History in detail
Bases of metallurgical production in Frýdek–Místek were found in 1833, when Tešínská komora (Tešín chamber) – owner of ironworks in Ustron and Baška – began with new company development in Lískovec near Frýdek–Místek, at the place called “Lipina”. Archduke Karel Ludvík commander–in–chief of Austrian troops during Napoleon wars was the owner of Tešínská komora – one of the largest feudal domain in Austrian Silesia. Karlova hut (the Charles Iron Works) called after its owner, archduke Karel, consisted of 6 tilt–hammers driven by water–wheels. Their construction was completed in 1834. Four refining hearths were added in 1836 and so called “frishhammer” came into existence. The new factory was intended to refining of pig–iron made in Baška and employed 50 persons.
Nevertheless, production of Karlova hut has been influenced by the beginning of industrial revolution. Usage of bituminous coal and of coke together with new technology consisting mainly of puddling and using heated air were introduced first. Six refining hearths with the same number of drop hammers were in operation in 1850.
Tešínská komora, after excellent practice with mill in Ustron, started with construction of a mill in Karlova hut, in 1851. This new mill construction absorbed the main part of placement within the framework of all economic sectors of Tešínská komora. The mill was completed and the first sheet iron was rolled in 1854. Many of additional constructions were carried out during the following years. Such as construction of puddling and welding furnaces, steam–boilers, large–scale water pipes, but also worker’s hostels and flats for white–collar workers. The largest and the most up–to–date metallurgical company of Tešínská komora had been built in Lískovec in five years. In 1856 it consisted of 11 puddling, 5 welding furnaces, 2 smelting furnaces and 3 hardening furnaces. Production was specialized in rail manufacturing, forged steel for tackles and tools, wagon axles, other steel and iron commodities, fine sheets and boiler plates. After main constructions completion, the production in Karlova hut has been developing relatively slowly. In 1856 production reached approximately 54 % of total capacity. The main reason was, among others, also the initial lack of workers and especially of specialists. Handling with technological equipment required certain knowledge and experiences of each employee. The most important sectors were occupied by foreign specialists from Prussian Silesia. They were to school and train local capable young workers. Tešínská komora proceeded in labor recruitment quite resolutely. The principle to employ only a few foreign specialists and to train local people limited faster development of Karlova hut during the initial years of its existence, but in the perspective of next years, it brought to Tešínská komora benefits which many times paid back the lower income during the limited production of initial years.
The fifties was a period of attenuation in the Karlova hut. As causes were mentioned lack of water in the Ostravice river, competition of Vítkovice Ironworks and also consequences of crisis due to overproduction, which caused drop in demand for iron and steel all over the world, during 1857 – 1859.
The biggest expansion of Karlova hut came at the turn of the sixties. Turning shop for rolls machining was erected in 1857, in 1863, a line for commercial, nail and rivet steel, in 1864, a tin plating shop was put into operation, next year a file manufactory arose in the vicinity of factory, in1868 the present rolling mill was enlarged by third tract and 1872, a foundry, locksmith shop, turning shop and joinery were erected there. Also the present operations were up–to–dated. In 1863 water–wheels were replaced by turbines, in own brick–field were produced bricks for construction and maintenance of puddling, wrought iron and annealing furnaces.
In the seventies of the 19th century an important period of Tešínská komora development has been closed. All metallurgical plants passed through the industrial revolution and launching of railway service on Košice–Bohumín railway during 1870–1871 created brand–new situation. The new railway connected ironworks of Tešínská komora with their fuel and especially with ore base. The new conditions, connoted the end of the great prosperity period of Karlova hut and its dominant place within metallurgical industry of Tešínská komora. The focus was gradually shifted to Tfiinec with its favourable position directly on the main railway–track. Although Karlova hut was also connected with Severní dráha (the Northern railway) in 1871, it had no effect on this fact. Construction of Ostrava–Frýdlant railway accelerated delivery of bituminous coal to Karlova hut and simultaneously connection with Baška Ironworks. New situation which arose so in Lískovec, opened the new period in the history of Karlova hut.
In 1877 the main sectors were moved to Trinec. Mainly it were: Bessemer plant, reversing rolling mill, fine rolling mill and tire rolling mill. The factory was then equipped for semi–products treatment, which were delivered here from other plants of Tešínská komora.
In 1881, the bridge building works from Ustron were moved to Lískovec. Bridge building works laid the basis of the new expansion of Karlova hut. Constructions of railway bridges and buildings e.g. town hall in Vienna, store houses in Budapest etc. were carried out there. Cupola furnace was erected in 1897. Till 1900, pig iron was refined in puddling furnaces and rolled into all kinds of commercial steel. During 1900 they started to process pig iron in open hearth (capacity of 20 tonnes) which was sufficient enough for rolling mill consumption. In addition to rolling mill in Karlova hut there were also shops for production of galvanized sheets and corrugated sheets, shovels, nails, files, forged plates for ploughs etc. The necessary energy for factory was delivered exclusively by steam engines.
