That's new at KSK

 

September 2021 - Dual studies at KSK

KSK welcomes its first dual student to the company! Tom has already been working in our workshop for just under a year as an apprentice for metal construction - specialising in construction technology. In cooperation with the Westphalian University of Applied Sciences, he is now also enrolled in the bachelor's degree programme in mechanical engineering for the beginning winter Semester.

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Like many paths, Tom's was not entirely straightforward last year. A long-planned stay abroad was cancelled due to the COVID-19 pandemic, and it was already too late to enrol at university for the winter semester - a good alternative was needed! Without further ado, Tom decided to do a trial internship at KSK's workshop. He quickly realised that "working here is really fun". His colleagues are also enthusiastic. "The boy is on his toes!" they agree. It was clear that the internship contract was exchanged for an apprenticeship contract a few weeks later. Here, too, Tom does excellently. Also, his ambition to study is still unbroken. We are therefore pleased to be able to offer Tom the opportunity to study mechanical engineering at the Westphalian University of Applied Sciences parallel to his apprenticeship in the upcoming winter semester. This makes Tom the first dual student in the KSK company's history!

For the upcoming tasks and the certainly challenging time, we wish you, dear Tom, a lot of stamina, a lot of fun and of course a lot of success!

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August 2021 - Small school bag, big expectations!

At the start of the new training year, we welcome a total of four new trainees at KSK GmbH and KSK Automation GmbH with our now obligatory school bag (electronics technician for industrial engineering and metal worker, specializing in construction technology). This means that the KSK Group currently employs 10 trainees.

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We are thus remaining true to our chosen path and ensuring that we have our own qualified young people in times of a shortage of skilled workers by consistently and successfully investing in the training of young people for many years. On their first day, the new trainees are welcomed by their foremen, the HR management and the managing directors. These are no strangers to some of the new KSK employees, as some of them have already had the opportunity to get to know each other during successful internships.

We wish them all a successful apprenticeship and much success in their new daily routine!

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July 2021 - Goodbye, Carsten!

Saying goodbye is often difficult. Especially when, like Carsten Oberhag, you say goodbye to your "baby" - KSK - after almost 30 years as a managing partner.

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Carsten's career began in the late 1980s as an accountant at a KSK shareholder company. At the beginning of the 1990s, as a young man, he finally wanted to take on responsibility himself and joined KSK as a shareholder-manager together with mechanical engineer Olaf Huscher. "Those were Wild West times back then, you can't imagine that today. I probably wouldn't take as much risk today as I did in the 90s as a young family man," smiles Carsten Oberhag as he bids farewell. The two long-time companions are certain that the high risk has nevertheless paid off, depending above all on three factors: 100 percent mutual trust, a good gut feeling, and committed and competent employees in the office and workshop. Together, the two built up the company over the years into an industry-renowned special plant manufacturer. While one of them often supervised customer projects outside the company, the other held the fort in the office and, among other things, was instrumental in planning the site in Haltern am See in the early 2000s. "I could always rely on having a strong business partner at my side to handle the many small and large, everyday and not-so-ordinary matters in Haltern, in my interest and in ours. I am very grateful to you for that," said a visibly moved Olaf Huscher in his farewell speech. With the company succession process initiated in 2019, Carsten amicably withdrew from responsibility bit by bit and transferred his knowledge and experience in all commercial matters to his young colleagues with great commitment and passion.

Well, and now the time has really come, Carsten. You have made it! At this point, therefore, there is not much more we can say than once again from the bottom of our hearts:

 

Thank You!

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June 2021 - Electrified towards the future

We put a public charging station into operation!

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The charging station can be accessed from two separate parking bays and has two charging points with a Type-2 connector and an AC output of 22 kW each. By comparison, most commercially available wallboxes for installation in the garage at home have a maximum output of 11 kW. The charging time at the 22 kW charging pole is reduced by about half for appropriately equipped vehicles.


"Installing the charging pole was a logical step for us," says Managing Director Olaf Huscher. "We have the necessary transformer power on our company premises and generate our own electricity during the day with our solar power system. We would like to make this available to our employees with electric cars, such as our Mr. Handke, in this way."


However, it is not only KSK employees who will benefit from the installed charging station. On request, the charging station can also be activated and used by commercial neighbors, such as the outpatient care service PuG Pflege- & Gesundheitsteam GmbH, or interested private individuals.


The idea was born at the "Entrepreneur's Breakfast" of the Economic Development Department of the City of Haltern am See on the topic of "Resource-efficient industrial estates," according to Managing Director Andreas Höwedes. "After it became clear that the transformer capacities publicly installed for the industrial park were not sufficient for the installation of charging columns, we decided in the follow-up to the discussions to become active ourselves and to use power reserves of our company-owned 10 kV transformer," Höwedes continued.


If the test phase with the first installed column proves successful, KSK plans to install further columns. The technical requirements have already been checked by an external service provider. It is still unclear whether charging columns can also be installed outside the company's own premises with a connection to the KSK transformer. Initial talks with the city failed due to the cabling of the columns across a public road.

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May 2021 - Work with style

You stand in front of the mirror in the morning and don't know what to wear to work? At KSK, that's no longer a problem! All colleagues in the workshop and office were able to enjoy new work clothes in the spring. Polo shirts and T-shirts are worn gladly and not compulsorily, while fleece jackets and loop scarves can fortunately be left in the closet at the moment.

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.... Our colleagues like it, as you can see!

 

Would you also like to wear KSK on your chest? Then take a look at our job ads, maybe there is something suitable for you!

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April 2021 (2/2) - Mission complete!

Passed! I did it! Finally! ...after a very intensive half year, a huge burden falls from the shoulders of our colleague Sinan. From now on he can call himself "Certified Accountant (IHK)".

