Tata Steel

News From Abroad: Green Transition and Expansions

/ ALUMINUM PROCESSING NEWS, HEAT TREAT NEWS

In today’s News from Abroad installment, we highlight one steel mill‘s environmental improvement efforts, an Indian aluminum plant expansion, and a self-learning furnace system for aluminum processing.

Heat Treat Today partners with two international publications to deliver the latest news, tech tips, and cutting-edge articles that will serve our audience — manufacturers with in-house heat treat. Furnaces International, a Quartz Business Media publication, primarily serves the English-speaking globe, and heat processing, a Vulkan-Verlag GmbH publication, serves mostly the European and Asian heat treat markets.

Tata Steel Praised for Low CO2

Tata Steel plant
Source: Furnaces International

“Jonathan Brearley, chief executive of Ofgem, has praised Tata Steel UK’s move to low-CO₂ at its Port Talbot site. The comments were made during a visit to the site in Wales, with Brearley partaking in a tour around the premises. Brearley said: ‘Back in 2016 and 2023, most of the conversation was about electricity and gas prices and the pressure they put on the steel business. What’s inspiring today is seeing Tata Steel moving towards electric arc furnace-based steelmaking and helping to deliver a green future.’ He further highlighted Great Britain’s energy regulator’s role in enabling investment by ensuring industrial customers, like Tata, have the right conditions to transition, including fair energy pricing and strong grid connections.”

READ MORE: “Ofgem chief executive praises Tata Steel UK’s green transition” at furnaces-international.com

Indian Aluminum Plant Expansion

The company is exploring different energy options to meet the smelter’s power requirements.
Source: Furnaces International

“Indian aluminium producer Nalco is continuing with its plant to expand its smelter in Angul. It will add approximately 0.5 million tonnes of capacity at the facility, with technology for the project being finalised it said. In its annual report for the year, the company said a project report with technology from the Technology Licensor is being prepared. ‘Pre-project activities have been initiated. The acquisition of requisite land through IDCO, Govt. of Odisha is underway and environmental clearance for the project is under progress.’ The company is exploring different energy options to meet the smelter’s power requirements.”

READ MORE: “Nalco continues smelter expansion…but reconsiders alloy plant plan” at furnaces-international.com 

Self-Learning Furnace System for Aluminum

The BatchPilot has transformed casthouse operations by increasing “right first time” batching.
Source: Furnaces International

“A furnace weighing system from Aluminium Casthouse Technologies (ACT) is now ‘self-learning’ to achieve higher production levels in casthouses. Knowing the correct weight of metal in the furnace is crucial to ensure slabs are consistently cast to the precise length ordered by the customer and the BatchPilot is used in casthouses worldwide to accurately measure furnace liquid metal weight. Determining exactly what is wanted aluminium and what is unwanted dross, it means casthouses don’t have to rely on visual estimates of furnace heel weight, which are unreliable. This often leads to short casts, overfilling of the furnace or potentially restricting the number of slabs cast, all hugely wasteful.”

READ MORE: “Aluminium Casthouse Technologies’ self-learning furnace system” at furnaces-international.com

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All 21 News Chatter To Keep You Current

/ FEATURED NEWS, HEAT TREAT NEWS, HEAT TREAT NEWS INDUSTRIES, MANUFACTURING HEAT TREAT NEWS

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry. Enjoy these 21 news items.