Two natural calamities struck Karlova hut in 1902. Fire broke out during the night from 16th to 17th May and destroyed pile for corrugated sheet production, joinery and tool shop. Floods which devastated barrages in the Ostravice river hit the factory in June. The factory was saved only by a supreme effort. Burnt out shops, joinery and corrugated sheet shop were renewed in 1903. In 1904, file manufactory which was, by its extent, the second factory of its kind in Austria (with daily production of 3000 pcs of files) was sold by Tešínská komora to the Iron company of St. Jiljí. By the end of 1904, operation in foundry and rolls production were taken over by foundry in Tfiinec. On February 1905, medium mill was closed down, than two–high heavy mill and a section mill of reversing rolling mill train. Rolling mill in Tfiinec began with manufacturing of products of these lines (bar iron, fine products). To Třinec was also moved finishing process of fine products.
Electrification of factory started in 1904. A new power station was built up. Main drive was carried out through three Francis turbines with independent regulators, concrete water canals and iron closing device. Power of water turbines even of steam engine was transmitted by shafting on generators. By the end of 1904 two generators were added from AEG firm for continuous current. This power station supplied the whole factory and bridge building works with light and power. Three–phase line enabled that lantern had voltage of 200V and electric motors voltage of 400V. In 1908, a new turbo–generator of AEG firm, for alternating current with capacity of 1,000 kW and 3,000 V was put into operation.
This enabled to link up on electric current also fine sheet rolling mill. Economic authorities of iron and mining companies of Tešínská komora tried to up–to–date their companies, in order to be able to compete with others, e.g. with Vítkovice Ironworks. Nevertheless, these determinations were not consistent, as chamber council was not able to centralize and rationalize production of all iron works. Total production was not much extensive, but it was scattered, the same manufacturing processes were in operation in several places. Analogous situation was also in management of particular companies. In the management of the chamber began to prevail opinion on sale of iron companies.
Factories and mines of Tešínská komora were changed over to newly established Rakouská bánská a hutní spolecnost (Austrian mining and metallurgical company) as at 1 January 1906. Proportion of the new company in the iron cartel was insignificant, pig iron production amounted to incomplete 80,000 tonnes and steel production about 90,000 tonnes. Other companies e.g. Vítkovice Ironworks, were far ahead of iron works of former Tešínská komora. New owner embraced this insufficiency in management of iron factories and from the first year of their ownership supported fast reconstruction of obsolete equipment. Modernization began in 1906. Karlova hut was turned into sheet rolling mill intended for production of fine and galvanized sheets and marginally also for production of heavy plates of normal plain steel. Factory in Baška was closed down. Radical reorganization and rebuilding of company was necessary. As to Karlova hut a big fire, also in 1906, played paradoxically a certain positive role, which enabled to realize both new reconstruction and even new company construction. Still in 1906, a fine sheet rolling mill assembly was completed to which a cold rolling mill for small sizes of sheets was added. In 1907, a new three–high stand construction for rough rolling began. The aim of the mill was to produce fine sheet bars for fine sheet rolling mill and to manufacture bridges units. It should have operated alternatively with heavy plate mill and with universal mill. Rough rolling and universal mills should have served as a two–high rolling mill with reversing operation instead of old rough and medium mills. Consumption of rolled steel substantially jumped during 1907–1908 and Tfiinec with Karlova hut were not able to meet themselves customers demands. For this reason management of Bánská a hutní spolecnost decided to build a second open hearth in Karlova hut. This was put into operation on 14 August 1908. Additional reorganization of Bánská a hutní spolecnost came true from 1 April 1909. Factories were transformed into a joint–stock company. Simultaneously, new general headquarters was established in Vienna and central headquarters and metallurgical headquarters in Tešín were disestablished. Jifií Gýnther former director of Škoda works became head of the Tešín factories. Coming of new general director implied substantial attenuation of Karlova hut, because the final decision was to move the whole production to Tfiinec. On May, 1909, an open hearth furnace, three–stand rough rolling mill and a section rolling mill were moved there and a fireclay factory by the end of year as well. Ironworks in Karlova hut were reconstructed for production of all kinds of sheets from semiproducts manufactured in Tfiinec only, further for production of bridge and other structures in bridge building works and for production of some finished products in machine shop. Principle changes and reorganization were implemented in 1909–1910. Production of shovels and ploughs was liquidated. Rolling mills were equipped with new devices, enlarged their production capacity, as growth in production reflected it. Production of sheets had begun to increase rapidly, since 1910. The highest increase was in production of fine sheets and hot dip galvanized sheets.
Normal operation of company was temporarily interrupted by outbreak of World War I and production had to be adapted to new manufacturing conditions and demands. During firsts months of war, production substantially dropped, especially due to lack of workers. This state did not last for long. Production for peaceful purposes was limited and production for military deliveries increased. For instance production of common corrugated sheet increased, while production of smooth galvanized sheet, having no military use, rapidly decreased. The highest production increase was in machining shop, thanks to introduction of ammunition and military material production.