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We would like to take this opportunity to congratulate you, dear Sinan, once again on passing your exam. You have fought your way through a very demanding advanced training course with a lot of dedication, hard work and willpower, and you did not let yourself be sidetracked even by Corona-related obstacles. We all tip our hats to this achievement!

We would also like to take this opportunity to thank your family, who gave you such great support during this time. Further, we would like to thank our "old hand" Carsten Oberhag for his valuable coaching, even away from work!

Dear Sinan, we are happy to welcome you back on board as a fully-fledged accountant after your perceived absence!

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April 2021 - KSK Idea Contest

Dreary office or workshop routine, Corona is omnipresent, it's gray and rainy outside...that's no fun anymore. That's right! That's why we're doing something about it!

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When our company founder Herbert Kuhlmann brought the company to life in 1983, it was as clear as day to him what the three letters "KSK" would stand for: Kuhlmann-System-Kühltechnik! Almost 38 years later, at the very least KSK employees still know Mr. Kuhlmann personally. The three letters, on the other hand, are omnipresent in everyday work. Reason enough for us to search for an (tongue-in-cheek) alternative meaning for "KSK" in a small, internal competition. Out of almost 100 entries, five winners were able to enjoy great prizes. And at least as important: we had fun doing it!

Konsequent Stark Kompetent

Konstruierte Steuerungen & Kühlsysteme

Klare Sache: Kuhlmann

Klotzen Sonst Kündigung

Knusprige Schoko Kekse

Kommando Spezial Kräfte

Kader Schlauer Kollegen

...the list goes on.

Of course, we are always happy to receive further suggestions from outside ;-)

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March 2021 - Get out your shorts!

After Haltern am See was briefly buried under masses of snow in mid-February, it is already almost time to get out the short pants again at the beginning of March due to the warm weather. In line with this, here you can see our latest model "Short Pants" from our series of curious and unique geometries of water-cooled components.

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To return to the hard facts: The component is a water-cooled part of an exhaust gas channel weighing more than 8 tons, which is installed at the plant of our long-term customer Metallo Belgium N.V. The component was process-optimized and simulated, designed and manufactured in Haltern am See in a joint project between KSK and Metallo. The "Short Pants" piece is divided into two parts, whereby the cover of the component is hinged and designed as an explosion flap.

Wouter Geelen from Metallo's project department and Erik Hofmans (asset manager) were very satisfied with the result of the months of joint development work: "The trust in KSK and the know-how available there in the field of water-cooled systems has definitely paid off for our new component. In addition, changes were flexibly accommodated right up to the end of the very tightly scheduled project. That is what makes collaboration enjoyable!"

KSK would also like to take this opportunity to thank Metallo's staff once again for the great and constructive cooperation and wish every success in operating the new component!

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February 2021 - Gute Botschaft(er) from Haltern am See!

Our everyday work always demands 100% commitment and attention from each and every one of us. Only in this way are we able to deliver service and quality at the usual high level. But in order not to lose sight of the big picture in our day-to-day business, we deliberately took a day off, did a Corona quick test....and played with colored glass stones.

 

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This very entertaining and insightful day was conceived and guided by Michael Buttgereit, one of the two managing partners of the Gute Botschafter ("Good Ambassadors") from Haltern am See. Connoisseurs will have noticed immediately: the colorful stones are part of the "eigenland" analysis - the participative process developed by the Gute Botschafter to analyze potentials and resources in the company.

We would like to take this opportunity to thank them for the wonderful day! The first great ideas have already emerged from the very intensive cooperation between all participants. We are very excited to see which further development potentials we will be able to leverage and we are looking forward to further cooperation! The Gute Botschaft ("good news") therefore to all partners, customers and interested parties: KSK is on the right track!

Translated with www.DeepL.com/Translator (free version)

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January 2021 - Furnace cradle repaired

The new year gets off to a busy start: Many hardworking KSK hands were busy with repairs at various construction sites between the holidays last year and the beginning of the new year.

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One of the major repair jobs was on a furnace cradle in a German electric steel mill (for all those who are not electric steel workers: the furnace cradle is a tiltable supporting structure on which the vessel of an electric arc furnace is fixed). The repair work became necessary because the partially water-cooled cradle was plastically deformed over time due to thermal and mechanical influences. Over several day and night shifts, the cradle's supporting structure was first cut open, realigned, secured and stabilized. Subsequently, the steel frame could be cleanly welded again. With the repair successfully completed, a new furnace vessel could be installed and the electric arc furnace could be put back into operation.

We would like to thank the maintenance team of the steel mill for the great and trusting cooperation!

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December 2020 (2/2) - KSK end-of-year review

KSK looks back on a successful year 2020 - considering the circumstances!

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2020 was not a normal year for KSK Group, as it was for most people and companies in Germany and the world. Nevertheless, we were able to successfully realize many smaller and large projects this year, such as the delivery and commissioning of a 20MW closed-loop re-cooling circuit for a new AOD converter, the delivery and commissioning of an optimized ladle furnace cover for Thyssenkrupp or the re-equipping and commissioning of two double ladle furnaces with a total of four newly developed ladle furnace covers for another, large, German steel plant.

In doing so, we remained committed to our strategic line and, with the appointment of Mr. Christoph Budde to KSK Automation GmbH's board of management at the beginning of the year, continued to consistently focus on a sustainable and professionally competent rejuvenation of our management team.

For the upcoming year 2021, we wish all our employees, customers, partners and suppliers first and foremost good health, confidence and the long-awaited return to normality - both professionally and privately!

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December 2020 (1/2) - We are sticklers for details!

This December, we stickled for details for a german converter steel plant - using our 3D laser scanner! The scanner captured millions of individual points of a chute opening component manufactured by us in Haltern am See. A program merged these coherent point clouds - shown in gray in the picture. The 3D model underlying the component can be seen in color. In detail, it was verified that there were only minimal deviations between model and practice due to the welding distortion. After this successful inspection, the part can now be installed in the existing converter chimney on site without hesitation.

