2004 PICKLING LINE MARKET STUDY

Transcription

1 2004 PICKLING LINE MARKET STUDY Final Report by: AIM Report No. 328

2 FOREWORD This Report was prepared by AIM Market Research. Neither AIM Market Research, nor any person acting on its behalf: a) makes any warranty, express or implied, with respect to the use of any information, apparatus, method, or process disclosed in this Report or that such use may not infringe privately owned rights; or b) assumes any liabilities with respect to the use of or for damages resulting from the use of, any information, apparatus, method, or process disclosed in this Report. AIM Market Research is a privately owned market research and development firm.. All rights reserved. This report or its contents either in whole or in part may not be reproduced, stored in a data retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the express written consent of AIM Market Research. Unauthorized and/or unlicensed copying of any part of this report or its appendices is in violation of copyright law. Page i

3 CONTENTS LIST OF APPENDICES...vi LIST OF FIGURES...ix LIST OF TABLES...xx EXECUTIVE SUMMARY... ES-1 PROSPECT ANALYSIS...S-1 CONCLUSIONS... C-1 INTRODUCTION... IN-1 Section 1 Characterizing the Technologies Employed Characterize the Pickling Operation Characterizing the Pickling Line Surveyed Pickling Tanks Number of Tanks Length of Tanks Total Length of Pickling Tanks Depth of Tanks Preparation of the Strip Prior to Pickling Shot Blasting Skin Pass Mill Scale Breaker / Tension Leveler Strip Edge Trimming Does this Pickling Line Have Strip Edge Trimming? Share of Production that is Edge Trimmed Width Trimmed Is the Strip Edge Trimming that is Now In Place Adequate? Does this Pickling Line Have Strip Oiling? Is Strip Oiling Adequate? Tapered Tension Does this Pickling Line Utilize Tapered Tension? Is the Tapered Tension Adequate? Tensioning Devices In Push-Pull Pickling Lines What Types of Tension Reels Are They Using In-line Slitting Deep-Draw or Other Coating Abilities Acid Application Method Page ii

4 Production of Pickling Lines Rated Capacity vs Production Production Share of Capacity vs Production Projected Production Section 2 OPERATING PRACTICES Operating Hours Hours per Day Days per Week Weeks per Year Types of Pickling Acid Used Carbon Steel Producers Specialty Steel Producers Are Acid Concentrations Changed Depending on the Grades Pickled Pickled Product Dimensions Strip Thickness Gauge Strip Width PIW Reasons for Altering Wet Section Speed Coil Dimensions and Mass Parameters Steel Grades End Product Destinations, Applications, Markets Outside vs. Internal Applications Major End-Use Markets New Products Being Considered for Pickling Lines Section 3 PRODUCTION BY GRADES, GRADES PRODUCED, AND THEIR IMPACT ON OPERATING PARAMETERS Grades / Production Characteristics Share of Production by Grades of Steel Quantity Produced by Grades of Steel Pickling Line Speeds by Grades of Steel Produced Low Carbon Steels Medium / High Carbon Steels HSLA Steels Stainless Steels Pickling Time by Grades Low Carbon Steels Medium / High Carbon Steels HSLA Steels Specialty Steel Most Difficult Grades of Steel to Pickle Carbons Carbons Carbons Other Grades Page iii

5 Section 4 PICKLING LINE PRIORITES, PROBLEMS, & OPPORTUNITIES The Fundamental Priorities Overall By Segment Relative Priority Increased Tonnage vs. Cost Reduction Assessing the Adequacy of the Existing Pickling Line Equipment Major Problems, Limitations, Needs, or Concerns The Adequacy of Current Capacity What Makes Hot Band Difficult to Pickle? Factors in Pickling Quality Section 5 FEEDSTOCK REQUIREMENTS & ENVIRONMENTAL ISSUES Feedstock Requirements of Pickling Operation Pickling Line Operations that Buy Hot Bands From Outside their Company Major Concerns for the Supply of Steel Feedstock Source of Feedstock for Pickling Operations (Open Market vs. In-house) Environmental Environmental Issues Acid Regeneration Acid Regeneration Plants Planned Section 6 AUTOMATION & CONTROL The Adequacy of Pickling Line Automation and Control Problems with Pickling Line Automation Leading Suppliers of Pickling Line Automation and Control Automation and Control Supplier Ratings Satisfaction with Current Automation and Control Supplier s Performance Age of Pickling Automation Systems Plans (Or Considerations) for Pickling Line Automation Projects Section 7 MAINTENANCE Characterizing Maintenance of the Pickling Lines Pickling Lines Where Maintenance Could Be Improved Availability of the Pickling Lines Scheduled Outages Annual Maintenance Cost for the Picking Line Pickling Lines That Are Having Problems with Rolls Page iv

