NEWS

a pubblication for our valuable customers worldwide

June 2011 - n.4
CONTENTS
T
he events of the last 24 months have had a profound impact on all the world
economies. In steelmaking and mining, the industries directly served by
Tenova, the response to the crisis has seen Asia and South America lead the
way down the path to recovery. This has had a direct impact on new plant investments,
where, at global level, the strongest demand is for advanced technologies to improve end
product quality, cut energy consumption and improve environmental impact. Tenova is
responding to the positive prospects offered by the market by maximizing innovation
and, at the same time, enhancing its focus on on-going direct contact with customers
all over the world in order to provide optimal, high-performance solutions for specifc
requirements.
Today, a key Tenova strength is the added value offered by a worldwide network of 33
companies and a global-local market approach: by combining direct communication
with customers with the opportunities offered by a major multinational group, entry on
to the different regional markets is facilitated.
TENOVA, THE ADDED VALUE
OF THE GLOBAL-LOCAL
APPROACH
>>>
Gianluigi Nova, Tenova CEO.
A TECHNOLOGIES
3
5
8
12
14
R&D, the advantages of the network
The benefts of Consteel Evolution

iRecovery

and EFSOP

, technologies
that care for the environment
Pomini Tenova builds a new roll grinder
for cluster mills
Tenova I2S focuses on high
performance control and automation
B CHINA
16
18
Consteel

breaks records in China

Advanced technology wins another
record line order
C INDIA
20
22
24
26
Indias strategic role in the Tenova
network
Industrial furnaces, a leadership
position for Tenova Hypertherm
Sail Bokaro chooses Tenova technology
Tenova TAKRAF focuses on the
cement industry
D NEW REALIZATIONS
28
33
The success of the Thyssen Alabama
project
Tenova HYL to build the worlds largest
direct reduction module
E MINING
36 Global Mining: new successes
at Tenova TAKRAF
F TENOVA IN THE WORLD
40 New frontiers for the Tenova network
44 NEWS
47 EVENTS
EDITORIAL 2 3
This issue of Tenova News attempts to
illustrate this approach with concrete
examples, looking at the most important
projects completed over the past few
months.
One instance is the completion of the
TKS Alabama project, where a consortium
formed by Tenova LOI Italimpianti and
Pomini Tenova with SMS Demag has
constructed the new ThyssenKrupp
production center in Calvert (Alabama),
a facility consolidating the customers
presence on the NAFTA market. The
newly opened Tenova commercial offces
in Vietnam and the Tenova TAKRAF
operating offce in Beijing testify to the
constant attention Tenova pays to the Far
East, continuing a strategy introduced
more than ten years ago.
Consteel Evolution and Re-Energy, who
recently became fully paid-up members
of the product portfolio, highlight the
unrivalled expertise Tenova offers in
integrating contiguous technologies for
solutions that advance the frontier of
innovation and environmental protection.
These are strengths the market recognizes
and appreciates, as witnessed by an
important Chinese customers recent
choice of Tenova insoluble anode
electrolytic tinning technology, the cleanest
and best performing technology on the
market. Tenova is to supply two tinning
lines and two electrolytic chromium
coating lines for a new 13 million t/y cold
rolling plant under construction in the
Chinese province of Hubei.
Advanced production performance and
important reductions in greenhouse gas
emissions are also the key to the latest
success in the USA of the direct reduction
technology developed by Tenova HYL,
who is to supply a 2.5 million t/y DRI
module, the largest ever built to date,
to a new factory in Louisiana. All over
the world, the Tenova commitment to
innovation has a constant focus: to deliver
a rapid response to customer needs with
high-profle solutions.
T
echnological innovation, with an offer of cutting-edge solutions to raise
productivity and reduce the environmental impact of production processes,
is proving to be a key growth driver for industrial plant suppliers, both on
consolidated Western markets and on markets resuming growth in the Far East and
South America. The speed of the investment upturn varies from region to region, but
in every area the fastest growing market sectors are niches with a higher technology
content. And the preference is for technologies guaranteeing an immediate return in
terms of productivity or cost reductions. In this scenario Tenova looks to the future
as the player offering the broadest and most complete range of new technologies for
steelmaking and the mining industry. Tenova R&D director Carlo Raggio explains:
Although investments were shrinking, we stayed in close contact with our customers
and the market. This enabled us to focus our development work to address new
requirements, often relating to energy savings and lower environmental impact, and
the concrete results we have achieved are now part of our product portfolio. The
cross-fertilization generated by the involvement of and cooperation among all the
Tenova Business Areas has helped us cut time-to-market for our R&D projects and,
at the same time, has fuelled development of integrated solutions combining and
enhancing the specifc value of adjoining technologies.
R&D, THE
ADVANTAGES OF
THE NETWORK
TECHNOLOGIES
Carlo Raggio, Tenova R&D Director.
Ever closer cooperation ties among the Business Areas. R&D projects in partnership with
customers. Innovative solutions integrating adjoining technologies. With its network of technology
companies covering all the different processes in steelmaking and mining, the Tenova R&D
pipeline is able to respond fast to new market requirements.
Bucket Wheel Excavator supplied by Tenova TAKRAF
in operation in an open cast mine.
View of an Electric Arc Furnace during the tapping phase.
TECHNOLOGIES 4 TECHNOLOGIES 5
Plenty of examples could be mentioned,
beginning with the enhancement of
the Consteel

process thanks to the

integration of Tenova Goodfellow
know-how in off-gas control systems
and Tenova LOI Italimpianti expertise
in latest-generation burners. Consteel
Evolution raises furnace productivity
without increasing electrical power
consumption. The process can also be
coupled with the technology of the Re
Energy subsidiary to recover a signifcant
portion of the heat generated by the
furnace and produce steam for industrial
applications.
The expansion of Tenovas network
of companies and its consequent
technological growth in the last few years
has provided an important stimulus for
R&D work. Synergies are not confned
to sales and marketing, but also involve
the networks production units around
the world and development of products
combining different technologies. For
example, the acquisition of Tenova I2S,
a specialist in highly automated cold
rolling mills for special applications,
has completed the offer of the Strip
Processing business unit, with the result
that today Tenova is able to supply the
entire technological process for strip cold
rolling and processing. Tenovas offer
also includes roll grinders, where Pomini
Tenova recently presented an innovative
wheel moving grinder for small-diameter
rolls used in cluster mills for cold rolling
of stainless steel strip. For this product,
Pomini Tenova and Tenova I2S are already
developing a joint promotions strategy for
packages comprising rolling mills and
grinders or automated roll shops.
Tenova adopts a similar approach to
innovation in mining, where Tenova
TAKRAF designs and supplies open-
cast mining equipment and bulk
handling systems. The challenge for
TAKRAF is to reconcile increasingly
demanding productivity requirements
with the reliability needed in the
extreme conditions in which mining
plants have to operate, Raggio explains.
The development of these huge mobile
machines, with lengths of up to 100
meters, heights of 50 meters and weights
normally up 4,000 t, goes hand in hand
with continuous improvements in operator
safety and environmental protection,
for example by cutting dust dispersal or
replacing wheel-based transportation
between the mine and stockpile areas
with automated bulk handling systems.
Completely new mobile mining systems
especially for In-Pit Crushing have been
developed. TAKRAF mining know-how
also complements the expertise of Tenova
Pyromet, a specialist in the design and
construction of submerged arc furnaces
for ferroalloys and non-ferrous ore
processing.
THE BENEFITS
OF CONSTEEL EVOLUTION
The new scrap charge reheating system realizes the full potential of Consteel

thanks to use of the

chemical energy from the furnace off-gas and recovery of the heat lost during the process.
F
ourty plants: a worldwide
reference that confrms the
leadership of Consteel

as an
innovative technology for the electric
furnace meltdown process. A leadership
established thanks to the reliability
of the system and its production and
environmental performance, the result
of continuous research and development
work integrating Tenova know-how over
the entire steelmaking spectrum. This
drive for innovation has now produced
Consteel Evolution

, a new system that

realizes the full potential of Consteel

by deploying Tenovas latest expertise in
the area of scrap charge reheating, use
of the chemical energy from the furnace
off-gas and recovery of the heat lost
during the process.
Compared with the traditional system,
Consteel Evolution

separates the scrap

charge loading and pre-heating tunnel
into two sections. The frst section is
equipped with high-effciency burners
developed jointly with Tenova LOI
Italimpianti, which speed up the pre-
heating phase and keep it thermally
separate from the EAF process.
As a result the scrap quickly reaches
a higher temperature than with a
conventional Consteel

system. The
second section, immediately adjoining
the furnace, channels the rising off-gas.
SAVINGS AND PERFORMANCE COMPARED TO A TRADITIONAL
EAF AND CONSTEEL

