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Mining
Completely Integrated Solutions leverage hidden potential to create greater profitability and productivity. From a single source. At all levels. Across the entire operation – and throughout the entire life cycle. This is how SIMINE becomes your tool for making your business even more competitive. In every way.
Ironmaking
For the first time ever, hot-rolled coils can now be commercially produced in a thin-slab casting/rolling plant directly from liquid steel in a continuous and uninterrupted manufacturing process.
Steelmaking
As the only global full-line provider and inventor of the LD process, we possess unique expertise. Backed by this extensive experience, we completely focus on process optimization – starting with individual converter designs, including tried and tested lance technologies as well as sophisticated automation packages and sustainable solutions for offgas utilization. In everything we do, we have one goal in mind: To increase the performance of your plant.
Continuous Casting
The economy is rapidly changing each day and becoming increasingly difficult to anticipate. Keeping up with these demands requires optimized, flexible solutions for your plant. By working in close collaboration with our customers, that‘s exactly what we at Siemens VAI deliver.
Integrated Plants
Siemens VAI stands ready to support you with extraordinary technological expertise in MiniMills, based on over 200 years of accumulated experience. Our customers can rely on industry-leading products spanning the entire range of partial processes. Performance-critical components are manufactured at our workshops inhouse. And a complete range of available services is your assurance of competitive performance throughout the entire life-cycle of your plant.
Hot Rolling
As a globally active full-line supplier, our expertise is unique in the steel production industry. We focus on process optimization for hot strip mills – starting with individual plant and logistics design and including innovative rolling technologies both for new mills and modernizations. In everything we do, we have one goal in mind: to increase the performance of your plant.
Cold Rolling
As a globally active full-liner, we possess expertise that is unique in the entire steel production industry. Backed by this extensive experience, we completely focus on process optimization for cold-rolling mills – starting with individual plant and logistics design, and including proven rolling technologies as well as sophisticated automation packages. And in everything we do, we have one goal in mind: To increase the performance of your plant.
Strip Processing
As a globally active full-liner, we provide you with expertise that is unique in the steel production industry. Backed by our extensive experience, our product solutions ensure that every aspect of your production process is optimized. Not only do we provide cutting-edge technology, we also offer top-notch service. In everything we do, our goal is to improve your plant’s performance.
Strip Finishing
Tube and Pipe Mills
As a full-line supplier active worldwide, we gather unique expertise in the entire production chain of metals. Backed by our extensive experience, our production lines feature solutions focused on process optimization. In everything we do, we have one goal in mind: to increase the performance of your plant.
Aluminum Rolling
As a globally active full liner, we possess expertise that is unique in the aluminium production industry. Our experience ranges from hot rolling to the finished product. This allows us to meet the demands both upstream and downstream – and to build the mill that fits perfectly your requirements.
Continuous Mining
SIMINE CONT combines our solutions for the individual process steps in continuous opencast mining into an overall system offering maximum availability. Our recipe for success is to bring together leading electro technical products with process technology expertise linked via perfectly matched interfaces, thereby providing the basis for excavating more material with less wear and tear on machinery and thus optimizing operating costs
Water Solutions
From the treatment technology to process automation and controls, Siemens provides turnkey water solutions for your mine. Engineering, commissioning and performance-based contracts are a few of the value-added services we provide. A single-source provider assists in the coordination effort and accelerates the time line from projects creation through to start-up.
Power Solutions
Optimized power supply and quality are the keys to safety and stability. Secure power supply is one of the prerequisites for successful plant operation. Our solutions are designed to meet the requirements of the industry and the high demands with respect to operator safety and operational reliability.
Turnkey packages
Siemens offers you a range of different turnkey levels to suit your needs, from turnkey implementation of the electrical section to complete delivery of machines, vehicles and systems - including life-cycle management and equipment for the secondary processes.
Production Management
Production Management makes the entire mining process transparent from excavation to ore processing. At the same time, it facilitates vertical information flow from production control level to the ERP system. Network solutions from Siemens provide both the infrastructure for exchanging data in the field and high-performance data highways for linking the areas together.