6 Section 8 ACID PUMPS Satisfaction with the Pickling Pumps Number of Pickling Acid Pumps in Use Pickling Acid Pump Suppliers Acid Pump Seal Arrangement The Use of a Seal Flush Primary Causes of Pickling Acid Pump Failures The Use of Caustic Soda (Sodium Hydroxide) Scrubbers for Fumes Awareness of Sealless Pickling Acid Pumps Impressions & Opinions About the Leading Acid Pump Suppliers Section 9 PICKLING ACID AND ADDITIVES Pickling Acid Consumption Pounds of Acid per Ton of Steel Total Annual Acid Consumption Strip Time In Acid The Use of Pickling and Rinse Additives The Use of Pickling Inhibitors Leading Suppliers of Pickling Rinse Additives Section 10 HEATING IN THE PICKLING OPERATION Heating Method Is the Heating System Adequate? Location of Heat Exchangers Type of Heat Exchangers The Problem of Acid Leaking Through the Heater Seals The Concern when Acid Leaks Through the Heater Seals Boiler Feed Water Temperature The Benefits of Strip Preheating Pickling Tank Temperature Anticipated Natural Gas Price Increases Section 11 COMPETITIVE ANALYSIS & PLANS TO ADD OR UPGRADE PICKLING EQUIPMENT The Leading Suppliers of Pickling Line Equipment Systems Supplier Ratings by Selection Factor Ratings By Supplier Plans to Invest in Pickling or Related Lines Type of Pickling or Other Lines Involved in these Projects Pickling Line and Related Investment Projects Coupling a Pickling Line with a Coating Process Exploring Any New Pickling Technology Pickle Line Equipment Decision Criteria The Most Important Factors in Selection of Pickling Line Equipment Vendors Page v

7 LIST OF APPENDICES The following Appendices provide the information specified for each of the plants surveyed: INTRODUCTION Appendix 1: Appendix 2: Appendix 3: List of Firms Contacted Individuals Contacted and Interviewed Prospect Analysis SECTION 1 - CHARACTERIZING THE PICKLING LINES SURVEYED Appendix 4: Appendix 5: Characterize the Pickling Producer Characterize the Selected Pickling Line and Plant Appendix 6: Characterize the Selected Pickling Line Part 2 Appendix 7: Characterize the Selected Pickling Line Part 3 Section 2 CHARACTERIZING THE PICKLING LINES SURVEYED PART 2 Appendix 8: Appendix 9: Appendix 10: Appendix 11: Appendix 12: Appendix 13: Appendix 14: Production and Operating Hours Grades Processed, Time, and Speed Most Difficult Grades to Pickle Type of Pickling Acid Used Pickled Product Dimensions and Factors That Determine Wet Section Speed End Product Destination New Steel Products Considered Section 3 PRIORITIES, PROBLEMS & OPPORTUNITIES Appendix 15: Appendix 16: Appendix 17: Appendix 18: Fundamental Priorities Relative Priorities for Investments Reduce Costs vs. Increase Tonnage Are Pickling Facilities Adequate? How Could Existing Pickling Be Improved? Page vi

8 LIST OF APPENDICES (Cont.) Section 3 PRIORITIES, PROBLEMS & OPPORTUNITIES (CONT.) Appendix 19: Appendix 20: Appendix 21: Improvement and Upgrade Priorities Major Factors that Contribute to Poor Quality Sourcing Of Hot Bands Section 4 FEEDSTOCK REQUIREMENTS AND ENVIRONMENTAL ISSUES Appendix 22: Appendix 23: Appendix 24: Appendix 25: Appendix 23: Appendix 24: Required Technology Investments Environmental Issues Acid Regeneration Plant Leading Pickling Line Suppliers Profile Situation Quality Concerns Section 5 PICKLING LINE EQUIPMENT Appendix 25: Coil Prep Station and Type of Payoff Reel Section 6 AUTOMATION AND CONTROL Appendix 26: Appendix 27: Appendix 28: Is Pickling Automation Adequate? Drives and Automation Suppliers Drives and Automation Plans Section 7 MAINTENANCE Appendix 29: Appendix 30: Appendix 31: Assessing Maintenance Program Pickling Line Outages, Maintenance Cost, and Roll Problems Is OEM Involved In Maintenance? Page vii