Equipment

  1. Tata Steel Meramandali, based in Odisha, India, placed an order with SMS group for the implementation of Paul Wurth coke oven gas injection technology at their Blast Furnace (BF) #1. This order is the first of its kind in India, setting a precedent for the industry’s move towards sustainable steel production. The project is expected to be commissioned by Q1 2026 and will be completed within 25 months.
  2. Sousa Corp., based in Newington, CT, installed its second Ipsen Turbo²Treater vacuum furnace to its production line, expanding its capacity to meet demand for heat treating services to the aerospace, automotive, medical, and general manufacturing industries.
  3. A Chinese partner has purchased a two-chamber VIM 50 kg induction furnace from SECO/WARWICK for casting gas turbine blades. The furnace will produce gas turbine blade castings in an equiaxed structure and has already obtained an export license.
  4. The modernization of a blast furnace at Salzgitter Flachstahl AG has been completed by SMS group. The new Paul Wurth parallel hopper Bell Less Top® (BLT) installed offers enhanced efficiency with less maintenance.
  5. Edwards AFB in California received delivery of a composition oven from DELTA H®/Phillips Federal. The equipment will be used for advanced materials applications R&D. The heat treat furnace supplier initially designed and engineered the walk-in oven using SolidWorks 3D modeling and developed the project as a “kit oven” for easy field assembly. After preassembly of key subsystems at their Carroll, OH facility, the system was shipped to Edwards AFB. The entire field assembly project required two weeks including commissioning and extensive training of USAF personnel.
  6. Tata Steel Nederland selected Tenova to develop a new state-of-the-art steel production line in IJmuiden, the Netherlands. The overall contract will include engineering, supply, and advisory services for a three million tons electric arc furnace to meet current operational specifications (high-quality steel for the automotive sector). 
  7. Cavendish Hydrogen ASA, a subsidiary of Nel ASA, has received a purchase order from Alperia Greenpower SRL for hydrogen fueling equipment to be used for light- and heavy-duty fuel cell electric vehicles in Bruneck, South Tyrol, Italy. This will be Nel’s first H2Station™ installation in Italy, built for the 2026 Winter Olympics to fuel vehicles for the transfer between the Olympic sports facilities.
Newly installed material hoppers at Salzgitter Flachstahl AG
Coke oven gas compressing station previously installed at HKM, Germany
DELTA H®/Phillips Federal providing composite oven for Edwards AFB
Left to right: Paolo Stagnoli (Tenova), Hans van den Berg (CEO Tata Steel Nederland), Jeroen Klumper (Tata Steel Nederland), and Nico Bleijendaal (Danieli)

Company & Personnel 

  1. StandardAero has appointed Kim Ernzen to serve as chief operating officer. In this role, Ernzen reports directly to Russell Ford, StandardAero chairman and CEO, and is responsible for global operational performance, efficiency, and excellence, as well as engineering and supply chain management for StandardAero. Additionally, StandardAero’s Engine Services and Component Repair Services division presidents will report directly to Ernzen, who will maintain close oversight of the company’s overall business performance. She replaces Kerry O’Sullivan, who is retiring from StandardAero, and will be located at the company’s Scottsdale, Arizona, headquarters office. 
  2. Steelhead Technologies launched Steelhead University, an online learning platform designed to expedite user training and streamline software implementation. The comprehensive curriculum of eight core administrative courses equips users with fundamental knowledge essential for navigating the intricacies of the company’s software.
  3. Solar Atmospheres’ newest acquisition, Solar Atmospheres of San Diego, has announced the addition of Chris Constable as their new vice president of operations. Chris has nearly 25 years of heat treating experience that includes quality, operations, management, plant safety, business development, and sales.
  4. Ipsen USA welcomes Max Stormo as the new Ipsen customer service (ICS) operations manager as the company streamlines its aftermarket services in Souderton, PA. Stormo comes to Ipsen after an extensive career working as a manufacturing operations leader in Texas, and a recent role as vice president of operations at a manufacturer in the Philadelphia region.
  5. Solar Manufacturing, Inc., announced the hiring of Nicholas Max, BSME Drexel University, as its chief mechanical engineer to head up its vacuum furnace mechanical design group. Nick is also pursuing an MBA at Lehigh University in Bethlehem, PA. He will be tasked to lead the further development of energy efficient hot zones, vacuum vessels, high pressure gas quenching systems, and vacuum pumping systems.
  6. Ipsen USA has confirmed its commitment to the growth of the Ipsen Customer Service (ICS) Parts Department by expanding staff and implementing strategic initiatives. Christina Connelly, parts manager for Ipsen in Cherry Valley, joined the team in 2022, and has since hired six additional employees. Connelly and her veteran team members and new hires are focused on reducing turnaround time and increasing customer responsiveness.
  7. Swiss Steel Group announced its participation in a renewable energy consortium, the “Initiative EE-Industrie.” This initiative, consisting of 19 small and medium-sized enterprises (SMEs) in Germany, aims to build, operate and utilize wind and photovoltaic plants for self-supply with green electricity.
  8. Kanthal and Danieli have announced a partnership to jointly scale up Kanthal’s demonstrated electric process gas direct-heating solution, Prothal® DH, to full industrial scale. With the installation in Energiron hydrogen-ready DRI plants, fully green DRI production will be achieved. Additionally, the introduction of Prothal® DH technology in blast furnace operation will reduce CO2 emissions in ironmaking.
Kim Ernzen, Chief Operating Officer at StandardAero
Screenshot of Steelhead University knowledge check on adjusting powder coat recipes
Chris Constable, Vice President of Operations, Solar Atmospheres of San Diego
Max Stormo, Customer Service Operations Manager, Ipsen USA
Nicholas Max, Chief Mechanical Engineer, Solar Manufacturing, Inc.
Dilip Chandrasekaran, Global Business Development Manager at Kanthal (L) and Marco Lapasin, Vice President Danieli Engineering Centro Metallics

