Reducing Dross Formation and Zinc Consumption in Galvanising Line
Key Takeaways Process Optimization is Key – Adjusting operating parameters like temperature profiles and bath chemistry significantly reduced dross formation. Improved Material Handling Reduces Contamination – Better storage and handling of steel coils minimized iron fines and oil contamination, enhancing strip cleanliness. Enhanced Productivity & Cost Savings – Optimized zinc bath management cut unplanned stoppages […]
Adjusting Reduction and Tension Patterns of Cold Rolled Steel
Key Takeaways Problem: A steel plant in Southeast Asia faced excessive steel breakages, averaging 8 per day—higher than the benchmark of 5 per day—leading to reduced throughput and increased costs. Challenge: Optimising reduction and tension patterns to improve process stability and product quality. Solution: Conducted a 360° diagnosis, identified reduction and tension settings as the […]
Optimising EAF Chromium oxide recovery and Oxygen Consumption for Duplex and Ferritic Stainless Steels
Key Takeaways Here are five key takeaways from this document: Problem: A client in Asia faced high oxygen and aluminium consumption in a 140-tonne EAF, leading to chromium losses in slag. Challenge: High operating costs due to inefficient raw material use and chromium losses. Solution: Reviewed and optimised EAF processes, including oxygen injection, charge mix, […]
Optimising AOD Chemical Composition of Duplex Stainless Steel
Key Takeaways Problem: A stainless steel producer in Southeast Asia faced quality issues due to non-optimised chemical compositions, leading to frequent casting defects. Challenge: Needed to optimise chemical composition to ensure consistent product quality. Solution: Adjusted desulphurisation and decarburisation steps and proposed SOP modifications for better chemical control. Improvements: Reduced steel sulphur content, controlled hydrogen […]
Operational excellence program at an Eastern European steel plant: Increasing yield by 15% with less than 1 million USD of capital expenditure
Key Takeaways Here are five key takeaways from this document: Problem: An Eastern European steel plant was underperforming, with low yield, high energy use, and inefficient scrap management. Budget for capital investments was very limited. Challenge: Key issues included long tap-to-tap times, outdated practices, and energy consumption far above benchmarks. Scrap operations and burner performance […]