9 LIST OF APPENDICES (Cont.) Section 8 ACID PUMPS Appendix 32: Appendix 33: Appendix 34: Pickling Acid Pumps Pump Failure Awareness of Sealless Pumps and Pump Decision Maker Section 9 PICKLING ACID RECOVERY Appendix 35: Acid Usage, Cost, Time in Acid, and Scale Breaker Use Section 10 HEATING IN THE PICKLING OPERATION Appendix 36: Appendix 37: Appendix 38: Appendix 39: Pickling Line Heating Heat Exchangers Direct Steam Heating Pickling Tank Temperature and Projected Natural Gas Increases Section 11 PLANS TO ADD OR UPGRADE PICKLING EQUIPMENT Appendix 40: Appendix 41: Appendix 42: Appendix 43: Appendix 44: Appendix 45: Plans to Replace, Add, or Upgrade Pickling Facilities Key Decision Makers Most Important Factors in Supplier Selection Pickling Line Survey Questionnaire Plants That Did Not Qualify List of Firms Contacted, But Survey Was Not Completed. Page viii

10 LIST OF FIGURES INTRODUCTION Figure 1 - Figure 2 - Functional Positions of 160 Individuals Interviewed...IN-4 Types of Plants Surveyed...IN-5 SECTION 1 - CHARACTERIZING THE TECHNOLOGIES EMPLOYED Figure 3 - Number of Tanks Per Pickling Line Overall Figure 4 - Number of Tanks in Pickling Lines by Type of Plant Figure 5 - Length of Pickling Line Tanks in Integrated Steel Plants Figure 6 - Length of Pickling Line Tanks in Outside Processors (That Do Not Toll Process Figure 7 - Length of Pickling Line Tanks in Outside Processors (That Toll Process) Figure 8 - Length of Pickling Line Tanks in Minimills Figure 9 - Length of Pickling Line Tanks in Specialty Steel Plants Figure 10 - Total Length of Pickling Line Tanks in Integrated Steel Plants Figure 11 - Figure 12 - Total Length of Pickling Line Tanks in Outside Processors (That Do Not Toll Process) Total Length of Pickling Line Tanks in Outside Processors (That Toll Process) Figure 13 - Total Length of Pickling Line Tanks in Minimills Figure 14 - Total Length of Pickling Line Tanks in Specialty Steel Plants Figure 15 - Depths of Tanks in Pickling Lines Figure 16 - Is A Skin Pass Mill Installed Before the Pickling Tank? Figure 17 - Is Scale Breaker / Tension Leveler Located Before the Pickling Tank? Figure 18- Is Skin Pass Scale Breaker Wet or Dry? Figure 19 - Does the Pickling Line Have Strip Edge Trimming? Page ix

11 LIST OF FIGURES (Cont.) SECTION 1 - CHARACTERIZING THE TECHNOLOGIES EMPLOYED (CONT.) Figure 20 - Figure 21 - Figure 22 - Figure 23 - Percent of Capacity Typically Edge Trimmed by Pickling Lines in Integrated Steel Plants Percent of Capacity Typically Edge Trimmed by Pickling Lines in Outside Processors (That Do Not Toll Process) Percent of Capacity Typically Edge Trimmed by Pickling Lines in Outside Processors (That Toll Process) Percent of Capacity Typically Edge Trimmed by Pickling Lines by Minimills and Specialty Steel Plants Figure 24 - Width Edge Trimmed by Pickling Lines in Integrated Steel Plants Figure 25 - Figure 26 - Figure 27 - Width Edge Trimmed by Pickling Lines by Outside Processors (That Do Not Toll Process) Width Edge Trimmed by Pickling Lines by Outside Processors (That Toll Process) Width Edge Trimmed by Pickling Lines by Minimills and Specialty Steel Plants Figure 28 - Does the Pickling Line Have Strip Oiling? Figure 29 - Does the Pickling Line Use Tapered Tension? Figure 30 - Types of Tensioning Devices Used on Push-Pull Pickling Lines Figure 31 - Is Push-Pull Pickling Line Tension Reel an One, Two, or Turret Type? Figure 32 - Does the Pickling Line Have In-line Slitting? Figure 33 - Does then Pickling Line Have Deep-Draw or Other Coating Abilities? Figure 34 - Acid Application Method Used in Pickling Lines Figure Production vs. Capacity of Pickling Lines in Integrated Steel Plants Figure 36 - Figure Production vs. Capacity of Pickling Lines in Outside Processors (That Do Not Toll Process) Production vs. Capacity of Pickling Lines in Outside Processors (That Toll Process) Page x