Kudos 

  1. Ipsen Global has received the German Innovation Award for the Atlas Green furnace platform, presented by The German Design Council. The award ceremony was held in Frankfurt, Germany, on May 14, celebrating the innovators that emerged from a field of 520 submissions from across 23 countries.
  2. Industrial Steel Treating Co. was named the Manufacturer of the Year by the Jackson Area (MI) Manufacturers Association. Accepting on behalf of IST was Tim Levy, current President of IST. Members of the Levy family in attendance included current VP, Tom Levy, and former IST President, Bernard Levy. Bernard was the 2nd generation Levy family owner and spent his entire 50-year career at IST before retiring and passing the reins to his three sons in 1998.
  3. Bluestreak Compliance™, a division of Bluestreak | Bright AM™, received approval as a Registered Practitioner Organization (RPO) by the Cybersecurity Maturity Model Certification (CMMC) Accreditation Body (Cyber-AB). This significant achievement enables Bluestreak Compliance™ to offer expert consulting services to defense contractors and suppliers aiming to comply with CMMC cybersecurity standards and prepare for their Cybersecurity Maturity Model Certification (CMMC) audits.
  4. IHEA has announced Dr. Avi Shultz as keynote at the first Industrial Heating Decarbonization SUMMIT. Dr. Shultz, Director of the U.S. Department of Energy’s Industrial Efficiency and Decarbonization Office (IEDO), will provide the keynote address at its first summit, to be held October 28-20 at the Conrad Indianapolis.
  5. Swiss Steel Group has launched a new website which focuses on customer needs, including a Product Finder that generates automated product suggestions based on customer requirements and specifications, and detailed information about green initiatives and sustainability as well as special requirements for steel grades for specific applications.
  6. IHEA recently announced its 2024–25 Board of Directors and Executive Officers. Taking over as President is Jeff Rafter of Selas Heat Technology Co. LLC; Vice-President is Gary Berwick of Dry Coolers, Inc.; and Treasurer is Jason Safarz of Karl Dungs, Inc. Brian Kelly of Honeywell Thermal Solutions assumes the Past President position. Finalizing the lineup of IHEA’s Board of Directors for 2024-2025, the following members continue their tenure: Scott Bishop, Electric Power Research Institute (EPRI); Bob Fincken, Super Systems, Inc.; Ben Gasbarre, Gasbarre Thermal Processing Systems; Doug Glenn, Heat Treat Today; John Podach, Fostoria Infrared; John Stanley, Karl Dungs, Inc.; Michael Stowe, Advanced Energy; Helen Tuttle, WS Thermal Process Technology Inc.; and Jeff Valuck, Surface Combustion, Inc.
Dr. Bora Ozkan-Paul van Doesburg (L) and Lutz Dietzold (R) with their German Innovation Award
Tim Levy (L) and Bernard Levy (R)
Dr. Avi Schultz, keynote speaker at IHEA’s Industrial Heating Decarbonization SUMMIT
The 2024-25 IHEA Board of Directors: Back row, left to right; John Stanley, Bob Fincken, Gary Berwick, Brian Kelly, Scott Bishop, Doug Glenn, and Jeff Rafter. Front row, left to right; Jeff Valuck, Ben Gasbarre, Helen Tuttle, IHEA Executive Vice President Anne Goyer, Jason Safarz, and John Podach. Not pictured: Michael Stowe

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39 Heat Treat News Chatter Items To Keep You Current

/ FEATURED NEWS, HEAT TREAT NEWS, HEAT TREAT NEWS INDUSTRIES

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry. Enjoy these 39 news bites that will help you stay up to date on all things heat treat.

