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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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Nucor has selected Danieli for its new Special Bar Quality Minimill in Memphis, TN. The new plant will embrace the complete SBQ bars production cycle, from steel melting to secondary refining, round bloom continuous casting, hot rolling, in-line inspection and cold finishing. Under the terms of the agreement, Danieli will supply all technological equipment for the meltshop and rolling mill, including an advanced Danieli Automation Level 1 and 2 automation system for the whole plant, as well as the electrical equipment for meltshop and caster. The meltshop will be based on a 90-t ultra high-power FastArc™ single-charge EAF, fitted with all latest technologies to allow the highest performance level at optimized energy consumption rates. Liquid steel processing will be performed in a secondary refining station made up of a LMF station and a twin-tank VTD station equipped with combined steam-ejectors/water ring pumps. The three-strand FastCast™ bloom casting machine will feature high-speed casting of high-quality blooms in the range of 267 to 511-mm-dia rounds. The rolling mill upgrade will involve a major modification of the billet mill Danieli supplied in 1997, and will transform it into a 150-tph modern SBQ mill for finished product. To this end, the new mill’s configuration will include: - A new 150-tph Danieli Centro Combustion walking beam type reheating furnace directly connected to the new conticaster for hot charge operation. - New 1,050-mm-dia reversing breakdown mill complete with work tables and manipulators for automatic operation. - New 54x20.5-m walking beam, turnover-type cooling bed. - Finishing facilities including abrasive type disc sawing, in-line straightening, NDT system for surface and internal defects detection, chamfering, marking, stacking, tying and final collection. These modifications will transform the existing plant into a complete new rolling mill for the production of 57 to 230-mm-dia finished rounds and equivalent squares -as well as 305-mm and 203-mm semi-finished squares for re-rolling- in a large variety of engineering and special steels for the automotive and mechanical construction industry. Startup of the new steelmaking/casting facilities and rolling mill is scheduled for the Q1t and Q2 of 2008, respectively.
Duferdofin has selected Danieli as supplier of the new 700,000-tpy bar and section mill that will be installed at its Giammoro works in Sicily, Italy. This project will make it possible to optimize and complete the works’ production capability for the smaller profile size range, and to enlarge the product mix of the heavy section and beam mill upgraded by Danieli in 2003. The 20-stand high-speed continuous mill, entirely made up of SHS housingless stands in H, V, and combined H/V arrangement with fast changing facilities, will use the slitting technology for the smaller bar sizes. A multi-strand QTB line located between mill and cooling bed will enable production of quenched and self tempered deformed bars. Bar finishing facilities will feature a 90-m long cooling bed fitted with water-spray extra-cooling system, CCL in-line straightening and cut-to-length services, single-head magnetic stacker, bundling and collecting facilities. Smaller bar sizes will be delivered onto cooling bed at speeds of up to 25 mps through a Double Twin Channel system, thus fully exploiting the full reheating furnace capacity (100 tph) also for the smaller product range. The mill will produce 8 to 25-mm-dia deformed bars, and a large range of sections.
On August 2006 Danieli has been awarded by Industrias Unidas S.A. the order for an innovative production complexthe for the production of high quality copper tubes. The target of the plant is to produce in endless mode up to 140,000 tpy of industrial and sanitary copper tube, mainly for the NAFTA market. Main feature of this revolutionary plant will be the endless production process, carried out trough the following main equipment: - Melting shaft gas furnace; The plant will be installed in Laredo (TX), USA, and its commissioning is expected by the end of 2007. With this new investment, Industrias Unidas S.A. is going to consolidate his market position in the NAFTA countries and to become one of the largest copper producers in the world.
During recent years, cost increases resulting from escalating raw materials prices and strong drilling activities caused a rise in demand for seamless pipes that resulted in intense negotiations for the same. This situation led the Industrialization & Energy Services Company (TAQA), through its subsidiary Company, Jubail Energy Services Company (JESCO) to award Danieli the order for a new 400,000-tpy seamless pipe plant, to be supplied on a complete turnkey basis, for installation at Al Jubail in the Kingdom of Saudi Arabia. This order confirms Danieli as market leader for the supply of complete turnkey plants and strengthens Danieli Centro Tube success as plantmaker in the fast growing market for seamless pipes. The new seamless pipe plant in Al-Jubail will produce tubes for the oil industry with characteristics in accordance with international standard specifications, and basically will consist of: - Hot rolling line for production of tubes in the range of 139 to 365-mm outside diameter, complete with in-line tube straightening, NDT, and cut-to-length facilities. - Tube heat treatment line. - Electricals and automation system for the whole plant. The FQM system has been further developed to the latest three-roll configuration, representing the leading edge of the technology. The mill is composed mainly of one set of rolling units, each one with three driven rolls mounted in a cartridge unit . Mandrel supporting units are provided at the first rolling unit inlet, at intermediate positions, and at the last rolling unit outlet. Rolling units and mandrel supports are inserted in a fixed and sturdy holding container, suitable for withstanding the rolling forces. For the roll-changing operation, all rolling units are pushed along the rolling axis toward the mill exit where a side-shifting-type quick change-over device is provided. Process control is fully integrated in the advanced automation system of the whole plant, supplied by Danieli Automation. Plant startup and commercial production is scheduled for the end of year 2008.
The new 100-t integrated vacuum degassing / ladle furnace facility will feature a very compact layout, arranged over: two vacuum tank cars, two separate vacuum-treatment positions with a single switch, one four-stage vacuum pump with water ring pumps, and a common heating position. This configuration will result in maximized operational flexibility and in consistent reduction of the teeming crane utilization factor. A set of auxiliary equipment (such as automatic sampling and temperature measurement units and argon gas stirring) will be provided for all working positions. The project includes all electrics and an advanced Level 2 process control system that, featuring metallurgical calculations, tracking, prediction functions, event data logging/replay functions, and process simulation, will make possible complete control of the refining process. Startup of the new plant is scheduled for the end of 2007.
