#175 - Tenova Factories

Our area of the Tenova Group specializes in R&D, analysis instrumentation, and process optimization. However, Tenova also has heavy manufacturing facilities worldwide.

Tenova Pomini

The Tenova Pomini factory, based in Castellanza, Varese (Italy), is the pride of Tenova’s internal production and assembly capability. Equipped with the most advanced CNC machine tools, the workshop is mainly focused on the production of Tenova Pomini roll grinders. With over 25,000 sqm of covered area the production facility is able to meet the most demanding delivery schedules and quality requirements.

Tenova I2S

The Tenova I2S production facility is located in Yalesville, CT. USA and takes up an area of about 12,550 sqm. The factory is equipped with one of the largest indoor cranes in the USA (125 ton) and a full service machine shop focused on the design, manufacture and assembly of cold reduction mills and thickness gauging systems. By combining quality manufacturing capability, a strong engineering foundation, and the latest in controls technology, Tenova I2S excels in the support of its customer's needs.

Tenova Metals India

Tenova's Indian manufacturing plants are located in the Thane district of Maharashtra (India), in the industry park near Mumbai, on an area of 1600 sq.m. The full-service workshops handle fabrication, machining, and equipment assembly for strip processing lines and cold rolling mills.

Fabrication and machining are restricted to critical items, while final assemblies and testing of the majority of equipment are conducted internally, to ensure compliance with Tenova quality standards.

Tenova Timec

Tenova Timec is Tenova’s production facility in China. Based in the industrial area of Tanggu (Tianjin) Tenova Timec is located near the third largest Chinese port, just 2 hours’ drive from Beijing. The factory is 54,000 sqm, including 15,000 sqm that is covered. The excellent quality of production is guaranteed under Tenova’s worldwide quality assurance program carried out to the strictest required standards.

Tenova TAKRAF

Tenova TAKRAF factory, based in Lauchhammer (Germany) is 235,000 sqm including 17,900 sqm that is covered and is divided into four separate bays used for:

- Metal prefabrication

- Steel construction

- Assembly

- Wearing parts manufacture

Tenova TAKRAF factory was constructed in 1996 and is equipped with new and efficient machinery. The internal fabrication is used just for complicated parts with elevated technological content, and for huge size and non-standard parts that would be difficult and time consuming to produce them through external fabrication. Twelve radio-controlled cranes with lifting capacities of up to 80 tons are installed in the bays. Equipped with the latest standards, the factory produces the key components for Tenova’s product range as well as all related spares and wearing parts.

More than 100 highly specialized and experienced workers contribute daily to the successful and on time delivery of the parts and components internally fabricated. Tenova TAKRAF factory is a highly specialized workshop with a specific focus on the production of:

- Bucket wheel drives and their components

- Crawler links of all types and sizes

- Ball bearing slewing rims up to a diameter of 6m, with hardened or as-rolled bearing races

- Gear rims in all diameters between module 20 and module 40

- Support bearings with ball diameter up to 1500 mm.

Here is a previous post with some other very cool Takraf-related information.

#127 - Tenova Expands Further into Heat Treatment Furnaces

Milan, April 22th 2013 – LOI Thermprocess GmbH has signed an agreement with the European Capital S.A. SICAR for the acquisition of MTH. The acquisition remains subject to usual conditions precedent including the approval by the relevant antitrust authorities.

MTH is a holding company based in Menden, Germany, and controls the companies Schmetz (Germany, established in 1945), BMI (France, 1947), Mahler (Germany, 1950), IVA/RIVA (Germany/Poland,1984) and Huisen-MTH (China, 2006).

MTH employs 321 employees working in the fields of manufacturing and service for vacuum and atmospheric furnaces for wide a range of markets (Heat Treatment Centers, Aerospace, Machine Tooling and Automotive) with a strong focus on Germany, Western Europe and Asia/China.

