Foundry and Steelmaking

Transcription

1 Division // Industry and Transport INDUSTRY AND TRANSPORT Foundry and Steelmaking We focus on developing and transferring technology, while providing comprehensive support to our clients at all points of their value chain. 1

2 TECNALIA, Inspiring Business TECNALIA worldwide EIRE DENMARK UK BELGIUM FINLAND GERMANY FRANCE HUNGARY BULGARIA PORTUGAL SERBIA ITALY USA SPAIN EGYPT KOREA IDEAS THAT CREATE VALUE A philosophy of work where only those ideas that can be transformed into value are acceptable. An entrepreneurial spirit that aims to satisfy the needs of our clients, offer them imaginative, creative, technological solutions... But above all, ideas that generate real results, those that become competitive business opportunities for our clients. That s TECNALIA Research & Innovation, the Nº 1 private applied Research Centre in Spain and one of Europe s leaders. A blend of technology, drive, effectiveness, boldness and imagination. TECNALIA is organised into 16 sector-focused Business Units that are 100% interlinked and grouped into 5 Divisions. This way of working is the best example of its innovative spirit applied to an operating model where cooperation really works, thanks to the transversal nature of our equipment, projects and clients, all collaborating to contribute their experience, commitment and knowledge. TECNALIA, Inspiring Business TECNALIA transforms Knowledge into GDP to improve the lives of Individuals while creating business opportunities for Companies Divisions and Business Units SUSTAINABLE DEVELOPMENT CONSTRUCTION ENERGY ENVIRONMENT METEO ICT-EUROPEAN SOFTWARE INSTITUTE MEDIA INFORMATION AND INTERACTION SYSTEMS INFORMATION SOCIETY SOFTWARE SYSTEMS ENGINEERING TELECOM HEALTH BIOMATERIALS-TISSUE ENGINEERING BIOTECHNOLOGY AND PHARMA HEALTH TECHNOLOGIES INNOVATION AND SOCIETY INNOVATION SYSTEMS INDUSTRY AND TRANSPORT FOUNDRY AND STEELMAKING INDUSTRIAL SYSTEMS TRANSPORT TECNALIA in figures Explotation of Industrial Property 46 M PANAMA ECUADOR PERU CHILE DOMINICAN REPUBLIC COLOMBIA Patents applied for Income from industrial property licenses New Technologically- Based Businesses created New Technologically-Based Businesses promoted (accumulated) URUGUAY ARGENTINA BRAZIL December 31st 2010 June 1st 2011 Participation in the 7th Framework Programme ,89 1ª Projects approved for the 7th European Framework Programme Projects Led Million Euros in total income First Spanish organisation JOINT VENTURE SHARED INNOVATION CENTRES Income TECHNOLOGICAL NODES CHINA 122 M 2010 COMMERCIAL NETWORK The importance of people 1,450 people from 23 different countries, working together towards a common goal: to generate business opportunities through applied research. 132 M Increase of +8% 2011 income forecast 3

3 Foundry and Steelmaking Unit We specialise in developing products, technologies, technological services and transferring technology for the Foundry and Steelmaking sector. This means that we innovate to add value by offering comprehensive support to the whole chain of production of our clients (supplier manufacturing sector end user), providing scientific excellence, internationalisation, technological alliances and our presence in the leading decision-making bodies and platforms of both sectors. We deliver the innovative difference needed to compete in a globalised world, creating business opportunities for our clients to increase their profitability and growth prospects. Fields of application FOUNDRY PROCESSES STEELMAKING PROCESSES INNOVATION IN PROCESSES AND EQUIPMENT CHARACTERISATION OF MATERIALS AND THEIR PROCESSES Sectors FOUNDRY INDUSTRY STEELMAKING INDUSTRY EQUIPMENT MANUFACTURERS AND SUPPLIERS USERS OF CAST AND TRANS- FORMED COMPONENTS 4 Over 50 years experience mean that we have a comprehensive, global and reconciled view of the present and a clear, agreed perspective of the future 5 Javier Moles Director Foundry and Steelmaking Unit

4 Fields of application In the Foundry and Steelmaking Unit, we pay special attention to each and every field of application, so that our clients can benefit from the transversal and complementary nature of our technologies. 01. FOUNDRY PROCESSES Materials / Innovative materials. High-performance materials. Nanomaterials. Cellular structures. Innovation and Technology / High-pressure injection systems. Intelligent systems. Total process control. Metallurgy and liquid metal treatment. Energy efficiency and saving. End products/ Simulation (reverse calculation, weight reduction of large parts, stress analysis, etc.). Recovery. Maintenance and characterisation of unique and/or standard products. In-service mechanical and structural properties. Edefu Use of new technologies for the manufacture of furnaces optimised for the non-ferrous foundry (aluminium), glass, cement and ceramics sectors, with reduced energy consumption, lower atmospheric emissions and better use of raw materials. In this field we are developing new technologies to manufacture furnaces for the sectors involved, taking into account their different production characteristics (temperatures, process times, treatment volumes, etc.). At the same time, we are studying improvements in the heating systems, the refractory materials to avoid loss of heat and systems for the recovery of smoke and particles emitted to the atmosphere. Finally, we design demonstration furnaces to evaluate their in-service performance, maintaining the product quality levels demanded by the end users. 6 7 We focus on developing and transferring technology.