Security Systems
Security Systems provided by Siemens take plant security as well as data security into account. Thus, providing a complete security system for your employees, equipment and information.
Service and Maintenance
The maintenance of your plant is a substantial cost factor. But even though it accounts for up to 40% of ongoing operating costs, it is the only alternative to unplanned downtime. That makes it even more crucial to optimize maintenance processes – for the performance of your equipment and your mine.
Excavater Stacker Reclaimer
Discontinuous Mining
SIMINE DICONT optimizes the individual process steps in discontinuous mining and the entire process chain. Modules of this overall solution are proven solutions with innovative features for draglines, shovels, trucks and conveyor belts. Individualized matching of these modules to one another produces synergies for more performance, security and availability of all equipment.
Minewinder
The performance of underground mines depends critically on the capability of the hoisting equipment. The aim is to increase this capability without endangering the safety of persons during the transport in the shaft.
Benefication Plant
Being competitive in this case means increasing output while at the same time reducing wear and tear and costs for service and repairs. Solutions from Siemens allow you to meet all these requirements.
Pellet Plant
Sinter Plant
Coking Plant
coupled pickling lines and tandem cold mills
cold mill complexes
Mechatronic packages
PLANICIM Shapemeter Roll
Fara Oiler Systems
Blast Furnace
Corex
Finex
Midrex
LD (BOF) Steelmaking
Stainless Steelplant
EAF Steelmaking
Secondary Metallurgy
Dedusting
Energy Management
Utility Systems
Slab Caster
Thin Slab Caster
Bloom Caster
Billet Caster
Beam Blank Caster
Strip Casting
Stainless Steel Casting
Innovations and developments
Mini Mills for Long Products
Manufacturing Execution System
Integrated Mills
Integrated Compact Mills
Mini Mills for Flat Products
Hot Strip Mill
Compact Hot Strip Mill
Arvedi ESP Plant
The world’s first endless strip production plant is now under construction in Cremona, Italy. This trailblazing technology offers the promise of revolutionizing flat-steel production in the same way that LD converter steelmaking technology and continuous casting changed the face of the steelmaking industry in the previous century .
Steckel Mill
Plate Mill
Plate Steckel Mill
Hot Rolling Automation
Surface Inspection &Vision
Long Rolling Mill
Tandem Cold Mills
Reversing Cold Mills
Skin Pass Mills
Cold Mill Stainless
Cold Rolling Automation
Picking Lines
Annealing Lines
Metallic Coating Lines
Organic Coating Lines
Strip Processing Automation
Tube &Pipe Mills
Strip Preparation
Strip Accumulator
Forming
Welding
Sizing
Cutting Device
Finishing
Engineering
Hot Mills Alu
Cold Mills Alu
Foil Mills Alu
Aluminum Rolling Automation
Metallurgical Services
Technology, mechanical engineering, automation and electrical engineering from a single source – fast and competent services for all operational tasks
Operational Support
Modernization and Optimization
Metals and Mining Service &Support Center
Energy
Environment
Water
Continuous Casting Automation
Ironmaking Automation
Steelmaking Automation
Hot Rolling Automation
Cold Rolling Automation
Processing Line Automation
Aluminium Rolling Automation
Power / Power Supply
Manufactoring Execution System
MES gives you the transparency of your entire business process from the enterprise level down to the current shop floor situation.
Production Management / Production Control
Material and Quality Management
Information Management / Process Analysis
Production Planning
Quality Management
Logistics and Warehouse Management
Energy Management Portal
Laboratory Management
Balance of Plant
Civil Works
Steel Structure
Cranes, Elevators and Vehicles
Building Services
Erection Engineering and Site Management
Utility Systems
Water Management
Piping Standardization
Special Topics
Cost effective packages
Compliance
Corex
The COREX® Process
Corex is an industrially and commercially proven smelting-reduction process developed by Siemens VAI for the cost-efficient and environmentally friendly production of hot metal from iron ore and coal. The process differs from the conventional blast furnace route in that non-coking coal can be directly used for ore reduction and melting work, eliminating the need for coking plants. The use of lump ore or pellets also dispenses with the need for sinter plants.
