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| Danieli Coporation is the North American representative of Danieli & C. SpA located in Buttrio, Italy |
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Danieli Corporation |
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This order reconfirms the confidence in Danieli after the success of the special steel meltshop in operation since October 2003 as part of the complete Baosteel Shanghai No. 5 minimill for long products. The new plant has a designed capacity of 1 Mtpy of 320x425-mm high-quality blooms, and will feature the most advanced and comprehensive Danieli Centro Met technologies to comply with the highly-demanding quality requirements in the cast product and in the worldwide steel market. The wide product mix will include cord wire, high-Cr for high-pressure boiler tubes, bearing, free cutting and gear grades. The meltshop will basically consist of the following main technological areas: 150-t AC EAF equipped with conductive arms and served by a 125-MVA transformer; 150-t ladle furnace; 150-t double tank VD/VOD unit; - 4-strand 14-m-radius FastCast™ large size bloom caster, equipped with hydraulic mould oscillators and mould EMS. The unbending unit will be designed for the application of soft reduction when casting high carbon grades aiming at a lower internal carbon segregation and porosity. Facilities for slow cooling of some critical steel grades will also be provided.
Tuning of the operations went then ahead smoothly, enabling the Company to continue to ramp up production and to have some billets in the lower-grade range already applied to orders at only one month after the start. The new plant is basically made up of a 75-t EAF, LF, single-tank VD unit and a 4-strand conticaster designed to cast up to 200-mm square sections, in a large variety of grades ranging from carbon to alloy steels for cold heading, cold forging, specialty spring, bearing, high carbon, and free-machining steels for automotive, aerospace, agricultural, and construction applications. The new melting facility will initially produce 350,000 tpy but production will be increased to about 700,000 tpy, when needed. Charter Steel, a division of Charter Manufacturing Company, is a full service supplier of hot rolled as well as processed steel rod, bar-in-coil and wire and has manufacturing and distribution facilities in Wisconsin and Ohio.
A new 120-t ladle furnace was started up at the end of July 2005. A vacuum degassing unit of the same size successfully operates at the same plant since December 2005, while a second 120-t ladle furnace was successfully started up in June 2006. The two ladle furnaces and the VD unit feed the existing round and square conticaster as well as a slab caster. The units are designed for treating 2.5 Mtpy and 1.2 Mtpy of liquid steel respectively. Danieli Automation has supplied the associated Level 1 and 2 automation systems.
A Danieli ladle furnace of the same size is successfully operating at the same plant since June 2003. When in full production the new EAF will enable the complete replacement of the plant’s outdated open-heart shop. The Danarc EAF is equipped with HiREG® electrode fast-response regulation system, automatic sampling device and Module O2-C injectors. The supply included all related auxiliary equipment such as water treatment, fume treatment plant and compressed air plants plus material handling system.
Sidetur Casima will install a new Danieli fume dedusting system at its 550,000-tpy steelmaking plant in Puerto Ordaz for treating the primary and secondary fumes of the existing 85-t EAF and ladle furnace units. The plant will be equipped with a canopy hood to control the secondary dust emissions that occur during charging and tapping phases. The “Pulse-Jet” type filter will be quipped with bags cleaning by compressed air to enhance the filtering performances. The new FTP, designed for a 1,200,000-m3/h maximum fume flow-rate and with 11,760-m2 filter surface, will make it possible to comply with the local environmental regulations, granting a maximum dust emission of 10-mg/Nm3 at the stack outlet. Plant startup is scheduled for autumn 2007.
The Blast Furnace-based Koverhar meltshop has a total production capacity of 600,000 tpy and presently operates with two 4-strand billet conticasters, namely the CCM No. 1 -which produces 160x160-mm, 7.2-m-long billets- and the CCM No. 2, casting 125x125-mm billets in up to 12-m lengths. Steel grade range includes rim qualities, welding wire, cold heading, high carbon and alloy grades, spring, bearing, tyre cord and similar. Danieli will provide the major modification of CCM No. 2 to enable casting of 145x145-mm billets with a 12.7-m length (approx 2-t) with the provision for a future additional increase of billet size (to 160 mm) and weight, up to 2.5-t. This will involve the installation of a new mould inserts, modification of the casting strands (bending sections, secondary cooling), new withdrawing /straightening units, rigid dummy bar as well as complete reconstruction of the billet finishing area with extension of the existing cooling bed and installation of a new one, plus associated roller tables and collecting facilities. As a consequence CCM No. 1 will also be slightly modified in its finishing end, for coping with the upgraded CCM No. 2 new layout arrangement. Based on Danieli’s well-known experience in upgrading existing plants, the machine modifications will be carried out according to an optimized schedule of activities, which will end up in minimized downtimes (21 days from CCM No. 2 stoppage to hot startup) and loss of production. CCM No. 2 startup after upgrading is scheduled for end of August 2007.