REFERENCE TOP
CHARGE EAF
CONSTEEL

CONSTEEL EVOLUTION
TM
Avg. preheating temp. c.a 250 C c.a. 500 C
Specic productivity t/h/MW 2.0 2.5 +25% 3.0 +50%
Scrap charge yield 90% 91.5% +1.5% 91.5% +1.5%
Electric energy kWh/t 395 345 -50 295 -100
Natural gas (total) Nm3/t 7.0 0.5 -6.5 7.0 0.0
Electrodes kg/t 1.20 1.12 -7% 0.95 -20%
Delta transformation cost /t -11.0 -15.0
Steam condenser of the iRecovery

system
at Georgsmarienhtte plant.
TECHNOLOGIES 6 7
The Tenova Goodfellow EFSOP

off-
gas analysis and control system operates
in this second section, maximizing
post-combustion of residual carbon
monoxide.
This subdivision improves stabilization
of the thermal fow: in the section where
the off-gas mixes with the fumes from
the pre-heating burners, the temperature
and available energy are constant with
respect to both a traditional EAF and
the conventional Consteel

system,
thereby creating the ideal operating
conditions for implementation of a Re
Energy residual heat recovery system.
The main strength of Consteel
Evolution

is the sharp reduction in

power consumption, which translates
into a signifcant increase in the plants
specifc productivity, says Mauro
Bianchi Ferri, Tenova Metal Making
Marketing & Sales Vice President.
A normal modern EAF, charged from
scrap baskets through the roof, produces
no more than two tons of steel per hour
per installed MW. Data from operating
Consteel

systems refect specifc

productivity of 2.5 tons/hour, while our
simulations for Consteel Evolution
indicate increased specifc productivity
up to 3 tons/hour per available MW,
a 50% improvement with respect to a
traditional EAF. Other advantages are
the reduction of harmful emissions,
thanks to the stable high temperature
of the off-gas, and the possibility to
recover a signifcant portion of residual
heat, thereby raising the overall energy
effciency of the process.
Although four Tenova operating units
and the Centro Sviluppo Materiali
(CSM), our Research Centre partner,
have been working on Consteel
Evolution in recent months, the
development project was kept strictly
under wraps until July 2010, when all
the international patents protecting the
process know-how were registered. The
start-up of the promotional campaign
has already elicited a positive market
response, especially in areas where
electric power is more expensive, like
Japan and Europe.
Without doubt our customers are aware
of the potential of the new version,
adds Bianchi Ferri. The system offers
the greatest benefts for medium/large
plants, where the savings on electricity
bills for the same production volumes
are particularly attractive. Moreover,
Consteel

systems can be upgraded to

the Evolution version by a revamp of
the preheating tunnel, so the investment
outlay is limited and the production
stoppage for the plant conversion is kept
to a minimum.
Simulations for Consteel Evolution indicate
increased specific productivity up to 3 tons/
hour/MW, a 50% improvement with respect
to a traditional EAF
Consteel Evolution

technology: view of the complete

process.
TENOVA
GOODFELLOW
RE ENERGY
TECHNOLOGIES 9
iRECOVERY

AND EFSOP

,
TECHNOLOGIES THAT CARE
FOR THE ENVIRONMENT
The optimization of the overall energy balance of the EAF reduces energy consumption
and greenhouse gas emissions, without limiting the productive performance.
S
teel production in an electric
arc furnace (EAF) is an energy-
intensive and, as far as traditional
furnaces are concerned, a quite
ineffcient process. Almost 50% of the
global energy, deployed in the process in
the form of electrical or chemical energy
and used for melting, is lost into the
atmosphere in the form of heat, together
with signifcant amounts of greenhouse
gases (GHG). Technology providers have
been working for years to improve EAF
energy effciency, but now steelmakers
are pressing even more for systems that
effectively cut energy consumption and
GHG emissions without limiting furnace
performance and productivity. Tenova
is meeting the challenge, says Tenova
Metal Making Marketing and Sales Vice
President Mauro Bianchi Ferri, with
an approach designed to optimize the
overall energy balance: A good 70% of
energy lost during the melting process is
due to the process off-gas, in the form
of unused heat and chemical energy.
Tenova Goodfellows EFSOP

technology
enables steelmakers to keep the meltdown
process under constant control in order
to optimize the chemical energy used and
thereby reduce the global energy in the
furnace. At the same time, a signifcant
portion of lost heat associated with the
off-gas can also be recovered, for example
to produce industrial steam or electrical
energy with a co-generation plant. This
is the goal of iRecovery

technology the
process developed by Tenova Re Energy,
the new group company in Dsseldorf,
which specializes in engineering and
construction of heat recovery systems,
not only for the steel industry but for all
energy-intensive industrial processes.
Through continuous, dynamic
measurement of off-gas, the EFSOP

system enables real-time intervention in
the process in order to optimize use of
chemical energy. Data from operating
plants indicates that in an EAF with an
annual production capacity of 1 million
tons, reduction of electric power through
the EFSOP

system is approximately 14
Steam drums and collectors in the Georgsmarienhtte
EAF cooling tower.
Integration of EFSOP

and i Recovery

technology
permits recovery of up to 25%
of total energy supplied to the EAF
SCHEME OF 2-STAGE HEAT RECOVERY FOR AN EAF
STEAM OUTTAKE STEAM OUTTAKE
FEED WATER
CIRCULATING PUMPS
STEAM-WATER-MIX
ELECTRIC ARC FURNACE
MAX 1.500-1.800C
ECS WASTE GAS DUCT
STEAM DRUM
WASTE HEAT BOILER
~ 600C
~ 200C
PRESSURIZED WATER AT BOILING POINT, I.E. 220C
TECHNOLOGY 10 11
kWh per ton of steel produced, while
GHG emissions fall by 18%. When
EFSOP

is combined with iRecovery

technology, the energy and environmental
benefts are even greater. Integration of
the two systems permits recovery of up to
25% of total energy supplied to the EAF
and 50% of energy that would otherwise
be lost as heat in the atmosphere,
Bianchi Ferri explains. For example, a
furnace with 80 MW nominal power
can recover approximately 15 thermal
MW in the form of steam, which can
be used in the steel plants production
processes, for instance for the vacuum
degassing plant, or to power a turbine
generator, or in a district heating system
in urban areas close to industrial sites.
iRecovery

is based on heat exchangers

using water at high pressure (15-40 bar)
and accumulation tanks that compensate
for heat interruptions between meltdown
cycles. In stable operating conditions,
a 140 t/h EAF guarantees continuous
production of 20 t/h of steam; thanks
to heat recovery, further reductions in
overall GHG emissions are possible.
It is no coincidence that some countries
are already introducing incentives to
shorten amortization on heat recovery
plants, which today is ranging between 4
to 6 years, adds Bianchi Ferri. In Canada,
for example, the Province of Ontario is
introducing a program for large energy
users which funds electricity production
projects based on heat recovery.
In other countries, similar incentives
are being developed to turn recovery
technology into a concrete, immediate
industrial option for energy-intensive
industries.
AVERAGE EFSOP

OPERATING RESULTS
IN GLOBAL MARKETS
% Decrease (Average)
Electrical Consumption 3,3
Oxygen Consumption 1,0
Natural Gas Consumtion 14,0
Charge Carbon Consumption 28,3
Injected Carbon Consumption 9,5
Power ON Time 2,9
% Increase (Average)
Productivity 5,2
Yield 0,7
TOTAL AVERAGE SAVINGS (US$/TON) 2,2
Tenova iRecovery

transferring 14 bar steam to a plants

steam network.
Performance Parameter Improvement over 40 Running EFSOP installed on EAF.
TECHNOLOGIES 13
POMINI TENOVA BUILDS A
NEW ROLL GRINDER FOR
CLUSTER MILLS
Completely designed by the technical department of Pomini Tenova, the new roll grinder achieves
superior performance to conventional machines.
A
n entirely new concept in
high-performance grinders,
developed with an engineering
approach that kept time-to-market to
a minimum: with the new MW479,
Pomini Tenova is aiming to set a new
benchmark in grinders for the small rolls
employed by cluster mills used mainly
to roll ultra-thin stainless steel strip.
The introduction of the new model in
its production range will enable Pomini
Tenova to enhance its references in this
particular sector which accounts for
almost 10% of the entire roll grinder
market where it also has signifcant
potential technological and commercial
synergies with Tenova I2S, a primary
player in cold rolling mills. In order
to address the needs and expectations
of the most advanced and demanding
cluster mill users, weve decided to
target the market with a completely
innovative machine, right from the basic
idea, says Pomini Tenova Senior Vice-
President Paolo Gaboardi.
The MW479 is a moving wheel roll
grinder for cluster mills, a solution
that delivers superior performance
and marks a major advance in terms
of ease of operation and maintenance
requirements, which have been
minimized through a modern, rational
design approach. Three patents have
already been registered to protect the
engineering solutions used to apply the
technology to the new machine. The
development project involved the entire
Pomini Tenova Technical Offce, whose
engineering work focused on a series of
basic concepts, such as the moving wheel
solution, a self-bearing structure to cut
erection time, automated operation and
extensive use of standard components
to maximize interchangeability and
simplify maintenance work. A decisive
contribution to the project came from
the insights and expertise of Thomas
Anderson, a widely experienced project
engineer and today head of Pomini
Tenova Nordic. Each new solution was
carefully analyzed and corroborated
with brainstorming sessions and
analyses by the entire project team and
independent consultants. Use of state-
of-the-art design software, such as Finite
Element solid Modeling with CAD 3D,
substantially reduced development
time for the prototype on which the
fnal function tests and fne tuning
MW479 TECHNICAL DATA
Maximum diameter that can be ground with a new wheel of 610mm 250 mm
Maximum distance between centres 2500 mm
Wheel motor power 15 kW
to optimize performance under any
operating conditions are currently being
completed. Confrming Pomini Tenovas
credibility and reputation for reliability,
fve key customers have already chosen
the new grinder, and a total of eleven
machines have already been sold, to be
delivered over the next six months.
The MW479 roll grinder under assembly in the Pomini
Tenova factory, Castellanza, Italy.
Five customers have already chosen the new roll
grinder, for a total of eleven machines already
sold
TECHNOLOGIES 15
TENOVA I2S FOCUSES
ON HIGH PERFORMANCE
CONTROL AND AUTOMATION
The Field Programmable Gate Array is state of the art technology for full real-time control
of the cold rolling process.
T
echnological innovation applied
to automation and control
of the rolling process is the
foundation on which Tenova I2S has
established its acknowledged leadership
in high-performance cold rolling mills.
Beginning in the 1970s, the company has
applied the know-how built up through
intensive in-house R&D work to develop
new hardware platforms and software
packages that enable important advances
in machine operating performance
and end product quality. Progress has
been particularly signifcant in the area
of rolled strip thickness and fatness,
where steelmakers require ever tighter
tolerances. Since the early 1980s,
Tenova I2S rolling mills have employed
high performance Automatic Gauge
Control (AGC) systems, which control
the thickness of the material being rolled
through precise regulation of the inter-
roll distance, rolling force, coil tension
and rolling speed. The value of the AGC
system is confrmed by the more than
350 systems installed to date around the
world. Now, the possibilities offered by
latest-generation software and hardware
have enabled new developments to meet
growing market demand for operating
fexibility and superior end-product
quality. The result is Field Programmable
Gate Array technology (FPGA): based on
an innovative hardware/software platform
developed by Tenova I2S, which provides
real-time management of the AGC system
and all control equipment associated with
the mill, to adapt the rolling process to
meet specifc operating requirements. The
hardware platform is fully confgurable
and able to interface with any Master
controller used on the mill in order to
optimize rolling operations. Today, the
FPGA AGC system is the technological
heart of the new high-speed cluster mills
developed by Tenova I2S for rolling very
thin stainless steel and special alloy strip
down to 0.02 millimeters, used in hi-tech
industry applications. The frst several
systems of this type installed to date
have met with the full satisfaction of the
customers, outperforming expectations
for production and quality requirements.
The FPGA system is the technological heart of
the new high-speed cluster mills developed by
Tenova I2S for rolling very thin stainless steel
FPGA internal architecture and component arrangement.
Main control pulpit of Tenova I2S ZR22B-52 Sendzimir
Mill.
Hierarchical block diagram illustration of the typical
AGC systems network topology, components and their
interconnections.
PROGRAMMABLE
INTERCONNECT
LOGIC BLOCKS
I/O BLOCKS
HIGH LEVEL
SYSTEMS
COMMUNICATIONS & CONTROL NETWORK
DATABASE
SERVERS
DRIVE
SYSTEM
COORDINATOR
GAUGING
SYSTEM
SUPERVISOR
MASTER
CONTROLLING
PLC
OPERATOR
STATION
AGCS HMI
USER INTERFACE
TENOVA I2S - AGC SYSTEM
TENOVA I2S - AGC REAL-TIME CONTROLLER
CORE 2 DUO PROCESSOR
CORE # 1
REAL-TIME OPERATING SYSTEM
CORE # 2
WINDOWS XP PRO
ACG
CONTROL
CYLINDER
CONTROL
GAUGE
INTERFACE
TACH
INTERFACE
ENCODER INTERFACE
FPGA
SERVO CONTROL
FPGA
SERVO
CONTROL
& FEEDBACK
TENSION TRIM
FOR ROLL GAP
COMPENSATION
WRAP
COUNTING
ENTRY
TENSION
CONTROL
THICKNESS
GAUGE
WORK ROLL
SPEED
MATERIAL FLOW
ROLL FORCE
CYLINDERS
STRIP
TACHOMETER
OPC
SERVER
HMI
PACKAGE
T
H
IC
K
N
E
S
S
M
E
A
S
U
R
E
M
E
N
T
S
P
E
E
D
/L
E
N
G
T
H
M
E
A
S
U
R
E
M
E
N
T
16 17
T
enova is to construct the biggest Melting Unit ever built in China for
MCC Beris Jiangsu Heavey Industry Corporation - Feida Group. The
plant will be located in Jiangsu province, an industrial area near Shanghai
which is home to Chinas most advanced production facilities. It will be equipped
with a Consteel

