2. Background
Operational aspect to the unique development
Overview- ArcelorMittal South Africa
Saldanha Works
Casting and unique metallurgy development, start of the development
Vanderbijlpark Works
Rolling and Galvanising operation to achieve mechanical properties
Introduction of new final product in 2015 (example of applications)
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3. Overview ArcelorMittal South Africa
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7.8 million tonnes
5.62.2Long Steel Products Operation Flat Steel Products Operation
• The flat steel operations at Vanderbijlpark
and Saldanha together have the capacity to produce
5.6 million tonnes of liquid steel per annum, the largest
suppliers of this commodity in Africa
The unique structural grade developed is hot rolled and
galvanised here. The final mechanical properties is
achieved via this process
• Vanderbijlpark has the capacity to produce 4.4 million
tonnes of liquid steel per annum
• Product range includes hot rolled steel in coil and plate;
cold rolled; hot-dipped galvanised; electro-galvanised;
colour coated and tinplate coil and sheets
• The unique steel chemistry is produced here via an
optimised casting process
• Saldanha produces 1.2 million tonnes of steel per
annum.
• The unit produces ultra thin hot rolled coil for stringent
applications in the domestic and select export markets
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• The company's Newcastle and Vereeniging
operations, service some 50% of the local market for
long steel products, while also exporting products
internationally
• About 80% of the company's long steel products are
generated by Newcastle, an integrated steel plant,
while Vereeniging is an electric arc furnace-based
steel works.
• Newcastle works has the capacity to produce 1.8
million tonnes of liquid steel per annum
• The profile products produced include low and
medium-carbon commercial grades, low-carbon
rimming steel substitutes, sulphur containing free-
cutting steels, micro-alloyed steels, high-carbon wire-
rod steels and low, medium and high-alloy steels
• Vereeniging produces 0.4 million tonnes of liquid
steel per annum
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5. Presentation Overview – processes involved
• ArcelorMittal South Africa – Overview
Saldanha Works
• Vanderbijlpark Works
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6. Saldanha Works
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Statistical information
1.2 million tonnes
• Nov 1995: Saldanha Steel project started
(Iscor and IDC)
• Jan 1996: First bursars, recruited from the
West Coast, sent to Newcastle for training
• Sep 1996: First steel column erected
• Aug 1997: Power available from Eskom
• 14 Jun 1998: First steel produced
• 20 Aug 1998: First hot rolled coil dispatched
• 31 Dec 1998: Corex commissioned
• 13 Jun 1999: Midrex commissioned
• Jun 2005: Full capacity reached
(103 000 tons HRC)
• Oct 2006: Record hot rolled coil production
of 113 336 tons
• September 2007 Record thin (<1.2mm)
production of 31 004 tons
1995
1999
1996
1998
2005
2005
1997
2006
2007
2011
• April 2008: Successful reline of Corex and
Midrex (78 days)
• July 2008: First 0.95mm rolled.
• July 2011: 20 375 tons <1.09
1995
1996
2008
2011
• Electricity consumption: 160 MW
• Daily water consumption: 7000 kilo liters (world best
for integrated steel plant)
• Manpower: 590 permanent employees
• Sales output: 1,2 million ton HRC pa
Head Count end of Q3: 542 (SAL)
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7. 7
Asset Configuration
• 1 Midrex Plant (DRI Production)
• 1 Corex Plant
• 1 Conarc Plant
• Continuous Caster - Slabs 1
• Hot Rolling Mill 1 (1 250 kt per annum)
• HRC Temper Mill
• Saldanha Works is a largely export-focussed plant
• It is in close proximity to the deep-sea port of
Saldanha
• The plant was commissioned and produced its first
hot rolled coil (HRC) in late 1998
• currently producing at its designed nameplate
capacity of 1.2 million tonnes per annum
1.2 million tonnes
Unique operations
• The plant is distinguished by merging leading edge
technologies to produce high quality ultra thin hot
rolled coil (UTHRC).
• plant is the only steel mill in the world to have
successfully combined the Corex/Midrex process into
a continuous chain
• This configuration replaces the need for coke ovens
and blast furnaces
• The plant is a world leader in emission control and
environmental management
• Facilities and technologies at Saldanha Works were
specifically designed to produce 'clean' steel
• The continuous production chain is exceptionally
short, taking only 16 hours from the time iron ore
enters the Corex or Midrex units to the rolled
product.
• The individual processes are linked very closely with
virtually no process stock between the units
Saldanha Works
Initial product development casting the steel
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9. Vanderbijlpark Works Final product development
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History/Statistical information Asset Configuration
• 3 Electric Arc Furnaces – Not in operation
• 1 Continuous Casters (V3) – Not in operation
• 2050mm Hot Strip Mill (7 Stand)
• 5mm Temper Mill + 6mm Temper Mill
• 3650mm Plate Mill
• 2 Pickling Line
• 2 Tandem Cold Mills
• 3 Temper Mill
• 2 Batch Annealers
• Electrolytic Galvanising Line
• 3 Galvanising Lines
• 2 Continuous Annealing Line
• Paint Line
• Electrolytic Tinning Line
• The Works was established in 1942
• Area of site: 2,300 Ha
• Perimeter: 20 km
• Rail networks: 254 km and 34 locomotives
• Daily electricity consumption: 6.93 GWh (230 000
families)
• Manpower ±4,896 permanent
4.4 million tonnes
Asset Configuration
• 5 Coke Oven Batteries (55-57 ovens each)
producing 1.4 million tons/year,
• Sinter plant with 2 strands, combined design capacity
of 230 kilo tons/month
• 2 Blast Furnaces
• 6 Rotary kilns, 2 of which are coupled to a power
generation plant
• 3 Basic Oxygen Furnaces
• 2 Continuous Casters (V1 + V2)
Head count end of Q3: 4 693 (VDB)
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10. Process Flow and optimisation to achieve mechanical properties
10Slab exports
Galv and Colour Sheet
Cold Rolled Sheet
EG Sheet
Plate
2050mm Hot Strip Mill (7 Stand)
Plate Mill
Continuous Pickling
Line Annealing process
Cold Mill
Hot Rolled Coil
Hot Rolled Pickled and
Oiled Coil
Electrolytic
Galvanising Line
Electrolytic Tinning
and DWI Line
Finishing
units
Hot-dip
Galvanising Line
Annealing process
Slabs
Rolling
3 Vanderbijlpark Works
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Slab
– On special
request
Cold Rolled Coil
• W = 800-1800mm
• T = 0.4-2mm
• Cold rolled or
annealed
• Various surface
finishes
Hot Rolled Pickle
& Oil
– Hot Rolled coil
pickles in HCl
and coated with a
rust preventative
oil
Plate1
– As Rolled &
Heat Treated
• L = 4-15m
• W = 0.9-3.2m
• T = 4.5-100mm
Electrogalvanised
Coil
• W = 850–1600mm
• T = 0.47–1.80mm
• Coating = Equal
or Differential
Hot Rolled Coil1
• W = 760-1870mm
• T = 1.6-16mm
• M = 17-31ton
Hot Dipped
Galvanised Coil
– W = 762-1225mm
– T = 0.27-3mm
– Coating = Z100-Z650
– Spangle = Regular &
Minimised
– Passivation and
Oiling available
Tin & DWI Coil
– W = 650-950mm
– T = 0.21-0.45mm
– Coating = Equal
or Differential
Galvanised and
Colour Coil –
Chromadek®
W – 775- 1225mm
T = 0.4-1.6mm
Vanderbijlpark Works
Product range produced
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