A 3-strand Danieli special steel billet/bloom caster, in operation at the same plant since the middle 90’s, will be upgraded with the installation of the 4th casting strand at middle 2007. The conticaster produces 135-mm and 240-mm square sections in a large variety of engineering and special steels. NKMK decided to install the new VD station in order to be able to fulfil the stringent requirements of the rail steel market. Danieli was selected for the advanced technology and high performances of its products and also being the only supplier able to furnish the new VD system as a complete package together with the associated water treatment and steam generating plants. The new single-tank VD station will treat 110-t heats in less than 40 min. The vacuum level of 0.3 torr will be granted by a 4-ejector steam pump fed by the new steam generator. Provision will be made for the future installation of a second tank. The supply will also include full electrical and up to level 2 automation systems suppled by Danieli Automation. A few months after contracting Danieli for the 0.5-Mtpy superflexible SBQ mill, CSH (Compañia Siderúrgica Huachipato) has reconfirmed its confidence by awarding the order for a new vacuum degassing facility for upgrading of its steelmaking plant with the aim of improving steel purity and cleanness. The new 105-t twin-tank VD unit will be installed in an extension of the existing building, with the capability to feed both the existing billet and slab conticasters. The installation will include two vacuum tanks, vacuum tank cover with dedicated car, steam ejector pump with dust separator, a complete set of auxiliary equipment such us wire feeding and automatic sampling equipment and a Danieli Automation Level 2 automation system. The supply will also include an intensive personnel training program in order to assure a fast learning curve and a consistent improvement in the steel quality.
The target of the upgrading is to increase production from present 650,000 tpy to up to 1 Mtpy thanks of the benefits coming from the installation of the FastArcä injection technology together with automatic sampling and with EAF process optimisation and automation. The new oxygen and carbon injectors will be supplied with fully independent valve regulation trains for each oxygen, natural gas, carbon and compressed air feeding lines, together with independent carbon dispensers. New automation system with dedicated PLC and HMI will allow automatic process setting and control, with interface with the EAF automation system. Automatic sampling will enable to perform temperature measurement and sampling during power-On, gaining additional saving on EAF tap-to-tap time and improving operation’ safety. Equipment installation is expected by middle of 2007.
OEMK (Oskol Electrometallurgical Kombinat), one of the pioneers in electric steelmaking in Russia, is currently producing 2.3 Mtpy of quality steel grades, with the target of reaching 3 Mtpy. The new “Twin-type” ladle furnace will equipped with two roofs and swivelling electrodes arms and will be served by a 25-MVA transformer suitable for continuous working cycle. The supply will also include a dedicated fume treatment plant, a ferroalloys feeding system for the new LF, as well as the revamping of the complete raw material handling for all the existing EAF and LF units.
At the beginning of May 2006 Yieh Phui contracted Danieli Centro Met for the supply of a 800,000-tpy specialty steel meltshop to be installed in Taiwan. E-United Group has recently awarded Danieli the orders for a continuous galvanizing line, a hot skinpass mill and a stainless steel slab grinder. Yieh Phui is also well known on the market as a major producer of galvanized and colour coated CR coils and this investment in the upstream technology marks the beginning of a new era and expansion program. The new Yieh Phui meltshop, designed for a capacity of 800,000 tpy of billets, will be based on the most updated and proven technologies. It will basically consist of the following technological area: - Two-bay scrap yard. - 100-t ladle furnace, tight roof design for reducing the air inlet to the ladle, thus minimizing the electrode side oxidation and consumption, the oxidation of liquid steel, and the hydrogen and nitrogen pick-up in the treated steel. - 100-t double-tank Vacuum Degasser equipped with independent temperature and sampling devices, hydrogen measurement equipment and steam-ejection type vacuum pump (suction capacity of 270-kg/h at 0.5 torr). - Material handling system. - All other auxiliary equipment and facilities for the operation of the meltshop. Startup of the new steelmaking plant is scheduled for spring 2008.
