gerdau Cosigua, RJ, Brazil

             Gerdau Cosigua contracted Stigelius for Consultancy Services related to the Electrical and Automation Equipment for their new Wire Rod Mill, being their Rolling Mill Nº 4.

Stigelius introducing process tuning at Celsa 3

             During 2011 we visit Celsa 3 in Barcelona three times to introduce our process tuning and assist the production department improving the knowledge and performance of their mill operators. We also assist them on improving their control plan. On 2012 we will continue to assist them on this process of continuous improving.

First visit of Stigelius at Gerdau Knoxville

             Stigelius successfully introduced their new functions to improve their performance and trained their production team to give them a better understanding of the control process that will help them to get a more stable mill.

Revisiting Gerdau Rancho Cucamonga

             Tamco Steel is now part of the Gerdau group and we revisit them to introduce our new functions developed during the last two years and to train the production and electrical teams.

Assistance at CMC Zawiercie

             Stigelius assisted CMC on improving the performance of the tail control on the laying head pinch roll at high speed, analyze the problems with the front end orientation and improve the loop control.