In 1915, presses for production of tubes for garnets with production of 800–900 pcs of 15 cm of ecrasite and mine garnets daily were erected in an empty building residual after open hearth furnaces. Total production during the war amounted to 620,000 pieces. World war which lasted four years finished up at the end of October 1918 by total defeat of so called central powers. Monarchy of Austria–Hungary was disintegrated and new independent states came into existence, among others also Czechoslovakia. This significant event had no well–marked influence on situation in Karlova hut. Military mode was cancelled during first days of November 1918. Situation in factory was very complicated. Production for military purposes was stopped and the rest of operations was unable to work sufficiently, due to lack of coal and means of transport. Production in all other sectors decreased largely. In such a situation factory stagnated, unnecessary finances were spent for maintenance of operations only. In 1920, Rakouská bánská a hutní spolecnost was renamed to Bánská a hutní spolecnost (the Mining and metallurgocal company) and its residence transferred from Vienna to Brno. In Bánská a hutní spolecnost, the following stage of Karlova hut development had started.
For judgement of this development period it is necessary to submerge into the history of rolling. The first rolling mill for fine sheets was erected in 1720–1728 in the South Wales. Rolling of fine sheets on two–high rolling stand was the oldest mode of rolling at all. Further technological development in this area of metallurgical production laid in gradual enlarging of rolls diameter and of their length and so also in enlarging of sheets wideness, in quality of sheets improvement, increase of output and introduction of partial mechanization. But the rolling principle remained untouched for long decades. The first conversion came only at the turn of the 19th and the 20th century, after discovery of so called Teplice mode of wide strips continuous rolling. This attempt for retrieval of new way in plate and sheet rolling inspired interest abroad, especially in the United States and efforts to use and improve present system started. In 1902, the first continuous rolling mill for sheets was pu t into operation in Pittsburg – USA and in 1923 production at the more up–to–dated tandem mill had started. At the beginning of the thirties a new manufacturing technology was proved enough in the USA and machinery was standardized. Up–to–dated “American” mode of sheet rolling enabled especially huge increase of production quantity. But new way of rolling influenced substantially quality of products as well. Metallurgical plants began with construction of special rolling mills using mixed manufacturing processes (cold rolling and hot rolling). They usually consisted of wide strip rolling mill with front–ended blooming mill (so called hot part) followed by finishing line (so called cold rolling mill). Share of automation increased strongly, demands on number of workers decreased and hard tiring labor of rolling mill operators was pretty eliminated. Production of fine and medium sheets increased and prices were substantially cut, due to high capacities of continuous wide strip rolling mills. In the thirties, European manufacturers of plates and sheets faced a problem of how to countervail with increasing competition of American producers. Classical plate and sheet production by hot rolling was in comparison with American mode greatly unprofitable.
Just the rolling mill in Karlova hut, still belonging to Bánská a hutní spolecnost became the largest producer of fine steel sheets in new Czechoslovakia. Important events occurred by the end of the twenties and at the beginning of the thirties. Bánská a hutní spolecnost concluded a treaty with the firm C.T. Petzold a spol. in Vienna, on the basis of which Petzold’s rolling mill operations in Rotava and in Nýdek were closed and the new plant was constructed in Lískovec. Construction of new rolling mill was completed on 15 April 1931. In this connection, the up–to–dated rolling mill for rolling of sheet bars and billets was launched in the Trinec Ironworks. Management of Karlova hut was taken over by the newly established Válcovny plechu (The Sheet Rolling Mill) joint–stock company with its residence in Prague. This company stepped out of Bnsská a hutní spolecnost alliance, which retained the half of stocks of the new company. Therethrough the bridge building works seceded from the rolling mill, remained at Bánská a hutní spolecnost and became an independent factory. Karlova hut had an old and new plants in 1931. During the new rolling mill construction, it has been emphasized that the whole working process from the magazine of sheet bars up to the loading of finished products had to pass out continuously in one direction without disturbing influences of cruising transport routes. For this reason cranes transported cut up sheet bars toward particular heating furnaces, after heating they were rolled to sheets, these were cut by shears into required sizes and passed through stretching line, pickling shop, polishing line and finish treatment to the magazine of final production according to prescribed quality grades.
Sheet production consisted of four main groups: black sheets, pickled sheets, polished sheets and special sheets. Sheet bars with width of 300 mm were delivered from Trinec Ironworks. They were cut into given lengths by two electrically driven shears with roller conveyer and after having been cut up they were transported toward particular heating furnaces. Six heating sheet bar furnaces and one push furnace were in the new rolling mill. Sheet bars heated to the rolling temperature were rolled firstin roughing mills into the slabs which were then manually bent and after additional heating in 15 double –chamber furnaces, 2 chain furnaces and 1 continuous furnace were finish rolled in finishers. Rolling mills were grouped into six lines. Rolled sheets, after cutting, were manually separated and then according to given sheet groups were variously treated. Finished sheets were stored in magazines which had long ramp for loading of sheets into wagons. The Karlova hut became at that time, as mention ed above, the largest producer of thin steel sheets not only in Czechoslovakia but also in the all Central Europe. The company had its way in domestic and foreign markets, especially due to quality of its products. Sale increased up to approx. 110,000 tonnes of fine sheets in 1937, what represented 75% of the whole Czechoslovak sale. Karlova hut exported 28,000 tonnes of fine sheets – this amount represented even 83% of total export share. Primarily, pickled and black fine sheets, then galvanized heets and newly also the tin plated sheets.