12 LIST OF FIGURES (Cont.) SECTION 1 - CHARACTERIZING THE TECHNOLOGIES EMPLOYED (CONT.) Figure Production vs. Capacity of Pickling Lines in Minimills Figure Production as a Percent of Capacity in Integrated Plants Figure 40 - Figure Production as a Percent of Capacity in Outside Processors (That Do Not Toll Process) Production as a Percent of Capacity in Outside Processors (That Toll Process) Figure 42 - Projected Increase in Production 2004 vs by Integrated Plants Figure 43 - Figure 44 - Projected Increase in Production 2004 vs by Outside Processors (That Do Not Toll Process) Projected Increase in Production 2004 vs by Outside Processors (That Toll Process) Section 2 OPERATING PRACTICES Figure 45 - Pickling Line Operating Scenario Days Per Week Figure 46 - Pickling Line Operating Scenario Weeks Per Year Figure 47 - The Use of Hydrochloric Acid for Pickling Figure 48 - Pickling Acid Used by Specialty Steel Plants Figure 49 - Pickling Line Strip Thickness Processed by Integrated Steel Plants Figure 50 - Figure 51 - Pickling Line Strip Thickness Processed by Outside Processors (That Do Not Toll Process) Pickling Line Strip Thickness Processed by Outside Processors (That Toll Process) Figure 52 - Pickling Line Strip Thickness Processed by Minimills Figure 53 - Pickling Line Strip Thickness Processed by Specialty Steel Plants Figure 54 - Pickling Line Strip Width Processed by Integrated Plants Figure 55 - Pickling Line Strip Width Processed by Outside Processors (That Do Not Toll Process) Page xi

13 LIST OF FIGURES (Cont.) Section 2 OPERATING PRACTICES (CONT.) Figure 56 - Pickling Line Strip Width Processed by Outside Processors (That Toll Process) Figure 57 - Pickling Line Strip Width Processed by Minimills Figure 58 - Pickling Line Strip Width Processed by Specialty Figure 59 - Pickling Line Strip PIW Processed by Integrated Steel Plants Figure 60 - Figure 61 - Figure 62 - Pickling Line Strip PIW Processed by Outside Processors (That Do Not Toll Process) Pickling Line Strip PIW Processed by Outside Processors (That Toll Process) Is Wet Section Speed Varied as a Function of Coil Dimensional and Mass Parameters? Figure 63 - Is Wet Section Speed Varied as a Function of Steel Grades? Figure 64 - End Product Destinations of Pickling Lines Figure 65 - Figure 66 - Figure 67 - Share of Production of Integrated Plants that is Processed for an Outside Destination Share of Production of Outside Processors (That Do Not Toll Process) Processed for an Outside Destination Share of Production of Outside Processors (That Toll Process) Processed for an Outside Destination Figure 68 - Share of Production of Minimills Processed for an Outside Destination Figure 69 - Share of Production of Specialty Steel Plants Processed for an Outside Destination Figure 70 - End Product Outside Destinations of Pickling Lines Figure 71 - Major End-Use Markets of Pickling Lines - Overall Figure 72 - Major End-Use Markets of Pickling Lines by Type of Plant Page xii

