STEELMAKING

New standards in productivity, quality and efficiency

SMS CONCAST
A technology powerhouse

Expertise and experience, reliability and flexibility

these are the hallmarks of SMS Concast. This
leading supplier of electric steelmaking and casting
technology helps customers worldwide achieve a
competitive edge in their markets. SMS Concast
offers high-performance plant and machinery for
steelmaking, secondary metallurgy and continuous
casting.

To perform well in areas such as consulting,

engineering, commissioning and service, our
employees offer a combination of both outstanding
expertise and flexibility. Thats why SMS Concast
solutions deliver such excellent benefits for their
customers.

SETTING BENCHMARKS WITH

EXPERIENCE
Since 1954, SMS Concast has supplied more
continuous casting installations than anyone else in
the industry. Over the years, it has designed a great
range of innovative products that improve the
steelmaking process.

INTEGRATED SOLUTIONS
SMS Concast belongs to the SMS group and is part
of the SMS Meer business area. Together,
SMSConcast and SMS Meer are able to better
serve the growing demand for state-of-the-art
minimills. The two companies turned the idea of an
integrated plant with an electric arc furnace (EAF)
and rolling mill into reality.

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MEMBER of the SMS GROUP
Strong, successful, together

The SMS group is among the leading plant and machinery construction companies for steel, aluminum and
non-ferrous metal processing. It comprises two business areas: SMS Siemag and SMS Meer.

SMS Siemag SMS Meer

SMS Siemag has more than 100 years experi-
ence in reduction processes. Additionally, it is a
leader in steelmaking and secondary metallurgy
technology. SMSSiemags extensive portfolio
also includes continuous casting, CSP technol-
ogy, hot and cold rolling mills, strip processing
plants, and aluminum plants. The high-quality
steel products of SMS Siemag start with thin,
medium and thick slabs. SMS Siemags products
are used in the steel, aluminum and non-ferrous
metal industry worldwide.
SMS Meer is a leading supplier of plant and
machinery for steelmaking, tubes, long products,
forging and heating technology. Its solutions
provide customers with tangible benefits in
challenging markets: steel for tire cord, tubes for
pipelines, heavy structural profiles, wheels for
high-speed trains, and aluminum for use in
skyscrapers and offshore wind turbines.
Within the SMS Meer business area, SMSConcast
is the specialist in long product steelmaking.

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Setting benchmarks
worldwide
The competency center for long product steelmaking
SMS Concast is the SMS groups competency
center for long product steelmaking and continuous
casting. The company has extensive experience in
this field and caters for the full range of long prod-
uct steelmaking systems.
OUTSTANDING EAF PERFORMANCE:
THE KEY TO SUCCESS
Ever since the first EAF was commissioned in 1997,
SMS Concast has been setting new benchmarks
with EAF installations worldwide. As the first step
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in the process chain, an EAFs performance is vital
to ensuring product quality and cost efficiency
across the entire process. SMS Concasts EAFs
achieve top results, as the steelmaking specialists
pay attention to every last detail: mechanical de-
sign, process and safety tools, power input control,
emission control and automation are all technologi-
cally advanced and tried and tested.
WELL-CONNECTED PROCESS CHAIN
SMS Concast employees focus on the entire
production process, from raw materials to end
products such as semi-finished goods or made-to-
measure rolled or forged products. Whatever the
business partner has in mind, SMS Concasts long
product specialists tailor all components exactly to
their individual requirements.
LEADER IN MINIMILL TECHNOLOGY
Working in close collaboration with SMS Meer and
SMS Elotherm, SMS Concast sets extremely high stan-
dards when it comes to minimills. There are excellent
examples of this across the globe, including the worlds
most productive minimill in Columbia City, USA.
CMTTM (Continuous Mill Technology) takes the basic
minimill concept one step further: the SMSMinimill
Team has developed a process that coordinates
continuous casting and rolling, achieving new levels
of efficiency. For example, by linking the rolling mill
directly with the steelworks, minimills can operate
without CO2-intensive heating furnaces between
the caster and rolling mill. Instead of oil or gas-fired
furnaces, an inductive heating system is used. It
does not reheat the billets, but simply evens out
their temperature profile. The elimination of the
heating process leads to a significant reduction in
energy costs and environmental pollution.
RAW MATERIALS
Solutions for all metallic input materials

The modern steelmaking industry processes a wide the DRI/HBI together with lime, dolomite lime and
range of raw materials containing iron. SMSConcast carbon, as well as the correct shell design and
provides EAF solutions for all types of metallic optimized power-input. A fully integrated automation
input materials. system controls the operational sequences.

