ScaleFree technology consists of two components: equipment and a coating product. These are applied in the following way: The ScaleFree equipment is installed in a location where scale formation is at its lowest, typically right after casting or descaling. The ScaleFree equipment then sprays the ScaleFree coating onto the hot billet/shell/slab/etc forming a 5-80µm protective layer on the surface. The ScaleFree layer then inhibits the formation of scale by significantly reducing the interaction of oxygen with the steel surface. The ScaleFree coating further reacts only with the existing surface scale to turn it into a lubricating paste. This results in a protective layer being formed on top of the steel so that
1) the billet/shell/slab/etc., can be reheated with only a limited amount of new scale being formed
2) rolling loads are reduced which then improves tool life
3) scale pickup on the rolls is reduced, further improving tool life
4) rolled-in scale defects are also minimized, thus improving surface quality
5) pickling costs shrink since the method improves pickling efficiency
6) sandblast costs are reduced due to improved surface quality
The benefits of ScaleFree technology are significant. With a yield improvement of 33% the customer’s plant could save almost 6,5 million euros annually. With increased pickling efficiency of 25% the customer could save an additional 4,4 million euros annually. With the average operating cost being 1-4 eu/ton the impact to the customer, not only in direct financial savings but also improved quality, increased efficiency and value-added prime yield is clear. Investing in ScaleFree technology is both financially and technically sound.
ScaleFree technology has been tested with major companies within the steel industry and is currently being implemented in locations around the globe. Design Management Konsulting Oy (DMK), is looking for new locations and interested partners to further implement ScaleFree technology.