BMZ (Byelorussian Metallurgical Works), located in Zhlobin, has selected Danieli Centro Met to perform the first significant revamping of the existing EAFs. According to the agreements, reached in July and October this year, the production increase will be achieved thanks to the benefits of installing the FastArcä injection technology and process optimization / automation package on the No. 1 and No. 3 electric arc furnaces, respectively. Two 6-strand Danieli billet casters have been in operation at the same plant since the mid ‘80s.
The Al Ezz Steel Rebars long products minimill in Sadat City was supplied by Danieli in the late ‘90s. The state-of-the-art plant is basically composed of a steelmaking plant started up in April 1998 with a nominal capacity of 750,000 tpy, and two bar mills (namely RM1 and RM2) that started commercial production in October 1996 and September 1998, respectively. In July 2001, the 95-t AC EAF was upgraded with the installation of three Danieli Modules, to enhance productivity and reduce consumption. In October 2006, Al Ezz decided to upgrade the fume dedusting system on duty at the EAF in order to adhere to the new Egyptian environmental regulations, with particular respect to the emission limits at the stack, such as dust, CO, SOx, NOx. The project concerns the installation of a new primary suction system, extension of the canopy hood system, and a new filter operating in parallel to the existing one. The new plant will be equipped with a new, larger combustion chamber to accept the dust load in the fume and to ensure the complete combustion of the carbon monoxide due to the EAF's improved oxygen injection. The bigger canopy hood will be designed to control the secondary dust emissions that occur during the charging and tapping phase. The new pulse-jet type filter working in parallel will ensure the constant ventilation of the EAF area. The fume dedusting system operating parameters are:
Startup of the upgraded facility is scheduled for autumn 2007.
The modification briefly involved the installation of new front / back mechanisation system and quick roll-package changing system for the two-high reversing breakdown mill stand, two new 800-mm-dia SHS super heavy duty H-V housingless stands with automatic quick changing system, revamping of the existing finishing stand with fast changing facilities and a new crank shear for dividing cut before the cooling bed. The upgraded plant has a nominal capacity of about 2 Mtpy of 118-mm and 145-mm square billets, in low, medium and high carbon, and alloy steels.
A new 500,000-tpy SBQ mill recently started its hot-run stage at Jiangyin Xing Cheng (Jangsu province), as part of a wider expansion program that includes a second 800,000-tpy mill for larger-size SBQ products (installed beside the first one), for which start of operation is scheduled for spring 2007. Jiangyin Xing Cheng, China's leading producer of bearing steels, placed the order for the two plants in the middle of last year, one order following the other by a couple of months. Two orders of this kind in just few months demonstrated full confidence in Danieli Morgårdshammar technology and reconfirmed our leadership in long products. The 130-tph No. 1 SBQ mill, designed for low temperature rolling of 15 to 60-mm-dia quality round bars for automotive and mechanical construction purposes, is made up of 18 SHS housingless stands, on-line water cooling boxes for LTR rolling, a five-pass Kocks/Danieli RSB Reducing and Sizing Block, and state-of-the-art finishing services with on-line heat treatment facilities. This project, as well as the No. 2 larger-size SBQ mill, have been executed by DME - Danieli Metallurgical Equipment (Beijing) Co. Ltd., the new company established in China last year and located in the Beijing BDA area.
The third and final stage upgrading will increase the mill's output capability by 30%, to reach about 400,000 tpy. Final upgrading will include the replacement of the 60-tph pusher-type reheating furnace with a new 80-tph Danieli Centro Combustion walking hearth furnace for heating up larger size/doubled length starting material (up to 160-mm, 12-m long billets). Also, two additional heavy-duty housingless roughing stands in H and V arrangement and cooling bed and services extension will complete the modification. Danieli Automation will supply electricals and automation system. Product range of the mill is 8 to 20 deformed bars, correspondent squares, 30 to 50 mm angles, and flats.
The state-of-the-art plant was commissioned in stages during the current year according to an optimized program that started with the bar line startup in February, continued with the EWR® first billets welding in June, and with the wire rod line started up (without TMB operation) in July. The TMB Twin Module Block unit, in operation since September, makes it possible for the mill to reach finishing speeds of 115 mps for production of 5.5-mm-dia wire rod in 2.5-t coils. The new mill was installed at the Saudi Iron & Steel Al-Jubail steel complex, where another high-capacity Danieli bar and section mill was installed in 1993. Made up of 18 SHS stands, a production outlet for straight bars, and a TMB-based high-speed wire rod line, it is designed to produce 8 to 40-mm deformed bars and 5.5 to 16-mm (including down to 6-mm-dia deformed) wire rod. The highlights of the new plant are the EWR billet welder for uninterrupted production at the mill; and the TMB system that, while enhancing the mill’s efficiency, grants very high wire-rod finishing speeds. The complete turnkey supply included the electricals and automation system, a 110-tph walking-hearth reheating furnace, all auxiliary plants and systems (water treatment and compressed air plants, roll turning shop, EOT cranes, etc.), all buildings, civil works, and road system, as well as construction of the entire plant.