plant and a 250 t/h EAF feeding a continuous casting unit for
slab production. We have now installed at least ten Consteel

furnaces in China,
but none as big as this one, says Giuliano Fanutti, Area Sales Manager for China
and South East Asia. Chen Jie, Business Development Manager for Metal Making,
China, notes that: The customer originally intended to install two smaller production
units, with locally made equipment. But after conducting a thorough technical study,
they decided our proposal of a single bigger plant would be more advantageous,
permitting greater fexibility thanks to the continuous charging possibilities offered
by Consteel

, the fact that, overall, the structure would take up less space and, above
all, optimization of production costs and environmental friendship. The plant will
become operational in the second half of 2011, and its construction has brought
together all Tenovas top technological experts in Italy and China. The process and the
engineering were perfected in Milan, says Guido Molteni, Vice General Manager
of Tenova China. Some high-tech components, particularly those linked with
automation, came from Italy, but the metal and structural parts, which make up about
CONSTEEL

BREAKS RECORDS
IN CHINA
CHINA
The new plant, with a capacity of 250 mt/h of steel, will be built in Jiangsu province, near
Shanghai, one of Chinas most advanced industry parks.
80 percent of the supply, were built by
Tenova Timec in China. This solution not
only enabled us to optimize construction
costs while maintaining a very high level
of quality, but permitted us to save time
and cut shipping costs. One of the keys to
the success of the project is that Tenovas
advanced technology prevailed over local
suppliers offers, in a highly competitive
economic context. On the Chinese
market, adds Giuliano Fanutti, there are
customers who are very conscious of the
quality of their equipment and interested
in investing in technologies offering
performance levels that bring benefts
for production in terms of dependability,
quality, cost containment and decreased
environmental impact. I think these are
the reasons why Beris and the Feida
Group chose Tenova to make this plant.
The project will also be a very important
reference, opening up good prospects for
the future. The size and characteristics
of the project are already attracting a lot
of interest among major local producers,
concludes Guido Molteni, including
those who initially didnt even take into
consideration the benefts offered by
our technology, which combines furnace
and Consteel

to permit unprecedented
fexibility in operations and production
capacity.
The impressive Consteel

system installed at Acciaieria

Arvedi, Cremona, Italy. Similar equipment will be
provided to the plant in China.
Started from 1997 Tenova has installed
11 Consteel

systems in China, out of 40

installations in the world, a tangible proof
of the great operational flexibility and
versatility of the technology that is well
appreciated in the Country.
CONSTEEL