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The component is the chute opening of a converter, which is subject to acceptance. The newly designed opening can be subsequently inserted into the converter chimney on site.

Would you also like to examine a component, the position of a component or a complete plant with millimeter precision? Do not hesitate to contact us!

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November 2020 - Automated track loading in the tank farm

KSK Automation GmbH automates the future track loading in the tank farm of our long-time customer Transtank in Gelsenkirchen. The first six switch cabinets for the project have now been delivered.

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The switch cabinets are intended for a new switch house in the tank farm, which was built especially for the project new track loading in the tank farm. From this switch house, pumps are operated for the transfer of fuel to the new track loading facility.

In the first step, a 1,000A main distribution, which is fed by two new 630 kVA transformers, as well as a sub-distribution was delivered and installed. Subsequently, the switchgear was commissioned.

In a further step the delivery of eight power switch cabinets and four EMSR switch cabinets, which are currently still in production, will take place. Commissioning to control and monitor the outsourcing by KSK Automation is scheduled for early 2021.

 

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October 2020 - Day of Training at KSK!

Are you looking for a training place and don't know what you want to do yet? Then you are welcome to drop by our headquarters in Haltern am See on the day of training! Download the flyer with all information about the day of training right here!

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If you would like to inform yourself in advance about the training occupations we offer, you will find everything you need to know about "Training at KSK" if you follow this link.

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September 2020 (3/3) - Publication in Stahl+Technik

A detailed article on our 20 MW recooling circuit installed at the beginning of the year (homepage article from June 2020) was published yesterday in the August/September issue of Stahl+Technik. The article is available for download here. The current issue of Stahl+Technik - together with our article - can also be purchased as an e-paper following this link for a fee.

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Enjoy reading!

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September 2020 (2/3) - Contemporary art in Pipe & Tectyl

Experts of a converter steel plant will immediately identify the component shown in the picture: a water/steam-cooled lance dome in a gas-tight welded pipe-to-pipe construction, approved by external inspection (TÜV) in accordance with Pressure Equipment Directive 2014/68/EU, Category IV, Module G.

Critics of the art scene could draw parallels with the sculpture "Singing Ringing Tree" by Liu and Tonkin or the "Sibelius Monument" by Hiltunen with this construction in pipe and tectyl.

Constructor Oleg D. and metal worker Constantin K. draw a rather matter-of-fact conclusion: "It was quite a lot of work! But it turned out well.".....

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One thing is certain: This is where the heart of a craftsman or engineer beats faster! More than half a tonne of gas-tight and X-ray tested welded construction made of seamless boiler tube, covered with a protective layer of Tectyl and designed for a pressure of approx. 20 bar and a water temperature of 220 °C, create an opening in the converter chimney through which a lance for blowing oxygen/inert gas can be inserted onto the surface of a liquid metal melt. The exhaust gases, which have a temperature of more than 1,500 °C in the converter stack, are (also) cooled in the lance dome by water/steam, which flows from the distributor to the collector evenly distributed over each pipe by means of inserted nozzles. Several hundreds of hours of calculations, design and production work have gone into the almost 2-metre high construction with an opening of about 1 m². In the steel industry, a five to six-figure sum is demanded for such a component - at Sotheby's in London or New York it would probably be unaffordable. In our opinion, to speak of craftsmanship here borders almost on blasphemy.

If you yourself are interested in a lance dome for your front garden or your converter, please contact us directly. The price is available on request - even without an auction!

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September 2020 (1/3) - Retrofit of a Peeling Machine

KSK Automation GmbH's staff had a busy summer, too, carrying out modernizations on three different sites at the same time for a large German steel plant in the Ruhr area. The main focus was on the electrotechnical retrofit of a peeling machine for the automatic production of precision bright steel.

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The core of the work was centred around the development, manufacturing and commissioning of entirely new patch fields and the fully renewed control panel, incl. operating desk. The previously utilized, old Siemens S5 control and the ageing Optronic path measurement system were replaced by a new Siemens S7-1500 control.

Further, a secondary cooling system was electrotechnically adjusted (S5 to S7-1500) and a skim off stand was electrotechnically modernized also.

We would like to thank all colleagues of the maintenance team for the smooth and productive collaboration!

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August 2020 - Same procedure as every year...

It is just like every year: "summertime = holidays" does not necessarily apply to KSK's staff. During the scheduled summer shut downs of various production plants, many of our colleagues are busy on site with repairs, maintenance tasks and revamps. This time, for example, for a couple of weeks we have a scheduled repair of an AOD-Converter Chimney from the 70's of a Belgian customer on our agenda.

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After examining the condition of the chimney (material properties, wall thickness), our staff replaced various worn out pipe sections during the summer shut down at the end of July/ begin of August. The scope of work, which has been executed by KSK's experienced and certificated welders, ranged from site planning and pre-manufacturing of precisely tailored replacement parts to (dis-) assembling up to non-destructive testing and approval in collaboration with the respective testing organisation. All work was right on schedule assuring that the AOD Converter can safely go back into operation after the summer shut down on time.

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July 2020 - There's something cooking...

Just recently, two out of four ladle furnace cover for a double Twin-Ladle Furnace of a major German steel producer left our workshop in Haltern am See. As soon as the entire delivery is complete and the two Twin-Ladle Furnaces are trouble-free and back to operation at the end of the year, we will clear up the mystery….

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….what is for sure, however, is that the overall technical concept - particularly the cooling system - of the two furnace cover incl. pneumatic and electrical mounting parts, as e.g. the furnace chamber camera, have been almost fully newly developed by KSK. The first two ladle hoods have been assembled successfully into the unchanged ladle furnace and are already back in (COVID-19-limited) Operation.