Development of the company during World War II stagnated – there were no shifts in development or in new investments. It is apparent that unclarity of the whole company way in 1939–1941 was not a good base for further development. At the end of war, the company had practically the same equipment and extent of plant as after its enlargement and modernization in 1931.
Immediately, after war ending there were carried out the most urgent repairs in the company. First, it was necessary to repair mains damaged during the war. This enabled start of production in the plate rolling mill and galvanizing shop in June 1945, in August in paint shop and in October in the old plant. In November, was already achieved 100% of 1938 output.
Industry of liberated country required for its economic recovery more and more sheets and present capacity was not able to meet this demand. The company management began to prepare production enlargement. First of all it was enlargement of rolling mills for hot rolling. In 1948, further efficient line No. VII was erected in the extended hall of new rolling mill, which had one three–high rolling mill and two two–high rolling mills with capacity approximately of 50,000 tonnes of fine sheets per year. Simultaneously, line V was mechanized, what caused production increase and lightening of hard tiring labor of operators. Mechanic and electric shops carried out enlargement of generator gas production, and for instance table shears, bending machine of modern design for sheets were produced by joint effort there and also equipment of the pickling shop has been improved. To assure sheet quality, an annealing capacity was increased by construction of the third normalizing furnace Ignis. In 1948, the universal mill was closed down and transferred to Bohumín, later then also the rolling mill for plates checkering. Thus, the necessary area for operation of heavy rolling mill was vacated.
In 1946, negotiations on tandem rolling mill delivery for cold strip rolling started. This line was ordered at firm United from the USA, its electric device in Switzerland and four–roll mill for cold rolling of body sheets in Germany. But after 1948, delivery of equipment was obstructed, notwithstanding that it was already produced and disbursed as well. Department of commerce of the USA declined to place the export license for wide–strip mill with justification that this export is in contradiction with public interest.
With aim to meet growing demands on plates and sheets, enlargement of hot mills was realized by construction of line VIII in widespread hall of the new mill. This mill had one three–high mill stand and three two–high mill stands and it secured increase of production by approximately 45,000 tonnes of sheets per year. The two newly constructed lines (VII and VIII) were equipped with new continuous heating furnaces. Transportation of heated sheet bars from furnaces to mills was mechanized and equipped with new type of bending machine of Schloeman firm, so that portion of hard labor of operators dropped out. The two new tunnel furnaces were constructed in order to increase production of hot rolled plates and sheets annealing capacity. Treating equipment was completed by new sheet straightening machines and table shears. In 1951, with aim to enlarge production, reconstruction of line VI. was carried out – involving erection of new three–high mill, new continuous walking beam furnace including mechanizing. Reconstructed line served for enlargement of production of packaging sheets which were tin–plated during the next manufacturing process. In the same year, four annealing hood–type furnaces were erected and a four–high rolling mill delivered by Siemag firm was constructed. This four–high rolling mill served for finish cold rolling of deep–drawing body sheets with aim to improve their properties. In subsequent years this mill was used for finish rolling of sheets from special steel grades. 1952, is the year of new pickling shop construction for production of larger sheet sizes and also the year of preparation of line No. II reconstruction and construction of walking beam heating furnace as well. During 1953, due to reconstruction of line II, erection of one three–high mill and up–to–dating of two two–high mills including walking beam heating furnace for sheet bars and slabs production increased. This construction practically completed up–to–dating and mechanization of hot mill in the new plant and simultaneously its highest capacity was achieved. Notwithstanding, further production devices were still added. In 1954, new pickling shop and enlarged vitriol building were put into service and o utbuilding of tin–plating shop was completed.
Growing demands on sheets of high–grade steel, especially of stainless, corrosion–proof, acid–proof and heat –resisting steels stimulated introduction of such new production in rolling mill. New technology was acquired and construction of new operation for this production prepared. Thus, construction of new pickling and stainless sheet treatment shops were completed and new sheet bar shears, straightening machine and grinding machine for rolls were put into operation in 1955. In 1956, the new continuous walking beam annealing furnace of Ignis type and hydraulic stretching press for stainless steel sheets production were put into operation. Assembly of transformer station for induction heating of rolls and construction of induction heating equipment which shortened preparing time during rolls replacement on production lines were completed as well. Line X in old rolling mill plant was mechanized on the pattern of former mechanization in the new rolling mill. During the fol lowing year, treating equipment was completed, especially by straightening machines for improvement of flatness of produced sheets.
1957, 1958 and 1959 started new period of the company development. It was decided on construction of cold strip rolling mill with aim, temporary – up to the erection of Východoslovenské Železárny (East Slovakian Ironworks) in Košice, to produce cold rolled deep–drawing and packaging steel sheets. Moreover, the task was to ensure development of production of oriented transformer strips and later also their production even strip production of high–grade steel.