SYSTEMS IN CHINA:
14 YEARS OF CONTINUOUS SUCCESS
FEICHENG
XINING
WUXI
EZHOU
GUIYANG
SHAOGUAN
TONGHUA
SHIZUISHAN
DANYANG
JIAXING
ANSHAN
19 CHINA
ADVANCED TECHNOLOGY
WINS ANOTHER RECORD
LINE ORDER
The largest order ever awarded to Tenova Strip Processing is for construction
of 4 high-speed lines.
T
enova Strip Processing was
awarded an order for four high-
speed lines two insoluble-
anode electrolytic tinning lines and two
electrolytic chrome plating lines for
Three Gorges Quan Tong Colored and
Galvanized Plate Co. China. The four
hi-tech lines Tenova shall be installing
will be used to produce materials of
superior quality which will be one of the
most advanced and distinctive features
of the plant, whose annual production
capacity will be 13 million metric tons.
The Tenova lines will produce tin- or
chrome-plated steel and are designed
for 1,250 mm wide strip at thicknesses
between 0.14 and 0.55 mm, with an
entry speed of 450 m/minute and an exit
speed of 600 m/minute. Insoluble-anode
technology is the key to the Tenova tinning
process, explains Giovanni Gallarati,
Tenova Strip Processing Marketing &
Sales Director, It delivers excellent
performance while minimizing operating
costs and environmental impact, and
enables a degree of tin coating control
impossible with traditional technology.
We were certainly chosen on the strength
of our references in this sector.
Tenova has installed more than 40
tinning lines to date, including eight
lines in the past eight years, of which
six in China alone. The plants built
in Spain for Arcelol-Mittar, in Turkey
for Erdemir and in China for Dajing
Metal Co. Jiangsu provided signifcant
evidence of the quality and performance
of Tenova electrolytic plating. This will
unquestionably be an important order,
2 ELECTROLYTIC TINNING LINES (PSA ELECTROLYTE)
2 ELECTROLYTIC CHROMIUM COATING LINES
TECHNOLOGICAL FEATURES IN ELECTROLYTIC TINNING LINES
Material to be processed Cold rolled annealed and tempered low carbon steel
Final use Cans and packaging
Strip dimensions Thickness 0.140.55 mm - Width 10001250 mm
Line performances Entry/Exit 600 mpm - Line Speed 450 mpm
in terms of both plant engineering and
construction, adds Gallarati.
We shall be making use of all the skills
and production expertise of the Tenova
network. The electrolytic cells will be
built by Tenova Timec in China, the
tension levelers by Pomini Tenova in
Italy and the thickness gauges will be
produced by Tenova I2S in the USA.
In selecting Tenova Strip Processing
lines for its high-quality production, the
customer has chosen the most advanced
technology on the market. This order
confrms the importance of Tenova
on-going investment in research and
innovation. It also demonstrates that
cutting-edge technology is a vital strategic
element to attract emerging producers as
well as established manufacturers and
to succeed on the highly competitive
Chinese market.
Vertical looper tower of a Tinning line.
Production capacity 100.000 350.000 t/y
Material to be processed Cold rolled annealed and tempered low carbon steel
Final use Cans and packaging
Strip dimensions Thickness 0,1 0,6 mm
Width 465 1,400 mm
Line performances Entry/Exit section
Speed up to 700 m/min
Process speed up to 600 m/min
Electrolytic Tinning Lines have always
been a key business activity for Tenova
as well as an important research and
process development area. On the right,
the general technical data of Tenova Strip
Processing Electrolytic Tinning Lines.
20 21
H
aving come through the 2009 crisis relatively unscathed, the Indian
economy is once again growing fast. In 2010 Indias GDP rose by 8.6%,
the highest increment of the past three years and one of the largest at
world level. The countrys key economic sectors are all working to meet the growth
challenge, generated so far not by exports as in other emerging countries, but by rising
domestic demand and important investment in infrastructures. So the Indian economy
will continue to progress at a rapid pace during the next few years, with very favorable
prospects for heavy industry in general and for steel in particular. Analysts expect Indias
steel production to expand by 7% in 2011 and subsequently to maintain signifcant
growth rates, with the result that by 2015 India will be the worlds second-largest
steelmaker, preceded only by China and outranking the USA and Japan. This level of
expansion will require massive investment to boost the countrys annual production
capacity, which will have to more than double from todays 70 million metric tons.
Investment not only by domestic producers, but also by the top international steel
groups. India offers very favorable conditions for heavy industry and mining, with
plentiful resources of iron, coal and other ores.
In this positive scenario Tenova is investing heavily to strengthen its operations: since
2008 it has increased its workforce in India from 15 to 420 people, employed by
four operating companies. Its main locations are in the Mumbai area, with Tenova
INDIAS STRATEGIC
ROLE IN THE
TENOVA NETWORK
INDIA
Indias steel industry capacities will increase significantly in next five years. Tenova operates
with four companies in this strongly expanding market.
Multiform and Tenova Hypertherm,
in Chennai with Tenova TAKRAF and
in Kolkata with Tenova LOI Wesman.
Tenovas strong local roots and well
distributed geographical base enable it to
maintain very close ties with customers
and the local markets and to respond
faster to needs and requirements on a
rapidly expanding market. In fact, India
accounts for approximately 10% of Tenova
global revenues, and is expected to grow
further, achieving a leading position
in our backlog. Yet Indias importance
inside the Tenova global network is not
limited to the contracts acquired and
the potential of the local market. The
presence of highly qualifed engineers
and the widespread use of English have
enabled the local operating companies to
create engineering hubs providing high-
profle design and executive engineering
expertise for the entire Tenova system.
A further demonstration of the growing
importance of the Indian subcontinent
within the Tenova network.
The Indian market contributes around 10%
of the global revenue of Tenova
Tenova took part in the eighth edition of
MMMM (Minerals, Metals, Metallurgy and
Materials), the most important Conference
& Exhibition in India for the steel industry
and all related technologies.
Tenova presented its brand, companies
and the full range of products and
solutions to the key people in the Indian
steel industry.
TENOVA AT
MMMM EXHIBITION
23 INDIA
INDUSTRIAL FURNACES,
A LEADERSHIP POSITION
FOR TENOVA HYPERTHERM
The Indian company, a brand of Tenova LOI Italimpianti, has a 60% share of the reheating furnace
market and is a key player in the current expansion of new plant investments, driven by rising
demand for high-quality steel products.
I
n parallel with the rapid expansion
of the Indian steel industry, the
industrial furnace market is enjoying
a period of growth, with hi-tech plant
suppliers at the forefront of the trend.
According to offcial estimates, Indian
demand for steel will continue to grow
until at least 2016, at an average annual
rate of 10%. Demand for steel products
will grow at a particularly fast pace at
the high end of the market, targeting
top-grade products for sophisticated
applications in automotives and
mechanics. Consequently, production
investments are putting priority on plant
and equipment with a higher technology
content, able to deliver end products
offering greater quality and reliability.
In industrial furnaces, key components
of the steel-making process, Tenova
Hypertherm leads the reheating market
with a 60% share, thanks to its local
roots and access to the technologies
developed by Tenova LOI Italimpianti.
The Mumbai offce is an important hub
in the Tenova LOI Italimpianti global
production network. Tenova Hypertherm
has established strong permanent ties
with all the top steelmakers in India and
during 2010 acquired an important series
of supply contracts of signifcant value
in terms of equipment and technology.
Key orders placed during the year
include an order for a roller furnace for
the second line of CSP of Bhushan Steel
&Power, to join the furnaces supplied
previously. In May, through Tenova
Hypertherm, Tenova LOI Italimpianti
signed a contract to supply a 60 t/h
reheating furnace to Kalyani Gerdau
Steels, a Company in Brazils Gerdau
group. Other important acquisitions
in 2010 were a contract with the Steel
Authority of India (SAIL), Indias
leading steelmaker, for a 225 t/h walking
beam furnace for fat products, to be
installed in the Roukela Steel factory,
and a turnkey contract with Bhushan
Steel Ltd. India for a 300 t/h walking
beam furnace.
The positive trend in new orders
continues this year: in January a contract
was signed for the revamping of a 300
t/h walking beam furnace for Tata Steel
India. India will continue to be the
Tenova LOI Italimpianti core market
over the next few years, with annual
investments in reheating furnaces
expected to rise rapidly from the current
50 million euro to approximately 100
million euro in fve years time.
The state companies controlled by
SAIL Bokaro Steel, Bhilai Steel and
NMD Steel have introduced the
most ambitious growth programs, with
projects to revamp existing lines as well
as install new plants. Meanwhile, all
the main Indian producers led by Tata
Steel and POSCO have planned an
investment program in Orissa State. An
exciting outlook for Tenova Hypertherm,
which continues to invest in know-how
and specialized resources in order to take
advantage of every new opportunity.
200 t/h Walking Beam furnace supplied to JSW, India.
In industrial furnaces Tenova Hypertherm leads
the reheating market with a 60% share
25 INDIA
SAIL BOKARO CHOOSES
TENOVA TECHNOLOGY
Pomini Tenova and Tenova Strip Processing will supply an automatic Roll Shop and an Inspection
and Recoiling Line for SAIL Bokaro plant expansion.
T
enova will help expand the plant
in Bokaro Steel City (Jharkhand
State, India), one of the biggest
productive units controlled by the Steel
Authority of India (SAIL), the countrys
public sector steel company.
Pomini Tenova will supply an automatic
Roll Shop, while Tenova Strip Processing
will supply an Inspection and Recoiling
Line for carbon steel strip. The two
Tenova plants will equip a new cold
rolling mill which will produce 1.2
million tons of high quality carbon steel
strip a year, destined primarily for the
automotive industry. These are the frst
two contracts Tenova has acquired from
SAIL. The project is a valuable reference
in a market as important as India. The
negotiations were complicated, but the
features of the Roll Shop meet all of the
customers very strict requirements, say
Paolo Gaboardi, Senior Vice President
of Pomini Tenova, and Niraj Kumar,
Pomini Tenova Service Director. The
Roll Shop consists of three grinders
and is complete with all the auxiliary
equipment required for Rolls and Chocks
movement, loading and maintenance,
with a very high level of automation.
Tenova Strip Processing will supply an
automated tension levelling, inspection
and recoiling line for fnal control of
strip prior to distribution on the market.
The line, which will operate downstream
of a new cold skinpass mill, can control
strips weighing 30 tons and measuring
800-1560 millimetres wide and 0.25
to 2.0 millimetres thick at a speed of
500 metres per minute. According to
Giovanni Gallarati, Marketing & Sales
Director at Tenova Strip Processing,
The plant is equipped with latest
generation strip tension, inspection and
control systems. The handling system
provides the best possible protection
of the strip surface to guarantee the
high fnishing standards required by
the automotive industry. The plant
will be supplied turnkey, complete
with all auxiliary components, within 24
months of the signature of the contract.
The project will be executed jointly by
Strip Processing and Tenova Multiform,
Tenovas new Indian company near
Mumbai, with over 130 employees and
workshops specialising in process lines
and cold rolling mills.
ROLL SHOP MAIN CONTENTS AND TECHNICAL FEATURES
INSPECTION AND RECOILING LINE,
MAIN TECHNICAL DATA
Total Mill Production 1.2 MTPA ( PLTCM, HDGL - SPM , SPM )
Grinders 2 Work Roll Grinder and 1 Combination Grinder with Future expansion possibility
Grinding output / month 1720 Work Rolls and Intermediate Rolls
40 BackUp Rolls
800 Work rolls ( Texturing )
Maintenance equipment Dechockers for WR and BUR, Chock Tilter and other equipment
Loading and Transportation Automatic Roll Loader, and all Lifting Beams for Roll and Chock Transportation,
Future expansion possibility for one Loader
Other Equipment Turn Key Supply includes EDT machine, Cleaning and Washing machines
and other equipment required in Roll Shop for Rolls and Chock Maintenance
Grinding Accuracy Accuracy on reference rolls to 2 m/m on prole error and taper,
2 m on roundness
Roll Change time on Grinder (from loading rack) Less than 6 minutes
Kind of steel Cold rolled, annealed and skin-passed low carbon
steel strip
Kind of material CQ, DQ, DDQ, EDDQ, IF, IF-HSS, BH
Yield strength (minmax.) 140440 N/mm
Tensile strength (min-max.) 270700 N/mm
Width (mm) 8001550
Thickness (mm) 0,252
Ys (kg/mm2) 140440
Total Production (ton/year) 550.000 (350.000 for tension levelling, 200.000
for inspection only)
max weight (ton) 30
Max elongation % 2
Max speed of the line (m/min) 500
View of a cold rolling mill installed by Pomini Tenova.
Tension Levelling and Recoiling line.
27 INDIA
TENOVA TAKRAF FOCUSES
ON THE CEMENT INDUSTRY
Thanks to innovative technological solutions, Tenova TAKRAF has won a 50% market share as a
supplier to the Indian cement industry, an area set for important growth over the next few years.
T
he cement industry has been
TAKRAF Indias mainstay in the
last 5 years and will continue to
be a priority sector for the company in
the coming years.
Since completing our frst installation
six years ago, we have supplied more
than 150 machines, says Kalyana
Krishnan Gopal, Sales Director. A
full range of stackers and scraper-type
reclaimers have been developed to
meet specifc customer requirements.
Currently our market share in India for
this type of equipment is around 50%.
Customer satisfaction has resulted in
several repeat orders. We have also
supplied equipment to cement plants in
Africa and the Gulf countries.
With India forecasting healthy GDP
growth of around 8% over the next few
years, the Indian cement industry is in
a comfortable position. The countrys
fast-growing economy requires a
more intensive pace of development
in infrastructure. India is the worlds
second-largest cement producer, but
its per capita cement consumption is
still a paltry 180 kg, whereas in other
emerging economies like China or
Brazil, the fgures are 1,100 kg and 290
kg respectively. Blessed with massive
local limestone reserves, the Indian
cement industry is poised to grow at a
staggering 10% over the next 10 years.
TAKRAFs success stems directly
from its R&D work on new equipment
enabling important advances in plant
operating performance and end product
quality. TAKRAF has been a supplier
of stockpile equipment for bulk
materials for many years. Synchronized
stacking and reclaiming are essential
for proper blending in cement plants.
TAKRAF India has developed special
equipment to stack the limestone in a
pre-programmed sequence and reclaim
the material as a representative sample
of the stockpile. This method ensures
that the limestone conveyed out of the
stockpile is blended to a high degree.
Due to the high level of automation
and safety features on the equipment,
stockpiling and reclamation operations
are fully automated, controlled from the
cement plant DCS.
2010 was a good year for us, says
Gopal. We began with a major
breakthrough right here in Chennai.
For years, Madras Cement had been
buying from our competitor. In January,
they chose Tenova TAKRAF to supply
three large circular blending systems for
limestone and one longitudinal system
for coal. Two of the circular systems
have a 100 m diameter, the third system
has an 82 m diameter. Nine months
later, when Madras Cement wanted to
procure two longitudinal systems with
portal scrapers, they chose us again.
Vicat, a major French cement maker,
recently set up their frst cement plant
in India, in Karnataka. After lengthy
technical discussions, in the frst half
of 2010 they ordered six machines
from Tenova TAKRAF for their cement
plant. Six months later, they ordered two
machines for their captive power plant.
In 2009, we made inroads into
Chettinad Cement on their brownfeld
expansion project near Chennai.
Chettinad Cement again chose Tenova
TAKRAF for their greenfeld project
in Karnataka. So far we have supplied
Chettinad Cement with 14 machines,
and the customer is expected to set up
two more plants in the second half of
2011.
Tenova TAKRAF Circular Blending System for Limestone
(Jordan).
28 29
O
ffcially opened on December 16, after just three years of work,
ThyssenKrupp Steel USA and ThyssenKrupp Stainless USAs new fve
billion dollar plant in Calvert (Alabama) is one of the largest foreign
industrial investments ever made in the USA. It also confrms the ThyssenKrupp
groups strategy targeting expansion on the NAFTA market. As ThyssenKrupp AG
Chief Executive Offcer Ekkehard Schulz observed at the opening ceremony, Our
processing facilities in Alabama are of the highest international standard and set a
benchmark for steel production sites in the USA. When fully operational, the new
facility will have an annual production capacity of more than four million metric tons a
year of high-quality carbon steel strip and one million metric tons of stainless steel strip.
The plant is a state-of-the-art operation set up at the heart of the NAFTA market, where
ThyssenKrupp intends to become a supplier of choice for Americas most advanced
industries, notably automotives. The facility is fully equipped to produce the highest
quality coiled carbon steel bands for sale as hot rolled and substrate for cold rolled and
coated products. The hot strip mill is capable of rolling thicknesses ranging from 1.5 mm
up through 25.4 mm, and the state-of-the-art continuous pickle tandem mill will have
the capability of rolling from 0.3 mm up through 3 mm for both exposed and unexposed
applications. The central element of the plant is a wide hot strip mill with a capacity of
over fve million metric tons per year. The frst coil was produced here in July. The cold
rolling mill started operation in September. The coating lines of ThyssenKrupp Steel USA
will be completed step-by-step. The frst cold-rolled products have already been shipped
THE SUCCESS
OF THE THYSSEN
ALABAMA PROJECT
NEW REALIZATIONS
After just three years of work, the new ThyssenKrupp AG facility in Calvert (Alabama) has begun
production. In a consortium with SMS Demag, Tenova LOI Italimpianti and Pomini Tenova supplied
cutting-edge technology and equipment for engineering systems and solutions.
The Tenova LOI Italimpianti
furnaces for the Calvert plant.
31 NEW REALIZATIONS 30
to customers. In the future the hot strip
mill will also be used by ThyssenKrupp
Stainless USA. Stainless operations got
underway in September 2010 with one
cold rolling mill and an annual capacity
of around 100,000 tons. Tenova is one
of the main technology partners on the
project. In 2007, the consortium set up
by SMS Demag and Tenova, with the
LOI Italimpianti and Pomini Tenova
Business Areas, was awarded a contract to
supply the hot and the cold rolling mills,
three 420 t/h walking beam reheating
furnaces and two complete automated roll
shops, each comprising four roll grinders.
The package presented by Tenova was
a decisive element in TKS choice of
supplier, together with the advantages of
an organization with permanent operations
in Germany and the USA, and so in a
position to maintain an on-going technical
dialogue with TKS at every stage, from
design to plant commissioning. The start-
up of on-site erection operations in June
2009 for the frst of the three Tenova
LOI Italimpianti reheating furnaces and
December 2009 for the two Pomini Tenova
roll shops highlighted the contribution
of Tenova Cores role as system integrator,
coordinating assembly work for reheating
furnaces, and the positive refections of
Pomini Tenovas 100% in-house design
approach to erection activities. The Calvert
facility has been constructed entirely with
European technologies, plant, components
and standards, but was assembled by an
American contractor and workers. The
requisites for the three furnaces and the
two roll shops are cutting edge in terms
of operating performance and automation.
The fact that TKS is a long-standing
customer of the business area certainly
facilitated communication, says Nicola
Cavero, Tenova LOI Italimpianti Senior
Vice President. The three furnaces for the
US factory are the same size and category
as the furnace delivered to the TKS plant in
Duisburg (Germany) in 2005. They deploy
The requisites for the three furnaces and the
two roll shops are cutting edge in terms of
operating performance and automation
Wide shot of the Pomini Tenova roll shop for TKS hot
strip mill.
View of the Flexytech