At the beginning of September 2006, Mukand Ltd, one of the leading stainless steel producers in India, awarded Danieli Morgårdshammar the order for a plant upgrade aimed at achieving higher production capacity, wider product range in terms of size and steel grades, closer tolerances on the finished product, excellent and constant quality of the final product at minimum production costs, avoiding as much as possible off-line treatment. The upgraded mill will produce 5.5 to15-mm-wire rod, 15 to 35-mm-dia coiled bars (in up to 1.5-t coils), and 20 to 45-mm-dia straight bars in low to high carbon, free cutting, low alloy, SBQ and spring steel qualities, plus ferritic, austenitic, and martensitic stainless steels at rates of up to 55 tph. The delivery will include a new 930-mm-dia housingless-type reversing shiftable rougher with associated front/back tables, plus rolling mill miscellaneous auxiliary parts. The new bar-in-coil line will consists of two garret coilers, coil-handling device, tank for in-line quench annealing of stainless steels, and a walking beam conveyor with fans for fast cooling. The bar line includes a new dividing shear, cooling bed, cold shear and a dedicated Sund Birsta bar handling plant. One single Sund Birsta coil handling plant will serve both the wire rod and the garret line.
The new 650-mm-dia unit, started up on October 19th 2006 and successfully in operation since then, has been installed between the existing 800-mm-dia blooming mill and the 550-mm open-type 3-high mill for optimizing plant operation, increasing efficiency, enhancing final material quality and minimizing operating staff. The mill produces a wide range of large-size SBQ rounds, squares and flat bars in special engineering steels.
To this end, the line will be significantly modified and expanded with the installation of a new water cooling line, and a new laying head equipped with the latest generation rotor, plus enlargement of the controlled-cooling line, modification of the coil forming station, new vertical type coil conveyor and coil compacting/tying unit suitable for the increased coil weight. Plant upgrading will enable production of 8 to 23.5-mm-dia wire rod in carbon and stainless steels at speeds of up to 90 mps and rates of up to 100 tph. Coil weight after modification will be 2,000 kg. Startup is scheduled for Q3 2007.
Smooth start up and commissioning of the Danieli Centro Maskin Casttgrind plant for hot conditioning of austenitic, ferritic and special stainless steel slabs, resulted into very fast plant operation in full commercial production. On October 20th 2006 the plant started full production on three daily shifts -just four weeks from the first hot test- and by November 10th all performance test were successfully completed according to contractual terms. The new slabs conditioning plant, which serves two continuous casting lines with a 1.5-Mtpy total yearly productivity, is composed of two grinding machines housing 915-mm-dia grinding wheels and the complete handling equipment for slabs transferring and tilting, with full flexibility to handle in automatic mode slabs from the conticasters and/or from the slabs temporary bay storage. The grinders are suitable for slab grinding either at room or at casting temperature (1000 °C). Danieli Automation has supplied all electricals and Level 1 and 2 automation systems.
The production cycle will range from scrap processing to steel melting, secondary refining, billet conticasting, hot rolling, on-line heat treatment and final off-line cold finishing of quality round bars. Danieli Automation will supply all electricals and an advanced level 1, 2 and 3 automation system for the whole plant. The 4-strand “FastCast™” high-speed conticaster will produce 130 to 180-mm square billets, and will be directly connected to the reheating furnace for hot charging operation. The Danieli Morghårdshammar super-flexible bar and section mill, fed by a 100-tph Danieli Centro Combustion walking hearth reheating furnace, will be made up of 18 SHS stands plus a 5-pass Kocks-Danieli RSB block, with on line heat treatment facilities that include Low-Temperature Rolling system or QTB facilities to be used depending on the steel grade being rolled. The mill will be equipped with the EWR® system that, through continuous billet welding, will enable endless rolling for uninterrupted production of bars and sections. This will be the first EWR unit to operate in Russia and in the whole of Eastern Europe. The product range of the mill will include 10 to 42-mm-dia quality steel round bars, equivalent hexagons and squares, up to 40-mm-dia deformed bars, 25 to 60-mm angles and corresponding channels, flats and tees, in al large variety of construction and special steel grades including bearing and stainless steels, mainly for automotive applications. Danieli Centro Maskin will supply a billet conditioning line and the bar cold processing facilities (quality bar inspection, conditioning and finishing). Plant startup is foreseen by the end of 2008. The Danieli VD/VOD station which will start operation at mid 2007, will complete the plant reconstruction.
The recent expansion, when if full commercial operation, will enable the Celaya minimill, to double its production capacity to over 2-Mtpy, thus further strengthening Deacero leading position as largest wire rod producer in Mexico and as one of the largest in the whole American continent. The No. 2 meltshop features a 120-t EAF, ladle furnace and a 6-strand FastCast™ conticaster for high-speed casting of 120 to 180-mm billets, directly connected to the rolling mill for hot charging operation. The No. 3 rolling mill, composed of 18 stands in continuous plus a 10-pass high-speed finishing block produces 5.5 to 16-mm-dia wire rod in up to 3-t coils. All electricals and the advanced Level 2 automation system have been supplied by Danieli Automation.
The new Danarc EAF is equipped by the latest hi-tech packages such as the high-performance Modules and the Hi-Reg Plus electrode control system. The state-of-the-art 2-strand FastCast™ conticaster, which features an advanced Quench Box system for product direct hot charge, casts 390x510-mm blooms in medium alloy and high carbon steels. Startup of these two units is another significant milestone in the long relationship between SeAH Besteel and Danieli, established with the previous expansion steps of the same steelmaking plant that included a 3-strand billet caster (2001), a 2-strand large-size bloom caster (2005) and the upgrading of No. 1 and No. 3 Electric Arc Furnaces.
The unit treats the liquid steel coming from two existing BOF converters and feeds two existing slab casters. For some highly demanding steel grades, it can be used in combination with an existing RH degassing unit. The mix of steel grades refers to a wide range of hot and cold rolled strip products, among which the most significant are galvanized, DDQ and Low C steel strip, strips for automobile structure, pressure vessel, shipbuilding, weather-resistant and bridge steels.