14 LIST OF FIGURES (Cont.) Section 3 PRODUCTION BY GRADES, GRADES PRODUCED, AND THEIR IMPACT ON OPERATING PARAMETERS Figure 73 - Grades Processed by Pickling Lines Figure 74 - Share of Production by Grades Processed by Pickling Lines Figure 75 - Production by Grades Processed by Pickling Lines Figure 76 - Figure 77 - Figure 78 - Pickling Line Speed Processing Low Carbon (<.08) Steels by Integrated Plants Pickling Line Speed Processing Low Carbon (<.08) Steels by Outside Processors (That Do Not Toll Process) Pickling Line Speed Processing Low Carbon (<.08) Steels by Outside Processors (That Toll Process) Figure 79 - Pickling Line Speed Processing Low Carbon (<.08) Steels by Minimills Figure 80 - Figure 81 - Figure 82 - Pickling Line Speed Processing Medium-High Carbon Steels by Integrated Plants Pickling Line Speed Processing Medium-High Carbon Steels by Outside Processors (That Do Not Toll Process) Pickling Line Speed Processing Medium-High Carbon Steels by Outside Processors (That Toll Process) Figure 83 - Pickling Line Speed Processing Medium-High Carbon Steels by Minimills Figure 84 - Pickling Line Speed Processing HSLA Steels by Integrated Plants Figure 85 - Figure 86 - Pickling Line Speed Processing HSLA Steels by Outside Processors (That Do Not Toll Process) Pickling Line Speed Processing HSLA Steels by Outside Processors (That Toll Process) Figure 87 - Pickling Line Speed Processing Stainless Steels by Specialty Steel Plants Figure 88 - Pickling Time Processing Low Carbon (<.08) Steels by Integrated Plants Figure 89 - Pickling Time Processing Low Carbon (<.08) Steels by Outside Processors (That Do Not Toll Process) Page xiii

15 LIST OF FIGURES (Cont.) Section 3 PRODUCTION BY GRADES, GRADES PRODUCED, AND THEIR IMPACT ON OPERATING PARAMETERS (CONT.) Figure 90 - Pickling Time Processing Low Carbon (<.08) Steels by Outside Processors (That Toll Process) Figure 91 - Pickling Time Processing Low Carbon (<.08) Steels by Minimills Figure 92 - Pickling Time Processing Medium-High Carbon Steels by Integrated Plants Figure 93 - Figure 94 - Pickling Time Processing Medium-High Carbon Steels by Outside Processors (That Do Not Toll Process) Pickling Time Processing Medium-High Carbon Steels by Outside Processors (That Toll Process) Figure 95 - Pickling Time Processing Medium-High Carbon Steels by Minimills Figure 96 - Pickling Time Processing HSLA Steels by Integrated Steel Plants Figure 97 - Figure 98 - Pickling Time Processing HSLA Steels by Outside Processors (That Do Not Toll Process) Pickling Time Processing HSLA Steels by Outside Processors (That Toll Process) Figure 99 - Pickling Time Processing HSLA Steels by Specialty Steel Producers Figure Low and Medium Carbon Grades of Steel Difficult to Pickle Figure Hi-Carbon Grades of Steel Difficult to Pickle Figure Hi-Carbon Grades of Steel Difficult to Pickle Figure Grades of Steel Hardest to Pickle Section 4 PICKLING LINE PRIORITIES, PROBLEMS & OPPORTUNITIES Figure Fundamental Priorities of Pickling Lines Surveyed - Overall Figure Fundamental Priorities of Pickling Lines Surveyed by Type of Plant Figure Relative Priority for Investments Cost Reduction vs. Increasing Tonnage Figure Will Pickle Line Be Sufficient for Future Needs? Page xiv

16 LIST OF FIGURES (Cont.) Section 4 PICKLING LINE PRIORITIES, PROBLEMS & OPPORTUNITIES (CONT.) Figure What Characteristics of Hot Band Make it Difficult to Pickle? - Overall Figure What Characteristics of Hot Band Make it Difficult to Pickle? - By Type of Plant Figure What are the Factors That Contribute to Poor Quality in the Pickling Operation? - Overall Figure What are the Factors That Contribute to Poor Quality in the Pickling Operation? By Type of Plant Section 5 FEEDSTOCK REQUIREMENTS AND ENVIRONMENTAL ISSUES Figure Plants That Now Buy Hot Band or Expect to Buy (Within Five Years) Figure Biggest Concerns for Hot Band Feedstock Figure Source of Feedstock for Pickling (Open Market vs. In-house) Figure Source of Feedstock for Pickling (US vs. Imports) Figure Are There Any Environmental Issues with Regard to the Pickling Line? Figure What Plants Have an Acid Regeneration Plant? Section 6 AUTOMATION AND CONTROL Figure Plants That Indicated That Their Pickle Line Process Automation is Not Adequate Figure Pickle Line Automation Suppliers Identified by Pickle Lines Surveyed Figure Pickle Line Automation Suppliers Identified by Pickle Lines by Type of Plant Figure Comparison of Ratings of Pickling Line Suppliers by Competitive Factor Figure Plants Not Satisfied with Present Automation Suppliers Figure When Was Present Automation System Installed in Pickle Lines Surveyed? - Overall Figure When Was Present Automation System Installed in Pickle Lines Surveyed? By Type of Plant Page xv