Startup of new facilities, supplied by Danieli Centro Met, was the latest meltshop modernisation step, aimed at increasing production capacity and at reducing transformation costs. A 3-strand Danieli billet caster (provided for future completion with a 4th strand) operates at the same meltshop since the late 1990’s. The new 50-ton Danarc EAF is served by a 40-MVA transformer and is equipped with Module carbon and oxygen injectors and HiReg Plus electrode and foaming slag control system. Electricals and automation systems (including new Level 2 for controlling the whole meltshop) were supplied by Danieli Automation.
Danieli Automation will take care of the automation and process control system implementation.
Installation of the new heavy-duty SHS housingless-type roll stands in place of two old rolling units will enhance plant efficiency and operating conditions and will contribute in minimizing the present maintenance requirements. The supply will include spare rolling units, set of entry/exit guides, workshop equipment for rolls changing and auxiliaries. The new breakdown units will be designed for taking up to 6-1\4” square billets and 10”x6” rectangular blooms. The hot rolling and finishing areas of the mill will be completely reconstructed. All this will enable production of 45 to 120-mm angles, equivalent unequal angles, up to 160-mm channels and I-beams, 50 to 200-mm flats and 50 to 80-mm tees, at rates of up to 120 tph. The upgrading project will be carried out in two subsequent phases, respectively in December 2006 and December 2007, for optimization of plant stoppages. Electricals and automation system will be supplied by Danieli Automation. Also in this case the project will be implemented in two subsequent implementation stages, with a first plant stoppage in August 2006 and another in December 2007. The mill produces 12 to 30-mm-dia round and square bars, 25 to 120-mm flats, up to 80x40-mm unequal angles, and correspondent channels and tees at rates of up to 100 tph. Both projects are focused at expanding the Company’s product range and at enhancing its presence in the long products market. · A new rolling mill for ultra-light micro-profiles (starting from round bar in coils) will be installed at the Feng Hsin steel works in Taichung. The new plant, based on the Danieli LPP process, will enable low-scale production of very small size flat bars (down to 15x3 mm -max 20x6 mm) at rates of up to 13 tph, starting from 14,18, 20-mm-dia coiled round bars produced at another mill of the Company. The plant will be basically composed of a coil feeding station with welding unit for endless rolling, straightening machine with mechanical descaler, induction heater for raw material heating up to rolling temperature, five SHS roll stands, cooling bed and finishing services with automatic lance-type stacker for flats. Danieli Automation will supply a dedicated automation and process control system. · The major upgrade of No. 2 rolling mill, with installation of a new production outlet for larger-size round bars and flats, is aimed at extending the mill’s present product range. The project will be carried out in three subsequent steps -with optimized plant stoppages in order to minimize production losses- between October 2006 and March 2008. Mill modification will basically include the installation of a new 4-stand continuous finishing mill, cooling bed facilities for large-size products including cold saw and automatic lance-type stacker. Mill upgrading will enable production of 70 to 130-mm-dia quality rounds and up to 300x25-mm flats, at rates of 85 tph. These two orders add another chapter in the long-lasting cooperation between Danieli and Feng Hsin which already counts several steelmaking, conticasting and rolling mills projects. Phase-1 plant upgrading, which already included two pre-finishing / finishing SHS stands, was completed at beginning of year 2004. All new stands are fitted with quick changing facilities. Danieli Automation has supplied electricals, controls and automation system for the new equipment. The 20-stand superflexible mill -which produced its first round bars on March 6th- also features a high-speed wire rod production outlet and a Spooler line for bar-in-coil production that will be started up later on this year. Direct connection to a 6-strand Danieli conticaster (in operation since 2001) makes it possible for direct hot charging of billets. The new multi-line mill has a 500,000-tpy designed capacity of 8 to 50-mm deformed bars, 16 to 75 mm quality plain bars, 5.5 to 20-mm smooth wire rod, 6 to 16 mm mm deformed wire rod in coils and 8 to 50 mm spooled plain (or 32-mm deformed) bar in coils weighing up to 3.4 t. Steel grades are low, medium and high carbon and alloyed steel for the construction and mechanical industries, including drawing, cold heading, spring, bearing and similar applications. Electricals and automation system are from Danieli Automation, while Danieli Centro Combustion has supplied the walking hearth reheating furnace (120-tph capacity in hot charge mode). This is today one of the most technologically advanced rolling mills for long products in the Country and in the whole Region. The latest Danieli technologies applied and the wide range of product type and sizes will make this super-flexible mill a powerful tool for Kroman Çelik to acquire new shares in the market of long products. The product range of the new twin plants is 