HEAT TREAT NEWS INDUSTRIES

SMS Group Commissions New Compact Steel Plant of El Marakby Steel

On August 2, 2016, the new compact steel plant of El Marakby Steel in Giza, Egypt, was officially opened with an inaugural ceremony. The electric steelworks supplied by SMS group has an annual capacity of 350,000 tons. It comprises a raw materials handling system, a 45-ton electric arc furnace, a ladle furnace with a transformer rating of 8 MVA + 20 percent and a three-strand billet caster supplied by SMS Concast.

“By producing billets in-house, we create value locally and strengthen our competitiveness by reducing our dependence on hard currencies. Additionally, the new plant allows us to expand our range of steel grades and produce rebars extremely flexibly,” said CEO Hassan El Marakby.

The ceremony was opened by a spokesperson of El Marakby who outlined the beginnings and the history of the factory. Subsequently, in a highly notable speech, CEO Hassan El Marakby explained the reasons for building the new plant and for choosing SMS as supplier. Next, Marcel Fasswald, Member of the Managing Board of SMS group, presented SMS group and its worldwide business activities, and emphasized the good cooperation with El Marakby. The ceremony was also attended by the Egyptian Minister of Industry and several representatives of local authorities. Also delegates of the German and Swiss embassies in Egypt were present during the event.

By producing reinforcing steel in the new compact steel plant, El Marakby is supporting the road network expansion in Egypt. The further development of the Egyptian road infrastructure is closely connected with the expansion of the Suez Canal by a second navigable channel. 3,000 kilometers of newly built roads will facilitate the exchange between the cities and ports in Egypt.

SMSgroup Image
Marcel Fasswald, Member of the Managing Board of SMS group (left) and Hassan El Marakby, CEO, MKS).

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Solar Atmospheres Group Adds Vacuum Pump Services Corp.

VPS LogoSouderton, Pennsylvania: Solar Atmosphere announced the formation of a new vacuum pump servicing company, Vacuum Pump Services Corp. Solar Atmospheres group of companies has over one hundred mechanical vacuum roughing pumps and mechanical holding pumps. Solar currently operates a fleet of vacuum furnaces across the United States many of which are still in operation after 30+ years.  Since mechanical pump life averages five to ten years, depending on usage, it became advantageous for the commercial vacuum heat treating company to establish its own vacuum pump service center.

Currently, there are three employees:  Bob Sandora, Vice President of Operations, a longtime Solar Atmospheres employee with over 40 years of mechanical vacuum pump experience; Steve MacInnes, Manager of Operations with 15 years of mechanical vacuum pump experience; and another recently hired pump technician.

According to William R. Jones, CEO of the Solar Atmospheres family of companies, “We know vacuum pumps, when to have the pumps serviced, and how to service them correctly.  This is the base reason for establishing our own organization.  We have also serviced pumps for other organizations including our competitors.  So we’re eager to share our knowledge and expertise and to offer our services broadly across the industry.”

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2016 Hephaestus Award Recipient

John Hubbard, Hephaestus Award

The Hephaestus Award will be bestowed this year to Mr. John Hubbard, P.E. for his contribution to the development of heat treating worldwide. Mr. Hubbard devoted his entire career to the thermal processing industry and was a driving force behind the remarkable growth story of Bodycote, the world’s leading provider of thermal processing services. Under his leadership, Bodycote expanded rapidly from a UK-focused heat treater to the preeminent global company. He made over 200 acquisitions before retiring to return to the United States in 2009. Mr. Hubbard didn’t stay away for too long. Earlier this year, he came out of retirement to return to the heat treating business, working with Calvert Street, a private US investment firm, both as an investor and a board member.

The Hephaestus Award recognizes contributions made by academic and industrial researchers and industry leaders to the field of heat treating that have had an impact on surface engineering, materials science, and industrial processes or production techniques.