MTH’s product portfolio encompasses horizontal and vertical vacuum furnaces, supplied by the German company Schmetz and the French company BMI. Batch and continuous type atmospheric furnaces are covered by the two German companies IVA and Mahler. The Chinese company Huisen, with its recently extended workshop and pre-assembly workshop, near Shanghai covers the entire product range for Chinese and Asian customers.

The acquisition of the MTH and its entire portfolio of highly specialized personnel will contribute to furthering Tenova’s engineering know-how, capability and experience, especially in the field of after-sales service where MTH is a leading company.

Furthermore, the acquisition of MTH will also provide a unique opportunity for Tenova, through its subsidiary company LOI Thermprocess GmbH, to expand the furnace business in the fields of heat treatment equipment and services for parts and components. The vision is to create a worldwide furnace company covering the entire range of equipment and services for heat treatment processes in steel, automotive, aerospace and machine tool industries.

http://www.tenovagroup.com/pdf/press/11-PR%20MTH%20-%20Versione%202.pdf

http://www.mth-group.com/Tenova-acquires-MTH-in-Germany-and

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#120 - Rapid Train Loading Systems by Tenova Takraf

I’ve always loved trains. Perhaps it’s the scale and power of the equipment. Perhaps it’s the history and variety of the industry.

A couple of historical highlights that appeal to me are: *

Regarded by many as The Ultimate Steam Locomotive of All Time -
the vast "Niagara" 4-8-4 of the New York Central Railroad.

The first main line diesel-electric in North America (Canadian National),
No. 9000, built in 1929, and split into two units for operation
following trial running. 

The Hiawatha Express
Top: Class A 4-4-2 No. 1 near Dearfield, Illinois, 1939.
Above: Class F7 No. 101 darkens the sky over Milwaukee
as it pulls with Train No. 101, the streamlined
13-coach "Afternoon Hiawatha".

The Swedish rod-drive triple-unit Class "Dm3" electric locomotives can
produce more than 200,000lb of tractive effort.

June 13/2013 - A part 2 to this post was added here - http://nova-gas.blogspot.ca/2013/06/126-takraf-train-post-was-big-hit.html

Speaking of trains, Tenova Takraf makes loading systems for railway cars. Tenova TAKRAF Rapid Rail Loading Systems use the flask loading system to load particulate material into moving trains:

• loading at rates of up to 8,000 t/h.
• handling a variety of rail wagons of different capacities and types.
• loading with accuracies, which meet most countries’ statutory requirements.
• allowing for a variation in material size and bulk density.

May 24, 2013 - More pictures added to this post; shown below.

The system pre-weighs each wagon load prior to depositing the load into the moving wagon. An optional extra is the integrated calibration system, which operates via a SCADA system. Flow of material outside the storage bin and weigh flask is controlled by single-pass radial gates. These are actuated hydraulically by a system that ensures that the gates close fully without jamming.

The Tenova TAKRAF Profile Chute system, through which material flows into the wagons, is self adjusting and allows for differences in the heights of wagons to ensure the correct profile of material in the wagons. The chute is designed to minimise potential dust emissions during loading.

The Profile Chute is fail-safe in the event of any electrical or hydraulic power failure. The Chute will automatically move out of the way of rolling stock entering the rapid rail loading system bay.

SELF LEARNING CAPABILITY

The Tenova TAKRAF Rapid Rail Loading System incorporates a programmable logic controller (PLC) and computer controlled measurement system, which has a learning capability.

As the first few wagons are loaded, the system assesses the effect of the loaded material’s density and flow characteristics; the latter is affected by particle size, moisture, temperature, etc. The system automatically accounts for prevailing conditions and loads subsequent wagons to a high level of accuracy.

CONTROL SYSTEMS

Tenova TAKRAF Rapid Rail Loading Systems are equipped with user friendly computer control, information and records systems.

The accurate loading capability avoids penalties because:

• individual wagons are not overloaded.
• axle distribution requirements are met.
• wagons are loaded to the correct height.