TSX Flameless Burners installed

at the Alabama facility.
and develop all the innovative concepts to
optimize combustion under any operating
conditions, reduce emissions and, above
all, enhance automation and the slab
feed control systems. For example, the
top limit for NO
x
emissions specifed
by TKS was 100 mg per cubic meter,
whereas the limit in Europe is 400 mg
per cubic meter. So the project involved
an intense engineering effort, which also
addressed TKS need to simplify plant
management once production began.
For instance, new engineering solutions
have been implemented to facilitate
access to system components in order
to simplify maintenance. A high level of
customization is also a feature of the two
roll shops. In terms of automation and
ancillary components, this is the most
complete project ever supplied by Pomini
Tenova, says Paolo Gaboardi, Pomini
Tenova Senior Vice President. Not only
do the new shops condense the expertise
acquired from installation of more than
thirty roll shops to date, they also deploy
innovative solutions developed in response
to the needs of the future plant operators.
Their input provided us with guidelines for
the design of the components and ancillary
plant, and, above all, enabled us to develop
powerful new automation software
packages, with more intuitive, versatile
user interfaces. The two roll shops are
Pomini Tenovas most important reference
ever, as Paolo Gaboardi notes: We are
represented in Americas most important
and innovative steel mill, with a project
bringing together our entire catalogue of
equipment and auxiliary systems for roll
shop automation and employing advanced
technical solutions. A unique showcase
for increasing the visibility of the Tenova
brand and Pominis know-how.
NEW REALIZATIONS 32 NEW REALIZATIONS 33
TENOVA HYL TO BUILD
THE WORLDS LARGEST
DIRECT REDUCTION MODULE
Nucor Corporation, the leading steel producer in the United States, has chosen Energiron ZR
for a 2.5 mt/y DRI production plant in Louisiana.
I
t will be the largest Direct
Reduced Iron (DRI) production
plant in the world, confrming the
reliability and effectiveness of Energiron
ZR technology.
Nucor, Americas top steelmaker, has
signed a contract with Tenova HYL
for construction of a new plant with a
2.5 mt annual production capacity at
the Nucor steel Louisiana facility in
St James Parish (Louisiana). The new
plant will turn out highly metalized,
high carbon DRI for top-grade steel
production at the steel plants of various
Nucor Group facilities.
Tenova HYL will supply a complete
module, excluding ancillary plants and
material handling systems, through
to plant commissioning and start-up,
scheduled for the Spring of 2013.
The new project confrms all the
strengths of Energiron ZR, the only iron
ore direct reduction process technology
not to generate the reducing gas in
a conventional reformer plant, but
directly in the reactor, which is fed with
natural gas.
The technology was developed entirely
by Tenova HYL and has been available
on an industrial scale since the end
of the 1990s, when a direct reduction
module began production at the Ternium
facility in Monterrey (Mexico).
Tenova HYL CEO Roberto Pancaldi
explains: Today the self-reforming
Energiron ZR process is the state-of-
the-art for DRI production. Wherever
natural gas is available, it is the most
competitive, fexible and environmentally
clean solution for upstream integration
with electric furnace charging.
After a full technical and economic
analysis, these were the characteristics
that convinced Nucor, a long-time
leading steel producer. Energiron ZR
is also the only process able to produce
DRI with a 96% metallic iron content
and over 3.5% carbon content in the
form of cementite (Fe
3
C), which does
not react with atmospheric oxygen. As
a result, the DRI is much more stable
and can be more easily stored and
transported.
Through continuous investment in
R&D, over the past ten years Tenova
HYL has fully developed the most
benefcial intrinsic characteristics of
ZR technology, which in many ways
now ranks as a competitive alternative
to the blast-furnace steel production
cycle. The reactor where the direct
reduction process takes place operates
at an internal pressure of approximately
The Energiron ZR process is the most efficient
direct reduction method in the field
View of the roll shop cooling down area.
NEW REALIZATIONS 34 35
7 bar; this optimizes the entry and
circulation of the reducing gas, while
simultaneously ensuring very high
specifc productivity of over 10 mt/hour
per square meter of reactor surface. By
changing the dimensions of the reactor,
the size of the plant can be tailored
to the specifc needs of the customer,
beginning with Micro-Modules for
production of 200,000 mt/year.
The 2.5 million mt/year for Nucor
will have a reactor diameter of just six
point fve meters, but the maximum
theoretical productivity limit has not yet
been reached.
The greatest potential of the ZR
process, however, lies in the area of
environmental impact: the by-products
of the reduction reaction, which uses
hydrogen and carbon monoxide from
natural gas or alternative sources like
syngas and coke oven gas, are steam
and carbon dioxide (CO
2
), extracted by
a special capture system before the top
gases are re-circulated and re-used. The
ZR process complies with the strictest
environmental standards governing
toxic emissions and greenhouse gas,
Pancaldi observes.
The capture system means the CO
2

