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Stuttgart, Germany

Opfermann A.,Badische Technology and Services GmbH | Grosse A.,Badische Stahl Engineering GmbH | Wohlfahrt S.,Badische Stahlwerke GmbH
SEAISI Quarterly (South East Asia Iron and Steel Institute) | Year: 2013

Synopsis: In 1968, production at the Badische steel plant started with a plant capacity of 300.000 t. Now, approx. 50.000.000 t and 630.000 heats later, the plant has reached an output of more than 2 Mio.t finished product per year. The improvement of the processes at Badische has therefore a 45 year old tradition. The combination of engineering at BSE and steel production at BSW leads to one of the most efficient mini mills worldwide. The plant is operated with reliable equipment by well-educated, trained, and motivated people - this is our "Badische Philosophy". And this is the foundation for a successful steel production with high productivity and low costs. BSW operates two AC arc furnaces with 102 t tapping weight and 75 MW average power input leading to an average tap-to-tap-time of 41 min. Two ladle furnaces prepare the heats in 20 min only; casting is done via eleven strands on two casting machines. With more than 70% of hot charging the billets are rolled in a wire rod and rebar mill. Chemical energy input and optimization of the EAF process with chemical energy tools for faster melting and refining have continuously gained in importance in the steel production process. The aim worldwide is to produce with low energy consumption at low costs and with a low impact on the environment. Chemical energy tools have been in use for 30 years now - from door lances to combined systems with side wall tools and injection of solid agents - to create a more homogeneous melting and heating. Results of different operational tests at the BSW arc furnaces are displayed and discussed. Our aim is to look into the details and thus optimize the operation. Source

Opfermann A.,Badische Technology and Services GmbH | Grosse A.,Badische Stahl Engineering GmbH | Wohlfahrt S.,Badische Stahlwerke GmbH
Stahl und Eisen | Year: 2014

Since 1968 wire rod and rebar qualities have been produced at Badische Stahlwerke (BSW). Two production lines with EAF, LF and casters are used to produce the billets from scrap. In two rolling mills the billets are rolled to wire rod and rebar. The main aim of BSW was and is the most efficient Operation of the plant for the effective production of these basic steel grades. In this article results of operational trials and the interaction of process parameters at the EAF are shown. Source

Grosse A.,Badische Stahl Engineering GmbH | Opfermann A.,Badische Stahlwerke GmbH | Baumgartner S.,Badische Stahl Engineering GmbH
AISTech - Iron and Steel Technology Conference Proceedings | Year: 2011

With increasing costs for energy and CO2 emission certificates the optimisation of the furnace with respect to productivity is not always the objective. Rather, a more complex view is required which involves market conditions, like steel demand, availability of raw material, local conditions, etc. Moreover an efficient production and use of materials and tools is essential. The tests, which have been described in this paper, should show the interrelation of parameters and their impact on productivity, yield and consumption figures. Source

Feger S.,Badische Stahl Engineering GmbH | Zehnle K.,Badische Stahl Engineering GmbH | Volkert A.,Badische Stahlwerke GmbH
MPT Metallurgical Plant and Technology International | Year: 2014

Analyzing the scrap yard logistics and operation methods is very likely to bring to light neglected potential for improvement and possibilities for cost savings at virtually every steel plant around the world. When looking for the optimal layout of a scrap storage facility or when comparing different layouts, various criteria have to be considered. The scrap storage capacity is limited by the size of the bays. Therefore, plants often build scrap bunkers. For smaller amounts of scrap, also delivery by truck is possible. But in that case, it has to be taken into consideration that the scrap bay is accessible by truck only at the front sides. A high degree of coordination between the crane drivers and the drivers of the towing vehicles or pallet carriers is needed, which may lead to delays. Also certain environmental issues have to be taken into account. Eventually, every steel plant has its particularities. These have to be taken into consideration when evaluating a layout and its ability to serve a highly productive steel plant. Source

Riedinger D.,Badische Stahl Engineering GmbH | Fleischer M.,Badische Stahl Engineering GmbH | Baumgartner S.,Badische Stahl Engineering GmbH | Feger S.,Badische Stahl Engineering GmbH | Hagemann R.,Badische Stahlwerke GmbH
MPT Metallurgical Plant and Technology International | Year: 2010

Consulting projects at steel-making facilities always have to take into account the human resource side and the organizational side of the company to be analyzed. Maintenance is a centrally controlled business unit. There are several obstacles to this organizational form. First of all centralized maintenance organizations in practice often operate as profit centers creating a conflict of interest between production and maintenance. The operational part of this maintenance organization structure is the strong link between the maintenance and production teams. The central steering by the superintendent Maintenance+Engineering needs to make sure that there is clear task sharing. The central Maintenance Competence Center (MCC) takes care of super-ordinate functions and specialized tasks of maintenance. It belongs to the strategic part of the organization. Source

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