The control system is based on client specified hardware and Windows™ based software allowing:

• overall SCADA control of the operation.
• automatic validation of truck numbers as they are entered into the SCADA system.
• visual monitoring of operations through closed circuit television systems.

Several optional facilities can be supplied, including:

• uninterrupted power supply for computer systems.
• communication networks to the other computers, PCs or mainframes.
• communications with other weighing equipment on the plant to control reclaim operations.
• built-in mass calibration systems to simplify calibration.

Tenova TAKRAF

Tenova Mining & Minerals (Pty) Ltd

1 Kramer Road

Bedfordview

Johannesburg

PO Box 75996

Gardenview, 2047

South Africa

phone +27 11 201 2300

fax +27 11 455 4547

enquiries.TMM@za.tenovagroup.com

TAKRAF GmbH

Torgauer Straße 336

04347 Leipzig

Germany

phone +49 341 2423 500

fax +49 341 2423 510

sales@takraf.com

Nova Analytical Systems
1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

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* Scanned from The Illustrated Directory of Trains of the World by Brian Hollingsworth © Salamander Books Ltd., 2000. Excellent rail resource with pictures and short summary of historic and modern locomotives worldwide.

#118 - Tenova Also Makes Marine Leisure Products

We were surprised to recently learn about this interesting nuance of our company. The Tenova Group is a technology supplier to the mining & minerals and iron & steel industries. These are heavy industries. However, we also have a group that makes walkway & platform systems for marine leisure applications.

Tenova Takraf manufactures the largest vehicles on earth. See this link.

Tenova TAKRAF is also now the sole distributor of the Jetfloat Modular System in southern Africa. The Jetfloat system was designed and patented through extensive research and development by Jetfloat International in Austria. Comprised of modular elements linked together to form the required shapes, Jetfloat platforms are quick to assemble on land and on water and are easily extendable. The Jetfloat system is a modular pontoon and marine docking system.

BENEFITS

■ No repair and maintenance costs.

■ Light-weight and easy to assemble without the need for cranes.

■ Easily extended or altered in steps of 500 mm.

■ No sharp edges, corners or connecting parts, making the product safe for all environments.

■ Various anchoring methods make it possible to use this system in many applications.

■ Secure handrail mounting, which can be supplied to specification.

■ Other accessories available for a versatile hassle-free installation.

■ High elastic resistance to impact by boats, wind and storms.

■ Long life, as they are fatigue and weather proof and resistant to saltwater, chemicals and acid.

The flexible and long-lasting Jetfloat modular pontoons and systems make ideal marinas, bathing jetties, bathing islands, floating pools, diving platforms, event platforms, self propelling rafts and aquaparks, which blend in harmoniously with their natural surroundings.

FEATURES

■ Single layered systems have buoyancy of 350 kg/m2.

■ Double and triple layered systems available for supporting heavier tonnage.

■ Wave and storm-proof – employable off-shore, with the correct anchoring system.

■ Resistant to UV rays, salt water and various other chemicals.

■ Resistant to weathering

SPECIFICATIONS

Jetfloat single element

■ Length: 500 mm

■ Width: 500 mm

■ Height: 400 mm

■ Weight: 6 kg

Jetfloat double element

■ Length: 1,000 mm

■ Width: 500 mm

■ Height: 400 mm

■ Weight: 11 kg

Standard colours are black, light blue and light grey. Handrails are available. Elements are blow-moulded using high quality Lupolen 5261 Z high density polyethylene. Superior quality control ensures a uniform thickness of 8 mm to provide best stability of the product all-round. Use of anchoring blocks, chain and eye props ensures that walkways and platforms remain in position for a long period.

INSTALLATION

Tenova TAKRAF is a qualified installer of the product, offering a highly competitive engineering works background. Its installation expertise is backed by numerous successful installations in Africa of the Jetfloat system for leisure applications since 2005.