Construction of the first four–high rolling mill started in 1959. Assembly of continuous decarburizing line and electric high–temperature hood–type annealing furnaces were completed in 1960. Together with this equipment started construction of facilities for controlled atmospheres production by ammonia dissociation and as part of this facility ammonia storehouse with particular service was erected. This equipment served for acquiring of new manufacturing technology of oriented transformer strip. Equipment was delivered by Austrian firm EBNER of Linz. Assembly of four–high mill dropped behind and its putting into operation broke also flooding on Ostravice river on 27 July 1960, when water penetrated into the entity of cold rolling mill and overran all understairs with assessory equipment and distribution system – water reached up to 150 mm of height above the floor of metallurgical works. Pumping out of water, replacement of electric engines and of part of wiring substantially broke assembly. The assembly of four–high rolling mill was completed on 23 December 1960 when the first strip was rolled during complex testing of this equipment. In addition to cold rolling mill enlargement another period of hall outbuilding was completed.
Intensive work was carried out during assembly of new equipment of cold rolling mill in 1961. Four–high rolling mill underwent a complex testing and pilot operation. Rolling mill stand was put into continuous operation on 17 May 1961. Five hood–type gaseous furnaces and three Exo–Mono 60 generators for production of protective atmosphere for these furnaces were put into operation in the annealing shop of cold rolling mill. Continuous pickling line of Ruthner firm and shearing line for strip cutting into tables, delivered by the same firm, were put into operation as well. Finishing line for coils rewinding, for lengthwise strip cutting and for application and removing of fire resistant insulation of oriented transformer strips were put into operation by the end of the year. From nonproductive operations, a storehouse of material for construction in process and storehouse of electric motors were completed.
In 1962, the extensive construction of cold rolling mill continued and second four–high rolling mill was put into pilot operation. Further, construction of annealing shop continued, four gaseous hood–type annealing furnaces were put into operation, of the same type like the previous ones, but they were modified for higher annealing temperature. Along with these furnaces, the Exo–Mono generator of protective atmosphere delivered by EBNER firm was put into operation, as the present generator did not guarantee the necessary values of protective gas and for this reason it was already unsatisfactory for technological parameters. Step by step, a shearing line for packaging of sheets and line for continuous strip degreasing were put into operation. In 1963, construction of seven gaseous hood–type furnaces was completed in annealing shop of cold rolling mill. In 1964, assembly of four vacuum high–temperature hood–type furnaces and three ammonia dissociating devices for hydrogen atmosphere production of EBNER firm were completed in cold rolling mill and construction of shop for assembly of Morgiol type bearings for four–high rolling mill stand was completed as well.
1965 was the year of preparations for construction of equipment for enlargement of oriented transformer strips capacity. Technical solution of the new three–purpose annealing line, high–temperature hood–type furnaces and equipment for protective atmosphere production was found. The new hood–type annealing furnace for high–temperature annealing with temperature up to 1,200 °C was put into operation. Equipment for production of suspension for protective layers during high–temperature annealing even for final electric insulation of oriented transformer strips was put into operation in 1966, in cold rolling mill. This equipment served primarily for development and production acquiring of these coatings. 1967 was the year of construction completion of manufacturing equipment for oriented transformer strip. Assembly was completed and complex testing of equipment including pilot operation was carried out. Grit–blasting device for rolls delivered from Poland and gradually eight electric high–temperature hood–type furnaces and continuous annealing line for recrystallizing, decarburizing and straightening annealing were put into operation at the beginning of the year. Also new ammonia dissociating devices for protective atmosphere production with 75% of hydrogen and new object – 100% hydrogen from electrolysis were put into operation. All mentioned facilities were delivered by EBNER firm, or with cooperation with it. New transformer station was put into operation with aim to assure sufficient power demand for newly built objects.
Modernization and automation continued also in hot rolling mill. In 1959, mechanization of line XI in the old rolling mill, mechanization of zinc–coating machine and mechanization of sheet bars charging. In the new plant were put into operation additional strengthening machines, new pickling shop for long sheets and new continuous walking beam annealing furnace of Ignis type. In 1960, lines XII and XIII in the old rolling mill were mechanized, hot rolling mill of new plant was completed in vitriol house by new crystallizer and ammonia compressor. In 1961, line X in the old plant was mechanized and sheet bar shears were erected at the south sheet bars yard. In 1962, new shearing line was put into operation in the rough treatment shop of old plant and lines Ia and Ib with wide rolls were mechanized in the new rolling mill, strengthening machine No.6 was mechanized and new table shears were put into operation in finish treating shop. Exhausting devices were added to drying stoves in order to imrove job environment. In 1963, machinery of new rolling mill was completed by table shears, measuring tables of specific losses for transformer and dynamo sheets and a new grinding machine for polishing and grinding of sheet table surface in stainless steel sheets production was put into operation. The machine was delivered by German firm Proll&Lohman. Similar completion of technological equipment, focused in the developing perspective of the whole company, continued also during the following years.