17 LIST OF FIGURES (Cont.) Section 6 AUTOMATION AND CONTROL (CONT.) Figure Plants With Plans or Considerations to Replace, Upgrade, or Add Pickle Line Drives and Automation Section 7 MAINTENANCE Figure How Would You Characterize Maintenance for the Pickling Line? Figure Availability of Pickle Lines - Overall Figure Availability of Pickle Line by Type of Plant Figure Scheduled Maintenance (Hours per Week) Outages of Pickling Line Figure 130 Scheduled Maintenance (Days per Month) Outages of Pickling Line Figure 131 Scheduled Maintenance (Days per Year) Outages of Pickling Line Figure 132- Maintenance Cost ($ per Ton) of Pickling Lines Section 8 ACID PUMPS Figure 133- How Many Pickling Pumps Including Spares Do You Have? Figure 134- Pickling Line Pump Suppliers Identified by Pickle Lines - Overall Figure 135 Share of Acid Pumps in Use by Pickling Lines Surveyed by Supplier Figure 136 Leading Suppliers of Pickling Line Pumps by Type of Plant Figure 137 Type of Seal Arrangement of Pickling Line Acid Pumps Figure 138 Is a Seal Flush Used? Figure 139 Leading Reasons for Pump Failure in Pickle Lines Figure 140 Most Frequent Reasons for Pump Failure by Pump Supplier Figure 141- What Brands of Sealless Pumps Are You Familiar With? Figure 142- Comparing the Opinions of the Two Leading Pump Suppliers Page xvi

18 LIST OF FIGURES (Cont.) Section 9 PICKLING ACID RECOVERY Figure 143- Pickling Acid Consumption of Pickling Lines Operated by Integrated Plants Figure 144- Figure 145 Pickling Acid Consumption of Pickling Lines Operated by Outside Processors (That Do Not Toll Process) Pickling Acid Consumption of Pickling Lines Operated by Outside Processors (That Toll Process) Figure 146 Pickling Acid Consumption of Pickling Lines Operated by Minimills Figure 147 Total Acid Consumption of Pickling Lines Operated By Integrated Plants Figure 148 Figure 149 Total Acid Consumption of Pickling Lines Operated by Outside Processors (That Do Not Toll Process) Total Acid Consumption of Pickling Lines Operated by Outside Processors (That Toll Process) Figure 150- Total Acid Consumption of Pickling Lines Operated by Minimills Figure 151 Strip Time in Acid in Integrated Plants Pickling Lines Figure 152- Strip Time in Acid in Outside Processors Pickling Lines Figure 153- Strip Time In Acid In Outside Processors Pickling Lines (That Toll Process) Figure 154- Strip Time in Acid in Minimills Pickling Lines Figure Strip Time in Acid in Specialty Steel Plant Pickling Lines Figure Type of Pickling Line Additives Used by Plants Surveyed Figure Type of Pickling Line Inhibitors Used by Plants Surveyed Figure Type of Pickling Line Rinse Additives Used by Plants Surveyed Page xvii

