30 Years of Niobium Steel Development in China Mariana Oliveira (1) , Steve Jansto (2) , Hardy Mohrbacher (3) , Jitendra Patel (4) , Marcos Stuart (1) (1) CBMM – Companhia Brasileira de Metalurgia e Mineração (2) RMC – Reference Metals Company (3) NiobelCon BVBA (4) International Metallurgy Ltd Abstract Over the past 30 years, niobium (Nb) has become an important asset in the search for engineering solutions to the most significant challenges facing humanity: environmental awareness, energy savings and infrastructure for growth. China is an extraordinary example of this progress since it has been addressing these same issues together with the need for rapid development. This paper presents successful examples of Nb applications in China over the last three decades, where all expectations were surpassed in the main steel domains: pipeline, automotive, structural and stainless. An overview of future trends for the development of Nb products is also presented along with evidence that Nb will continue to be among the first microalloying choices and the best solution for new demand. CBMM, together with its Chinese partners, will continue to optimize Nb applications and new developments, always striving for higher value added products from the beginning of the supply chain to the end user. 1. Introduction Niobium (Nb) was first applied as an industrial material in 1933 to stabilize stainless steels against intergranular corrosion. Through the late 50s and early 60s, Nb was discovered to have microalloying properties that simultaneously enhance steel strength and toughness. In the 70s, Nb was also established as the material of choice for several advanced technological applications, mainly at high temperatures, in the form of superalloys i . During recent years, Nb applications have increased tremendously in several business segments, such as: Microalloyed steels Superalloys Thin films Medical implants Titanium and aluminum base alloys Superconductors and copper alloys Ceramic and electrolytic capacitors
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30 Years of Niobium Steel Development in China
Mariana Oliveira(1)
, Steve Jansto(2)
, Hardy Mohrbacher(3)
, Jitendra Patel(4)
, Marcos Stuart(1)
(1) CBMM – Companhia Brasileira de Metalurgia e Mineração
(2) RMC – Reference Metals Company
(3) NiobelCon BVBA
(4) International Metallurgy Ltd
Abstract
Over the past 30 years, niobium (Nb) has become an important asset in the search for
engineering solutions to the most significant challenges facing humanity: environmental
awareness, energy savings and infrastructure for growth. China is an extraordinary example
of this progress since it has been addressing these same issues together with the need for rapid
development. This paper presents successful examples of Nb applications in China over the
last three decades, where all expectations were surpassed in the main steel domains: pipeline,
automotive, structural and stainless. An overview of future trends for the development of
Nb products is also presented along with evidence that Nb will continue to be among the first
microalloying choices and the best solution for new demand. CBMM, together with its
Chinese partners, will continue to optimize Nb applications and new developments, always
striving for higher value added products from the beginning of the supply chain to the end
user.
1. Introduction
Niobium (Nb) was first applied as an industrial material in 1933 to stabilize stainless steels
against intergranular corrosion. Through the late 50s and early 60s, Nb was discovered to
have microalloying properties that simultaneously enhance steel strength and toughness. In
the 70s, Nb was also established as the material of choice for several advanced technological
applications, mainly at high temperatures, in the form of superalloysi.
During recent years, Nb applications have increased tremendously in several business
segments, such as:
Microalloyed steels
Superalloys
Thin films
Medical implants
Titanium and aluminum base alloys
Superconductors and copper alloys
Ceramic and electrolytic capacitors
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As shown in
Figure 1, the main use for Nb was in pipeline steels. More than 55% of the ferroniobium
(FeNb) produced by CBMM was dedicated to this application. Currently, Nb usage is still
concentrated in microalloyed steels, but it is more equally distributed between pipeline (32%),
automotive (20%) and structural (33%) segments. The remaining 12% goes to markets that
show promise for growth, including stainless steels and superalloys.
A milestone for FeNb consumption occurred around the year 2000 when FeNb sales began to
outpace the growth in steel production, Figure 2, eventually more than doubling the growth
rate over the decade. This growth illustrates the strong acceptance of Nb alloying solutions in
the world steel market, caused not only by improvements in traditional materials but also by
the development of new products.