produced by the reaction can be
stocked and sold on the technical gas
market. Given the good results achieved
with other plants already in operation,
Nucor too is taking advantage of this
opportunity, which will reduce operating
costs still further.
Together with high energy effciency, the
low level of CO
2
atmospheric emissions
makes the ZR process an attractive
alternative to the blast furnace process,
as Pancaldi explains: The CO
2
per ton
of fnal liquid steel generated in the
Energiron ZR and EAF production chain
is approximately half that of the blast
furnace Oxygen converter cycle, and
almost half that CO
2
can be captured
and either sold or sequestrated And if
you also consider that the great majority
of blast furnaces operating around the
world have an annual capacity of less
than 2 million mt of cast iron, then from
the production viewpoint too, the two
processes are equivalent today.
Not to mention that for equivalent
production capacity, the overall
investment in Energiron ZR is far
smaller.
17
REDUCING GAS
SOURCES
Natural Gas
Reformed Gas
Coal Gasication
COG
Others
PARTIAL OXIDATION
AND REFORMING REACTIONS
2H
2
+ O
2
> 2H
2
0
2CH
4
+ O
2
> 2CO + 4H
2
CH
4
+ H
2
O > CO + 3H
2
O
CO + H
2
O > CO
2
+ H
2
REDUCTION AND
CARBURIZATION REACTIONS
Fe
2
O
3
+ 3H
2
> 2Fe + 3H
2
O
Fe
2
O
3
+ 3CO > 2Fe + 3CO
2
3Fe + CH
4
> Fe
3
C + 2H
2
ENERGIRON DIRECT REDUCTION PROCESS
The recent Nucor project makes a total of 12 million tons
of new Energiron plant capacity since 2006.
DRI
NG
FUEL
OXYGEN
PG
HEATER
HUMIDIFIER
CO
2
RG COMPRESSOR
TG HEAT
RECUPERATOR
H
2
O
H
2
O
CG
COMPRESSOR
DR SHAFT
IRON ONE
37 36
I
n Chile, Tenova TAKRAF has just been awarded a 50 million euro contract by
BHP Billiton to relocate two crushers at the Escondida copper mine.
We have been in Chile since 1994 and it is our single most important market,
accounting for 20 to 25 per cent of all our revenues, Tenova TAKRAF Germany Sales
Director Thomas Eckel tells us. Besides BHP Billiton, we also have strong ties with
Codelco, the State-owned company which is the other major player in the mining
sector. On the Chinese market, Tenova TAKRAF has won a contract to build one
of the Asias largest bucket wheel excavators, at the Zhahanaoer coal mine, for the
CPE Mengdong Energy Group. This order confrms the huge growth potential of the
Chinese market in this sector with respect to a generally diffcult global situation,
comments Eckel. I should point out that this is the frst system of this kind to be
built in China for 15 years. Moreover, we were awarded the contract just eight months
after our entry on to the local market, while our international competitors have been
here for many years. And to consolidate our local operations, we have opened an
offce in Beijing. Another important success for Tenova TAKRAF is the award of a
project in Mauritania: the company has just signed a 35 million euro contract to supply
equipment for the re-organization of the Nouadhibou port terminal in Mauritania, the
loading hub for iron ore extracted at the Zoureat mine. This is a new market for us in
a country with enormous potential in the iron mining industry, says Thomas Eckel.
Our customer, the National Industry and Mines Company, is already planning to
expand the plant, and there will certainly be a role for us.
GLOBAL MINING:
NEW SUCCESSES
AT TENOVA TAKRAF
MINING
The latest projects won in Chile, China and Mauritania confirm Tenova TAKRAFs global
leadership in the mining business, both on its traditional markets and in areas where
it is a more recent entrant.
CHILE: NEW ORDERS WITH AN HISTORIC CUSTOMER
The Escondida Ore Access project awarded to Tenova TAKRAF
in Chile by BHP Billiton involves the relocation of two crushers,
explains Tenova TAKRAF Chile Managing Director Christian
Cavagnaro.
It comprises all the engineering, the partial restructuring of the
two crushing systems and the construction of a new conveyor
system over a distance of about five kilometers, with an hourly
capacity of 8,800 metric tons.
Escondida is the worlds largest copper mine and operates to a
major extent with equipment from Tenova TAKRAF.
The latest order confirms the superior performance of the
machines and the reliability of the service provided, which has
always kept the system in top working order.
We have a long-standing relationship with this customer, based
on mutual esteem and trust, says Christian Cavagnaro, and
every two years or so, they award us a new order. So we are
confident that, for the future too, we shall continue to play a
significant role in the important modernization and enlargement
projects planned at the Escondida mine.
Escondida W9 conveyor extension after semi-mobile crushing plant relocation,
Escondida copper mine Chile.
MINING 38 39
CHINA: A RECORD-BREAKING PROJECT ON A COMPETITIVE
MARKET
MAURITANIA: IMPORTANT FIRST STEPS IN A NEW CONTINENT
With an hourly capacity of 10,000 metric tons and a wheel diameter
of 12 meters, the bucket wheel excavator Tenova TAKRAF is to build
at the Zhahanaoer coal mine for the CPE Mengdong Energy Group
will be Asias largest. The 44 meter boom can excavate terraces
with a block height of 30 meters and a block width of 50 meters,
says Tenova TAKRAF Asia CEO Holger Lieberwirth, and the
excavator will operate under extreme conditions. The Zhahanaoer
coal mine, with an estimated 827.93 million tons of lignite at
depths ranging from 85 to 356 meters, is located north west of
the city of Tongliao in Inner Mongolia, where the temperatures
fluctuate from 39C above zero to 39 below. The system will
begin operations in October 2013: this is the 56th excavator of
this type built by the company. Similar systems built by Tenova
TAKRAF more than 30 years ago in Kazakhstan for the Ekibastus
mine, are still operating, in even more severe climatic conditions.
We were awarded this project thanks to our positioning as world
constructors of giant bucket wheel excavators adds Holger
Lieberwirth. The customer was also familiar with the excellent
performance of similar equipment built by Tenova TAKRAF some 15
years ago at Yuan Bao Shan. Another source of satisfaction is that
the contract marks our return to the important Chinese market,
where we intend to establish ourselves as a fully fledged member
of the local community, making synergetic use of local materials
and workers and international contacts and experience.
In Mauritania, at the Nouadhibou port terminal, which is linked
by rail to the Zoureat mine, Tenova TAKRAF is to install a
conveyor system linking the materials deposit with the port, and a
continuous ship loader with an hourly capacity of 12,000 metric
tons. In addition to the two equipment supplies, the contract
provides for the demolition of the existing systems and a series
of plant modifications, explains Tenova TAKRAF Germany Project
Director Norbert Neumann. One of the most complex aspects
will be the integration of the new units with the old components
still in operation. But the greatest challenge will be to keep
to a minimum the plant shutdown for the start-up of the new
equipment. Project execution time has been set at 30 months
from the date of the contract, worth a total of 26 million euro.
About two thirds of the contract value relates to the design and
construction of the conveyor system, to be handled by our Leipzig
office, says Tenova TAKRAF Italy Sales & Marketing VP Pietro
Bibolini. One third relates to construction of the continuous
ship loader, to be handled by our Genoa team. Our references as
ship loader constructors were a vital factor in the acquisition of
this project. The customer was highly impressed by our systems
in Brazil, among the worlds largest with an annual capacity of
approximately 110 million tons. Just recently Tenova TAKRAF
Germany signed a further contract with SNIM Mauritania worth
another 22 mill . Under this contract Tenova TAKRAF will supplky
two conveying bridges for handling and disposal of waste material.
This new investment is in context with the expansion of capacities
at the iron ore mine site in Zouerate.
SRs 2000.32/5.0 Bucket Wheel Excavator, similar machine will be installed
in the Zhahanaoer coal mine, China.
Mobile Stacking Bridge, length 420 m, similar machine will be installed in the Guelb II
project of SNIM, Mauritania.
41 40
O
ver the past few years the Tenova network has achieved further
growth in all fve continents, expanding its operations in line with the
development of the emerging markets.
Specifcally, Tenova has strengthened its presence in the worlds fastest growing
industrial regions and today it is active all over the world, deploying a glocal strategy
that combines its global vision with strongly rooted local operations.
Three new locations have joined the network over the last year:
In Beijing, the mission of the new Tenova TAKRAF unit is to broaden and develop
Tenova TAKRAFs presence in mining, an industry with important growth prospects
where demand for high-tech, energy-effcient equipment is rising constantly.
Tenova has been active in China for a number of years with Tenova LOI Italimpianti
in Tianjin; Tenova Timec, a workshop in Tanggu, the Tianjin industrial district, and
Tenova Industrial Technologies in Beijing.
Tenova TAKRAF has been operating from the Beijing offce since 2008; in 2009
it won its frst contract for one of the biggest Bucket Wheel Excavators, a success
subsequently confrmed by other orders from the Chinese mining industry.
The newly set-up mining offce has a staff of 18, active in sales, engineering,
procurement, quality control, project management, project and fnance control.
In Vietnam, a very promising market on the international scene, Tenova has opened
NEW FRONTIERS
FOR THE TENOVA
NETWORK
TENOVA IN THE WORLD
Think global and act local, is the Tenova strategy to grow in new emerging markets as well as well-
established industrial areas. The goal is to create an increasingly customer-oriented network.
a new offce in Ho Chi Minh City. The
southern part of the country was chosen,
because the majority of investments are
located around Ho Chi Minh City, where
many industry parks are springing up.
The new offce will be Tenovas
bridgehead into the whole Indochina
region and will handle sales, engineering,
project execution, procurement and
customer service activities.
The investment decision was immediately
confrmed by the acquisition of two
interesting contracts by Tenova Key
Technologies and Pomini Tenova. For the
frst contract, Tenova Key Technologies is
to build a turnkey plant to regenerate acid
and remove silicon from hydrochloric
acid pickling baths for the cold rolling
mill of China Steel Sumikin Vietnam (a
joint venture set up by China Steel Corp.
of Taiwan and Japans Sumitomo).
For the same customer and at the same
plant, located in the Phu My area (Ho
Chi Minh City), Pomini Tenova will
supply a complete Roll Shop.
To strengthen its position in small roll
grinders, Pomini Tenova has established
a company in Sweden, Pomini Tenova
Nordic AB.
The location is Vallentuna, where
important customers are within close
traveling distance. The new company will
focus on development and servicing for
Pomini Tenova small roll grinders, but it
will also provide service and rebuilds for
any brand of roll grinder on the market.
The new product line of small roll
grinders includes the MW 479 Cluster
Mill Roll Grinder, on the market since the
middle of 2010. More than 10 units are
currently under assembly at the Pomini
Tenova plant in Castellanza, Italy, and
will soon be ready for delivery to leading
steel makers around the world. The
international expansion strategy pursued
over the last years has strengthened
Tenovas position as a global player.
Following the establishment of the
new offces, the network now has more
than 30 operating companies and 3,000
people across 21 countries. Thanks to
its integrated network, Tenova provides
unique solutions through a unifed
approach that translates into perceptible
added value and tangible benefts,
constituting a technological benchmark
for its customers.
Tenova has strengthened its presence in the
worlds fastest growing industrial regions and
today it is active all over the world
43 TENOVA IN THE WORLD 42
WIEN - AUSTRIA
LIEGE - BELGIUM
DSSELDORF - GERMANY
ESSEN - GERMANY
LAUCHHAMMER - GERMANY
LEIPZIG - GERMANY
GENOA - ITALY
MILAN - ITALY
VARESE - ITALY
VALLENTUNA - SWEDEN
CALGARY - CANADA
TORONTO - CANADA
DENVER - USA
PITTSBURGH - USA
YALESVILLE - USA
MONTERREY - MEXICO
BELO HORIZONTE - BRAZIL
SO PAULO - BRAZIL
SANTIAGO - CHILE JOHANNESBURG - SOUTH AFRICA BRISBANE - AUSTRALIA
BEIJING - CHINA
SHANGHAI - CHINA
TANGGU - CHINA
TIANJIN - CHINA
CHENNAI - INDIA
KOLKATA - INDIA
MUMBAI - INDIA
ALMATY - KAZAKHSTAN
TASCHKENT - UZBEKISTAN
HO CHI MINH CITY - VIETNAM
SOFIA - BULGARIA
KATOWICE - POLAND
TARGU JIU - ROMANIA
MOSCOW - RUSSIA
THE TENOVA NETWORK
Tenova operates through more than 30 companies located
in 21 countries in 5 continents
44 45
NEWS
TENOVA
TENOVA INCREASES ITS ACHIEVEMENTS
AND ITS PRESENCE IN VIETNAM
Tenova has opened a new Representative
Offce in Ho Chi Minh City, Vietnam, one of
the worlds most promising markets.
The new offces opening has also been
greeted by the acquisition of two new orders
from China Steel Sumikin Vietnam: Tenova
Key Technologies, the Austrian company part
of the Tenova Group, has been awarded the
order for a turnkey plant for acid regeneration
and removal of silicon dioxide from the
baths on a hydrochloric acid pickling line,
installed at the cold rolling mill complex of
China Steel Sumikin Vietnam, a joint venture
between Taiwans China Steel Corp. and
Japans Sumitomo. For the same customer
and at the same facility, located in the Phu
My district (Ho Chi Minh City), Pomini
Tenova will supply a complete Roll Shop
which includes three CNC Roll grinders
complete with automatic loaders and Roll
Shop Management System.
TENOVA LOI ITALIMPIANTI
TENOVA REVAMPS TENARIS DALMINE
ROTARY HEARTH FURNACE
Tenova LOI Italimpianti has successfully
coordinated the project to revamp the rotary
hearth furnace on the Tenaris medium-pipe
line. The goal was to charge larger billets
up to a length of 5,300 mm and to improve
productivity by about 35%. A signifcant
savings in fuel consumption (by about 15%)
has also been achieved.
ALUMINIUM NORF ORDERS TWIN-
CHAMBER MELTING FURNACE (TCF)
FROM LOI ITALIMPIANTI
At the beginning of the year Alunorf has
placed a contract with LOI Thermprocess
for a TCF twin-chamber melting furnace
for stage two of the recycling centre. The
new recycling system is to be designed for
a daily throughput of 150 tonnes of liquid
metal, which will be produced entirely from
aluminium scrap.
GERDAU AOMINAS SELECTED TENOVA
LOI ITALIMPIANTI TO SUPPLY TWO
WALKING BEAM FURNACES FOR THE
NEW STECKEL/PLATE MILL
GERDAU ACOMINAS and Tenova LOI
Italimpianti signed, at the end of July 2010,
a contract for the supply of two Walking
Beam Furnaces for Slabs to be installed in
the new Plate/Steckel mills of the GERDAU
ACOMINAS Plant, Ouro Branco, Brazil.
The two walking beam furnaces, having
a production of 220/265 t/h each, will be
designed according to the last innovative
concepts of LOI Italimpianti in the feld of
high quality reheating furnaces FlexyTech
technology saving energy and offering the
maximum protection of the environment
aspect.
TENOVA LOI ITALIMPIANTI STARTS-UP
A WALKING BEAM FURNACE IN TAIWAN
In June Tenova LOI Italimpianti has
successfully completed the start-up of a 200
metric tons/hour walking beam reheating
furnace for billets in the new rolling mill
at the Kaohsiung China Steel Corporation
(Taiwan). The new fuel-effcient furnace
is equipped with Tenovas state-of-the-art
Flexytech