The Nanjing I&S meltshop produces plates and coils in a wide range of steel grades for shipbuilding, pipe lines and automotive demanding applications.
Plant modernization will involve the mill stands replacement with new H, H/V and Universal housingless-type rolling units and associated auxiliaries. In addition, a new Danieli CCL system made up of a multi-strand straightener and a pendulum-type cold shear will be installed at cooling bed delivery side for continuous straightening and on-the-fly cut-to-length of the range of products. The new stands will be fully standardized with those presently being supplied by Danieli for the upgrading of two other rolling mills of the Beltrame Group, namely the “T320” mill at LME-Laminés Marchands Européens in Trith Saint Leger, France, and the bar / light section mill at AFV Beltrame in Vicenza, Italy. Stand standardization will end up in higher overall efficiency and rationalization of spare parts, consumables and maintenance procedures at Group’s level. The San Didero section mill produces a wide range of profiles at rates of up to 100 tph.
It is made up of a 14-stand roughing/intermediate mill on SHS housingless stands, a 10-pass high-speed finishing block, controlled-cooling line, wire rod coil forming and finishing facilities. Danieli has also supplied the associated electricals and automation systems, as well as the auxiliary plants and services such as water treatment plant, compressed air system, roll turning shop, etc.
The line, basically made up of a 10-pass high-speed finishing block, laying head and DSC controlled-cooling line, is designed to operate at finishing speeds of up to 110 mps for production of 5.5 to 20-mm-dia plain wire rod in coils weighing 2,000 kg. The range of steel grades includes quality structural carbon steel, welding qualities and low alloy steels.
Plant modification will basically include the addition of a high-speed Twin Channel device, dividing shear and auxiliaries at the cooling bed entry side. Danieli Automation will supply the associated electricals and automation systems. The plant produces 10 to 76-mm-dia bars and 5.5 to 20-mm-dia wire-rod in 2.1-t coils, in low, medium and high carbon steels, low alloy and spring steels. In two previous plant upgrading steps Danieli supplied the 100-mps wire rod line (1997) and the 100-tph Danieli Centro Combustion WB furnace (2001) plus the completion of the continuous roughing mill. This additional expansion project, based on the good results of the previous jobs, strengthens the long-lasting cooperation between the two Companies and reconfirms once more Danieli worldwide leadership in long products, both for new plants and for upgrading and modification of existing ones. The startup of the upgraded facilities is scheduled for Q4, 2007.
This has enabled production of high tensile/high ductile deformed bars starting from low carbon steel billets, making the use of the more costly micro-alloyed or low-alloyed billets no more necessary, thus benefiting the transformation cost. The new double-strand QTB line processes 10 to 16-mm-dia rebars at finishing speeds of up to 16.5 mps.
The state-of-the-art line processes 8 to 32-mm-dia rebars (on two strands for the
In two previous expansion steps, carried out by Danieli between years 2001 and 2006, the plant was gradually transformed into a modern fully-continuous highly efficient high-speed bar mill, with a 70-tph rated capacity (when operating in hot charging mode) of 8 to 40-mm-dia bars and rebars. The new Spooler line will enable to expand the product range to 8 to 16-mm-dia quenched deformed bars, spooled at speeds of up to 35 mps into ultra-compact coils weighing 1.9-t, opening, this way, new important market niches to Marienhütte. Danieli Automation will supply electricals and automation systems for the new line. The present scorecard, which includes a total of 32 Spooling units supplied or under supply worldwide, reconfirms Danieli as the undisputed leader for this innovative technology.
This 20-stand multi-line state-of-the-art rolling mill, installed in Gebze near Istanbul, is now one of the most modern and advanced plants of this type in Turkey and in Europe. Featuring all latest Danieli production technologies for long products and covering a very wide range of product type and sizes, it grants the Company high competitiveness and market flexibility. Product range is 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 deformed wire rod in coils and 8 to 50 mm spooled plain bar (or up to 32-mm deformed) in coils. Coil weight is up to 3.4-t, both for wire rod and spooled bars. Steel grades are low, medium and high carbon and alloyed steel for construction and mechanical applications, including drawing, cold heading, spring, bearing and similar grades. The recently started up Spooler line enables production of on-line heat-treated round and deformed bars, twist-free wound in ultra-compact, ultra-heavy coils. Spooled coils feature a unique cobble-free un-coiling capability that enable their direct feeding to the downstream cold processing lines without intermediate off-line treatments, like the traditional uncoiling, stretching and cold recoiling, with consequent significant benefits in production costs. The rolling mill is fed by a120-tph Danieli Centro Combustion walking hearth reheating furnace directly connected to a 6-strand Danieli conticaster (in operation since 2001) for direct hot charging of billets. Danieli Automation has supplied the electricals and the automation systems for the whole plant.
The new state-of-the-art line, in operation since early September 2006, is made up of a 42-m-long rake-type cooling bed with feeding and delivery tables, cut-to-length, bundling and collecting services plus associated electricals and automation systems. The line processes 18 to 105-mm-dia rounds and equivalent squares and hexagons, collected in up to 3-t regular bundles, at production rates of up to 50 tph.