Also nonproductive operations were up–to–dated. As to the internal transport within the company, old steam locomotives were replaced by diesel–electric ones. Reconstruction of trackage and construction of internal and accommodation roads continued. Gradually, drinking water distribution was innovated and enlarged. New canteen was reconstructed and operational dining–room constructed. In 1967, construction of new modern building of factory management was completed and at the same time new underpass for pedestrians under track of public railway was put into service. New electric shop in which were placed also rooms for apprentices education was completed in 1968.
Growing importance of automation and mechanization and development of new equipment in hot rolling mill, but primarily in the cold rolling mill placed more and more requirements on solution of new tasks. For this reason, the development designing office was created which objective was not only new equipment development but also production of new pilot plant devices for needs of company research and development in developing shop.
Gradually, the new technology came into play also in power operations. These operations, originally manufactured generator gas and steam, carried out power distribution small part of which they produced themselves. They looked after service and drinking water distribution. Step by step they undertook care about production and distribution of compressed air, hot heating water and about distribution of other heating gases e.g. coke and natural ones. Production and distribution of gases for protective atmospheres during production of oriented transformer strip was added as well. Important changes were made also in distribution and production of electric power. Initial high voltage supply of 22 kV was transformed to 6 kV and 3kV for main drives of rolling mills and to 22/380V for other motors and for lighting. In 1952, high–voltage line of 22 kV from Ostrava–Mariánské hory was liquidated and the company was connected to new switching station in Žaben with supply of 110 kV into the new transformer station from which was distributed as 6kV by cable to secondary switching statio ns within the company and supply of 22kV into the old transformer station. Conversion to electric power supply exclusively of 110 kV was completed only in 1965. Self–production of electric power in the company was satisfying only for emergency operation of some facilities. Electric power was originally produced in the hydro–electric power plant which had three Francis turbine driving generator with output of 125 kVA. This production of electric power was liquidated and replaced by back–pressure turb ine and a generator in newly constructed power and heating plant. Its reconstruction to output of 6 MVA was carried out after additional boilers outbuilding.
Growing production needed better supply of service water. New pumping station together with filtration plant and main distribution supply with diameter of 800 mm were constructed at the Ostravice river. Compressed air production, in the process of growing production, was ensured by new compressors construction which were placed differently in operations. For this reason it was decided to erect a new central compressor house. Energetic operations were enlarged by the pure 100% hydrogen production, which was used during high–temperature annealing of oriented transformer strips. Oxygen nascent by decomposition is compressed and used for flame welding. In addition to protective atmospheres also other kinds of atmospheres are produced e.g. HNX atmosphere from town gas by its combustion with following cleaning. Another kind of atmosphere is produced by ammonia dissociating in the special dissociating devices which consists fr om 75% of hydrogen and of 25% of nitrogen. All these atmospheres and also atmosphere of pure hydrogen are additionally cleaned and treated by drying and in this or differently treated composition are used in manufacturing process of oriented transformer strip during annealing cycles. Problem of waste water cleanliness is an integral part of power engineering management. Period of the last development is associated with construction of new cold rolling mill. Till then, utilized pickling baths were neutralized by lime milk and then they were discharged to sludge bed, rinse water was drained off directly into river. Cold rolling mill construction represented the end of the first period of construction of neutralizing station, equipped with sedimentation tanks. Utilized pickling baths from cold rolling mill are regenerated in regeneration station, rinse waters from continuous pickling shop and waters from degreasing line are treated and cleaned in the new neutralizing station. Sludge is then transported to dump. Till 1967, all sludge from sedimentation tanks were drained off into the Ostravice river at the time of the high water level.
Implementation of oriented transformer strips production in cold rolling mill production of hot rolled transformer sheets was limited only for sheets with warranty of magnetic permeability. Hot rolling mill was reconstructed and production of hot rolled plates and sheets of plain carbon steel was gradually restricted and due to it some lines were liquidated in the new rolling mill after 1972, and also the lines in the old rolling mill. This production decrease occurs as a consequence of erection accomplishment of metallurgical complex of Východoslovenské Železárny. Production of hot rolling mill was specialized on production of sheets of high–grade steel with higher quality parameters. Fine sheet lines both in old and in new rolling mill were then, after 1972, gradually liquidated – theirs out–of–date and obsolete technology of sheet hot rolling was not perspective for future, with only minor exceptions. In 1979, line X in hot rolling mill was closed down, in 1981 line IV, in 1985 line II and in 1988 line V. As in the eighties, consumption of thick stainless plates abnormally increased and production was not able to meet requirements of inquiries, it was decided to construct another heavy rolling mill including treating capacities. This investment project was put into operation in 1988. But new economic conditions at the beginning of the nineties showed that it is not viable and for this reason it was suspended, in 1992. Production of plates, predominantly of plain carbon steel is further realized at the old heavy line, which had against parameters of liquidated new heavy line substantially higher assortment use efficiency in view of dimensional alternatives of rolled plates. In the nineties, restriction of fine sheets production continues and that is why other lines were liquidated; in 1990 line VI and in 1998, line VIII. At present, only two lines are in operation. For fine sheets production, it is line VII and three–high Lauth rolling mill stand, so called old heavy mill, for heavy plates production. Besides hot rolling plates production hot rolling mill plant is historically adherent to production of hot dip zinc coated products. Original manufacturing of galvanized sheets produced till 1994 was replaced by new products as zinc coated strip and wire, in the nineties. New zinc coating line for continuous strip zinc coating was put into operation in 1993. Due to market requirements, the line was gradually in 2001 and 2002, completed by two winding machines, which enabled collateral zinc coating both strips and wires. Production of this assortment, required both in domestic and in foreign markets, amounted to 3,129 tonnes of zinc coated strip and 534 tonnes of zinc coated wire, in 2002.