19 LIST OF FIGURES (Cont.) Section 10 HEATING IN THE PICKLING OPERATION Figure Type of Heating Method Used by Pickling Lines Surveyed Figure The Location of the Heat Exchangers in Pickling Lines Surveyed Figure Type of Heat Exchangers Used by Pickling Lines Surveyed Figure Have You Had Any Acid Leaks Through Heater Seals? Figure What is the Concern When Acid Leaks Through the Heater Seals? Figure Boiler Feed Water Temperature of Pickling Lines with Direct Steam Injection Figure What Would Be the Benefit(s) of Preheating the Strip To Bath Temperature Prior to the Pickling Tank? - Overall Figure What Would Be the Benefit(s) of Preheating the Strip to Bath Temperature Prior to the Pickling Tank? By Type of Plant Figure Pickling Tank Temperatures in Pickling Lines in Integrated Plants Figure Pickling Tank Temperatures in Pickling Lines in Outside Processors Figure Pickling Tank Temperatures in Pickling Lines in Toll Processors Figure Pickling Tank Temperatures in Pickling Lines in Minimills Figure Pickling Tank Temperatures in Pickling Lines in Specialty Steel Plants Figure Projected Increase in Natural Gas Prices 2004 to 2005 by Integrated Plants Figure Projected Increase in Natural Gas Prices 2004 to 2005 by Outside Processors (That Do Not Toll Process) Figure Projected Increase in Natural Gas Prices 2004 to 2005 by Outside Processors (That Toll Process) Figure Projected Increase in Natural Gas Prices 2004 to 2005 by Minimills Figure Projected Increase in Natural Gas Prices 2004 to 2005 by Specialty Steel Plants Page xviii

20 LIST OF FIGURES (Cont.) Section 11 COMPETITIVE ANALYSIS AND PLANS TO ADD OR UPGRADE PICKLING EQUIPMENT Figure Leading Suppliers of Pickling Line Equipment Figure Comparison of Ratings of Pickling Line Suppliers by Competitive Rating Figure Comparison of Performance Ratings of Pickling Line Equipment System Suppliers in Each Category Overall Figure Competitive Ratings of SMS / Pro-Eco by Type of Plant Figure Competiitve Ratings of VAI by Type of Plant Figure Plans or Considerations to Replace, Upgrade, or Add Pickling Facilities Figure Plans or Considerations to Replace, Upgrade, or Add Pickling Facilities By Type of Line Figure The Most Important Factors in the Selection of Pickling Line Equipment Vendors Figure Leading Suppliers of Pickling Line Pumps by Type of Plant Page xix

21 Prospect Analysis LIST OF TABLES Table A - Table B - Summary of Prospects...S-1 Best Prospects...S-1 Section 1 CHARACTERIZING THE TECHNOLOGIES EMPLOYED Table 1 - Table 2 - Number of Pickling and Related Lines Operated By Plants Surveyed by Type of Plant Overall Increase in Steel Production of Pickling Lines Surveyed by Segment Section 4 PICKLING LINE PRIORITIES, PROBLEMS & OPPORTUNITIES Table 3 - Plant That Said Their Pickling Line Equipment Was Not Adequate for Present Needs Table 4 - How To Improve and the Target Area Table 5 - Plants That Said Their Pickling Equipment Will Not Be Adequate for Future Needs or Don t Know (D.K.) Section 5 FEEDSTOCK REQUIREMENTS AND ENVIRONMENTAL ISSUES Table 6 - Environmental Issues of Pickling Operations Table 7 - Pickling Operations with Acid Regeneration Section 6 AUTOMATION AND CONTROL Table 8 - The Problem with Pickling Line Automation Table 9 - What Corrective Action is Needed or Planned Table 10 - Plants Not Satisfied with Present Automation Suppliers Table 11 - Table 12 - Table 13 - Plans or Considerations for Pickling Line Automation Projects (Integrated Steel Plants) Part A Plans or Considerations for Pickling Line Automation Projects (Integrated Steel Plants) Part B - Comments Plans or Considerations for Pickling Line Automation Projects (Other Types of Plants) Part A Page xx

22 LIST OF TABLES (Cont.) Section 6 AUTOMATION AND CONTROL (CONT.) Table 14 - Plans or Considerations for Pickling Line Automation Projects (Other Types of Plants) Part B - Comments Section 7 MAINTENANCE Table 15 - Pickling Lines with Only Adequate Maintenance Section 11 PLANS TO ADD OR UPGRADE PICKLING EQUIPMENT Table 16A - Continuous Pickling Line Projects Integrated Steel Plants Table 16B - Continuous Pickling Line Projects Other Types of Plants Table 16C - Other Types of Lines Table 16D - Push-Pull Pickling Line Projects Page xxi