Batch Annealing Modernization at California Steel Industries0 pages

"Batch AnnealingModernization at CaliforniaSteel Industries nn

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In the mid-1960s and early 1970s, as U.S.cold roll sheet producers were building 5-
stand sheet cold reduction mills, manyadded batch annealing facilities in
order to process the additional
cold reduction throughput. Often
these facilities consisted of a 4-
stack-per-operating-base configu-
ration, which led to handling and
equipment efficiencies.With these units being in service30+ years, operators must now con-
sider whether to continue to repair,
replace in-kind or upgrade to
newer technology. California Steel
Industries (CSI) faced such choices
in the late 1990s with its 1970s-vin-
tage single-stack shop and an older
4-stack facility.CSI considered the upcomingrepair needs of the aging equip-
ment and took the opportunity to
gain operating, maintenance and
spares efficiencies by consolidating
to a modernized single shop.
Through a careful evaluation of the
advantages of 100% hydrogen
atmosphere annealing, CSI decided
to modernize all its annealing
equipment in order to utilize this
technology.Working with several potentialsuppliers, CSI developed a compact
design strategy to place the project
in the available space ahead of the
temper mill. A single turnkey sup-
plier was chosen to finalize the
design, direct the construction and
commission the equipment. All this
activity was to take place in close
proximity to operating areas yet betransparent to the flow of cold rolled sheet
product to CSI customers.The project was successful in that it startedearly and was completed under budget.
Numerous safety features for both hydrogenand natural gas were incorporated into the
base, furnace and control systems. Stringent
California NOx emission targets were met using
the best available control technology. Savings
of 50% or more in electricity and natural gas
consumption were welcomed in a time of price
and supply volatility in California utilities.

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California SteelIndustries faced the
choice of whether
to repair, replace in-
kind or upgrade the
anneal shops to
newer technology.
Modernizing to a
100% hydrogen
anneal shop was
justified based on
significantly
reduced operating
costs and the logisti-
cal advantages of
consolidating two
shops into one. Background

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Integrated mills began constructing the next
generation of hot strip mills in the 1960s.
These mills had more heating capacity,
power and finishing capability than their
predecessors. The resulting increased output
made more bands available to cold rolled
sheet products. Higher speed 5-stand cold
mills and new annealing facilities, primarily
4-stack HN shops, followed.Capital expenditures were directed backtoward the primary end in the 1970s and early
1980s. BOF steelmaking was expanding, and
continuous casting became a competitive
necessity. Considerable sums were spent on
related environmental issues and controls.After the 1960s and until the late 1980s, onlylimited batch annealing capacity was added to
steel plants. Annealing in a 100% hydrogen
inert atmosphere made its first significant
domestic debut at an integrated plant at U. S.
Steels Mon Valley Works at its Irvin Plant.

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California Steel Industries

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Kaiser Steel was built in 1942 to supply steel
for West Coast shipbuilding and other mar-
kets. The plant was strategically positioned
in southern California during the war years,
thus making raw materials and the markets it
served highly accessible. However, Kaiser
Steel was shuttered in the early 1980s.A 50/50 venture, under the nameCalifornia Steel Industries, soon followed
between Companhia Vale do Rio Doce of
Brazil and Kawasaki Steel of Japan. CSI Authors

David W. Johnson , ManagerҗCold Sheet Mill and Roll Shop (left), and Harold E. Parker II , ManagerEngineering Department, CaliforniaSteel Industries, Inc., Fontana, Calif.; Michael W. McDonald , VicePresident, General Manager of Entec Div. (center), and Christopher G.Williams , Senior Design EngineerחProject Manager (right), Rad-Con,Inc., Cleveland, Ohio (mike.mcdonald@rad-con.com) >
52 AISE Steel Technology November/December2002 size="-1">

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