This will create the second “Direct Casting/Rolling” plant at Jiangsu Huaigang, after the pioneering Danieli “Black-Box” minimill operating there since the end of the ‘90s. The project will be followed by DME-Danieli Mechanical Equipment, the Danieli China Company located in the Beijing Industrial Zone. The new 180-tph rolling mill, one of the largest plants for long products ever constructed in China, will produce 70 to 250-mm-dia SBQ bars and 150-mm square billets, for automotive and mechanical manufacturing purposes. The wide steel grade range will include quality carbon, alloy structural, spring, free-cutting, bearing steels and gear grades. Starting material will be 380, 450 and 500-mm-dia round blooms weighing up to 9 t, coming directly from the new Danieli bloom caster by direct hot-charge through the walking beam reheating furnace (the so-called Direct Casting/Rolling process). Blooms off-line slow cooling practice will be applied for those steel grades not suitable for hot charge. In addition of preparing the feeding sizes for the 6-stand intermediate / finishing mill, the BDM will also act as finishing mill for billets that will be cooled, cut to length and collected in a dedicated finishing station located after the reversing stand. Round bars finishing facilities after the continuous mill will include hot saws for net-end cut-to-length of SBQ bars, on-line thermal treatment (slow or natural cooling depending on steel grade and final use of the product) and final collecting. Startup of the new rolling mill is scheduled for Autumn 2007.
The order for Phase 2, awarded to Danieli Morgårdshammar in April 2006, involves the modernization of the mill finishing end, downstream of the wire rod finishing blocks. Phase mill’s upgrading, concluded in January 2006, included the replacement of the old billet reheating furnace with a new 150-tph Danieli Centro Combustion walking hearth unit (180 tph in hot-charge) and installation of two new roughing stands for rolling of larger-size billets. Phase 2 includes the upgrading of the DSC lines after the finishing blocks with the extension of both water cooling facilities and controlled cooling conveyors, plus the installation of two HSS high-speed shears for wire rod head/tail automatic cropping before loop laying, new laying heads of the latest Danieli “Oil-Film Bearing” generation and a new Sundco-V vertical coil handling and finishing line. The supply is on a complete turnkey basis, excluding only civil works. Mill’s product range after upgrading will be 5 to 20-mm-dia wire rod for deep drawing purposes, welding wire and weldable grades for reinforced concrete applications. This is only the latest step of the Ferriere Nord wire rod mill long-term modernization program, developed over the past years. The original 0.5-Mtpy Danieli mill started operation at the end of the ‘70s and underwent a first modernization approximately ten years later with the upgrading of the controlled-cooling lines and coil finishing facilities. Main plant modification were then the replacement of the 8-pass finishing blocks with two 10-pass DWB Delta-type high speed blocks (designed for 120-mps working speed) in early 2003, and the installation of a new six-stand compact double-strand pre-finishing mill which started operation in June 2004. The Ferriere Nord minimill is part of the Pittini Group, Europe’s leading manufacturer of steels for the modern building industry. This latest upgrading, thanks to the renewed layout arrangement and the latest technologies applied, will further enhance plant performances contributing to reinforce the Company front position in the market. Danieli shiftable reversing blooming mill at Metal Ravne, Slovenia The contract, signed on July 20th 2006, foresees the supply a new two-high reversing blooming mill to replace the old unit in order to enhance plant efficiency and productivity, as well as for enlarging the rolled products range. Mill’s production will cover a wide range of engineering steels, special steels and high-alloyed tool steels. The new 930-mm-dia, shiftable-type blooming stand, featuring stiff housingless design, fast gap setting, quick roll-package changing system and a 5700-kW AC motor drive, will grant higher quality rolled stock, better mill efficiency and higher productivity compared with the present situation. The entire stand height will be adjustable to the roller table level by means of screw jacks for compensating not only the difference from new roll diameter to scrap diameter, but also to cope with the different pass height on the bullhead and in the box grooves. Electricals, control and automation systems will be from Danieli Automation.
Mill’s modification will also improve the production of the smallest sizes deformed bars to reach the 40-tph reheating furnace capacity. The order, awarded to Danieli Morgårdshammar in July this year, foresees the completion of the existing mill with six new housingless finishing stands arranged in H and H/V position, replacement of the existing water quenching line, new dividing shear and new cooling bed with associated cut to length services at delivery side. This will enable to enlarge the present range to 12x3 to 50x6-mm flats, 20 to 50-mm angles, and corresponding squares, tees and hexagons. Danieli Automation will supply the electrical, control and automation systems. The upgraded stacker, which was restarted at middle July 2006, can now to operate in one single or in two independent and symmetrical sectors, enabling to process four 6-m-long or two 12-m-long or one 18-m-long bar layers, thus enhancing plant’s production flexibility. The mill produces up to 75-mm angles and channels, 25- to 100-mm flat bars and up to 35-mm plain and deformed rounds, in up to 5-t stacks, at rates of up to 110 shtph. Danieli Automation has supplied the electricals and automation and process control system.
Operation of the second line makes now possible to fully exploit rolling mill’s full capacity for production of bar-in-coils (up to 150 tph), with a product range of 8 to 32-mm rebars or up to 22-mm plain bars, in up to 3.5-t ultra-compact coils at finishing speeds of up to 35 mps. Nervacero was first in Spain to operate the revolutionary Danieli spooling technology.
Plant production started immediately on two shifts, while operation on three daily shifts started only one week after the first bar was rolled. This intensive operation schedule, along with the high plant efficiency, led to a total of over 34,000 t of sellable rolled product produced during the first month operation, which was a remarkable result for a brand new plant at only 4 weeks from the start. The new mill has a 0.8-Mtpy nominal capacity of 5 to 22-mm-dia plain (and 6 to 16-mm-dia deformed) quality structural and engineering steel wire rod in 2-t coils, rolled at finishing speeds of up to 110 mps. The new 130-tph wire rod mill is part of the wider MMK rolling mills reconstruction program carried out by Danieli, which also included a new 0.8-Ktpy section mill and a new 0.6-Ktpy bar mill that started operation already at middle 2005. The new wire rod mill was officially inaugurated on July 14th 2006 in a ceremony attended by high-ranking local authorities and representatives of MMK who expressed satisfaction for the quality of the job performed by Danieli and for the extremely positive results obtained, not only for the wire rod mill but also for the other two plant inaugurated last year.
