Operational Due Diligence of two Celsa EAF Steel Plants in the UK and Norway
Key Takeaways Here are five key takeaways from this document: Problem: A private investment firm needed operational due diligence to validate seller claims and uncover hidden technical or financial risks before acquiring two EAF steel plants in the UK and Norway. Challenge: The team uncovered critical “red flags” – including outdated automation systems, deviations in […]
Reducing Steel Breakages and production stoppages in a cold rolling mill plant
Key Takeaways Problem: Frequent strip breakages and stoppages in a Bangladesh cold rolling mill. Diagnosis: 360° assessment identified process and procurement issues. Solution: Optimised rolling patterns, lubrication, and roll specifications. Enhancements: Improved pickling line and implemented alternative roll sourcing. Impact: +30% productivity, USD 35M revenue increase per annum, 3 new SOPs approved. $ 0 M […]
Addressing Edge Crack Issues in Duplex Stainless Steel during Hot Rolling
Key Takeaways Comprehensive Process Analysis – A systematic review of the hot rolling process identified key factors contributing to edge cracking in duplex stainless steel plates. Enhanced Product Quality – Improved slab handling, including edge chamfering, significantly reduced edge cracks and improved final product quality. Optimised Chemical Composition – Adjusting the balance of ferrite and […]
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 […]
Reducing Longitudinal Depression and Hot Cracking in Duplex Stainless Steel Slabs
Key Takeaways Problem: A stainless steel producer in Asia faced defects in duplex stainless steel slabs due to improper casting parameters and powder formulations. Challenge: Defects led to material loss, reducing yield and disrupting downstream operations. Solution: Identified defect causes, optimised casting settings and powder formulations, and provided staff training. Improvements: Reduced grinding loss to […]
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 […]