Saarschmiede delivers turbine shaft to blast furnace gas power plant in Dillingen

With its innovative materials technology, the Völklingen-based Saarstahl subsidiary Saarschmiede GmbH Freiformschmiede is making a significant contribution to a path-breaking project

The wholly-owned Saarstahl subsidiary Saarschmiede GmbH Freiformschmiede in Völklingen, Germany, has manufactured the turbine shaft for the innovative blast furnace gas power plant to be constructed at the Dillingen location and has delivered it for subsequent processing. The power plant project which was agreed as part of a cooperative partner¬ship between Saarstahl, Dillinger Hütte, STEAG Saar Energie and VSE will enable path-breaking innovation. Construction work on the blast furnace gas power plant commenced on 27.06.2007.

The state-of the-art, highly efficient blast furnace gas power plant will supply energy to the companies Dillinger Hütte, Rogesa and Zentralkokerei Saar (ZKS) which are located in Dillingen. Rogesa and ZKS are joint subsidiaries of Saarstahl AG and AG der Dillinger Hüttenwerke, each holding a 50% stake. The use of the best systems engineering currently available ensures that the power plant offers the optimum in environmental protection and maximum energy utilization.

The shaft produced by Saarschmiede is a medium and low-pressure turbine shaft which requires different properties along its length in order to suit the operating conditions in the individual parts. The particular combination of properties is achieved by using a special steel developed at Saarstahl in the nineteen nineties. This steel is now one of the most common steels used in the manufacture of turbines. Due to special heat treatment, the medium and low pressure parts are each subjected to different conditions during annealing. As a result, the shaft attains the desired material properties.

The turbine shaft was manufactured by Saarschmiede from a forging ingot weighing 105 t which was manufactured in the forge's own electric steel plant. The shaft had a forging weight of 69.5 t. The delivery weight is 33.6 t. In delivery condition, the shaft has a maximum diameter of 1495 mm and a total length of 7560 mm. All heat treatment processes, the complete processing and all the desired tests were successfully carried out by Saarschmiede.

Besides the manufacture of the turbine shaft, the Völklingen-based Saarschmiede is also responsible for manufacturing the so-called cap rings for the generator shaft in the first construction of a new large-scale power station in the Saarland region for 20 years. Furthermore, the Saarstahl subsidiary is currently involved in numerous large international projects. For example, turbine and generator shafts as well as components for multi-part turbine shafts are manufactured. The most important international projects currently include the Finnish atomic power station Olkiluoto which will have the largest steam turbines ever built, the new German fossil fuel-fired power stations with efficiency increases of up to 46 % (e. g. in Neurath and Datteln) as well as numerous gas turbines which, combined with steam turbines, achieve efficiency levels of up to 60%.

As the shaft was being delivered, Dr. Dieter Bokelmann, Technical Director at Saarschmiede commented, "With its innovative material development and technologically sophisticated forge products, the Völklingen-based Saarschmiede has become a recognized global leader in energy engineering, mechanical engineering and in the aviation and space industries. We not only want to retain this position but also to extend it further as part of qualitative growth."

Völklingen, 30.07.2007

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Investments amounting to 35 million euros for
Saarschmiede GmbH Freiformschmiede at the Völklingen location

Saarschmiede GmbH Freiformschmiede is one of the most significant open die forges worldwide. It is market leader in the field of power engineering, for example, with the products heavy turbine and generator shafts for power stations. In addition, it is an internationally recognised supplier in the field of mechanical engineering, for example with high pressure containers and spin casting moulds as well as products manufactured from special materials for the aviation and space industry, for example, for parts of the booster rockets for the Ariane 5 rocket.

In a meeting that took place on 20.09.2006, the Supervisory Board of Saarstahl AG took the decision to invest an additional 35 million euros in the Saarstahl subsidiary, Saarschmiede GmbH Freiformschmiede, at the Völklingen location.

The individual investments will be made in the following equipment: a 4,000 T press, a rail mounted forging manipulator, a freely movable forging manipulator, several forging and annealing furnaces as well as lathes and crane systems.

The new investments are essentially aimed at increasing the efficiency of the existing facilities as well as allowing specialisation in production. Hence, Saarschmiede GmbH Freiformschmiede is able to implement its existing production programme more economically and to offer increased diversification. Furthermore, it has also been able to open up new markets in the field of aviation and space technology.

Dr. Klaus Harste, Member of the Board of Management at Saarstahl AG, commented:

"Global energy consumption will continue to increase sharply over the next two decades. These investments, which are oriented towards the growing demand in the power engineering sector, will enable Saarschmiede to keep pace with the rapid increase in demand and thus to further strengthen its leading position on the market. The new facilities will enable us to continue to commit ourselves, in future too, to our customers’ most demanding projects and requirements. In the product range of special materials for aviation and space technology, we want to present ourselves even more competitively and to continue to expand our position on the market. This comprehensive investment programme will make a decisive contribution towards securing existing jobs at the Völklingen location of Saarschmiede and even allow the creation of new jobs in line with growth."

Völklingen, 21.09.2006

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Commissioning of three new quench and temper furnaces and a new forging furnace

Within the context of a strategic partnership with one of its most important customers, after successful trials, Saarschmiede GmbH Freiformschmiede has put three new quench and temper furnaces and a new forging furnace into operation.

The new aggregates enable Saarschmiede GmbH Freiformschmiede, in the first instance, to meet additional demand for furnace capacity within the context of development planning. Furthermore, it allows the company more flexibility to react to the customers’ needs concerning material and the geometry of components required.

As from now, Saarschmiede GmbH Freiformschmiede has over 12 forging furnaces and 25 heat treating furnaces at its disposal.

The investment makes a significant contribution towards meeting the continued high global demand for forgings for high quality applications on schedule as well as strengthening the competitive position of Saarschmiede GmbH Freiformschmiede in the long term.



Völklingen, 01.02.2006