Past Recipients

tacikowski
Professor Jan TACIKOWSKI of the Institute of Precision Mechanics, Poland, Ground-breaking work in controlled nitriding.
funatani
– Dr. Kiyoshi FUNATANI, Leading role in the development and industrialization of various nitriding technologies in the automotive industry.
totten
Dr. George TOTTEN, Long-standing efforts in quenching and tribology, as well as his contributions to standards development.
Liedtke
Dr. Dieter LIEDTKE, 50 years of dedication to the practical development of heat treating at Bosch and lifetime service to the AWT (German Association for Heat Treatment and Materials Engineering), as well as his positive guidance in the classroom.

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ALD’s New Location in Hanau Offers Possible Metallurgical Melting Plants and Heat Treatment Systems

ALD Vacuum Technologies GmbH, supplier of plants and services in the field of vacuum thermal process technology, inaugurated its new site in Hanau. The decision to leave the previous location on the premises owned by Heraeus, a precious metals manufacturer, was made due to Heraeus’ conversion and expansion plans.
It was important for ALD to continue the close interconnection of production, development, test operation and administration at the new site. The Hanau Industrial Park Wolfgang offered a suitable location in the midst of an existing technology cluster. ALD blends in perfectly with the new site’s accumulated expertise in material technology due to the close proximity to the Fraunhofer Science Park and the Fraunhofer Institute for recyclable materials and resource strategy which is currently under construction.The project, including planning, construction and relocation to the new site was realized within only 15 months. The new site comprises a building space of 16.300 m2 for production, research and administration for currently 420 employees, allowing further expansion.

The production factory adjoining the office area offers the possibility to assemble large and complex metallurgical melting plants and heat treatment systems. The production building is equipped with all necessary media to allow hot testing of the plants.

A technology center with the latest ALD plant technology is available for heat treatment services as well as for research and development. Meanwhile, an energy management system was implemented, registering the consumption of resources for all plants, thus enabling a perfect management of resources.

At the new site, ALD will continue to develop innovative processes, products and services in the field of vacuum technology and considers itself well equipped for the future.

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Brazilian Steel Producer Purchased Continuous Slab Caster

A two-strand continuous slab caster supplied by Primetals Technologies has gone on stream at Companhia Siderúrgica do Pecém (CSP), a Brazilian steel producer. The plant has a capacity of 3 million t of slabs per annum. The continuous slab caster is part of a new steel works in the Pecém Industrial and Port Complex in São Gonçalo do Amarante in the state of Ceará. Primetals received the order in 2012 from Posco E&C, a company based in South Korea.
The continuous slab caster has a machine radius of 9.5 m and a metallurgical length of 39.8 m. It produces slabs in thicknesses of 220, 250 and 300 mm, and in widths ranging from 1,100–2,300 mm. A wide range of steel grades are cast, from low-carbon structural steels to peritectic and micro-alloyed medium and high-carbon steels, such as ULC, LC, MC, HSLA and HC. The slabs are then rolled into plate and sheet metal for use in mechanical engineering, shipbuilding, boiler and pipeline construction. The maximum casting speed is 1.8 m/min. Primetals engineered the entire plant and supplied core components, the fluid systems, the basic and process automation, and technology packages. The project also included training the operator’s personnel, and supervising the construction and commissioning work.The scope of supply from Primetals included straight Smart Mold molds plus the DynaWidth technology package for dynamic width adjustment during casting. LevCon mold level control and an electromagnetic, multi-mode mold-stirring system were installed to ensure an optimum bath level in the mold. The DynaFlex mold oscillation provides flexible adaptation of the oscillation parameters. The caster’s strand-guide system has a remotely adjustable Smart Bender and Smart Segments which, together with DynaGap Soft Reduction 3D, means that slab thickness can be changed quickly and automatically. I-Star strand-guide rollers support the strand.The Dynacs 3D secondary cooling process model dynamically calculates a three-dimensional temperature profile along the whole length of the strand. This helps to determine precisely the working points of the secondary cooling and the final strand solidification in response to the casting speed, slab format and steel grade. The internal quality of the slabs is improved by using DynaGap Soft Reduction 3D. The roller gap is dynamically adjusted during final solidification based on the working points calculated by Dynacs 3D. DynaJet spray cooling with movable nozzles in the segments ensures uniform, optimum cooling of the slabs, and consequently a high quality surface.