5 Fields of application Providing comprehensive support to our clients at all points of their value chain. INDUSTRY AND TRANSPORT STEELMAKING INNOVATION IN CHARACTERISATION OF PROCESSES PROCESSES AND MATERIALS AND THEIR EQUIPMENT PROCESSES Analysis of processes to improve product quality and optimise process times / Secondary metallurgy (Fluid dynamics, Predictive simulation for the elimination of inclusions). Continuous casting: Thermal evolution, solidification. Reheating furnace: Thermal evolution. Improvement of mechanical properties and development of new steels / Design of Rolling Sequences. Addition of nanoparticles. Bulk Metallic Glasses. New steel grades for special applications. Improvement of manufacturing systems and reduction of environmental impact / Ecodesign of processes: we contribute towards achieving a sustainable society. Energy efficiency (HEA and reheating). Nupross Development of technologies that allow companies in the steelmaking sector to obtain higher quality products with less environmental impact, thus responding to the ever more demanding requirements of clients in the increasingly competitive global marketplace. In addition, given the far-reaching nature of the field of research, NUPROSS has given priority to a number of broad themes that are listed below: Optimisation of processes, focusing on saving energy, raw materials and time. Sustainability of steelmaking processes. Traceability and identification of not only products but also processes and the characteristics of the same. Reduction of waste, both through reducing faulty material and by the revaluation of non-compliant material. Improvement of the quality of most of the processes, allowing us to make a qualitative leap forward that distinguishes products generated in the Basque Autonomous Region. Competitiveness of companies in the sector. New plasma fusion technologies / Plasmapour. Recovery and valorisation of waste. Plasma technology for metallurgical treatment / Re-engineering the casting process. Just in time casting / Energy and financial optimisation of the industrialisation stage. Plasmapour High Power Thermal Plasma heating (HPTP) in automatic casting units: Tomorrow s technology applied to today s casting. We are internationally renowned in the fields of high power plasma technologies applied to metallurgy. In particular, this technology is subject to a patent that has been exclusively licensed to the French company SERT-Metal. The value we provide with the technology consists of: precision, quality and savings: Precision: Reduced need to overheat the metal and heating time. Improved control of the temperature of the iron at the time of pouring. Quality: Improved metallurgical quality of castings. Reduced formation of slags. Savings: Energy savings to maintain the metal at casting temperature. Energy efficiency of 75%. The first two plasma heating units have been installed in Spain: Fuchosa S.L. (pressurised casting furnace with nodular cast iron). Lingotes Especiales S.A (casting ladle with grey cast iron). Failure analysis / A team with over 20 years experience in the field. A wide range of test equipment, laboratories and pilot plants. Expert advice on selecting materials and manufacturing processes, maintenance procedures and in-service conditions. Identification of fracture mechanisms. Joining technologies / Solid state processes: Linear friction, Welding, Local alloys. Fusion welding processes: Selection of processes, design of joints, optimisation of parameters. On-line process control. Brazing and Soldering processes: Development of sandwich joints and high temperature alloys. Baip With the aim of analysing future manufacturing methods in the shipbuilding sector, we have based our analysis of the study of manufacturing methods according to materials, thicknesses, joint preparation and cost of different welding processes. Basically, we have analysed the cost associated with manufacturing options involving one pass, two passes, etc. The information was evaluated by the mechanical and microstructural characterisation of the effect of changes in the essential variables of each of the processes analysed: MAG/ LASER/ LASER-MAG. 8 9

6 Comprehensive solutions The Foundry and Steelmaking Unit is highly specialised in processes and materials. We are an extremely experienced team with our own technologies as well as our own facilities (pilot plants as well as those at a more industrial scale). In addition to our knowledge base, our facilities are equipped with infrastructure including advanced simulation tools that permit flexibility and adaptation to the particular circumstances of our clients. Such a complete scope of experience, facilities and client base allows TECNALIA to develop and implement valuable solutions throughout the whole value chain. R+D+I Projects Development of new alloys and materials. Implantation of intelligent management and production process control systems. Manufacture of prototypes. Reverse engineering. Intelligent manufacturing systems. Laser. Thermal evolution and energy efficiency of furnaces. Design of rolling sequences. Improvement of the quality of production processes. Technological Consultancy Technological innovation in processes/ materials. Improvement of process (from raw materials to end products). Environmental quality (reduction of CO 2 emissions, energy efficiency of processes). Advanced simulation services (Electric Arc furnace, secondary metallurgy, solidification process, reheating furnace and design of Rolling sequences). Technological audits (process, energy efficiency, layout). Joining technologies (selection of processes, development and characterisation of joints, etc.). Characterisation of materials and their processes Chemical, metallurgical, mechanical and surface characterisation. Quality control tests and analyses. Consultancy services for companies (certification and homologation of systems, processes and staff). Advanced technological services (failure analysis, design of materials, residual life, expert studies). Technology transfer and diffusion Sale and licensing of Industrial Property. Courses, seminars, technical conferences, congresses, publication of articles and books

7 TECNALIA Parque Tecnológico de San Sebastián Mikeletegi Pasealekua, 2 E Donostia-San Sebastián (Spain) T T (International calls) JAVIER MOLES Director Foundry and Steelmaking Unit javier.moles@tecnalia.com PATRICIA CABALLERO Manager Cast Steel and Steelmaking Market patricia.caballero@tecnalia.com LUIS COBOS Manager Innovation of Processes and Equipment luis.cobos@tecnalia.com ANTTON MELÉNDEZ Manager Cast Iron Market antton.melendez@tecnalia.com ALBERTO PELAYO Manager Characterisation of Materials and Processes alberto.pelayo@tecnalia.com IBAN VICARIO Manager Non-Ferrous Casting Market iban.vicario@tecnalia.com FOUNDRY & STEELMAKING UNIT