Meanwhile, of course, we work at full speed to finish the two remaining hoods...

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June 2020 - KSK supplies 20 MW turnkey recooling system

Earlier this year KSK supplied a closed-loop recooling system with a peak cooling capacity of 20 MW for several melting units of BGH Freital (amongst others for a new AOD converter delieverd by Primetals) and took it into operation.

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BGH Freital requested a fully automatized, closed-loop recooling for several, parallel, water-cooled melting units as a turnkey solution. One of these melting units was the simultaneously delivered AOD converter by Primetals.

The pump station powering the cooling system is one of KSK's tried and tested/ trusted plug-&-play container solutions. Most of the necessary aggregates, fittings, sensors as well as a separated control cabinet room were pre-installed in the container. Subsequent to the hydraulic connection of Güntner's dry cooling unit (containing 9 single table cooler) and the piping system as well as to the steel plant's power supply, the pump station was taken into operation without any further constructional measures.

The station features a water treatment, an emergency diesel pump, a leackage detection, temperature-level regulation etc. and has a thermal output of 20 MW peak at 975 m³/h.

We would like to thank the entire team of BGH Freital for their trust and wish all the best for operating the converter and the cooling circuit!

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Mai 2020 - Trainee-Sponsoring-Project "Equipment Room"

In May some of our trainees were able to gain first practical assembling experiences on their first construction site. However, they did not jump into a steel plant right away. The trainees autonomously assembled a fencing solution for storaging sports equipment of the local handball club HSC Haltern-Sythen.

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The newly seperated room enables HSC Haltern-Sythen's handballers to store away their equipment safely in the jointly used, public sports gym. Thanks to an additional supporting beam also the moveable goals can be leaned againt the fence.  

Enjoy the new "room" and good luck for the upcoming season HSC Haltern-Sythen!

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April 2020 - Ladle furnace cover for thyssenkrupp Steel

The twin ladle furnace of thyssenkrupp Steel's "Oxygenstahlwerk 1" in Duisburg, Germany, was equipped with a new KSK ladle furnace cover. First, the old cover incl. secondary installations of stand 2 was dismantled. Subsequently, the new cover was installed fitting perfectly to be taken into operation.

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Based on the technical advancements of the new cover for stand 1, which was delivered in 2018, in 2018/ 2019 a new model for stand 2 was developed. Compared to the previous model the new model features an optimized mounting system, an improved cooling system, revised exhaust gas ventilation geometries and a newly developed swichting concept for single components.

The ladle furnace cover, which was manufactured in Haltern am See, was installed in March/ April. In order to do so, first, the old cover of stand 2 incl. all secondary installations was dismatled. Subsequently, the new cover was lifted in position, aligned and then fixed in place. The previously dismantled secondary equipment - partially refurbished, partially new - was mounted back on the new cover. At the end, all cooling sections were measured and hydraulically balanced before the ladle furnace cover went back into operation.

We would like to say Thank You to thyssen's team "Rohstoffe/Maschinen/Energie" of Oxygenstahlwerk 1 for the pleasent and constructive collaboration. May the new cover do even better than the old one!

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March 2020, COVID-19 - KSK group is on duty

In March 2020 the corona-crisis hits Germany and Europe. Measures and announcements of the government to contain the virus change and toughen daily.

In these turbulent and uncertain times KSK GmbH, KSK Automation GmbH and KSK Concept & Engineering GmbH try to available for every customer, order and request. While sticking to the common measures (social distance, washing hands, home office etc.) we are striving to protect our employees and colleagues and, by implication, the adherence to schedules and Arrangements, too. If, against all expectations however, there will be a delay, we will inform our clients in this particular matter immediately. In this case, please bear with us - we are a small, middle-class group of companies whose ressources and capacities are a little constrained in such a massive and unpredictable crisis.

However, one thing is for sure: we continue to be here for you!

February 2020 - Container village at KSK Automation

Since a couple of days the view of KSK Automation GmbH's office buildings has changed significantly. At the moment, e-containers shield a complete view of the building. After equipping the containers by KSK Automation they will be shipped to a new refinery in Hungary.  

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On behalf of Scherzer KSK Automation GmbH builds and wires the PSC-, PLC, MSR and network switch boards. Further, KSK Automation fits the swtich boards in the containers and continues with the internal wiring inside the containers. Finally, the containers will be shipped to Hungary, ready for installation.

Drop off - Pick up - Done! We are happy to do the rest!

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January 2020 - New Managing Director for Automation

As of 01.01.2020 KSK Automation GmbH designates Christoph Budde (38, right) as its second managing director in addition to Dieter Vortanz (64, left), in order to create a coordinated and controlled transition in the management body.

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After his qualification as a power electronics technician at Oberland Glas AG with succeeding twelve months of military duty, Christoph Budde signed up for Schaltanlagenbau Krüger GmbH in 2003. In 2010, Christoph successfully took the exam for the industrial supervisor electronics and worked as the forman of the electrical workshop from then on. Since the formation of KSK Automation GmbH in 2015 Christoph Budde operated as foreman as well as project manager and knows the company in almost every division. "Besides my technical work I have always enjoyed the collegial and familiar atmosphere at KSK Automation. On this basis I will gladly take over more responsibility from now on and I am looking forward to all challenges to come.", as Christoph says.

With this new dual Leadership both a smooth transition and continuity in in the management body of KSK Automation GmbH are secured.

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December 2019 - KSK end-of-year review

KSK group looks back on a successful year 2019!