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Bodycote Acquires Nitrex Metal Technologies

Dan McCurdy, Bodycote
Dan McCurdy, President of Bodycote Automotive and General Industrial Heat Treating in North America and Asia

Bodycote, the world’s largest thermal processing services provider, announced today that it has acquired Nitrex Metal Technologies. Nitrex Metal Technologies specializes in precision gas nitriding and ferritic nitrocarburizing in both batch and continuous forms. Continuous gas nitriding and ferritic nitrocarburizing are unique in the industry and are particularly suited to high-volume automotive work. The addition of Nitrex Metal Technologies to the Bodycote Group broadens the range of thermal processing services that Bodycote offers, which already range from conventional atmosphere heat treatments like batch IQ, vacuum, and induction to more exotic specialty technologies like LPC, BoroCote®, and Corr-I-Dur®.

Dan McCurdy, President of Bodycote Automotive and General Industrial Heat Treating in North America and Asia, commented that “Nitrex Metal Technologies is a great addition to the Bodycote Group. Along with the rest of Bodycote’s existing service offerings, this acquisition really cements our position as the go-to expert source for all things nitriding”.

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“My Little Hundred Million” – An Interview with Hank Rowan

HTT Original Content 50x50

By Doug Glenn, Publisher of Heat Treat Today


One of the great privileges of being the publisher of an industry publication is meeting many outstanding people. Some are exceptionally wealthy, some not. Some have a deeper degree of “outstandingness” in that they are kind and others-centered; others not so much. Due to the kindness of Ginny Smith, daughter of Hank Rowan, both of Inductotherm fame, I had the great honor of meeting Hank Rowan, the founder and former CEO of the Inductotherm Group of Companies. This short article is mostly about Mr. Rowan, although it is also about the people Mr. Rowan, I’m sure, would have championed.

My brief encounters with Mr. Rowan were two and both very brief. I’ll tell you more about my experiences with Mr. Rowan and his daughter, Mrs. Smith, below, but for now, you should take some time to listen to the excellent podcast that Malcolm Gladwell did about Hank Rowan shortly after Mr. Rowan’s passing in 2015. Fascinating.

Click here to be taken to the podcast that Mr. Gladwell did about Hank Rowan.

Mr. Rowan

Encounter #1. Not long into my publishing career with BNP Media (I was the publisher of Industrial Heating magazine from 1994-2014), I heard about Mr. Rowan’s book The Fire Within. Wanting to get a little better acquainted with the induction industry, I searched for the book. This was pre-Amazon days…or at least before I knew how to use it! Being a rather forward person, and not having any luck finding the book elsewhere, I called Inductotherm in Rancocas, NJ, to see if I could obtain a copy of the book from them. They answered the phone.

Receptionist: “Hello, Inductotherm, how can I help you?

Me: “Hi, my name is Doug Glenn and I was wondering if I could get a copy of Hank Rowan’s book from you?”

Receptionist: “Hold please.”

Next Voice: “Hello. This is Hank Rowan, how can I help you?”

Me: (Stone-dead silent…….) “Mr. Rowan! Nice to meet you….”

I went on to explain why I was calling and we had a nice discussion. Needless to say, I was surprised and appropriately impressed that Mr. Rowan took calls of this nature. He was a genuinely nice person. I got two copies of the book several days later with a short, hand-written note from Mr. Rowan.

Encounter #2. Multiple years later when I was making a sales call on Ginny Smith, Mr. Rowan’s daughter, who I mentioned earlier, I was about ready to leave and Mrs. Smith asked me if I’d like to meet her father. I was a bit surprised but, of course, said “yes.” We commenced to walk up the steps and directly into Mr. Rowan’s office. He had just completed some sort of minor surgery on his face and was slightly bandaged up…but still at work…and if I remember correctly still coming into work nearly every day even at the advanced age of 80+. His reception was warm and the three of us had a brief and pleasant conversation. No pretension; just a normal guy…as was his daughter, Ginny. I, of course, recounted the book request incident to him (not knowing what else to talk about) and he didn’t act surprised.