Process History
The Corex process was developed in the late 1970s and its feasibility was confirmed during the 1980s. Following the first industrial application of a Corex C-1000 plant (nominal production of 1,000 tons of hot metal per day) at Iscor Pretoria, South Africa, four C-2000 plants (nominal production of 2,000 tons of hot metal per day) were subsequently put into operation at Posco/Korea, Mittal Steel/South Africa and at JSW Limited/India. In early November 2007, the first Corex C-3000 plant was started up at Baosteel, China. It has a nominal production capacity of 1.5 million tons of hot metal per year.
Process Description
In the Corex Process all metallurgical work is carried out in two separate process reactors – the reduction shaft and the melter gasifier. Lump ore, sinter, pellets or a mixture thereof are first charged into a reduction shaft via a lock-hopper system where they are reduced to direct-reduced iron (DRI) by a reduction gas moving in the counter-flow direction. Discharge screws convey the DRI from the reduction shaft into the melter gasifier where final reduction and melting takes place in addition to all other metallurgical and slag reactions. Hot metal and slag tapping are carried out as in conventional blast furnace practice. The quality of the hot metal is equivalent to that produced in a blast furnace.
Viewing the process from the coal-route
perspective, non-metallurgical coal is directly
charged into the melter gasifier via a lock-hopper
system. Due to the high temperatures predominating
in the dome of the melter gasifier (in excess of
1000 °C), a portion of the hydrocarbons released
from the coal during devolatilization are
immediately dissociated to carbon monoxide and
hydrogen. Undesirable by-products such as tars and
phenols, etc. are destroyed and therefore cannot be
released to the atmosphere. Combustion with oxygen
injected into the melter gasifier results in the
generation of a highly efficient reduction gas.
The reduction gas exiting from the melter gasifier
consists mainly of CO and H2 laden with fine coal,
ash and iron dust. This dust is largely removed from
the gas stream in a hot-gas cyclone and is then
recycled to the process. Through the addition of a
cooling gas, the reduction-gas temperature is
adjusted to its optimum working range. After leaving
the hot-gas cyclone, the reduction gas is then blown
into the reduction shaft via a bustle, reducing the
iron ores in counter flow.
The top gas is subsequently cooled and cleaned in a
scrubber, after which it is available as a highly
valuable export gas with a net calorific value of
approximately 7,500 –
8000
kJ/m³ (STP). This gas is suitable for use for a wide
range of applications.
Process Economy
Because coking and sintering plants are not required for the Corex Process, substantial cost savings are achieved in the production of hot metal. The extent of such savings depends, of course, on the local site conditions, however, can be in the range of up to 20% as proven under actual operating conditions.
Environmental Aspects
Corex plant emissions contain only insignificant amounts of NOx, SO2, dust, phenols, sulphides and ammonium. Emission values are already far below the maximum values allowed by future European standards. Also, waste-water emissions from the Corex Process are far lower than those in the conventional blast-furnace route. These environmental features are additional key reasons for the attractiveness of the Corex Process.
Use of Export Gas
After the cleaning and cooling of the top gas which exits the reduction shaft, it is then available for use in numerous industrial applications. These include electrical power generation, production of DRI (direct-reduced iron) and for heating purposes throughout the iron and steel works. In the chemical industry the Corex export gas can also serve as a feed stock for many other applications.
Additional Considerations
Corex C-3000 Plant, Boasteel, China
The latest generation of Corex plants, the
C-3000, is ideally suited for integration into
green- or brown-field steel works projects. It can
replace the blast furnace, or can be used as a
source of virgin iron for minimills. The economics
of the Corex plant already provide an answer to
future scrap and coke shortages, and the continually
increasing demands placed on steel quality. Another
alternative is the installation of a Corex C-3000
plant as a stand-alone merchant plant for the
production of hot metal and/or pig iron.
Contact
Siemens Metals Technologies
Ironmaking