12 to 60-mm-dia SBQ bars and rebars, in alloy and carbon steels at rates of up to 160 tph each. The two 18-stand lines feature all latest Danieli Morgårdshammar technology available in long products mills. This include Low Temperature Rolling process applied to the finishing mills when producing SBQ bars or multi-strand slit rolling for smaller-size rebars. Danieli Automation has supplied two HiGAUGE® bar measuring units and an advanced automation system for LTR process control. Later on this year, a Danieli Spooler line will also be started up as completion of one of the two bar mills, enabling production of twist-free-wound bars in ultra-compact, high-weight coils. This will make Tianjin Tiangang first in China to operate the revolutionary Danieli Spooler process for bar-in-coil production. Integration with the Danieli Group means access to a larger and stronger organisation, which will secure the newly-formed “Danieli Wicon” future development of the products both from the technical as well as from the marketing point of view. The acquisition of Wicon strengthens Danieli Group’s leading position as the leader in roll pass design. The 10-pass heavy-duty wire rod blocks and the associated loop laying heads and auxiliaries are designed for finishing rolling of 5.5 to 16-mm-dia wire rod in coils weighing 2,000 kg, at speeds of up to 105 mps and at output rates of 90 tph per strand. Product mix will include low, medium and high carbon and HSLA structural steels. Significantly, in the last 14 months Danieli has been awarded the order for a total of eighteen high-speed finishing blocks, thus further strengthening its worldwide leadership in long product rolling mills. The United Arab Emirates’ largest and first integrated DRI-based minimill will be constructed at the EISF-Emirates Iron Steel Factory site in the Mussaffah Industrial Area (GHC group) in Abu Dhabi. The new steel complex, one of the largest of this type ever constructed in the Gulf Region, will be supplied, installed and started up by Danieli on a complete turn-key basis. It will be one of the newest generation of integrated minimills conceived to exploit specific local (competitive) energy availability and raw material resources. The order, awarded in January 2006, foresees a new integrated minimill to produce structural steel long products, and consisting of: a 1.6-Mtpy direct reduction plant ; a 1.4 Mtpy steelmaking and casting plant; a 620,000-tpy high-speed bar mill; and a 480,000-tpy high-speed wire rod mill. Danieli will be in charge of the complete turn-key supply for the whole plant, including all the above mentioned main technological production units, the auxiliary plants and auxiliary services (such as the 220kV electrical substation, WTP, compressed air, workshops, laboratories, etc.), all infrastructures, civil works, buildings, as well as installation and startup of the whole plant. The 1.6-Mtpy direct reduction plant engineered and manufactured by Danieli is a HYL ZR type which, due to high plant capacity, will be enhanced by some technology concepts developed and applied to other plants by Danieli. This job represents a milestone in DRI plant construction as Danieli and HYL Technology will jointly and exclusively market innovative DRI plants incorporating technologies and process know-how acquired by HYL Technology and Danieli over the years. Further R&D activities to be carried out jointly are part of the agreement, which aims to gain an significant market share. The new minimill will feature all the latest Danieli technologies and “high-tech” equipment available in steelmaking, casting, and rolling of long products. The new 150-ton full-platform, split-shell AC EAF will operate based on 100% Hot DRI coming from the new nearby DRI plant, in continuous charge mode through the fifth hole. The EAF will be equipped with HiJet Modules and HIREG electrode digital regulation system for enhancing furnace operation and for energy consumption optimization. Steel refining will take place in a 150-ton inert roof-type LF. The six-strand “Fast Cast” conticaster will be equipped with the latest generation tundish and mould design, hydraulic oscillators, and all means to enable high-speed casting of 130 and 150-mm structural steel billets (designed for up to 200-mm square size). In addition, it will be suitable for future upgrading for casting of higher grade steels. The meltshop will outfitted with all auxiliary plants and equipment, including material handling system, and primary and secondary fume dedusting plant. The bar mill, made up of 16 SHS stands plus two six-pass DWB high-speed blocks, will produce 8 to 12 -mm-dia rebars delivered onto the cooling bed through the Double Twin Channel system at up to 37 mps. High-speed finish rolling will take place at two DWB blocks, fed by incoming stock slit into two strands at the upstream intermediate mill. The wire rod mill, made up of 16 SHS stands and a 10-pass DWB high-speed finishing block, will produce 5.5 to 8 mm plain and 8 to 16-mm-dia deformed wire rod in two-ton coils at speeds of up to 110 mps. Each mill will be fed by a 120-tph Danieli Centro Combustion walking hearth reheating furnace. Danieli Automation will supply all electicals and an advanced, fully integrated automation system for the entire plant. Project planning foresees a progressive startup of the various sections of the plant, starting with the rolling mills in the second half of year 2007.