Some exceptionally wealthy people are aloof. Not Mr. Rowan.

Other Industry Champions

I’m going to step out and speculate a bit here because I did not know Mr. Rowan well enough to say what I’m about to say emphatically…I could be wrong, but I think Mr. Rowan would probably champion the not-so-rich-and-famous people in the heat treat industry. People like Dan Reardon of Paulo Products with whom I’ve had the privilege of developing an online relationship (!). Dan and I have corresponded by LinkedIn only. I’ve never met him in person. Nonetheless, I consider Dan to be an industry (and life) champion. I think Mr. Rowan would as well.

If you’ve listened to the Malcolm Gladwell podcast (see above), you know that Mr. Rowan donated millions of dollars to educate the every-day engineers in and around his New Jersey home. It would be hard to say how many educational lives Mr. Rowan has impacted.

Mr. Reardon, on the other hand, father of five, is, as I am, struggling to get our kids (Dan has 5, I have 4) through college. Based on the LinkedIn exchanges Dan and I have had, it is easy to conclude that Dan is not independently wealthy. By his own admission, it is a “struggle” to know how he and his wife are going to do it — how are they going to put all the kids through college and still have a half decent retirement. My guess is that if Dan had to choose, he’d sacrifice his retirement for the benefit of his kids. Go Dan!

These are the types of people that make the heat treat industry tick. There are undoubtedly thousands of others that could be mentioned. Malcolm Gladwell doesn’t have time to profile them all; nor do I, but please know that each and every one of you that sacrifices himself for the good of others is a champion.

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PT Krakatau Steel Orders Hot Strip Mill

PT Krakatau Steel, Indonesia, has placed a turnkey order with SMS group for the supply of a high-performance hot strip mill. The order comprises the entire process equipment, ranging from the slab yard to the coil yard, the electrical and automation systems, the auxiliary facilities such as water management, roll shop and crane systems, and the construction of the pertaining infrastructure and bays. Planning and execution of building construction and civil engineering is carried out by the Indonesian consortium member, PT Krakatau Engineering.
The hot strip mill is scheduled for commissioning in early 2019 in Cilegon on the Indonesian island of Java. This is where PT Krakatau Steel (PTKS) operates an integrated steel plant for which SMS group had supplied a hot strip mill, among other equipment, in the 1980s.The new hot strip mill for strips with a maximum width of 1,650 mm will have a capacity of 1.5 million t/a in its first expansion stage. Key components are a reheating furnace, a four-high reversing roughing stand with edger, the six-stand finishing mill, a laminar strip cooling section, a universal coiler and the coil transfer system. At a later stage, the annual production can be increased to up to 4 million t/a.

The hot strip mill is equipped with numerous technology packages and Ecoplants components required for the economic manufacture of high-quality hot strip. Thanks to the utilization of low-emission burners, the walking beam furnace achieves low pollutant values, which are monitored constantly via an online system. The four-high reversing roughing stand operates with the technology for camber-free rolling, which enables the avoidance of strip camber due to temperature or thickness rundowns. The temperature losses in the transfer bar are reduced by newly developed and highly efficient heat retention hoods between the roughing stand and the crop shear.

The finishing stands are equipped with the CVC plus system (Continuously Variable Crown) with integrated work roll bending and hydraulic roll-gap adjustment systems, enabling strips to be produced with very close thickness, profile, contour and flatness tolerances. The Ecoplants components in the finishing mill include the Sieflex HT high-performance spindles, the design of which allows the trans­mission of higher rolling torques with smaller work roll diameters. A further innovation is a highly efficient two-stage work-roll cooling system, operating with various pressure stages.

SMS supplies the entire plant automation, the drive technology and the electrical power distribution. On Level 0, this equipment comprises the sensor technology, the technological measuring devices, the main and auxiliary drives, as well as switchgear units and compensation equipment. The Level 1 automation systems are designed completely on the basis of the most up-to-date embedded technology, involving an efficient and, at the same time, lean hardware design.