Figure 1: Evolution of CBMM’s worldwide FeNb market by business segment.
* Actual Jan-Oct, estimated Nov-Dec.
30 Years of Niobium Steel Development in China 121
Figure 2: Increase in crude steel production and FeNb sales worldwide over the last 10 years.
* Actual Jan-Oct, estimated Nov-Dec.
China is one of the main reasons for increased Nb consumption, especially over the past 10
years, Figure 3.
Figure 3: Increase of FeNb consumption in China during the last decade.
* Actual Jan-Oct, estimated Nov-Dec.
Sales in China increased an average of CAGR 31% over the previous 10 years, Figure 3,
which completely modified CBMM s sales profile, Figure 4. At present, China is the strongest
FeNb market. This trend is forecasted to continue since Chinese crude steel production is
predicted to continue growing in coming years, reaching 650 million tons by 2013ii.
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Figure 4: CBMM’s sales by geographical region in 1999 and 2008.
Despite being the most apparent reason, steel production growth is not the only driver of
increased Nb sales. Another important factor that must be taken into consideration is the rise
of specific FeNb consumption, expressed in grams of FeNb consumed per ton of crude steel
produced. China has more than tripled its specific FeNb consumption from 11g/t in 2004 to
35g/t in 2008, proving that the incubation time necessary to develop the foundation for Nb
technology in China has passed and, therefore the intensity of FeNb consumption will
continue to grow.
Comparing China s FeNb distribution by segment to the world s, Figure 5, it is possible to
conclude that the automotive and stainless steel segments still have room to grow, while the
pipeline and structural steel segments have already matured.
Once China is developing fast the steel industry and producing more value added products,
FeNb specific consumption will continuously grow and reach the same or higher levels of
regions like North America and Europe, Figure 6.
30 Years of Niobium Steel Development in China 123
Figure 5: Nb consumption in 2008 by business segment in the world and in China.
Figure 6: Specific Nb consumption in select countries in 2008 (g FeNb / t crude steel).
2. Strategic View
CBMM s main strategy is to apply Nb where it is the best solution for adding value,
particularly in addressing what are considered the main challenges of today: environmental
awareness, energy savings and infrastructure to grow, Figure 7.
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Figure 7: Today’s challenges are where CBMM is concentrating efforts to apply Nb for
innovative solutions.
The company s goals are not only to supply the demand for Nb in the form of ferroalloy,
oxide or metal, but also to provide and develop the technological potential involved in the use
of this element to discover how Nb can help to overcome the main challenges worldwide:
growing wisely and in a sustainable way.
CBMM has a strong technical group developing Nb applications, acting together with
steelmakers, research universities, institutes and end users. At the moment, the company is
involved with more than 50 research projects around the world, 17 of them are with Chinese
universities and steel companies.
At least 1% of CBMM sales is invested in a research and development program. As part of
this technological effort, 237 researchers in the steel industry attained their university degrees
through scholarships granted by CBMM in areas relevant to Nb. This talent is working around
the world and is receptive to Nb technology, helping to develop Nb worldwide.
To promote environmental awareness, the technology program sponsors the development of
materials that minimize pollution emissions, such as ferritic stainless steels used in vehicle
exhaust systems as well as lighter steels for car bodies that reduce fuel consumption and
extend the components life cycles, which together save energy and raw materials.
Lighter weight is also a focus in the infrastructure area in order to create more resistant steel
structures with less material since nowadays there is a strong commitment to lowering
financial and environmental costs, not to mention feasibility issues in urban infrastructure.
Nb-bearing steel is an ideal solution because it is a higher strength steel, which results in less
material volume for the same project, which not only lowers costs, but also uses less raw
material and generates fewer emissions during the steel production process.
30 Years of Niobium Steel Development in China 125
The main challenges regarding energy savings are the need to improve existing processes, like
obtaining higher efficiencies in thermal power plants, and to develop new clean sources. Nb
bearing steels can work at higher temperatures, allowing these higher efficiencies and energy
savings.