Modernizing process of cold rolling mill continued also in the following years. Owing to necessity to cut claims caused significantly by improper packaging and increase competitiveness of our products a special stand for packaging of coils and strips equipped with progressive making–up technology was built up. In 1982, four–high rolling mill No 1 was up–to dated so that controlling section of mill was replaced while drive remained unchanged. Control system of four–high rolling mill stand was changed by implementation of equipment for automatic control of rolling slot and precise stop system. Simultaneously, an equipment for control of working rolls deflection for planishing rolling was installed which brought production quality improvement and decrease of maintenance costs. In 1985, a reconstruction and modernizing of four–high rolling mill stand started, which in contradiction to four–high rolling mill stand No 1 included complex exchange of drives of train including transducers replenishment. Control desks were replaced and new thickness gauge installed. Further reconstruction followed as reactions on requirements for quality improvement, increase of production and work safety and elimination of hard work. During the last decade of the previous century two important treating aggregates were put into service. First of them is draught and bending straightening machine which expressively improved quality parameters of strip flatness including of lateral trimming, the second, a new longitudinal cutting line. In 1995, company management decided on construction of new hood–type furnace, which would meet requirements for annealing of deep–drawing high–grade steel and for bright annealing of stainless chrome steel. Consequentially, contract with EBNER firm from Austria was concluded, for construction of a gaseous hood–type furnace of type HICON/H2, enabling to anneal coils in protective atmosphere of 100% of H2. Construction of the new furnace started in August of 1996 by liquidation of present gaseous hood–type furnace of series 7, which served for basic annealing of stainless chrome steels and continued by building work in September. After completing of building work, firm EBNER together with our subsidiary VP BESS spol s r.o. started assembly of the whole equipment. From 16 December 1996 functional tests began and on 16 January 1997 the first reference annealing of deep–drawing coils was run. Nearly 100 thousand tonnes of deep–drawing sheets were annealed in this furnace for more than 6 years of its operation. Constrained reconstruction caused a fire of four–high rolling mill stand No 2, at the beginning of 1999. This reconstruction involved new control system from Siemens including drive transducers and cabling.
Still the last investment action was the construction of new transversal cutting line for hot rolled strip, production of which should gradually replace a production of hot strips in the hot rolling mill which was energetically more demanding. Present machinery of cold rolling mill consists of continual pickling line using technology of pickling in sulphuric acid, two four–high rolling mill stands, gaseous hood–type furnaces for deep–drawing strip annealing, electric hood–type furnaces for transformer sheets high–temperature annealing, two continuous annealing furnaces for electrical steel, seven treating lines ensuring geometric parameters of strips and/or of tables and packaging center purpose of which is to facilitate products against mechanical damage or pertinently against weather influences. The most important aggregates operate continuously, which enables to achieve up to twenty thousand tonnes of produced production per months, in the process of suitable structure of production.
Nová hut Ostrava, a.s. (New metallurgical company) is supplier with preference of low carbon and dynamo strips inputs, while inputs for transformer strips are imported from Russia. Commercial policy of Válcovny plechu, a.s., in relation to cold rolling mill was oriented predominantly on plain and low carbon steels. Sheets intended for electric purposes – transformer, dynamo, pertinently stainless chrome sheets were produced in limited quantity. In the nineties of the twenties century, the share of sales of final production in domestic market amounted 70% of total volume of sales, only 30% was exported mainly into countries of present EU. Insolvency of customers in the home market and problems related to production financing during 1999–2000 led to decrease of production, volume of sales of goods intended for domestic market dropped down. But in 2001 came to market stimulation, growth of production volume, increase of labor productivity and repeated battle for domestic customer acquiring began. Nowadays, sales of final production of cold rolling mill is divided in approximately, 40% for domestic market and 60% for export.
By 1 April 1991, the Válcovny plechu, state enterprise, was transferred to the form of joint stock company, in which the only owner was the government, represented by the Ministry of Industry and Trade of the Czech Republic. Válcovny plechu, a.s., was a medium metallurgical enterprise which employed 3,300 of employees at that time; basic object of activity were as follows: research and development, production of hot rolled and cold rolled sheets and plates, cold rolled OTN sheets for electrical purposes, cold rolled longitudinally cut strips, heat treatment and finish treatment of rolled products and other sequential activities. Further prospect of our company development shall be judged in context of the Czech, European and World metallurgical engineering development. It was evident that the company had to get through the process of restructuring followed by liquidation of non–effective assortment production. Restructuring program in the process of production drop, also implied substantial reduction of number of employees to approx. 2,000 employees. Besides proper manufacturing activity rationalization, this number was achieved also by gradual separation and privatization of various activities which were not connected with production. By transformation of previous divisions Dodávky (Deliveries), SluĎby (Service trades) and of Druhovýroba operation (Wire and wire products), by 1 May 1995, new companies with 100% stake of Válcovny plechu, a.s. came into existence: Válcovny plechu BESS, s.r.o., Válcovny plechu Služby, s.r.o. and Válcovny plechu TECHNOTRON, s.r.o. and in 1999, also with 100% stake of Válcovny plechu, a.s., it was: Spalovna prumyslových odpadu Válcoven plechu, s.r.o. (Incinerator of Sheet Rolling Mill Wastes).