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In many regards 2019 was a successful year for KSK group. Our order books were filled with many different projects, as for example the supply and commissioning of a new, water-cooled furnace cover incl. cooling circuit of an electrical smelter for a customer of the non-iron Industry, the supply and commissioning of several, steam-producting converter hoods or the beginning of our joint research project together with the RWTH Aachen's IOB . Further, we took some forward-looking steps in terms of business succession.

We are looking forward to all the challenges we'll face in 2020 and wish all the best to our customers, partners and suppliers!

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November 2019 - Waste Heat from EAF's for Heat Grid

Within the frame of a master's thesis in collaboration between KSK GmbH and FH Aachen (faculty of power engineering) we were able to develop a concept, which demonstrates, if and how low-temperature waste heat resulting from the production of electric furnace steel can be mainstreamed into local and district heat supply systems.

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It was the thesis' objective to designate possibilities and potentials of waste heat decoupling in steel plants and to develop a systematics to evaluate the actual heat costs and the profitability of the waste heat's distribution for steel plants. The results of the thesis indicate clearly, that low-temperature waste heat in the cooling water resulting from the production of electric furnace steel (EAF and exhaust gas system) can be provided economically feasible to local and district heat supply systems (having a temperature level of up to 130 °C) - under certain circumstances. Despite the profitability of the waste heat decoupling determined, steel plants will profit from an improved CO2-footprint as well as the associated, polished corporate image.  

If you are interested in the topic in general or would like to execute a potential analysis yourself, please do not hesitate to contact us!

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October 2019 - New Furnace Cover for electr. Smelter

After a Long period of planning and manufacturing, in October 2019 we successesfully assembled and commissioned a new, water-cooled furnace cover incl. cooling circuit of an electrical smelter for a customer of the non-iron industry.

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The new, water-cooled furnace cover of the electrical smelter replaced an old furnace cover made of refractory material. The new cover features various, symmetrically arranged single cooling elements made of copper pipes. The cover is floating, covers the top of the 8,5m-furnace largely and absorbs approx. 4 MW heat (peak). The single cooling elements can be dismounted separately from an accesible platform.

All key components of the new cooling system - consisting of a pump station and a dry cooler - were supplied by KSK also. Key features of the cooling circuit are, amongst others, frost protection and leckage detection.

We are very happy about the well-made new system, are grateful for the good team effort and wish all the operating staff well und success until the next shut down!

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September 2019 (2/2) - Enrolment of apprentices

Four pupils became apprentices in August 2019 when starting their training at KSK GmbH. They proudly present their jam-packed apprentice cones….

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Our four apprentices Joshua, Daniel, Furkan and Lennart layed the foundation of their professional futures by starting a training as construction and precision mechanics at KSK GmbH. As a result, the total number of apprentices at KSK GmbH increases to eleven.

For 2020 we are still looking for new apprentices! Have a look!

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September 2019 (1/2) - RWTH Aachen University and KSK

Elite University and idyllic small-town - doesn't fit? Why, yes! KSK GmbH, KSK Automation GmbH and RWTH Aachen University's Department for Industrial Furnaces and Heat Engineering (IOB) are joining for a ZIM-funded research project in order to develop an electrotechnical and mechanical retrofit-solution for small scale lectric arc furnaces (tap weight < 20 t).

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This research project will be particularly interesting for the casting industry! Together with RWTH Aachen University's Department for Industrial Furnaces and Heat Engineering (IOB), KSK GmbH and KSK Automation GmbH are developing a solution to electrotechnically and mechanically retrofit and update (old) electric arc furnaces (tap weight < 20 t).

One of the main focuses of this holistic retrofit solution is to replace outdated electrode controls - regardless of the propulsion system - with a simplified, digital control system. Possible total breakdowns/ costly maintenance of the mostly mechanical controls will be dropped. Further, the new EAF will be simulated stoichiometrically in order to optmize the mechanical wear parts, like the furnace roof and potentially replace them by water-cooled components to expand Lifetimes economically.

The project extends over a period of two years and is funded by the ZIM program of the BMWI.

If you have any questions regarding the project or want to participate in the realization of the results at your EAF do not hesitate to contact us! We are looking forward to hearing from you.

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August 2019 - On your pedals, get set, GO!

Promoting your own health and reducing your environmental impact at the same time? From now on, KSK's employees are able to achieve these goals by getting on their very own company bikes.

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Starting August 2019 KSK GmbH and its affiliated companies enable their emloyees to conveniently and affordably lease a company bike. Because what is for sure is: a healthy and happy staff is key to a pleasent working atmosphere and thus, at the end of the day, to the highest product quality. The company bike concept is implemented by the service contractor JobRad.

Since 2008 JobRad is one of the pioneers in terms of leasing of company bicycles and offers bikes, e-bikes and pedelecs through more than 5.000 retailers Germany-wide.

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July 2019 - KSK co-workers prove stamina

EPC projects can be lengthy and debilitating from time to time - a good stamina is in great demand! In Duisburg, Germany, some of KSK's co-workers just proved that they fill the bill. However, it was not a project for our longtime customer Thyssen-Krupp which gave occasion to do so (as one might assume) but the 36. Rhein-Ruhr-Marathon.

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The 36. Rhein-Ruhr-Marathon was entirely characterized by hot midsummer temperatures. Three of KSK's co-wokers took up the challenge of a half-marathon on the glowing asphalt of Duisburg. Despite a sufficient water-cooling (for once a spray cooling was applied instead of a pipe construction as otherwise customary) no best times were possible. Nevertheless, Alexander Handke and Florian Röhl finished the 21 km in outstanding 1:46 h!

Congratulations!

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June 2019 - KSK at METEC 2019

As usual, KSK showcased at the international trade fair for metallurgy - METEC - end of June in Düsseldorf.

