Nucor Corp. broke ground on its 400-job, $1.7 billion steel-plate manufacturing mill in Meade County, Ky. The project is expected to employ up to 1,500 contractors during construction. Located along the Ohio River in Brandenburg, the 1.5-million-square-foot operation will provide Nucor with 1.2 million tons of annual capacity for steel-plate production. Full-time jobs will include equipment operators, production specialists, safety and environmental technicians, engineers and office support staff. The mill is scheduled to open in 2022.
The COVID-19 pandemic took us all by surprise this year. It has affected everyone and every business. A very large portion of manufacturing was shut down in an effort to “flatten the curve,” and even those who remained open have dealt with COVID issues such as employees who are afraid to come to work for fear of being exposed.
Can-Eng Furnaces International Ltd. received a contract from a Tier 1 manufacturer of forged suspension components for a system that will produce lightweight forged-aluminum parts for passenger vehicles. The system includes a pre-forging rotary-hearth aluminum heating furnace, water quench and continuous aging furnace. The equipment will be integrated into an automated forging cell that includes specialized material-handling components and advanced controls.
Andritz received an order from Allegro, a subsidiary of Evraz and RailService established to produce train wheels in Russia, for a complete production line for train wheels. The production process includes several stages. Blanks produced by Evraz are heated to 2282°F (1250°C) in a rotary-hearth furnace, then descaled and pre-formed in a hydraulic press with 10,000 tons of press force. The blanks are then rolled in a wheel-rolling machine developed by Schuler and forged into a finished product in a crimping and piercing press with 5,000 tons of press force. This is followed by a geometric test in a laser measuring system and permanent marking in a marking press. Finally, the wheels undergo heat treatment, and the running surfaces are hardened.
Cleveland-Cliffs Inc. entered into a definitive agreement with ArcelorMittal S.A. pursuant to which Cleveland-Cliffs will acquire substantially all of the operations of ArcelorMittal USA LLC and its subsidiaries for approximately $1.4 billion. Upon closure of the transaction, Cleveland-Cliffs will be the largest flat-rolled steel producer in North America, with combined shipments of approximately 17 million net tons in 2019. The company will also be the largest iron-ore pellet producer in North America, with 28 million long tons of annual capacity. The assets acquired include six steelmaking facilities (Indiana Harbor, Burns Harbor, Cleveland, Coatesville, Steelton and Riverdale), eight finishing facilities, two iron-ore mining and pelletizing operations, and three coal and cokemaking operations.
It is a well-known fact that too many recordable safety incidents will result in the good people from OSHA showing up to hang around and ask a lot of questions. Nobody wants to get hurt on the job. Everyone at the facility has some other place to be once their shift is over, and many employees have family waiting for them. With that being said, why would people continue to operate poorly maintained manufacturing equipment and material-handling machinery?
Viking Analytics, a Swedish provider of advanced analytics solutions for predictive operations, and Bharat Forge Kilsta, a Sweden-based supplier of forged components, began collaborating in a data-driven production quality project. In the coming months, Viking Analytics will prepare an assessment of the data collected by sensors installed in the oven that heats steel rods used in the production of crankshafts and front axle beams for heavy-duty vehicles. In Bharat Forge Kilsta’s Karlskoga plant, the forged steel is first heated in an induction oven, whose temperature varies according to different steel grades and products. If a disruption occurs, the oven must be adjusted to keep the metal at a constant temperature. This process is currently performed manually, which sometimes causes human-related deviations in the proper temperature-level records.
ArcelorMittal announced its intention to build an electric-arc furnace (EAF) steelmaking facility at AM/NS Calvert in Alabama. Once completed, the planned facility will be capable of producing 1.5 million tons of steel slabs annually for the hot-strip mill. It will also produce a broad spectrum of steel grades required for Calvert’s end-user markets. Construction is expected to take 24 months, and the new facility is anticipated to create 300 new jobs.
The Process Heating & Cooling Show is a conference and tradeshow that will bring together industrial manufacturing and engineering professionals to learn, connect, share and explore all things related to the process heating and cooling industries.
Check out the October 2020 issue of FORGE, featuring our cover story on "Fever Screening and Forging Quality". Other features include "Forging with Hybrid Steel", "FutureForge in Scotland: The Goldilocks Effect", and much more.