Successful examples of these technical efforts in China are described below.
3. Successful Examples of Development in China and Future Trends
3.1. Pipeline
China’s rapid economic growth shows no signs of slowing, with a gross domestic product
increase of over 10% reported for 2008 and an annual growth rate of 9% for the year. China is
now the world’s second-largest and fastest-growing energy consumer and is a major player in
world energy markets. According to EIA projections, by 2030 China will be the world’s
largest energy consumer, Figure 8.
Figure 8: Actual and projected global energy demand - 2005 & 2030 (3).
Although coal is the cornerstone of the country’s energy system, natural gas comprises
approximately 2-3% of total primary energy demand. This share hides the significance of the
large volumes of natural gas consumed and the required demand in linepipe steel needed for
long distance transmission systems. Consequently, this has led to the installation of new steel
mills and hot rolling mills, as well as the need to quickly develop modern and advanced high
strength steels for the construction of energy infrastructure.
The required growth in energy demand has meant a significant expansion of China’s existing
pipeline network. A summary of some of the key transmission lines is provided below:
During 1970-1980 the natural gas trunk pipeline network was formed in Sichuan.
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In the 1990s, several famous pipelines were built in China such as Ya-13-1-Hong
Kong Pipeline, the Pinghu-Shanghai Pipeline and the ShaanCi-Beijing Pipeline.
During 2000-2005 a number of major pipelines were built adding significant capacity
to the network, including Sebei-Xining-lanzhou Pipeline, West-East Pipeline, a
second pipeline from ShaanXi to Beijing and Zhingxian-Wuhan Pipeline.
In 2008, the total length was approaching 35,000km and transport capacity amounted
to 81bcm per year.
By 2020, there is an expectation that more than 25,000km of new pipeline will be built and
the national gas pipeline system will be moving gas from the western to the eastern regions
and from the northern to southern regions. Significant future developments are also expected
offshore, where China has only started to make notable developments.
Today there are eight major gas production regions in China. The production amounted to
77.5bcm in 2008 and is expected to reach near 220bcm in 2020. Figure 9 highlights the
concurrent development in production and consumption and also translates directly into the
growth needed in the pipeline network.
For example, the growth in China’s pipeline network can be dramatically seen in Figure 10.
Although the first and second West-East Pipelines make a significant contribution, over the
last 10 years the laying of nearly 20,000km of major trunk and branch lines has been
outstanding.
Figure 9: Annual gas production and consumption in China.
30 Years of Niobium Steel Development in China 127
Figure 10: Pipeline lengths per year in China.
In order to cater to the required demand in linepipe, China has seen the construction of over
15 new hot rolling mill projects in the last 10 years, as highlighted in Table 1. With this newly
installed capacity and performance capability, today China has become one of the leading
countries able to develop the necessary high strength plate and hot rolled coil required for the
oil and gas sector, both for domestic use and exports.
Table 1: New plate mills installed in China during the last 10 years.
Producer/Location Plate mill width Year ordered
Yingkou 5,000mm 2009
Baotou 4,100mm 2007
Xiangtan 3,800mm 2007
Shagang No.2 5,000mm 2007
Wuhan 4,300mm 2006
Laiwu 4,300mm 2005
Wuyang 3,800mm 2005
Angang 5,000mm 2005
Shougang 4,300mm 2004
Shagang No.1 5,000mm 2003
Xinyu 3,800mm 2003
Baoshan 5,000mm 2002
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The installation of state-of-the-art steel making and rolling facilities has permitted Chinese
steel producers to fully exploit the Nb technology that has been previously enjoyed by other
leading world mills. However, in order to capitalize on this new capability the learning has
been rapid, sustained and above all, successful.
In the last 10 years Chinese mills have successfully mass produced X70 and X80 linepipe
steel grades for both LSAW and HSAW application. The high quality steel has been designed
around new pipeline design practices such as strain-based design and modern pipe-making
and welding techniques. For example, Figure 11 shows the annual increase in production for
NISCO for API steel grades going from around 25,000t to 350,000t in two years.