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With more than 500 exhibitors and 17.000 visitors METEC is taking place all four years in Düsseldorf since 1979 as a highly prestigious trade fair for metallurgy with national and international companies. As usual, KSK presented as an exhibitor with its own booth this year, too. Besides meeting long-year acquaintances and companions, customers and suppliers, we had the chance to establish delightful new contacts all around the globe.

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May 2019 - Management grills (for) Trainees

Life's not easy at the bottom they say. At KSK, trainees enjoyed their freshly made burgers after work anyway - served by the management in person. We do have a good and simple reason to do so: we have to take care of tomorrow's professionals already today!

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The situation is not news to us: finding skilled professionals - particularly in craft - is getting more and more difficult. In order to be able to supply high-quality products "made in Germany" in the long run however, we train young people in different areas ourselves. At the moment, we employ eight trainees in the areas of metal constructions, precision mechanics, electronics/ automation, technical product design for plants and machines and office management.

As a little treat the management of KSK GmbH and KSK Automation GmbH invited all trainees to a homelike barbecue to say thank you for the daily efforts and top performances so far.

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April 2019 - Converter Hood departs from Haltern

On a flatbed truck a 16 t Converter Hood left our workshop in Haltern am See during the night for the factory halls of a big, German steelmaker.

 

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The exchangeable Converter Hood weighing about 16 t is the first-line wearing part of a more than 30 meters high Converter Chimney. The pipe construction is used for steam production.

At the time of delivery several thousands of construction and manufacturing manhours went into the Hood.

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March 2019 - Spring Cleaning in Essen

Winter is drawing to an end and the time is just right to tidy out all the dusty stuff and let the wind of change blow through your old switchboards…

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KSK Automation GmbH is currently bringing the wind of change to a company in Essen, Germany, which is specialiazed on coke, graphite and anthracite.

On the left side of the picture above you can see an old Siemens S5 control of a bagging and palletizer machine which is being exchanged for a state-of-the-art Siemens S7-1500 control (right side). Of course, this retrofit does not end with the exchange of hardware - the entire program control had to be re-written from the scratch.  Amongst others, this was due to a new weighing system (Siemens Siwarex) which replaced an old, no longer available system. Despite the complicated time schedule KSK staff coped with successfully commissioning the bagging machine incl. the new control in step one.

We are looking forward to the ongoing collaboration with the staff in Essen and to the finalization of the retrofit in step two!

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February 2019 - "Service Desert" Germany? As if!

The year is 2019 A.D. Germany is entirely occupied by the dogma "Service Desert". Well, not entirely...one small troop of indomitable KSK co-workers still holds out against this impression.

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Being a small, specialized plant manufacturer, collaborative long-term relationships to our clients are of major importance. Hence, of course, we support our clients also after commissioning their new plant.

At the moment, for example, KSK's staff is out in the field for an Austrian carbide manufacturer where we have successfully commissioned a new water-cooled carbid furncace cover (diameter round about 9 meters) two years ago together with the Austrian staff. The currenctly executed work is a further optimization of the virtually trouble-free construction. Our well-practised staff takes care of the complex renovations in order to unburden the plant's staff during the time of the shut-down.

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January 2019 - Business succession

As of 01.01.2019 KSK GmbH designates Dipl.-Wirt.-Ing. Andreas Höwedes (32, middle) as its third managing director in addition to Carsten Oberhag (54, left) and Dipl.-Ing. Olaf Huscher (56, right), in order to lay the foundation for a business succession as early as possible.

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The native "Halterner" Andreas Höwedes started off his career as a business consultant for three years after studying business administration and engineering at RWTH Aachen University. Following this, he worked as a project engineer for KSK GmbH for another three years. "My personal affinity to Haltern am See combined with the professional perspective to work for a hidden champion in the German "Mittelstand" were the main reasons for me to come to KSK back then", Höwedes remembers. The two longstanding managing directors Oberhag and Huscher are glad about the growth of their management body. "The company will further gain momentum by the early designation of Mr. Höwedes as a managing director. Also, this way we will have sufficient time to have a regulated business succession.", Oberhag comments. His managing colleague Olaf Huscher agrees and continues: "This company sort of is our life's work which you do not give away carelessly. Mr. Höwedes is a competent and inspiring young man who will continue to stand for knowhow and quality made in Haltern am See, Germany. We are very happy to have him."

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December 2018 - KSK end-of-year review

KSK group looks back on a successful year 2018!

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In many regards 2018 was a successful year for KSK group. Our order books were filled with many different projects, as for example the revamp of the hot water primary dedusting of Georgsmarienhütte or the commissioning of an acid mixing plant in China by KSK Automation GmbH. Further, KSK Automation GmbH and KSK Concept & Engineering GmbH took some forward-looking steps with the occupation of their new offices spaces and production hall in Haltern am See.

We are looking forward to all the challenges we'll face in 2019 and wish all the best to our customers, partners and suppliers!

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November 2018 - Ladle furnace for thyssenkrupp Steel

thyssenkrupp Steel's "Oxygenstahlwerk 2" has a new, 265 ton twin ladle furnace - we had our share...

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The Austrian plant manufacturer INTECO was awarded with the construction of a new 80 MM € twin ladle furnace for thyssenkrupp Steel's "Oxygenstahlwerk 2" in Duisburg, Germany. Some of the key components of the new furnace were subcontracted to KSK GmbH - the two ladle furnace covers. In collaboration with INTECO and the staff of "Oxygenstahlwerk 2" the two covers were designed, constructed and manufactured in Haltern am See in 2017 and commissioned in Duisburg in 2018. The two mostly identically constructed covers feature, among others, an additional skirt and a side-draft hood for an enhanced exhaust gas extraction and a water-cooled supporting frame.

Further information and pictures regarding the new twin ladle furnace can be found here.

 

We are looking forward to the future collaboration with the staff of the "Oxygenstahlwerk 2" on the ladle furnace covers.