The new system has replaced the previous bar feeding system which was part of the high-speed bar mill originally supplied by Danieli. The upgraded mill is designed for production of 8 to 32-mm-dia rebars, rolled on two strands at production rates of 160 tph. All electricals and an advanced Level 2 automation system for the new line are from Danieli Automation.
This 20-stand multi-line state-of-the-art Danieli rolling mill, installed in Gebze near Istanbul, started production with the straight bar line in March this year while the new Spooler line for bar-in-coil production will be due for start up at middle September. The new wire rod production outlet, dimensioned for up to 110 mps finishing speed, features a 10-pass DWB finishing block, DSC controlled-cooling line with QTR system for on-line quenching and self tempering of deformed wire rod, and a HSS-High Speed Shear for automatic on-line head and tail cropping of wire rod before the laying head. The line is designed to produce 5.5 to 20-mm smooth (or 6 to 16- mm deformed) wire rod in coils weighing up to 3.4 t. The bar line range is 8 to 50-mm rebars and 16 to 75-mm quality plain bars while the Spooler line will produce 8 to 50-mm plain (or 32-mm deformed) bar in 3.4-t spooled coils. Steel grades are low, medium and high carbon and alloyed steel for various applications in construction and mechanical industries, including drawing, cold heading, spring, bearing and similar. Danieli Automation has supplied electrical and automation systems, while the 120-tph walking hearth reheating furnace is from Danieli Centro Combustion.
The Spooler line was installed as an additional production outlet at one of the two Danieli 160-tph superflexible twin bar mills started up in the Q1, 2006. The line is able to produce 12 to 32-mm-dia quenched and tempered deformed bars and 16 to 40-mm-dia plain bars, twist-free-wound in ultra-compact spooled coils with a designed coil weight of up to 3.5 t. Thanks to their unique cobble-free uncoiling capability, spooled coils can directly r feed the downstream cold processing lines without any intermediate operation (uncoiling, stretching and recoiling) with considerable benefits to both hot rolling operation and to product end-users. To date, the Danieli scorecard lists a total of 28 Spooler lines supplied or under supply worldwide since year 2002.
The minimill, installed in Ba Ria (Vung Tau province), was supplied by Danieli on a complete turnkey basis and includes a 400,000-tpy bar and rod mill which started operation in August last year. The meltshop is basically made up of a 70-t full-platform Danarc Plus EAF, tight-roof design ladle furnace, 3-strand FastCast™ high-speed caster (provided for future 4th strand) directly connected to the rolling mill reheating furnace for hot charging operation, plus auxiliary services including fume treatment plant and automation system. The turnkey supply for the minimill included all auxiliary plants, equipment and facilities such as electrical substation, water treatment plant, buildings, civil works, cranes and product handling facilities. Final product range is 10 to 50-mm-dia plain and deformed bars, 40 to 100-mm angles, corresponding channels and 5.5 to 16-mm-dia wire rod in coils weighing up to 2000 kg. Danieli Automation has supplied the electricals and automation systems for the whole plant.
The Final Acceptance Certificate was released on June 2nd, 2006, to full Customer satisfaction only 21 days after cold commissioning started. The new line has enabled production of 6 to 16-mm-dia high-yield strength wire rod with good weldability and ductility, starting from low carbon steel (the so-called “Seismic®QT”, a Fletcher Steel product) at speeds of up to 85 mps. The reduction, or for some grades, the complete elimination of Vanadium as alloying element will result in significant savings in production cost that will end-up in a short pay-back of the investment. A corresponding QTB line for in-line processing of ribbed straight bars successfully operates at the Pacific Steel bar mill since October 2005. The new QTR and QTB lines have enabled Fletcher Steel to expand its product range, adding the new “Seismic®QT” to the “Seismic®MA” Micro Alloyed reinforcing steel product, to meet any specific Customer requirement.
The Final Acceptance Certificate was released at mid June 2006, to full Customer satisfaction. Danieli Automation has supplied the complete automation system.
The new 210-t facility (which will replace an old ASEA-SKF station) forms an integrated vacuum degassing/ladle furnace unit in a new, innovative arrangement: there are two vacuum tank cars, two separate vacuum treatment positions and one common heating position with electrodes. All positions are accessible by both vacuum tank cars for complete flexibility. The full set of auxiliary equipment, such as automatic sampling and temperature measurement units, wire feeders and argon gas stirring, is provided for all working positions. A new material handling system, dedicated for the facility, is also provided. An advanced Level 2 process control system with metallurgical calculation/tracking/prediction functions, event datalogging/replay functions and process simulation will enable complete control of the refining process. Products to be processed in the new facility include ULC grades, HSLA grades and low and medium alloyed qualified grades. Startup of the new plant is scheduled for the end of 2007
Usha Martin is a world leader in production of high-quality alloy and special steels for the automobile industry, for the fastener industry and for wire and wire ropes production. The 2-strand, 12-m-radius FastCastTM conticaster will produce up to 500,000 tpy of 150x150 to 300x360-mm special steel blooms in spring, bearing, CHQ and alloyed steel grades. The machine is designed for future installation of a soft reduction system, which will make it possible to produce ball bearing steels and super clean steels such as SAE 9254. New caster installation will contribute in increasing the existing works capacity from current 350,000-tpy to over 850,000-tpy. The new state-of-the-art machine will incorporate all the latest technology available in conticasting of special steels, including electromechanical stopper rods, Danieli Rotelec mould EMS, hydraulic oscillators, air-mist secondary cooling, three unbending points as well as sampling and marking facilities. The machine will be served by an advanced Level 1 and 2 automation system that will include the tundish steel mixing model, which allows real-time heat tracking to perform mixed steel control. Other important functions within the automation package are: mPMD (mould Powder Measuring Device), ELTM (dynamic spray control based on Element Lifetime Model) and QUART (Quality Assessment in Real Time). Startup of the new caster is planned for the end of October 2007.