SCRAP REMAINS THE MAIN HOT METAL IS AN ENERGY-

METALLIC CHARGE MATERIAL
Whereas in the past, a two-bucket operation was
usually required to process scrap, SMS Concast
successfully implemented single-bucket operated
EAFs. Single-bucket charging minimizes downtime
and allows for higher energy input rates thanks to
the optimized diameter/height ratio of the shell.
DRI AND HBI ARE BECOMING
IMPORTANT
In the past few years, DRI and HBI have been used
as metallic charge material for minimills increasingly
often. Depending on the percentage of DRI in the
charge, SMS Concast employs either batch charging
using the bucket together with scrap, or continuous
charging through the furnace roof. Continuous
charging DRI requires a dedicated set-up for feeding
EFFICIENT CHARGE MATERIAL
Hot metal charging reduces electricity consumption
by using the chemical and thermal energy con-
tained in the raw liquid iron. The CONSO oxygen
technology system ensures the best possible
decarburization rates, with high oxygen utilization.
A special liquid iron charging system guarantees
operational safety combined with reliable process
control throughout the entire charging process.
HANDLING OF ALLOYS AND
SLAG BUILDERS
SMS Concasts state-of-the-art EAF features a fully
automated charging system. Additional equipment
is ready to be used at the charging location when-
ever it is needed. Feeding and conveying processes
are adapted to the type of aggregate.

BENEFITS AT A GLANCE

Flexibility for processing a wide range of

metallic charge material
Single-bucket charging concept for minimal
downtime
Energy-efficient CONSO oxygen technology
Reduced energy consumption through
liquid iron charging concept
Reproducible high-quality steel thanks to
fully automated handling of alloy additions
and slag builders

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OPTIMALLY INTEGRATED:
TWIN EAFS AT TIANJIN
The EAFs at Tianjin Iron & Steel Company in
China are the first ever example of two
identical, optimally designed production
chains. This well-engineered melt shop layout
is synonymous with high quality at extremely
competitive manufacturing costs. By purchas-
ing all its components from SMS Concast,
Tianjin did not only enjoy state-of-the-art
plant and machinery, they also experienced
trouble-free assembly, commissioning and
day-to-day operation. Recognizing the
benefits of the concept, Tianjin did not just
order a single melt shop the Chinese
company decided to set up two plants with
the help of SMS Concast.
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Both EAFs have a tapping weight of 110 tons
and are equipped with CONSO burners, with
6 x 6 MW per furnace. They each produce up
to 1.15 million tons of high-grade or high-car-
bon steel per year. Charging with up to 40%
hot metal ensures the production process is
flexible and easy to manage. Even the results
of the first heat exceeded Tianjins expecta-
tions. With the establishment of the two
plants, Tianjin and SMS Concast have taken
their 20-year partnership to the next level:
around one month after commissioning the
second melt shop, the two companies signed an
agreement for the supply of spare and wear parts
a real win-win situation for both partners.
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ELECTRIC ARC FURNACE
Optimum efficiency in both energy and
material consumption
EAFs by SMS Concast set new standards in produc-
tivity, product quality, and also energy and material
efficiency. State-of-the-art processes and techniques
enable precise steel analysis during the melting
process.
MAXIMUM FLEXIBILITY FOR ALL
CHARGING MATERIALS
SMS Concast tailors each EAF exactly to its opera-
tors individual needs. The furnaces can be charged
with a variety of source materials: scrap metal,
sponge iron, HBI, DRI, or up to 50% liquid iron (some-
times even 100%). This ensures maximum flexibility
for plant operators.
ULTRA-HIGH CHEMICAL POWER (UHCP)
SMS Concasts UHCP concept offers a wide range of
benefits, including greater efficiency, optimized use
of chemical energy and reduced maintenance
requirements. Because the EAFs are larger, the
concept also increases productivity. The UHCP EAF
supplied by SMS Concast to ICDAS in Turkey is a
particularly good example: with a productivity of
320 tons per hour, it offers outstanding performance.
Special design features ensure a high-power input of
230 MW, enabling ICDAS to produce 2.2 million tons
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of high-quality steel products each year a truly
outstanding result.
SMS Concasts EAF design comes with features
including full-platform tilting, a split shell, water-
cooled panels in steel and copper, a three-point
roof lifting system, conductive electrode arms and
electrode regulation. Melt shop operators therefore
benefit from extremely high power-input rates, low
operating costs and the most efficient use of
energy and raw materials.
BENEFITS AT A GLANCE
High-quality products guaranteed
Energy-efficient with CONSO technology
Maximum flexibility for all types of charging
materials
Reduced manufacturing costs thanks to
tailored EAF concepts
Complete customization depending on the
plant operators needs
PROCESS TOOLS
Achieving the highest standards of quality

Thanks to cutting-edge extraction and recovery

technology, SMS Concasts EAFs meet the most
stringent environmental regulations and make a
significant contribution to improving resource
efficiency in steel production. Plant operators
benefit from various tools, including CONSO
technology and the fully automatic slag door
CONDOOR.