 

Equipment Chatter

  1. The precision forging manufacturer Jiangsu Pacific Precision Forging Company has placed an order with SMS group for a fully automatic MP 3150 eccentric closed-die forging press. Pacific Precision will be able to forge aluminum chassis components on a much larger scale. This new expansion provides Pacific Precision with access to the growing automotive market segment for more lightweight designs.
  2. A commercial heat treater in Mexico purchased a third vacuum furnace from SECO/WARWICK Group.
  3. Ecocat India, a catalyst manufacturer, has ordered an advanced technology vacuum gas cooling furnace from SECO/WARWICK. The system will carry out brazing and annealing processes.
  4. Several new CAB lines have been ordered from SECO/WARWICK to be delivered to manufacturers in China. Two companies specifically chose EV/CAB lines while another manufacturer purchased a CAB line.
  5. SECO/WARWICK delivered two CAB lines and one universal chamber furnace for aluminum brazing to an automotive manufacturer in China. The systems will braze large-size coolers for vehicle batteries.
  6. Oetzbach Edelstahl GmbH, a hardening plant, has purchased a third furnace from SECO/WARWICK.
  7. A Swiss commercial heat treater ordered a brazing furnace to be used for nickel and silver from SECO/WARWICK.
  8. Tenova LOI Thermprocess has completed the production optimization of a new Twin-Chamber Melting Furnace (TCF®) at E-Max Billets in Kerkrade, the Netherlands.
  9. An Asian thread rolling die conglomerate selected a SECO/WARWICK vacuum furnace. The Vector® will be used for vacuum hardening and tempering fastener dies.