The first step of the Republic Engineered Products, Canton (OH) existing steelmaking upgrading project was made on January 22nd 2006, with the first billets successfully delivered by the new Danieli 5-strand FastCast billet and bloom caster and with the first heat processed at the new single-tank VD station on February 9th. The job was performed in an extremely smooth way, to full Customer satisfaction. The new high-speed CCM, featuring all latest technological packages, such as stopper rods, hydraulic oscillators, mould EMS, air mist cooling and full process automation, is suitable for casting from 170-mm square billets up to 250x190-mm rectangular blooms, at maximum rates of 155-tph. The new conticaster and the single-tank VD station are part of a complete expansion project of the existing steelmaking facilities, carried out by Danieli which also includes a new 200-t LF and the major upgrading of the existing 200-t EAF. Startup of these units will take place in the next few months. Republic Engineered Products, Inc. is a leading producer of high quality special bar products, for highly engineered applications such as bearings, aircraft, automotive and similar.
GMTC has awarded Danieli Centro Met the contract for a new secondary refining station made up of a 35-t Ladle Furnace and VOD unit, for its existing steel works. Gloria Material Technology Corp, with its wide range of high-quality products, is the only special high-alloy steel manufacturer in Taiwan. Product range to be processed at the new secondary refining station includes tool steels, stainless steels and various materials that will undergo subsequent ESR process. Both LF and VOD units are equipped with automatic sampling and temperature measurement devices, wire feeders, inert gas bottom stirring and hydrogen measurement unit. The “tight roof” type LF is specifically designed to prevent liquid steel oxidation in the ladle during refining. Danieli Automation will supply the HIREG® system (that is key equipment for the LF performances) as well as the Level 1 and Level 2 advanced automation to ensure proper equipment operation and complete control of the refining process. Startup of the new units is scheduled for the end of 2006.
Jiangsu Huaigang (part of the Nanjing I&S Group) has awarded Danieli the order for a six-strand large-size bloom caster for special steels to be installed as an extension of the of the existing Huaigang facilities. The new caster, featuring curved mould 14-m main radius and designed for up to 500-mm-dia round cast sizes, will be put in operation within the end of 2006. The caster will be designed for hot or cold charging of the downstream rolling mill facilities. Off-line slow-cooling practice will be applied in case of cold charge mode for some specific steel grades before the round blooms are transferred to the rolling mill area. The new conticaster total requested capacity will be as high as 1.2 Mtpy of 380, 450 and 500 mm high-quality round blooms in alloy structural, spring, free cutting, bearing and gear steel qualities. In order to cope with the upstream steelmaking process route (based on a 90-t converter, LF and VD technology), the new caster will be designed for a total hourly steel output ranging from 190 to 240 tph (typical of the short converter heat cycle) depending on cast size and steel grade. New caster main highlights are the latest generation tundish design, combination of mould and final EMS, hydraulic mould oscillation and bloom on-line quenching technology (for hot-charge of low alloy, fine grain, Nitrogen-content steel grades). Other main features are the electromechanical stopper rod mechanism in tundish, radioactive mould level detection system, air-mist secondary spray cooling, multi-point unbending design and a Level 1 and 2 automation system for the full equipment operation and process control.
