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Siemens VAI Restarts AOD Converters in Record Time for ThyssenKrupp Nirosta

08/11/2009 - Siemens VAI Metals Technologies starts up two new exchange-type AOD converters for ThyssenKrupp Nirosta with all installation work carried out within only three weeks' time.

Siemens VAI Metals Technologies recently started up two new exchange-type AOD converters that it supplied to German stainless steel producer ThyssenKrupp Nirosta in Krefeld. To minimize production downtime, all installation work up until the converter start-ups was carried out within only three weeks' time.
 
In the course of a modernization project, Siemens VAI replaced two existing stationary AOD converters with new exchangeable AOD converters. The project scope comprised complete dismantling of the existing vessels down to their foundations, installation of two new horse-shoe-type trunnion rings with tilting drives for the exchange-vessel system as well as the engineering, supply and installation of the new converters and related equipment. Siemens VAI also provided civil works, steel structure, charging bins, and modifications to the existing alloy- and flux-feeding system. Additional equipment included new process-gas regulation stations, new waste-gas hoods, a converter exchange car, the converter relining and wrecking stand with tilting device, two converter transfer cars, two converter-preheaters, and one jib crane.
 
As part of the project, Siemens VAI had to adapt some of the existing equipment and interfaces with the new equipment, and also modify the main control desk and the Level 1 automation system to meet the new converter requirements. Siemens VAI also renewed or upgraded electrical equipment as required and provided personnel training for plant operation, refractory lining and maintenance of the new plant equipment.
 
A particular challenge of the project was that converters were to be replaced with minimum interference to ongoing production operations and under extremely restrictive space conditions. This required parallel installation and start-up work, with the highest priority placed on personnel safety. Siemens VAI credits the combined efforts of the start-up teams from ThyssenKrupp Nirosta and Siemens VAI for meeting the challenge.
 
All onsite work for the two converter replacements was completed within only three weeks during an operational standstill. Full production capacity of Converter No. 1 was attained within only six days, while full production capacity for Converter No. 2 was attained within only three days after the respective converter start-ups. Siemens VAI received the Final Acceptance Certificate from ThyssenKrupp Nirosta after completion of the required guarantee figures.

ThyssenKrupp Nirosta uses its new converters for the production of mostly high-quality austenitic chromium-nickel grades used for a wide range of flat-steel applications.
 
The Siemens Industry Sector (Erlangen, Germany) is a leading international supplier of production, transportation, building and lighting technologies. The Sector consists of six Divisions: Building Technologies, Drive Technologies, Industry Automation, Industry Solutions, Mobility and Osram. With around 222,000 employees worldwide Siemens Industry posted in fiscal year 2008 a profit of EUR3.86 billion with revenues totaling EUR38 billion.
 
With the business activities of Siemens VAI Metal Technologies (Linz, Austria), Siemens Water Technologies (Warrendale, Pa.), and Industrial Technologies (Erlangen, Germany), the Siemens Industry Solutions Division (Erlangen, Germany) is one of the world's leading solution and service providers for industrial and infrastructure facilities. Using its own products, systems and process technologies, Industry Solutions develops and builds plants for end customers, commissions them and provides support during their entire life cycle. With around 31,000 employees worldwide Siemens Industry Solutions achieved an order intake of EUR 8.415 billion in fiscal year 2008.
 
ThyssenKrupp Nirosta GmbH is a company of ThyssenKrupp.