The innovative operating concept X-Pact vision is designed according to state-of-the-art ergonomic knowledge and enables the operator to act intuitively to achieve optimum process control. The Level 2 process automation contains the technological process models, ranging from the pass schedule calculation PSC (Pass Schedule Calculation) via the profile, contour and flatness model PCFC (Profile Contour Flatness Control) up to the cooling section model CSC (Cooling Section Control) and temperature control. Likewise, SMS supplies a microstructure model MPM (Material Property Model), which determines the mechanical properties of the products and supports and simplifies the introduction of new materials.

Within the framework of Industry 4.0, a powerful PQA (Product Quality Analyzer) system will continuously monitor all process and product quality parameters. The new hot rolling mill will be one of the most modern facilities of this type worldwide, enabling PTKS to fulfill highest demands regarding quality, productivity, and production cost.

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Radiant Tube Manufacturer Completes 3-Phase Expansion

Holland, NY:  One of North America’s leading high-temperature radiant tube manufacturers, INEX Incorporated, recently completed a three-phase building expansion nearly doubling the companies footprint in Holland, New York, 30 miles southeast of Buffalo. According to Mike Kasprzyk, president and owner of INEX, “we’re now able to meet the growing needs of our expanding customer base.”

The expansion included additional production, engineering, and shipping/receiving floor space as well as the addition of new manufacturing equipment and technologies to meet consistently increasing demand. The company’s high-temperature silicon/silicon-carbide (Si/SiC) radiant tubes are one alternative to conventional all-metal radiant tubes and tend to have long life cycles and a higher BTU output per square inch than traditional all-metal radiant tubes.

For more on this expansion, listen to an audio interview with Mike Kasprzyk conducted by Heat Treat Today publisher DougGlenn by clicking here.

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Majority of Heat Treatment Done In-House at SKF — New Equipment Purchased

Ipsen recently installed both atmosphere and vacuum heat-treating systems at SKF’s state-of-the-art manufacturing facility in St. Louis, Missouri. With the relocation of their existing facility to a new location, SKF continues to focus on enhancing the quality, efficiency and overall effectiveness of their heat-treating equipment. Among this new Ipsen equipment was a complete ATLAS atmosphere heat-treating system, including two ATLAS integral quench batch furnaces and ancillary equipment – washer, temper, endo generator, loader/unloader and a feed-in/feed-out station. SKF also purchased a TITAN® vacuum heat-treating system to round out their production capabilities.

Heat-treating is considered a core competency at SKF, and this new equipment will allow them to bring the majority of heat treatment in-house and efficiently handle the increase they’ve seen in production demands and volume of parts. Reflecting on the equipment purchased and what appealed to SKF, Bryan Stanford said, “Initially, I would say it was the general purposefulness of these Ipsen products that appealed to us. We run a very large variety of parts and batch quantities here. A custom solution designed to run tens of thousands of the same parts was not going to work for us. We wanted a low-cost, off-the-shelf-type solution that would allow us the flexibility we required – which is what the ATLAS and TITAN delivered. Now after having performed some pre-training, I would say what stands out the most is the ease of use and control of the equipment.”

The ATLAS batch furnaces feature a 24″ W x 36″ D x 30″ H (610 mm x 910 mm x 760 mm) load size with an 1,100-pound (500 kg) load capacity. They also operate at temperatures of 1,400 °F to 1,800 °F (750 °C to 980 °C) and have a quench oil capacity of 1,030 gallons (3,900 L). The TITAN vacuum furnace features an 18″ W x 24″ D x 18″ H (455 mm x 610 mm x 455 mm) load size with a 1,000-pound (454 kg) load capacity. It operates at temperatures of 1,000 °F to 2,400 °F (538 °C to 1,316 °C). Overall, this Ipsen equipment will be used for carburizing, carbonitriding, brazing and annealing and will process a wide variety of parts that support SKF’s Lubrication Business Unit.

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