To inquire about this product, contact:

Tenova Mining & Minerals (Pty) Ltd

1 Kramer Road

Bedfordview

Johannesburg

PO Box 75996

Gardenview, 2047

South Africa

phone +27 11 201 2300

fax +27 11 455 4547

enquiries.TMM@za.tenovagroup.com

#115 - EAF Process Flow and the Tenova Group

The Steel Manufacturers Association (SMA) has released its Public Policy Statement for 2013-2014. The SMA is the primary trade association for scrap-based electric arc furnace (EAF) steelmakers.

Tenova Core and Tenova Goodfellow are both associate member companies in the SMA. Tenova Core also has a representative on the 2013 Associate Member Executive Committee.

EAF steel producers are the largest recyclers in North America. Over 90 percent of the material input to EAFs is recycled ferrous scrap. EAFs also play a large role in conserving energy – steel produced from melted scrap consumes approximately one third the energy that steel produced from iron ore consumes.

The production share of EAF furnaces of total steel production has grown from approximately 35% in 1990 to 60% in 2012.

In the back of the print copy of the Public Policy Statement, there is a nice diagram of the EAF process flow. This simple graphic prompted me to compare the standard EAF process with the expertise and products that can be found within the Tenova Group. Many of the areas do have a match. My summary of the Tenova capability is no doubt incomplete, but this is a good start.

__________

Steel Scrap Handling

Scrap steel has a high weight per volume and requires energy to receive and move around. Scrap steel is usually not received in geometrically and compositionally homogenous states. Material handling is therefore an important part of the EAF input process. I wasn’t able to find a direct match in the Tenova Group to steel scrap materials handling. However, Tenova Takraf is a world leader in materials handling for ore and mining applications. They may have equipment in their product line that is suited for steel yard and scrap handling.

__________

Electric Arc Furnace

This is the heart of the EAF process where the input material is melted down by electric arc. There are several areas of the Tenova Group that have a high relevance to the EAF.

• Tenova Melt Shops manufactures electric arc furnaces. Tagliaferri is the historical brand of Tenova Melt Shops which has been designing and manufacturing EAFs since the very beginning of electrometallurgy.
• Consteel is a continuous metallic charge feeding and preheating system made by Tenova Melt Shops.
• EFSOP is an off-gas based process control technology produced by Tenova Goodfellow for energy optimization of electric arc furnaces.
• The KT Injection System is a wall-mounted, multi-point system for injecting oxygen and a wide range of fines of carbon, lime, DRI and other materials into the slag layer of an EAF.

__________

Ladle Metallurgy Station

After tapping the molten steel, the ladle metallurgy station fulfills several functions in preparing the melt to be processed in the continuous casting machine. Ladle furnaces also act as a buffer between the EAF and continuous casting line. Tenova Melt Shops offers complete ladle furnace packages.

Tenova Melt Shops offers complete ladle furnace packages including:

• Electric power supply
• Ladles
• Ladle transfer cars
• Additives charging and injections systems
• Dedusting
• Electrode make-up stations and other auxiliary equipment

__________

Caster

Continuous casting is the process by which the molten metal is cooled and solidified into heavy steel strips called billets, blooms, or slabs. The produced steel may be stored or immediately rolled into finished products. There does not appear to be a Tenova company that makes continuous casters.

__________

Rolling Mill

Rolling mills further process the slabs and strips into other semi-finished products such as bars, billets, beams, or wire. The Tenova Rolling & Finishing division manufactures all kinds of strip processing lines and cold rolling mills.

• Tenova Key Technologies - acid regeneration, iron oxide production, waste water treatment
• Tenova I2S - cold roll mills
• Tenova Presind Automation - integrated control systems and drives for processing lines and cold mills
• Tenova Multiform - strip processing line and cold rolling mills in the Indian and Asian markets including India, Bangladesh, Vietnam and Indonesia.
• Tenova Pomini - worldwide leader in production of roll grinders, for rolls belonging to flat products mills (steel and non-ferrous metals such as copper, aluminum) as well as paper mills.