INCREASED PRODUCTIVITY,
REDUCED PRODUCTION COSTS
CONSO oxygen technology is a key feature of a
cost-efficient melting process. It combines a gas
burner with supersonic oxygen injection in one
device. The technology significantly increases
productivity while reducing production costs. The
injectors are installed in the EAF side wall or in the
horizontal EBT panel. The burner capacity reaches
up to 8 MW, and the oxygen injection capacity up
to 4,500 Nm3/h per unit. It is also possible to inject
carbon and lime through side wall lances. The
burners are individually controlled, fully automatic,
and linked with electrode regulation and foaming
slag control.

THE NEWLY DEVELOPED

CONDOOR SYSTEM
The CONDOOR system for automated cleaning of
the sill-breast area enables closed-door operation. BENEFITS AT A GLANCE
It provides reliable access for automatic sampling
and managing the temperature gauge. With this More efficient production
highly dependable and productive tool, SMSConcast Level 2 control systems for documenta-
guarantees the highest standards of quality, tion and analysis
reduced material and energy consumption, as well Reduced material and energy consumption
as greater yield. Last but certainly not least, it also Increased metallic yield
ensures maximum operator safety. More efficient use of electricity and
chemical energy
The level 2 control system enables companies Greater environmental protection through
to optimize processes by defining individual reduced emissions
process steps, operating documentation and
analysis tools.

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ENVIRONMENTal Protection
Because it matters
All components supplied by SMS Concast are
designed to ensure high levels of productivity and
quality with minimal material and energy consump-
tion. For plant operators, this delivers both ecological
and economic benefits in other words, they help
companies save money and protect the environment
at the same time.
SMS Concast is focused on continuous improve-
ment in steelmaking. The company pays great
attention to its research and development activities,
ensuring in-house knowledge of and expertise in the
latest eco-friendly technology.
REDUCED EMISSIONS
One key environmentally friendly technology is the
Dust Emission Control (DEC) system featured in the
EAF. SMS Concast offers comprehensive solutions
for dust emission control in melt shops:
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Primary off-gas systems with high temperature
quenching or hairpin cooler
Hot cooling system in the primary off-gas system
for heat recovery
Filter units with pulse-jet bag filters to ensure
minimum dust content in clean gas
Dust treatment systems
Noise Emission Control (NEC) is another key factor
in the set-up of an EAF. Either a dog house or
elephant house solution can be implemented for
a melt shop EAF.
BENEFITS AT A GLANCE
Highly efficient emission control
Economic benefits through less energy
and material consumption
Reliable solutions even fit for the strictest
environmental regulations
Improved working conditions
AUTOMATION
Immediate access to valuable data at any time

SMSConcast is a leading provider of innovative,
integrated automation and process control solu-
tions for the steelmaking industry.
With a proven record of satisfied customers and
successful installations all around the world,
SMSConcast has gained considerable expertise.
The constant focus on understanding and meeting
customers needs makes SMSConcast a reliable
business partner for any project.
FULLY AUTOMATED OPERATION
The EAF control system is based on an integrated
architecture: the automation system collects all
data which are valuable and important for the
estimation of material and energy flows in the
furnace. The information gathered is processed by
a set of control packages. The result: highest
process efficiency with optimized steel quality,
minimized resource consumptions and maximum
productive time.
The dynamic melting profile, which is featured in
the level 2 control system, recalculates the ma-
chine settings based on the current process status,
automatically and dynamically. It transmits them to
the PLC machine immediately, closing the control
loop and ensuring prompt, flexible responses to
specific process conditions.

DEDICATED EAF TECHNOLOGICAL

PACKAGES INCLUDE:

Control packages for advanced electrode

regulation for AC and DC furnaces
Foamy slag detection and control
Carbon injection
CONSO supersonic oxygen technology
Scrap yard inventory management
Automatic real-time tracking of the scrap
bucket charging process
Scrap charging optimization
Wireless operator interface for scrap yard
cranes
Heat and mass balance models
Dynamic melting profile
Tapping alloy addition model
Process analysis and simulation
Metallurgical data management

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SMSConcast

Toedistrasse 9
8027 Zurich
B200.04/13 en Printed in Switzerland

Switzerland

Phone: +41 44 204 65-11

Fax: +41 44 204 69-21
sales@sms-concast.ch
MEETING your EXPECTATIONS
www.sms-concast.ch

IMPRINT SMSConcast AG, Jean-Pierre Papadopoulos (Editor), Toedistrasse 9, 8027 Zurich, Switzerland
Phone: +41 44 204 65-11, Fax: +41 44 204 69-21, sales@sms-concast.ch, www.sms-concast.ch

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 obligation to
deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.