low NO
x
burners as well as with
an advanced thermal model-based Level 2
control system.
TENOVA RECEIVES THE ACCEPTANCE
CERTIFICATE FOR THE PIT FURNACE
SUPPLIED TO VALLOUREC &
MANNESMANN (GERMANY)
In June VALLOUREC & MANNESMANN
TUBES Deutschland GmbH has issued the
Acceptance Certifcate for the pit furnace
installed in Dsseldorf-Reisholz realized
by Tenova LOI Italimpianti. The new pit,
supplied in addition to the existing ones,
has load capacity of 220 t of round pieces
having different steel qualities and heated
up to 1,320C and it is equipped with the
newest innovative combustion technology
considering the use of LOW-NO
x
High-
Speed-Burners, designed for running
with natural gas and controlled in on / off
sequential mode.
TENOVA MELT SHOPS
THE 20
TH
TENOVAS CONSTEEL

IN
ASIA: FINAL ACCEPTANCE CERTIFICATE
ACHIEVED IN JAPAN FOR THE BIGGEST
CONSTEEL IN THE WORLD
After the recent Consteel

start-up in Korea,
China and Vietnam, Tenova has successfully
commissioned a new Consteel

plant in
Japan. Tokyo Steel has equipped its new steel
plant in Tahara (Japan), which is going to
produce 2.5 M tons/year of quality steel, with
360 tons of steel per hour Consteel

system,
the highest installed capacity Consteel

in
the world. The new giant Consteel

system
has been coupled with an electric arc furnace
of 300 tons nominal tapping capacity and 420
tons total capacity.
THE PREMIER PUTIN STARTED UP THE
NEW TENOVA MELT SHOPS AT ISHVESK,
RUSSIA
At the presence of the Russian Prime
Minister Mr. Putin, the new Tenova Melting
complex located at Izhevsk steelworks in
Udmurtia Republic, Russia has been started
up on September the 7
th
.
Tenova contract covered a full-scale
upgrading of the melt shop n23 of Izhstal
OAO plant, owned by the Mechel group,
among Russias top mining and metals
companies. Tenova supplied a new electric
arc furnace (EAF), Ladle Furnace (LF) and
a vacuum degassing station. The EAF will
provide a capacity of 40 tonnes.
Tenova will also provide the auxiliaries
plant such as fume dedusting system, water
treatment plant and the ferroalloy plant.
TENOVA PYROMET
POS-HIMETAL SIGNS REPEAT ORDER
WITH TENOVA PYROMET
In January 2011, Dongbu Corporation
contracted Tenova Pyromet to design and
supply a ladle furnace and a slag holding
furnace for the PosHimetal project.
The slag holding furnace comprises of a
furnace whose complete shell tilts on a set of
rollers. The electrodes are retracted from the
furnace when the tilting operation occurs.
Tenova Pyromet has supplied furnace
equipment for many manganese operations,
but this project is unique in the methods and
processes used to produce a low phosphorous
and low carbon manganese product.
TENOVA PYROMET AND TENOVA CORE
TO SUPPLY ARMSTRONG WORLD
INDUSTRIES A SUBMERGED ARC
FURNACE FOR BLAST FURNACE AND
FERROALLOY SLAG SMELTING
In September Tenova Core, in conjunction
with Tenova Pyromet (South Africa), has been
contracted to design and supply a 12.5 MVA
submerged arc furnace (SAF) for Armstrong
World Industries new 30,000 square foot
manufacturing plant, located in Millwood,
West Virginia. The SAF will feature advanced
electrode clamping technology and a single
phase transformer with three independent
on-load tap changes as well as state-of-the-art
process control systems.
TENOVA GOODFELLOW
SUSTAINABLE DEVELOPMENT
TECHNOLOGY CANADA PARTNERS
WITH TENOVA GOODFELLOW INC. ON
ENERGY EFFICIENCY PROJECT AT
ARCELORMITTAL DOFASCO
February 2011 - Tenova Goodfellow Inc.
(TGI) is pleased to announce a contribution
agreement with Sustainable Development
Technology Canada (SDTC) to demonstrate
TGIs proprietary Next Gen Energy
Effciency Breakthrough Technology System
for the Electric Arc Furnace (EAF) industry.
TGIs second SDTC supported project to
develop leading edge clean technology will
be completed in collaboration with Canadas
leading steel producer ArcelorMittal Dofasco.
TENOVA GOODFELLOW RECEIVES
FOUR NEW ORDERS FOR EFSOP

INSTALLATIONS FROM CELSA GROUP
(SPAIN)
In February 2010, Tenova Goodfellow
installed its proprietary EFSOP

system on
the 140 ton EAF #2 at Celsa Barcelona,
with the objective of improving performance
and operating cost primarily by reducing
electricity, oxygen, methane, injected carbon
and charge carbon use. Prior to EFSOP

optimization, a performance guarantee was
mutually agreed upon by both parties. In May
2010, Celsa Barcelona signed off that Tenova
Goodfellow had successfully fulflled the
performance guarantee as per the contract.
TENOVA GOODFELLOW ACHIEVES EAF
SAVINGS AND INSTALLS EFSOP

WATER
DETECTION SYSTEM AT ARCELORMITTAL
CONTRECOEUR OUEST INC., CANADA
In October ArcelorMittal Contrecour Ouest
Inc. has confrmed that Tenova Goodfellow
Inc. has achieved EAF operating savings
of over US$ 2.00 per ton liquid steel using
the EFSOP

system at its plant just east of

Montreal Canada. These savings include
signifcant reductions in electrical energy,
natural gas and charged carbon, as well as
increased productivity.
The performance benefts were accomplished
through a combination of various EFSOP

optimization strategies.
TENOVA CORE
TENOVA CORE CONTRACTED FOR
MATERIAL HANDLING SYSTEM
At the beginning of the year Tenova Core
received an additional contract from
Armstrong World Industries to provide a
complete material handling feed system for
the new 12.5 MVA submerged arc furnace
(SAF) at Armstrongs new Millwood, West
Virginia facility. Tenova Core, in conjunction
with Tenova Pyromet (South Africa), was
contracted earlier to supply the new SAF.
METALLIX CONTRACTS TENOVA CORE
FOR ROLLER HEARTH FURNACE
At the beginning of 2011 Tenova Core has
been contracted by Metallix Refning, Inc.
to design and supply a custom roller hearth
type furnace. The furnace will be installed as
part of the precious metal recovery process at
Metallixs Greenville, NC, refnery.
TENOVA CORE CONTRACTED FOR
CONSTEEL