__________

Finishing and Shipping

Further processing into finished products may follow the rolling mill or be integrated in with it. Inventory systems are used to store and stage the finished products prior to delivery.

• Tenova Strip Processing – pickling, tinning, galvanizing, color-coating, silicon steel, stainless steel lines, and many others

__________

The Tenova Group is an intelligently diversified company that covers many areas of the steel-making process. The expertise accumulated among the Tenova companies is available to steel-makers around the globe.

NOVA Analytical Systems plays a small role in this value chain by manufacturing gas analysis equipment for a wide range of industries.

For information on gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/
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#110 - Tenova Takraf – builds the largest vehicles on earth

Bucket Wheel Excavators (BWE) are among the largest terrestrial vehicles ever constructed. BWEs function basically as continuous cutting machines for soft to semi hard materials like clay, sand, gravel, marl and their blendings, as well as lignite and hard coal. They are used primarily in open pit mining operations.*

The characteristic parts of a Bucket Wheel Excavator are the cutting wheel with buckets, the wheel boom, the superstructure with counterweight boom, the substructure, the undercarriage with crawler tracks and a transfer boom to the bench conveyor (or a connecting bridge to the loading unit).

The bucket wheel concept has been in use in mining operations since the 1920’s. However, it was in the 1950’s that it came to be applied on truly massive scales in Germany. The biggest machine ever built, the Tenova TAKRAF Model SRs 8000, has a weight of 14,200 tons and moves 240,000m³ of overburden per day. This machine is also famously known as the Bagger293.

Project

Customer:  RWE Power AG (former Rheinbraun AG), Cologne

Plant Location:  Open Cast Mine Hambach (Germany)

Scope of work:  Turn-key project

Project Figures

Capacity per day: 240,000 m³ / 314,000 yd³

Cutting height: 51 m / 167 ft

Cutting depth: 17 m / 55 ft

Max. outreach of bucket wheel: 72.2 m / 236.9 ft

Center of discharge pulley: 138.75 m / 455.2 ft

Bucket wheel diameter: 21.6 m / 70.9 ft

Bucket wheel drive power: 3 x 1,120 to 1,680 kW

Nominal bucket volume: 6,600 L / 8.6 yd³

Length: 502 m / 1647 ft

Service weight: 14,200 t

Commissioned: 1995

Here is an excellent picture of this machine in action: http://en.wikipedia.org/wiki/File:Braunkohlenbagger_im_Tagebau_Hambach.jpg

Tenova TAKRAF manufactures BWE’s in a wide range of capacities between 200 and 16000m³/hr. Models are available with working heights from less than 5m to a maximum of 51m. The type and size of excavator used on a mining site is determined by the local mine conditions and the required cutting height and width.

Here is an excellent wide angle picture of a Takraf rail-based Bucket Conveyer Excavator (BCE): http://upload.wikimedia.org/wikipedia/commons/4/49/F60_in_Betrieb.jpg

It is worth pasting the above link into your browser and viewing it at its source. The picture is quite large and shows a high level of detail.

This style of excavator has its buckets attached to a conveyor instead of a wheel. This allows excavation from within and below their scope of movement. This is useful if the pit floor is unstable or even underwater. As shown in the picture link above, TAKRAF's BCEs travel on rails rather than on crawlers.

Agencies or companies that are in the market for one of these machines, should contact:

TAKRAF GmbH

Torgauer Straße 336

04347 Leipzig

Germany

phone +49 341 2423 500

fax +49 341 2423 510

sales@takraf.com

Tenova TAKRAF

Tenova SpA

Via Albareto 31

16153 Genoa

Italy

phone +39 010 6054067

fax +39 010 6054710

bulkhandling@it.tenovagroup.com

NOVA Analytical Systems

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/


* Open pit mining has declined somewhat in recent years for environmental reasons. However, many lignite mines remain in operation. Open pit mines and the land around them require a fair amount of rehabilitation after mining operations have ceased. See http://en.wikipedia.org/wiki/Open-pit_mining

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#66 - Delkor – Liquid Handling Experts

Separation of liquids and solids is important for many reasons. Two obvious ones are to extract a wanted or un-wanted solid, or to clarify a liquid (often water). Liquid / solid separation is a key component of waste water treatment plants and ore extraction plants.