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October 2018 - Converter Hoods "in vogue"

About the same time in 2017 planning and manufacturing at KSK was all about laddle furnace covers. This year it seems as if there was a "trend" towards converter hoods with our customers.

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At the moment, quite some converter hoods for different steel plants can be found in KSK's order books, some more hoods are in the offer phase. Order scopes range from TÜV-certified manufacturing (incl. cladding) to the re-design of cooling circuits with steam-decoupling or to the re-engineering of the construction parts.

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September 2018 - Brand new Brochure

We make no secret of the change at KSK over the last couple of years. Apposite to our new website we are proud to now also present our company through our brand new Multi Media Brochure.

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KSK's new multi media brochure was developed in collaboration with JS Deutschland - a specialist for interactive brochures - as well with selected partners and contractors. The brochure is available as a printed and as a digital version (download below). Through a QR code on the backside of the brochure you will reach our website.

The brochure expresses what KSK stands for and what we are all about. It shows the company's development and introduces our products and Services.

Follow this link to get access to our new brochure!

 

 

Selected Partners and contractors in KSK's new brochure:

KSB SE & Co. KGaA

PHOENIX CONTACT Deutschland GmbH

c.dasbach SPEDITION GmbH

STABIKON Stahl - Biegen - Konstruktionen GmbH

IBK Wiesenhahn GmbH

 

 

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August 2018 - Cleaning in the desert

KSK Automation GmbH's staff operates around the globe these days -  commissioning an acid-mixing maschine in China and a cleaning system for air-cooled condensors in Qatar.

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Having sand in the gears can turn into a serious problem in the desert of Qatar. In particular, when the fine desert sand accumulates on the cooling rips of air-cooled condensors (ACC-Units) at a height of round about 50 meters in one of Qatar's largest refineries. In order to clean the cooling rips and thus re-boost the plant's efficiency, a fully automated cleaning system was installed.

KSK Automation GmbH supplied the electric controls for the entire system and was able to successfully commission the plant on site. The interconnection between the single components in the field was implemented via Profinet. For this Purpose, a S7-1200 (Failsafe) was deployed. The entire cleaning system can be operated fully via a control panel at ground level. A mobile panel enables the maintanance staff to also operate the plant directly at a height of 50 meters.

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July 2018 – summer SHUTDOWN? Not for us!

In July 2018 it was the time for the traditional summer shutdowns in many steel producing companies again. The associated revamps - as usual - meant busy times for KSK's staff. In particular, this year KSK GmbH ran three assemblies simultaniously for different customers. One of the assemblies was an extensive exchange of Georgsmarienhütte GmbH's 140t-EAF's exhaust gas system (see picture below).

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Since September 2017 KSK Concept & Engineering GmbH was occupied with the conceptualization of an optimized exhaust gas system for 140t-EAF of Georgsmarienhütte GmbH as a replacement for the existing system with "135° bow". Like the existing system, the new system is able to produce and decouple saturated steam. The optimized exhaust gas system is based on several flow simulations conducted by Georgsmarienhütte GmbH. In February 2018, when the concept was finalized, the possibly record-breaking production of the single components started (water-cooled connection piece with hydraulic hinge mechanism, post-combustion chamber and hot gas duct - within four months time). Subsequently, in July, the existing system was dismantled, the new exhaust gas system installed and commissioned successfully. The eyecatcher of the new system certainly is the connection piece, which replaces the old "135° bow". The 10t-piece can be hinged up to 54° by a hydraulic mechanism when a batch of scrap comes in (see picture above).

Like in Georgsmarienhütte, also the components and systems on our two other sites (a post-combustion chamber with sleeve and pump-skid and another pump-skid with piping system for an EAF) were commissioned successfully.

We would like to thank all involved colleagues of the different steel plants as well as our subcontractors for the successful collaboration and wish all the best for the operation of the revamped systems!

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June 2018 - Centralisation of Cooling Systems

As part of a multi-year project KSK Concept & Engineering GmbH conceptualised a new cooling water supply of a steel plant as a closed-loop system with a centralised pump Station.

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Since 2015 the staff of KSK Concept & Engineering GmbH is planning and designing the centralisation of (most of) the cooling circuits in a steel plant.

The steel plant has several big, energy-intenisve aggregates such as electric arc furnaces, laddle furnaces etc. on their disposal, requiring a huge amount of cooling water. At the moment the respective cooling systems are designed as single cloosed-loop circuits. The currently installed pump station occupies the designated space entirely. Also, the installed cooling capacity is insufficient. Therefore, the plant seeked for new cooling system.

In total more than 2.000 manhours of planning and designing went into the new desgin. The new pump station now brings together 21 circuits with a total amount of 2.270 m³/h cooling water, dissipating 12,4 MWpeak to several plate heat exchangers. The latter emits the heat into an open cooling system which was also designed by KSK Concept & Engineering GmbH.

We would like to thank the staff of the steel plant for the positive and constructive collaboration so far and whish all the best for the rest of the project!

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May 2018 - A move towards the future

Finally KSK Automation GmbH moved into their new offices with attached production facilities.

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Contiguous to KSK GmbH a new office building with attached production facilities was set up, meeting all spatial requirements and strategic directions of KSK Automation GmbH.

The new offices supply enough space for new employees and are adaptable to our customers' requirements in the area of automation and low voltage switch gears.

All phone numbers and email addresses remain the same. Our new address is:

An der Ziegelei 9 

      45721 Haltern am See

 

We are looking forward to your visit and are happy to show you around our new facilities.

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April 2018 - Succesful assembly of submerged lance furnace

In mid-March KSK's 25-headed assembly team startet assembling the twelve meter high 53t-submerged lance furnace for Weser-Metall GmbH in Nordenham, Germany. The assembly was succesfully completed at the beginning of Arpil (on the picture below you see two of five parts of the furnace).