The new facility is based on double bay-type layout with EAF bay (135-t EAF), teeming bay and covered scrap yard. The scrap yard cranes will be equipped with magnets and grabs, and double independent hooks and will allow the cabin to move independently from the main hooks, in order to maximize the efficiency of both wagon discharging operation and scrap bucket charging. All cranes can work at temperatures of down to -40°C, in order to fit with the very severe working conditions of Urals region. The cranes will be designed and manufactured with the most updated mechanical and automation solutions to grant the highest level of operational safety, efficiency and availability.
The CCM casts 135-mm and 240-mm square sections in a large variety of engineering and special steels. Asil Çelik is a major producer of high-quality alloyed and non-alloyed hot-rolled long products for the automotive and machine manufacturing industry.
The mill’s product range includes up to 1,100-mm parallel-flange beams, rolled in up to 120-m-lengths. To this end the existing intermediate stands and the associated mechanization equipment will be replaced by a 2-stand universal-reversing Tandem Mill with automatic fast changing system, installed in-line with the present UF finishing stand, at a distance of over 120 m far from the same. The Tandem Mill will give several reversing rolling passes the leading stock coming from the existing BD mill and will feed the existing universal finishing stand, where the rolled bar will undergo the final sizing pass. A high degree of automation will be made available by the HPC/AGC control systems and a reliable minimum tension adjustment. Danieli will be responsible of the supply of equipment and services on a complete turnkey basis.
After the first test-weldings, performed on January 23rd 2006, normal production operation significantly started just one week later, to full Customer satisfaction. In the first month of operation the line successfully welded a total of 19,500 high-Carbon steel billets, corresponding to approx 27,000 t of endlessly-rolled wire rod coils. Operation of the new billet welder has brought substantial benefits in plant productivity and efficiency. Plant yield increased from previous 95.5% to present 99.5%, mainly due to the elimination of interbillet times. Significant savings in plant manpower have been achieved due to elimination of operators at roller conveyor and at trimming stations (12 people less over 4 shifts). The consequent positive effects on production cost will lead to an extremely short return of investment. The line performs automatic continuous welding of 130x130 mm, 11-m-long high-Carbon steel billets at rates of up to 100-sht/hr, in a wide range of grades for engineering steel wire rod for automotive applications, mainly for spring steels. Coil weight selection from the endlessly-rolled wire rod is performed by a new shearing unit installed in the coil reforming tube, at the end of the roller conveyor. The wire rod produced at the mill is directly drawn to different diameters and oil tempered in various downstream Companies belonging to the same Group. Another important feature of this state-of-the-art line is its particular layout. Installation of the EWR line behind the existing reheating furnace with consequent reversing of the furnace unloading side and passing of the welded billets throughout the same, has enabled Sterling Steel to overcome a problem of space unavailability between the furnace and the first roughing mill stand. This tailor-made solution can be the answer that makes endless rolling operation possible for many other rolling mills around the world featuring similar space constraints.
This patented innovative technology grants absolute operation stability with lower wear rate and extended laying pipe life, as well as minimized maintenance. High stiffness, high-dumping capability grants optimal response even at high unbalance conditions and vibration-free wire rod coiling at speeds of over 100 mps. An oil-film laying head was practically tested at the SN Longos high-speed 2-strand wire rod mill in Portugal since middle 2005. Based on its extremely satisfactory operation results, the order for a second unit was awarded to Danieli in May 2006.
The two 4-pass TMB blocks will be designed to produce 5- to 16-mm-dia plain (or down to 6-mm-dia deformed) wire rod at guaranteed rolling speeds of up to 115-mps (design speed 140 mps), into 2.3-t coils, with very strict end product size tolerances. Material grade range is carbon structural, medium/high carbon and alloy steels including cold-heading and spring steel qualities. Finishing rolling of all section ranges at the TMB units –and their quick changing facilities- will grant high operating flexibility and high yield for the mill and the plant. The supply also includes two latest-generation Danieli laying heads of the and auxiliaries.
Provision has been made for installation of automatic quick-changing facilities, as well.
Magnitogorsk Iron and Steel Works (MMK) 800,000-tpy new wire rod mill has been successfully started up in May 2006, following the 0.8-Mtpy section mill and the 0.6-Mtpy bar mill that started operation already at middle 2005. New wire rod mill’s start of operation has completed one the largest single-step reconstruction projects ever undertaken in recent years in the field of long products mills in Europe. The three superflexible rolling mills supplied by Danieli Morgårdshammar, with an overall designed capacity of over 2 Mtpy, have completely replaced previous MMK hot-rolling facilities and are now the most modern rolling mills for long products in Russia. The three new mills with their broad production mix, large total annual capacity and high final product standards, allow to supply high quality input to the MMK Group's downstream processing facilities, producing steel wire, cables, mesh, fasteners and other products and to boost shipments to the domestic and to the major international markets. The new 130-tph, two-strand high-speed wire rod mill is designed to produce 5 to 22-mm-dia plain and 6 to 16-mm-dia deformed quality structural and engineering steel wire rod, in 2-t coils at speeds of up to 110 mps. Danieli Centro Combustion supplied the walking hearth reheating furnaces for the three rolling mills, while all electricals, automation and process control systems up to Level 2 were supplied by Danieli Automation. MMK is Russia's largest single-site integrated steelworks (with a 10-Mtpy overall capacity), and one of world's largest steelmaking companies.