Not all solids and liquids separate easily. Particle size, geometry, electrical charge, and other factors may keep the solids uniformly distributed throughout a liquid phase. Various techniques, chemicals, and equipment may be employed to counteract these effects.

Delkor is a diverse solutions-based equipment supply company in the Solid / Liquid Separation field which is grouped under Delkor Technik B.V, a wholly owned subsidiary of Tenova S.p.A
www.tenovagroup.com

Delkor is the leading supplier in the Solid / Liquid Separation field and has built a reputation for the supply of quality engineered products to their client base in the minerals, chemical and industrial markets. Their track record stretches over 35 years and includes more than 3000 installations worldwide.

Delkor services metallurgical, chemical, industrial, fertilizer and municipal solid liquid separation applications from the following global regional offices:

Asia Pacific:
Australia | China

Americas:
Canada | Chile | Brazil | Mexico | Peru

Central Asia, Middle East & North Africa:
India

Europe & CIS:
United Kingdom | Russia

Sub Saharan Africa:
South Africa

If you are interested in liquid / solids separation or any other liquid handling application, contact Delkor for more information about their award-winning products and systems.

For information on gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.
1-800-295-3771
sales at nova-gas dot com
websales at nova-gas dot com

http://www.nova-gas.com/
http://www.tenovagroup.com/
http://www.delkorglobal.com/global/en/home.aspx

If you have a LinkedIn account, search for Nova Analytical Systems under Companies and follow us if you want.

#64 - Tenova Lands on South Korean Shores by Acquiring Envita

Milan, April 6th 2012 – Tenova's growth strategy continues with the acquisition of Envita Co. Ltd. The South Korean company, founded in 1995 and with headquarters in Incheon (near Seoul), is active in the fields of industrial furnaces, processing lines, and heat treatment furnaces for aluminum components in the automotive industry. Its people, over 100, are operating in three locations in South Korea, Vietnam (Ho Chi Minh City), and China (Yantai).

The company is well known to Tenova, who began working with Envita in 2007. Thanks to the collaboration with Envita, Tenova has been awarded contracts in the country with major steelmakers such as Hyundai Steel and Posco.

The acquisition marks Tenova's first step into South Korea, the 6th highest crude steel producer in the world with 68.6Mt in 2011. This is a +16.2% increase over 2010. South Korea has the highest density per capita production of steel in the world: a strategic market in the global post-crisis scenario.

The Tenova Iron & Steel division achieves the goal of entering South Korea through an engineering hub with excellent references and manufacturing centers. The combination of these factors allows the expansion of our commercial and operating network in Asian countries such as Vietnam, Thailand, Indonesia, Malaysia, Philippines, Singapore, Laos, and Cambodia. It also provides an expansion of the Tenova Iron & Steel product portfolio in the business of cold rolling and aluminum for the automotive industry.

Tenova is a worldwide supplier of advanced technologies, products, and services for the iron & steel and mining industries. With about 3,100 people, Tenova operates through more than 30 companies located in 22 countries on 5 continents.

THIS TRANSACTION STRENGTHENS TENOVA IRON&STEEL DIVISION'S GROWTH OF COMMERCIAL AND OPERATING NETWORKS IN ASIAN COUNTRIES AND AN EXPANSION OF ITS PRODUCT PORTFOLIO

 

If you are a steel maker interested in higher productivity and lower costs, contact Tenova for more information about their award-winning products and systems.

For information on gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

http://www.tenovagroup.com/

If you have a LinkedIn account, search for Nova Analytical Systems under Companies and follow us if you want.

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