The construction of the lead furnace was executed by KSK Concept & Engineering GmbH. The procedural and thermothechnical design, the project management as well as the manufacturing was supplied by KSK GmbH.

 

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For the assembly of the new furnace KSK GmbH was granted a two and a half week time window. Due to the special spatial surroundings the assembly was quite a challenge: Six meter high components had to be lifted over and into the 60 meter high furnace building by a mobile crane. Inside the building an indoor crane lifted the components up to 50 meter to place them in the right spot - accurate to the Millimeter.

A new pump-skid for the supply of the cooling water was also part of the scope. The pump-skid is equipped with two redundant recuperators, two redundant pumps and with a 1000l-expansion tank. All components were installed in time and in the usual KSK-quality, so that Weser-Metall GmbH was able to begin furnace operations on schedule.

We would like to thank the staff at Weser-Metall GmbH for the positive and constructive collaboration!

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March 2018 - TuS Haltern youngsters at KSK

As one of the sponsors of TuS Haltern's "Talentschmiede" (talent pool), KSK hosted an information event about "Careers apart from the football pitch" for TuS Haltern's U17 footballers.

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TuS Haltern, maybe Germanys best-known amateur football club, takes care of its kids' development on the pitch in an outstanding way. As one of the sponsors of TuS Haltern's "Talentschmiede" we are happy to contribute to the kids' development apart from the football pitch.

The youngsters and their manager Sebastian Amendt were invited to inform themselves on the upcoming professional live and on jobs and opportunities at KSK listening to a presentation followed by a tour through the workshop. "Most of the boys have never been to a workshop like this before. This is impressive indeed!", Amendt said. "For most of them it is yet important to get a feel for what an everyday job really means."

We are happy to continue our support of the "Talentschmiede" in the future and keep our fingers crossed for the promotion to the "Bezirksliga"!

Further information and photos can be found here.

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February 2018 - Automation custom-made

"KSK Automation GmbH is specialised on user-friendly solutions for all electrotechnical requirements in the industry" - that's what our homepage says. As the following picture shows, every once in a while these requirements might be a bit unusual, too...

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A German steel mill was looking for a revamp of its control station, particularly for a new operating desk and hit paydirt at KSK Automation GmbH.

The new operation desk comes in an ergonomic design and can be used sitting or standing (0,7m to 1,2m). It is equipped with a wooden table top. As our electricians at KSK Automation GmbH are always up for an unusual challenge they made the wooden table top themselves without further ado!

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January 2018 - Craftsmanship in the spotlight

Amateur photographer Ulla Berse, a member of Haltern's photo club, and her camera paid a visit to our workshop in Haltern am See at the end of last year. Since lately, the results of her visit can be seen in Haltern's townhall.

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Ulla Berse is a passionate photographer and knows all the technical finesses of her camera. This enthusiasm for technics was key for her extraordinary photos, which she made during her visit at KSK's workshop in Haltern am See last year.

She wanted to show that "also in green Haltern am See people carry on a craft". Berse's intention was to pint out the tension between material and men at work: "There is more life in KSK's rigid pipe constructions than you might suspect in the first plays", she says and smiles to herself. We think so, too, and are very grateful for Ulla's amazing photos, which you can also find on our homepage and on our yearly desk calendars.

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December 2017 - Wire spool-in system for Christmas

At the end of 2017, general contractor KSK GmbH made itself and Deutsche Edelstahlwerke Specialty Steel GmbH & Co. KG (Witten, Germany) a nice Christmas present as we successfully commissioned a new wire spool-in system for a ladle furnace.

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Together with the steel plant's project-/ operating- and maintenance staff, KSK was able to plan, manufacture, install and commission the newly revamped wire spool-in system for the ladle furnace. The new fourfold spool-in system allows the customer to alloy additives more precisely and with a greater diversity. Also, the entire system was further enhanced in terms of occupational safety and exhaust ventilation.

At the beginning of the project, the existing plant was captured by KSK Concept & Engineering's 3D laser scanner. On this basis, we were able to conceptualise and model the new wire spool-in system collision-free in a very confined space (incl. a new, water-cooled spool-in nozzle integrated into the ladle furnace and a telescopic tube with a bayonet shear). Also, the electrical part of the spool-in system was designed from the scratch and fitted with new switchboards and software, which was integrated into the existing system by KSK Automation.

After the revamp during the winter shutdown, the new spool-in system was finally commissioned successfully (for test operation) at the beginning of the new year.

We wish Deutsche Edelstahlwerke Specialty Steel GmbH & Co. KG success with their new fourfold wire spool-in system and gratefully acknowledge the very pleasant and fruitful collaboration!

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November 2017 - Workshop full with ladle covers

Ordering a KSK ladle cover in 2017 is trendy!

 

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2017 appears to be the year of the ladle cover. Solely in November four of these components left our workshop in Haltern am See to three different customers with different requirements, ideas and philosophies. Whether an elaborate sandwich-construction, a pipe-to-pipe construction, with or without cladding - an individual and targeted solution was found for every customer and manufactured by the specialists of our workshop.

 

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October 2017 - KSK promotes local craftsmanship

As part of a joint promotion together with handball club HSC Haltern-Sythen we manufactured a brand new barbecue during the club's 25. anniversary .

 

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That KSK is into heat transfer is nothing new - but when it comes to bratwurst it is different. Nevertheless, thanks to many helping hands of the HSC Handballers our premiere in barbecue manufacturing was a success. Together we prepared welded the barbecue based on an especially self-developed construction during the club's 25. anniversary. On 07.10.2017 the time finally had come and we were able to fire up the grill during a championship match of the senior team.

With this unusual sponsoring we achieved to attract local young people for the local craftsmanship and engineering in Haltern am See.

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