Metallurgy’s closest alloy

From the humble paperclip to the majestic Eiffel Tower, metals have shaped our world in more ways than most of us imagine. 

Industry today uses many different metals and alloys, each having its particular applications. Each metal has its own manufacturing process, involving numerous steps from raw material to finished product. ABB supports metals manufacturers with numerous products and services, from arc furnaces and rolling mills to control systems and sensors.

Arc furnaces

Whether extracting metals from ores in smelting, or melting down scrap metal in recycling, the manufacture of metals typically requires intense heating (and also stirring). Arc furnaces accomplish this with powerful electromagnetic fields that induce large amounts of energy into the charge (as the material in the furnace is called). 

With this process being power-hungry, there is a clear case for reducing the energy footprint, savings both costs and emissions. ABB supports this by helping manufacturers optimize the process to reduce energy waste, ensuring just the right amount of energy is applied. ABB’s unique ArcSave technology can reduce energy expenditure in arc furnaces for steelmaking by 3 to 5 percent while lifting productivity by 5 to 7 percent.

Rolling innovation

Whereas some metal items can be cast directly in the foundry, many others need further processing. Typically this is performed in a rolling mill. Such a mill uses rolls to flatten slabs into sheet metal (or form into girders, pipes or other shapes). Multiple passes through the rolls are required, with the metal being pressed to very precise thickness and with great homogeneity. The rolling process can furthermore impart other physical properties to the metal such as strength and flexibility.

In steel manufacturing, hot rolling is differentiated from cold rolling, with the resulting steel having different properties.

Rolling mills must not only apply huge pressures but must do so with high accuracy. Motors are used to move slabs in a demanding environment, accurately and efficiently,  at the required speed and under varying load conditions.

The South Korean steelmaker, POSCO, recently upgraded a hot strip mill by replacing legacy DC motors with state-of-the-art AC motors and drives packages from ABB. The scope of delivery included 70 roller-table motors. The new motors are expected to deliver considerable savings through greater reliability and lower maintenance needs.

The ACS880 industrial drivers promise further energy savings through greater efficiency, while enabling precise control.

Motors matter

Metals manufacturer, Aurubis, is implementing a major upgrade at a copper plant in Bulgaria. It is replacing 460 older, inefficient motors by highly efficient IE4 and IE5 motors. Many of these will be paired with matching ABB drives. The upgrade will save so much energy that the project will pay for itself in only 3.5 years. Other benefits include reduced energy consumption by 28 percent and carbon emissions by 12,000 tons annually, increased process flexibility and improved performance.

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