REVAMP
In December Gerdau Ameristeel has
contracted Tenova Core to provide a major
revamp of the existing Consteel

system
located at the Charlotte, North Carolina
plant. Consteel

is the continuous
steelmaking process, which preheats and
feeds scrap and other raw materials directly
into the EAF via a patented conveying system
through the EAF sidewall.
TENOVA CORE TO SUPPLY ARMSTRONG
WORLD INDUSTRIES A SUBMERGED
ARC FURNACE FOR BLAST FURNACE
AND FERROALLOY SLAG SMELTING
In September Tenova Core, in conjunction
with Tenova Pyromet (South Africa), has
recently been contracted to design and supply
a 12.5 MVA submerged arc furnace (SAF)
for Armstrong World Industries new 30,000
square foot manufacturing plant, located in
Millwood, West Virginia.
The SAF will feature advanced electrode
clamping technology and a single phase
transformer with three independent on-load
tap changes as well as state-of-the-art process
control systems.
TENOVA CORE INSTALLS PLATE HEAT
TREATING FURNACE FOR OUTOKUMPU
In September Tenova Core has completed
the successful start-up of a walking hearth
plate heat treating furnace at Outokumpus
stainless plant located in New Castle,
Indiana. The furnace was installed as part of
a plant upgrade project.
The walking hearth furnace features state-of-
the-art low NO
x
burners as well as a complete
47 NEWS 46
control and automation system that includes
an advanced Level 1 tracking system. Tenova
Core also designed and supplied a custom jet
air and water mist cooling system to reduce
the temperature of the stainless plate product
after it exits the furnace.
TENOVA I2S
TENOVA I2S TO SUPPLY A NEW 4 HIGH
TEMPER MILL FOR OLYMPIC STEEL,
INC. IN GARY, INDIANA
In November Tenova I2S has signed a
contract with Olympic Steel, Inc. to supply a
444 & 1067 x 2134mm 4 High Temper Mill
at the companys planned new site at U.S.
Steels Gary Works plant in Gary, Indiana.
The new Tenova I2S Mill will be the third
Temper Mill supplied to Olympic Steel, Inc..
The frst two Temper Mills are located at
Olympic Steel, Inc. facilities in Cleveland,
Ohio and Bettendorf, Iowa and have been in
operation for over a decade. Olympic Steel,
Inc. is a national steel service center.
TENOVA I2S WON A NEW CONTRACT
FOR A 4 HIGH REVERSING MILL IN
UZBEKISTAN
In November Tenova I2S has signed a
contract for the supply of a new 75 & 320
x 310mm 4 High Reversing Mill for APO
Uzbek Metallurgical Plant in Bekabod,
Uzbekistan. The Company produces high
quality precision strip of Copper and Copper
based alloys. The Tenova I2S Mill is equipped
with the latest Tenova I2S automation and
control systems which produce precision strip
to a minimum thickness of 0.03mm. The
mill includes Tenova I2S Automatic Gauge
Control (AGC), Contact Thickness Gauges,
AC Drives and Tenova I2S Mill Control
Systems.
TENOVA STRIP PROCESSING
TENOVA FIRST ZERO EFFLUENT
PICKLING LINE IN UGANDA
In November 2010 Tenova Strip Processing
has received a contract from Roofng Mills
Ltd to design and supply a Zero Effuent
Pickling Line Push Pull type. The plant,
which includes a proper HCl (Hydrochloric
Acid) Regeneration Plant, is part of the frst
Cold Rolling complex under construction
in Uganda to produce galvanized and colour
coated coils mainly for construction and
building application.
TENOVA STRIP PROCESSING
COMPLETED A NEW SILICON LINE AL
NLMK RUSSIA
In December 2010 Tenova Strip Processing
received the fnal acceptance certifcate for
the annealing, thermofattening and coating
line for grain oriented silicon steel for NLMK
in the Lipetsk Plant.
The line has been based on a new innovative
technology developed by Tenova Strip
Processing in collaboration with Tenova LOI
Italimpianti Genoa for the thermal part. The
line has a capacity of 60.000 ton/year.
TENOVA TO SUPPLY A NEW LINE TO
STEEL AUTHORITY OF INDIA
In April Tenova Strip Processing has received
an order from SAIL (Steel Authority of India)
for a Tension Leveling and Inspection Line
for the Bokaro steel plant, in the Indian state
of Jharkhand. The project will be executed on
a turnkey basis in Consortium with Mumbais
Multiform now part of Tenova Group, and
Kolkatas Sunag Engineering, in charge for
local supplies and services.
TENOVA TAKRAF
SUCCESSFUL PERFORMANCE TEST OF
COMPACT BUCKET WHEEL EXCAVATOR
SRS(H) 1050 AND SPREADER A2RS-B
5500.60 IN MACEDONIA
Between 16 and 26 February 2011, the
Compact Bucket Wheel Excavator SRs(H)
1050 and Spreader A2Rs-B 5500.60 were
tested to verify their guaranteed performance
parameters. The test was successfully
completed despite diffcult local conditions
characterized by permanently changing block
parameters. All performance parameters
specifed for both machines were met during
the test.
TENOVA TAKRAF FACILITATE THE
EXPANSION OF SUEKS COAL EXPORT
TERMINAL AT THE PACIFIC SEA
On Friday the 4
th
of February 2011 both
partner companies SUEK and Tenova
TAKRAF signed a contract for the expansion
and upgrading of the SUEK owned coal
export terminal Vanino.
For the event of contract signing Mr. Vladimir
Rashevsky (CEO SUEK Siberian Coal
Energy Company), Mr. Vladimir Artemiev
(VP SUEK), Mr. Sergey Grigoryev (VP
SUEK), Mr. Walter Kng (CEO TAKRAF
GmbH) and Mr. Nils Scharfenberg (VP Sales
TAKRAF GmbH) met in Moscow on Friday.
TENOVA TAKRAF AND VALE, A NEW
ORDER IN GUINEA
At the beginning of the year Tenova TAKRAF
signed a contract in Belo Horizonte with VBG
to supply a reclaimer with a nominal capacity
of 6,000 t/h, a design capacity of 7,200 t/h
and a 40 meters boom. The contract covers
all basic and detailed engineering, FOB
supply of all structural, mechanical, electrical
and control components, supervision of
erection, commissioning, operating assistance
and on-site personnel training.
TENOVA TAKRAF TO SUPPLY A GIANT
IRON STACKER IN BRAZIL
In October COMPANHIA VALE DO RIO
DOCE has awarded Tenova TAKRAF with
a new order for an iron ore Stacker to be
installed at Ponta de Madeira Terminal,
Brazil.
Under this order, Tenova TAKRAF is to
supply on a turnkey basis a new giant iron
ore stacker with a nominal capacity of
16,000 t/h and project capacity of 20,000
t/h as well with a 55 m boom. The machine
which is expected to be delivered in 730
days represents a further success of Tenova
TAKRAF with VALE under VALEs plans to
expand the Ponta de Madeira terminal in So
Lus to 130 Mt/y.
TENOVA TAKRAF SIGNED A NEW
CONTRACT IN MAURITANIA
In October Tenova TAKRAF has signed a
contract for the turnkey supply of a Ship
Loader and a Conveyor System with Socit
Nationale Industrielle et Minire (SNIM),
the state-owned company in Mauritania. The
new ship loader has an iron ore capacity of
12,000 tons/hour and is part of an ambitious
program aiming to the expansion of the
company mine in Zouerate.

EVENTS
TENOVA CORE, HYL
STEEL SUCCESS STRATEGIES XXVI
USA - June 2022, 2011
TENOVA LOI ITALIMPIANTI, STRIP PROCESSING
GALVATECH 2011
Italy - June 2225, 2011
TENOVA LOI ITALIMPIANTI, METAL MAKING, POMINI
METEC/THERMPROCESS/GIFA 2011
Germany- June 27July 1, 2011
TENOVA LOI ITALIMPIANTI, METAL MAKING
STEELSIM AND EECRSTEEL 2011 TOGETHER WITH METEC
Germany - June 27July 1, 2011
TENOVA LOI ITALIMPIANTI, POMINI
ALUMINIUM CHINA
China - July 1315, 2011
TENOVA TAKRAF
AIMEX
Australia - September 69, 2011
TENOVA TAKRAF
OIL SAND SHOW
Canada - September 2021, 2011
TENOVA TAKRAF
EXPOSIBRAM
Brazil - September 2629, 2011
TENOVA LOI ITALIMPIANTI, MELT SHOPS
CLEAN TECHNOLOGIES IN THE STEEL INDUSTRY
Hungary - September 2628, 2011
TENOVA PYROMET
4TH SOUTH AFRICAN FERRO-ALLOYS CONFERENCE
South Africa - September 2830, 2011
TENOVA LOI ITALIMPIANTI
HRTEREIKOLLOQIUM WIESBADEN
Germany - October 1210, 2011
TENOVA TAKRAF
CHINA COAL & MINING
China - October 2831, 2011
TENOVA LOI ITALIMPIANTI, METAL MAKING, POMINI
IAS 18
TH
STEELMAKING CONFERENCE
Argentina - November 14, 2011
TENOVA MELT SHOPS
ILAFA
Brazil - November 1311, 2011
TENOVA WILL BE PRESENTING ITS STATE-OF-THE-ART PRODUCTS FOR THE STEEL INDUSTRY AT THE FOLLOWING
INTERNATIONAL EVENTS:
EDITOR
Mario Galli
EDITORIAL
CO-ORDINATION
Alessandra Bertoli
PUBLISHER
Tenova SpA
Via Monte Rosa, 93
Milano
LAYOUT
AND GRAPHICS
Rumore Bianco
PRINTING
Larovere S.r.l.
Via Maffucci, 3
Milano
Registrazione
Tribunale di Milano
n. 511 del 10-09-2001
JUNE 2011 - N.4