Company privatization which was completed in 1998, when Nová hut, a.s. Ostrava became the majority stockholder, influenced additional company development. This interconnection with Nová hut, a.s. pursues sequence on hot rolled strip production which creates deciding share of input materials for cold rolling mill. In the nineties, the company suffered from frequent management changes. Different opinions of top management led to considerable doubtfulness relating to future. The vague proprietary and managing structure deepened this problem much more. The crisis culminated in 1999, when production strongly decreased from the beginning of year and in July and August it practically stopped. Extraordinary general assembly in October 1999 caused stabilization and pacification of mutual relations among stockholders. New supervisory council elected new board of directors and consequentially the new management was established. Further development of Válcovny plechu, a.s. was straight reflection of these radical changes. Implementation of deep organizing restructuring changes resulted in decrease of number of managing levels and in substantial reduction of employees number, which dropped to 1.000. In 2000, the board of directors submitted “Plan of Válcovny plechu, a.s. restructuring”, aim of which was disencumbra nce of firm by means of capitalization of receivables with following creditors: Nová hut, a.s., KONPO, s.r.o. and Konsolidacní banka s.p.ú. Praha. In January 2001, an agreement was reached among largest creditors and stockholders, who started to work on “Standstill agreement”. Plan of restructuring got the final form in March 2001. Agreement with proposed procedure was confirmed by signature of “Standstill agreement” by all partners, namely: Konsolidacní banka Praha, s.p.ú., KONPO, s.r.o. Praha, Nová hut, a.s. Ostrava and Válcovny plechu, a.s. Program of restructuring and capitalization of receivables in Válcovny plechu, a.s., pertinent to it, was definitively authorized by the Resolution of government of the Czech Republic on 25 June 2001. As Nová hut, a.s. Ostrava became a majority owner of Válcovny plechu, a.s., the following development of this company is closely connected with privatization of Nová hut. Entrance of LNM Holdings into the Czech steelmaking is considered to be very auspicious for Válcovny plechu, a.s. as well.
Management of the company pays extraordinary attention to quality assurance and environmental protection. As an expression of permanent care of quality and environment, serves realization and development of quality and environmental system according to requirements of EN ISO 9002 and ISO 14001 standards. Cold rolling mill operation of Válcovny plechu, a.s. obtained Certificate on quality management system according to EN ISO 9001 standard from corporation RW TÜV, in February 1994. The validity of the certificate was extended on hot rolling mill, in March 1996. In virtue of repeated audits and of extending audit, validity of certificate was extended to March 2000. Successful extending audit according to EN ISO 9002 was carried out in March 2000. Moreover this year, the Board of directors of Válcovny plechu, a.s. decided on beginning of work on extending of present quality system by environmental management system according to EN ISO 14001 standard with aim to complete certification up to the half of 2001. Certifying audit of environmental management system was successfully carried out according to EN ISO 14001 in June 2001 and simultaneously validity of the certificate according to EN ISO 9002 was prolonged. Company management is prepared to maintain and improve efficiency of both these systems also in the following years. Válcovny plechu, a.s. besides system certificates, gained also series of products certificates, as follows :
- for plates for pressure vessels production from RW TÜV
- for plates for shipbuilding from Germanischer Lloyd
- for products marking by “znak bezpiecze?stwa” (safety mark) from Polish company SIMPTEST
- for marking of steel used for civil engineering by mark Ü–Zeichen” from RW TÜV
Restructuring program is base for further functioning of Válcovny plechu, a.s. Consumption of domestic steel per dweller is high within the Czech Republic. Also sheets delivered from Válcovny plechu, a.s. have important share in it and that is a good perspective also for further growth of the company. Due to financial problems of the company the share on domestic market substantially dropped. When in the half of 1999 production started again with aim to re-establish cash flow, most of production was intended for export. Share of export increased up to 80% in comparison with 30 % in the middle of the nineties. Production of special steels substantially sank due to working capital and raw material deliveries shortage. Company operated only with help of tolling system, what means that third parties undertook raw materials ownership and financed operations which were carried out. The economic stabilization of the company represents necessary condition for Válcovny Plechu, a.s., to become again one of the leading deliverers in the Czech market. For this reason management of company sets its mind two targets :
- to increase deliveries for home market
- to change assortment of manufactured products on products with higher added value, it means change of orientation from present low carbon steel to special steel products.
Both these changes should substantially influence created profit of the company.
Last update: 30.6.2008