Danieli will supply a new cam-based drawbench, plus a seven-roll V and H straightener to enable drawing and straightening of up to 25.4 mm finished size round bars, as well as hexagon and square bars of up to 19 mm. The entire package will be completed with a state-of-the-art automation system, and is expected to reach the final commissioning stage by mid 2007.
The plant modernization included a new billet hot-charge connection to the conticaster; a new Danieli Centro Combustion pusher-type reheating furnace with a capacity of 70 tph in hot charge mode; and a new continuous H-V roughing mill made up of six ESS compact cantilever stands to replace the old three-high roughing stand. The present fully-continuous configuration allows the best possible operation of the Danieli high-speed bar finishing line installed in 2001. Made up of a six-pass twist-free finishing block and a Twin Channel high-speed delivery system, it is capable of producing small bars at speeds of up to 35 mps. The mill's product range is 8 to 30-mm-dia merchant bars and 8 to 40-mm-dia rebars.
The performance tests were successfully completed just two days after the restart, to full Customer satisfaction. An extension of the cooling bed and associated feeding and delivery facilities, with installation of new entry table, dividing shear, plus miscellaneous for the rolling mill area now allows slit rolling system and makes it possible to cope with the higher productivity. The mill produces 3\8” to 1” rebars for concrete reinforcement.
· Nucor Steel Seattle (WA) With 80,000 t produced, March 2006 was the all-time record month for the Nucor Steel Seattle bar mill, far exceeding the originally designed nominal plant capacity. This 18-stand super-flexible merchant bar and section mill has been in operation since the early ‘90s and produces a wide range of rebar, rounds, and profiles, which are delivered to the Pacific Northwest, and Canada. · CMC Steel (SC) The new all-time record shift at CMC Steel SC was achieved on February 14, 2006, with an outstanding production of 2,417 t of 19-mm-dia bars (equal to 201 tph), surpassing all past record shifts, for any product size! This 17-stand state-of-the-art super-flexible mill, in operation since early 1999, has a production capacity of over 800,000 tpy of rebars, rounds, angles, channels, flats, squares, and T-posts.
Celsa (Compañia Espagñola de Laminación, S.L.) bar and rod mill in Barcelona restarted operation on March 27, 2006. Two SHS housingless roughing stands in H and V arrangement were added as an extension of the four-stand compact Danieli roughing mill, in operation since 2000. This allows Celsa Barcelona to process larger-size billets, weighing up to 3 t.
This will introduce for the first time in the Country the latest long product rolling technologies making this state-of-the-art plant the most advanced and highly productive rolling mill in the region. The 18-stand mill, entirely made up of heavy-duty SHS housingless stands, will make use of an advanced multi-strand slit-rolling system (up to 4 strands for down to 8-mm-dia rebars) to produce the smallest rebar sizes and exploit the mill’s full capacity. A multi-strand QTB line is provided at the finishing stand delivery side, for on-line rebar quenching and self tempering, making it possible –for the first time in the country- to produce on-line treated high-tensile/weldable rebars. The new mill’s product range will be 8 to 38-mm rebars produced at rates of up to 60-tph. Plant startup is scheduled for summer 2007.
Siderurgica Barra Mansa SA (part of the Votorantim Group) has contracted Danieli Morgårdshammar for the supply of a new state-of-the-art flexible bar and section mill with a 400,000-tpy designed production capacity. The mill will be installed at the Unidade de Aço Barra Mansa production site (RJ). The 17-stand continuous rolling mill will be made up entirely of SHS housingless stands in H, V, H\V and combined H/U universal arrangement (the latter being particularly dedicated to production of high-quality parallel-flange beams). Bar finishing facilities will feature a 66-m long cooling bed fitted with water-spray extra-cooling system, start & stop type in-line straightening and cut-to-length services and a single-head magnetic stacker, plus bundling and collecting facilities. The new mill’s product range will include 31 to 76-mm-dia quality rounds, 76 to 152-mm parallel-flange beams, up to 100-mm angles and correspondent channels and flats. Danieli Automation will supply the electricals and an advanced automation system.
Ascometal is a major player in special steel long products with a global presence in the market for automotives, bearings, springs and mechanical industries. The project foresees the complete replacement of the existing bar production outlet, in operation since mid 1980s/early 1990s, with a new state-of-the-art finishing end suitable to fulfil present Ascometal more demanding quality and production requirements. The new line will be basically made up of a 5-pass Kocks-Danieli RSB Reducing and Sizing Block, new 78-m-long cooling bed fitted with hoods for retarded cooling, bar cut-to-length services, and automatic lance-type stacker, bundling and collecting facilities suitable for up to 7.5-ton regular bundles. RSB block’s 3-roll technology and its wide free-size range will grant the tightest tolerances on the whole range of the rolled products as well as higher operation flexibility and increased mill efficiency, enhancing operating costs. Provision is also made for future low-temperature rolling at a second step plant upgrade. The upgrade will make it possible to extend the present 16 to 80-mm-dia bars range to up to 100-mm-dia rounds in a broad variety of special steel grades including engineering, bearing, spring, micro-alloyed and similar grades, at rates of up to 90-tph. Danieli Automation will supply the electricals and an advanced automation system. The restart for the upgraded mill is scheduled for summer 2007.
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. | |||