TSW Trierer Stahlwerke GmbH has contracted Danieli for the major upgrading of its existing casting and rolling facilities in Trier for enhancing plant production, efficiency and product quality. The rolling mill facilities will be upgraded and completed with the installation of a new high-speed Wire Rod Line after the existing roughing and intermediate mill. The upgraded mill will be designed for the production of approximately 500,000 tpy of 5.5 to 22 mm wire rod for a wide range of quality steel grades, as low- medium-high carbon, cold heading, spring steel, pre-stressed and welding wire and drawing grades, rolled at finishing speeds of up to100 mps. The coil weight will be max 1.6-t (equipment design for future 3-t coils). The mill layout considers various advanced features for the efficient production of first class quality wire rod as, e.g., the facilities for temperature-controlled rolling. To this end the project foresees: · Several modifications in the existing roughing and intermediate mill including new crop and cobble shears and 2 new ESS pre-finishing compact cantilever stands in H-V arrangement. · A cooling and equalization loop in front of the finishing block for temperature-controlled rolling. · A 10-pass DWB high-speed finishing block, loop layer, DSC controlled cooling line and a combined vertical / horizontal Sund coil handling and compacting system. In addition, the existing Danieli continuous casting machine will be modified for casting larger-size billets and for higher grades steels. This will involve the installation of protected stream casting technology and Mould Electromagnetic Stirring system. New cast size will be 160 x 160-mm, 8.5-m-long billets. The conticaster will also be completed with new hot and cold charging facilities, including a quick billet transfer for the existing billet cooling bed. Danieli Automation will supply all electricals and a new automation system (up to Level 2) for both the conticastrer and rolling mill upgrading. Danieli will also supply a complete new water treatment plant and will be in charge of all the erection works. Plant startup will take place at beginning of 2007.
At the end of January 2006, voestalpine Schienen new rail mill in Leoben/Donawitz restarted operation after the transformation from the previous arrangement into what is to be considered today the most modern rail rolling mill in the world. New plant’s construction was carried out by Danieli in two different subsequent steps: · The first construction stage was completed on September 30th 2005 with the hot tests of the new 1100-mm-dia BD reversing mill, only 4 weeks from the end of equipment installation and without interruption of plant production. · The second and final step was successfully completed on January 31st (a few days ahead of schedule), with the 1st rail rolled after the start-up of the new UFR reversing intermediate/finishing mill. This stage has called for interruption of plant operation from November 29th 2005. The use of the advanced “Prefabricated Module” technology for the execution of new equipment foundation, has strongly contributed in minimizing the plant stoppage period. The new state-of the-art plant applies the latest Danieli Morgårdshammar technology in hot rolling of rails. In particular the UFR mill, based on the latest-generation SCC (Stand Core Concept) stands and on the innovative Ultra-Flexible Reversing rolling technology, grants higher precision and quality in rails production, higher plant flexibility and efficiency as well as an increased specific hourly production. The UFR mill is made up of three 980-mm-dia SCC stands universal housingless stands, suitable for operation in 4-roll universal and 2-roll horizontal arrangement, according to needs. An advanced automatic quick changing system for the stand’s ”Core” (e.g.: the rolls and guides package) enables sections replacement time of down to 15-min only. New mill’s advanced arrangement gives VAS a unique possibility of “Just-in-time” production even with small-volume order lots, considerably contributing in enhancing Company’s market leadership. The mill produces all kind of rails such as Vignol rails, grooved rails, and other special sections for the rail market, rolled in 125-m lengths. Great appreciation and satisfaction on the job done thanks of the high degree of professionalism and the timeliness of all participants the project has been jointly expressed by VAS and Danieli.
In January 2006 a new Danieli EWR line started billet welding operation at Sonasid 400,000-tpy bar and section mill, making this Company the first in Africa able to operate in endless rolling through automatic continuous on-line billet welding, for uninterrupted production of long products. The new billet welder was added to the Danieli rolling mill in operation since July 2002 as part of the Jorf Lasfar minimill where a Danieli steelmaking plant with a potentiality of over 1 Mtpy operates since August 2005. The new EWR Endless Welding Rolling line will benefit rolling mill’s productivity, efficiency and material yield, resulting in lower overall production cost. Final product range of the Sonasid 80-tph endless rolling mill plant is 8 to 40-mm-dia plain and deformed bars and up to 60-mm sections. At the end of December 2005, first high-carbon steel billets were successfully welded at the new Danieli Morgårdshammar EWR® line installed at Sterling Steel Company’s 12” high-speed wire rod mill in Sterling (IL). Line’s testing smoothly continued in January 2006 with extremely good results granting a considerable increase in plant hourly production, to full Customer satisfaction. This has enabled endless rolling for uninterrupted production of long products to take place for the first time in the USA and, significantly, on high-carbon steel billets right from the start. The new Endless Welding Rolling line is designed for automatic continuous welding of 130x130 mm, 11-m-long billets at rates of up to 100-sht/hr for low, medium and high carbon spring steel wire rod. The billet welding process is particularly beneficial in wire rod mills as it enables production of customized-weight and extra-heavy coils, even starting from low weight billets. Coil weight selection out from the endlessly-rolled wire rod is performed by a new Danieli shearing unit installed in the coil reforming tube, at the end of the roller conveyor.