Company and Personnel Chatter

  1. Hubbard-Hall has expanded its product offering and customer resources by acquiring the assets of Torch Surface Technologies, a specialty chemical company based in Whitmore Lake, MI.
  2. New simulation software is being launched at CENOS Simulation Software. The application portfolio expands with some new electromagnetic case software apps. The first apps will be launched in Q4 or a little later.
  3. Solar Atmospheres of California announced it has been awarded the approval to process parts for Lockheed Martin (LMCO) owned Sikorsky. The Sikorsky approval adds to the existing LMCO process specifications held for vacuum heat treatment of titanium, nickel alloys, and stainless steel per AMS 2801, AMS 2774, AMS 2759/3, and others.
  4. Nel Hydrogen US, a subsidiary of Nel, has entered into a joint development agreement with General Motors to help accelerate the industrialization of Nel’s proton exchange membrane (PEM) electrolyzer platform. The two companies are looking to enable more cost competitive sources of renewable hydrogen.
  5. The Supervisory Board of thyssenkrupp AG extended the appointment of Oliver Burkhard by five years. Burkhard has been a member of the Essen-based group's Executive Board since February 2013, Thyssenkrupp AG director of Labor since April 2013, and additionally CEO of thyssenkrupp Marine Systems since May 2022.
  6. Joe Coleman, cyber security officer of Bluestreak Consulting™, has earned his Cyber AB CMMC Certification as a Registered Practitioner (RP). CMMC is a U.S. Department of Defense (DoD) program that applies to Defense Industrial Base (DIB) contractors.
  7. CG Thermal welcomes associate process engineer Signe Laundrup to the Process Systems Group. Laundrup is a 2021 chemical engineering graduate from the University of California, San Diego. Her background is in manufacturing and research and design.
  8. Tata Steel signed a memorandum of understanding with SMS Group to reduce carbon emissions at Tata’s integrated steel plants across India.
  9. Two heat treat technology companies integrate: C3 Data’s real-time pyrometry compliance software enables digital uploading of certificate data of all TT Electronics.
  10. Ipsen Japan announced the addition of Mr. Masakazu Kanaka in the role of customer service director. Kanaka is responsible for the growth of all Ipsen Japan customer service business, which includes retrofits, parts, and service. He will oversee the aftermarket sales team and field service engineers.
  11. Solar Atmospheres of California announced Honeywell approval to heat treat austenitic steels, martensitic steels, pH steels, tool steels, nickel alloys, cobalt alloys, titanium alloys, and magnetic alloys.
  12. Aluplast – ZTG, an Altest company, recently expanded its production capacity with a second Nitrex nitriding system. The second furnace, a model N-EXT-612, is capable of processing a load of extrusion dies weighing up to 1300lbs.
  13. Solar Atmospheres of Michigan is pleased to announce the addition of Chris Molencupp as their new sales manager.
  14. Metal Exchange Corporation announced that Matt Rohm, current President and Chief Operating Officer (COO), will be promoted to Chief Executive Officer (CEO) of Metal Exchange Corporation effective January 1, 2023. At that time, current CEO Rick Merluzzi will assume the title of executive vice chairman, serving as an advisor to executive chairman, Mike Lefton, on key strategic initiatives for the organization, through the end of 2023.
  15. Quintus Technologies joins the newly opened Application Center at RISE to support further development of additive manufacturing. The AM Center will also include the Quintus press model QIH 15L-2070.
  16. Abbott Furnace Company announced that it has partnered with Obsidian Technical Group for sales and service support across much of the eastern United States.
  17. Robert Roth announced the appointment of Nelson Sanchez as RoMan’s new president, effective January 1, 2023. Sanchez is the first non-family member to hold the office.
  18. Hubbard-Hall hired Aaron Mambrino as chief financial officer. Her expertise lies in driving process changes to create operational synergies, developing strategic partnerships, and LEAN manufacturing.
  19. John Savona, vice president of Americas Manufacturing and Labor Affairs, Ford Blue, will retire on March , after more than 33 years. Bryce Currie will step into the role.
  20. AFC-Holcroft welcomed employees and their families, company retirees, and invited guests to view their newly renovated building as part of an open house.
  21. Solar Atmospheres of California participated in the “Spark of Love” toy drive in coordination with the San Bernardino County Fire Department.
  22. Raytheon Technologies expands Bengaluru operations with opening of Pratt & Whitney India Engineering Center. The facility is co-located with Pratt & Whitney’s India Capability Center and Collins Aerospace engineering and global operations centers.
  23. Lucifer Furnaces in Warrington, PA, a manufacturer of heat treating furnaces and ovens for the last 80 years, has added Brett Wenger to its leadership team as vice president of sales.

 

Kudos Chatter

  1. Global Thermal Solutions celebrates 15 years in Mexico.
  2. Hitchiner Manufacturing receives Nadcap Accreditation.
  3. Ipsen USA announced that 2023 represents a milestone anniversary. This year marks 75 years since Harold Ipsen founded the company.
  4. Desktop Metal is sponsoring on a new season of BattleBots. The completely rebuilt robot is aided by the design freedoms and fast turnaround times of metal 3D printing.
  5. Solar Atmosphere’s Michigan and Western Pennsylvania facilities have recently been awarded Nadcap Merit status for vacuum heat treating and brazing.
  6. In September, the Swiss Steel Group (SSG) held the 1st Hydrogen Symposium at the Henrichshütte Iron and Steel Works in Hattingen. Speakers from academia, business, and politics held lectures in four sessions.
  7. Borikengineers, a team mentored by Pratt & Whitney employees in Puerto Rico, has advanced to the Qualifiers’ Finals Competition in the FIRST Tech Challenge DC Qualifier. The team won the Judges Choice Award.

 

Heat Treat Today is pleased to join in the announcements of growth and achievement throughout the industry by highlighting them here on our News Chatter page. Please send any information you feel may be of interest to manufacturers with in-house heat treat departments especially in the aerospace, automotive, medical, and energy sectors to sarah@heattreattoday.com.