In January 2006, a new Kocks/Danieli 4-pass RSB Reducing and Sizing Block started operation at the Aços Villares special steel bar and rod mill in Pindamonhangaba, where a Danieli high-speed wire rod line operates successfully since the beginning of year 2004. Remarkably, commercial production of quality bars started in the evening of Tuesday, January 24th following the RSB hot run which started only a few hours before, the same day. The RSB, acting as finishing block for quality straight bars and bar-in-coils or for preparing the feeding sizes to the wire rod finishing block, enhances plant efficiency, productivity, and product quality. Based on 3-roll technology and provided for future low-temperature finishing rolling, the new RSB is designed for finishing rolling of 17.5 to 76-mm-dia stainless and special steel bars, 18 to 38-mm-dia bar-in-coils, plus the feeding sizes for the wire rod block. A Danieli QTB on-line rebars surface-quenching and self-tempering line successfully operates at the Fletcher Steel Ltd existing bar mill since October 2005, to full Customer satisfaction. The new line has enabled production of 10 to 32-mm-dia high-yield strength rebars, starting from low carbon steel (the so-called “Seismic®QT” Fletcher Steel product) at speeds of up to 14 mps. A corresponding QTR line has also been installed at the existing Fletcher Steel wire rod mill and will be started up in spring 2006 for production of quenched & tempered deformed wire rod in coils. Installation of the new line has enabled Fletcher Steel to expand its product range, adding the new “Seismic®QT” to the “Seismic®MA” microalloyed reinforcing steel product, to meet any specific Customer requirement.
The Megasa two-strand bar mill in La Coruña will be upgraded with installation of a new double twin channel high-speed bar delivery system of the latest Danieli Morgårdshammar generation. The new system will replace the present bar feeding unit at cooling bed entry (part of the high-speed bar mill originally supplied by Danieli) and will be designed for production of 8 to 32-mm-dia rebars at finishing speeds of up to 40 mps and at production rates of 160 tph. This will be one of the fastest Danieli high-speed bar delivery systems ever supplied. Danieli Automation will supply all electricals and an advance lev-2 automation system for the new line. Startup is scheduled for summer 2006.
In January 2006, a new Danieli Centyro Maskin conditioning line for special steel slabs was started up at JISCo, Jiyuguan (Gansu Province), PR of China. The line, designed for processing 250,000-tpy of stainless steel slabs at temperatures of up to 500 °C, is basically made up two grinding machines for conditioning of the slab wide faces. Each unit is equipped with edge grinder for processing of slab narrow faces. The two grinders are served by slab handling equipment and auxiliaries including secondary dust collecting filter and swarf handling. The successful startup of the new line further strengthens Danieli Centro Maskin leading position in China in this field.
Simec International S.A. de C.V. has contracted Danieli Centro Maskin for the supply of a new billet conditioning line as an upgrading of its existing plant for high quality steel bars production near Puebla in Mexico. The new state-of-the-art line will be designed for processing of 160x160-mm, 5 to12-m-long engineering steel billets with a yearly capacity of about 100,000 tpy. Core of the line will be the billet grinding machine which, like the others supplied in the last years by Danieli Centro Maskin, will be based on the latest Hi-Grind technology (the digital evolution of the previous analogical PowCo system) for granting the best surface quality according to standards. The grinder will be equipped with a 160 kW AC motor and will have the flexibility to use different sizes of grinding wheels. The high standardisation with the in house presence of all the critical components and the well proven process utilised in this case, will allow Danieli to deliver all the equipment in less than 8 months, thus making it possible the start of production already by the end of summer 2006. The electrical equipment and the automation system will be supplied by Danieli Automation. For further information please contact Mr Giovanni Salvador, Tel +39 0432 598263, e-mail g.salvador@danieli.it |
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One million-tpy Danieli steelmaking plant at Baoshan Group, P.R. of China