 

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New Solution to Reduce Emissions and Increase Throughput at Tata Steel

/ BURNERS COMBUSTION SYSTEM NEWS, FEATURED NEWS, MANUFACTURING HEAT TREAT

HTD Size-PR LogoTata Steel will receive an IIOT (industrial internet of things) solution for their industrial furnaces. This solution is designed to reduce emissions and increase furnace throughput by measuring, maximizing, and maintaining energy input through the combustion process.

PSNERGY LLC's Total Combustion Solution consists of combustion monitoring and alerting, which delivers simple and actionable combustion performance reports resulting in reduced equipment downtime, as well as radiant tube inserts to absorb and radiate energy into the load. This package is set to increase productivity and reduce emissions at Tata Steel furnaces. The project will be completed by the end of Q2 in 2022.

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Steel Production in UK Gets Boost from Global Investor

/ MANUFACTURING HEAT TREAT

A leading global steel producer recently announced multiple projects as part of a series of planned investments in its UK business. Around £30 million is being earmarked to help secure the future of steelmaking in South Wales, UK.

Tata Steel, headquartered in Mumbai, Maharashtra, India, with steelmaking in the UK and Netherlands, and manufacturing plants across Europe, will replace a Basic Oxygen Steelmaking (BOS) vessel — weighing 500 tonnes – at its Port Talbot site. At the same time, the company is replacing the massive cranes in the steel plant and installing enhanced dust extraction hoods and energy-efficient drives to minimize emissions.

The 11-meter high BOS vessel is a steel cauldron used to convert iron into steel before it is further processed and delivered to customers making products like cars, innovative packaging, and energy-efficient buildings.

Earlier this year Tata Steel unveiled the UK’s most advanced robotic steel welding line which supplies material for car makers from its site in Wednesfield, UK.

Port Talbot produces high-quality steel which is further processed at Tata Steel’s steel mills around the UK for manufacturers in Britain, mainland Europe and other countries around the world. Once installed, the new steelmaking vessel will be able to convert 330 tonnes of iron into steel in each cycle. This is done by pumping oxygen through liquid iron at twice the speed of sound, removing unwanted carbon and allowing employees to produce critical grades of steel.

“We have two steelmaking vessels and they run 24/7 at temperatures of up to 1,700C, apart from short planned maintenance periods. Despite this, they last for around 20 years each and replacing them is an important part of ensuring reliable operations,” said Dave Murray, Project Manager.

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Tata Steel’s First Greenfield Ferro-Chrome Plant Starts Production

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

The recently commissioned ferro-chrome plant of Tata Steel at Gopalpur Industrial Park in Ganjam district of Odisha, has achieved a major milestone with the first ever production of ferro-chrome  on February 25, 2017, with compliance to all technical parameters.

Chromite briquettes used for making ferro-chrome have been produced by the Briquetting Plant at the ferro-chrome plant complex. The Briquetting Plant had earlier commenced production on January 23, 2017. For the plant, the steel major is sourcing chrome ore from its chromite mine at Sukinda in Jajpur district of Odisha.

Speaking on the occasion Mr D B Sundara Ramam, Executive-in-Charge, Ferro Alloys & Minerals Division of Tata Steel said, “This marks the completion of the commissioning of the ferro-chrome plant. It also goes a long way in consolidating our footprint in Odisha and the long standing partnership with the state towards industrial progress of the region.”

As part of the anchor investment in Tata Steel’s Gopalpur Industrial Park, the Rs 542 crore Ferro-chrome plant has an installed capacity of 55,000 tonne per annum (TPA). The plant was inaugurated on November 30, 2016 by the Chief Minister of Odisha, Shri Naveen Patnaik. It is a unique environment-friendly plant with state-of-the-art pollution control equipment and technology such as the ETP (Effluent Treatment Plant) and STP (Sewage Treatment Plant). It has 100% water harvesting facility that caters to most of the water needs of the plant. It has an indigenously built semi-closed hybrid furnace, which is first of its kind in India and components procured from all over the world to maintain high standards of quality and safety. Also, it is the first plant in India to use briquetting method of Chrome ore fines agglomeration.

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