PR. of China

Second DRI-based minimill
continues success at
Emirates Steel, UAE.
Aluminium plate stretcher
successful startup at Dalian
Huicheng, P.R. of China.
1.1-Mtpy universal rail and
section mill inaugurated at
Mechel Chelyabinsk, Russia.
Page 12
Page 8
Page 53
Danieli News n.168 October 2013, Danieli Group
DaNews
168
ALSO IN THIS ISSUE
IRON AND STEELMAKING
14 COMMSSIONING ON INDIA’S
LARGEST BF AT SAIL RSP.
17 OFFICIAL OPENING AT ACM-ABS
CENTRE METALLURGIQUE
18 SECOND DANIELI NANO MELTSHOP
STARTES UP AT BVK, RUSSIA.
FLAT PRODUCTS
29 FOURTH-GENERATION THIN SLAB
CASTER AT DONGBU STEEL, KOREA.
32 PLATE/STECKEL MILL UPGRADE
PROJECT AT JSPL RAIGARH, INDIA.
36 500,000-TPY PUSH-PULL PICKLING
LINE AT ABUL KHAIR, BANGLADESH.
LONG PRODUCTS
40 EXCELLENT RESULTS FROM DANIELI
CONTICASTERS FOR LONG PRODUCTS.
46 800,000-TPY HIGH-SPEED BAR MILL
AT STEELASIA, THE PHILIPPINES.
54 1-MTPY LARGE-BAR MILL STARTED
UP AT HENAN JIYUAN, P.R. OF CHINA.
HOT AND COLD PROCESSING
70 DANIELI MODERNIZING THE
“HISTORY" AT VOLGOGRAD STEEL
WORKS “RED OCTOBER”, RUSSIA.
+ Highlights AUTOMATION INSERT
PARTNERSHIP LEADS TO SUCCESS
The Final Acceptance for the 4th minimill at Deacero, Mexico, underlines
a successful partnership lasting for over 30 years between two companies
which share the common passion to innovate and perform.
D
eacero is a successful, dynamic,
and privately owned company that
has achieved its growth by
establishing a highly competitive position
to satisfy the demands of national and
international markets. Deacero is an
important player among steelmakers
supplying long products not only in Mexico
but in 20 countries around the world.
With this 4th minimill Deacero decided
to enter into the market of sections, after
having consolidated its leadership as bars
and wire rod producer. The 1.5-Mtpy
meltshop has been designed both to supply
the downstream flexible merchant mill and
provide the balance of required billets
for the various rolling mills of the Group.
The EAF and the overall layout of the plant
are designed already for the future
installation of a continuous scrap preheating
and feeding system.
Deacero already operates two scrap
preheating systems supplied by Danieli,
in two out of the three existing meltshops.
The skill of their team, together with the
reliability of the equipment, make Deacero
performances a worldwide benchmark:
existing meltshops achieved up to 42 heats
per day, and are performing regularly above
30 heats per day on average.
’ Page 4
Danieli W+K continuous
improvement approach in
process and design, and the
extensive know-how inherited
from Hoesch, led to state-ofthe-art pipe mill technology.
Design, manufacturing,
modernization, erection and
commissioning of single
machines up to complete
turnkey plants are provided.
DANIELI W+K
WELDED PIPE TECHNOLOGY
TO PRODUCE
LARGE DIAMETER
QUALITY PIPES
> EWR 26” LSAW 64” HSAW 120”
> For oil & gas, chemical,
petrochemical, and power applications
Since 1968 Danieli W+K designed and built
35
welded pipe plants
1914 / 2014
Longitudinal and Spiral Welded Pipe Plants
2
DANIELI
CENTURY
DANIELI THE RELIABLE
INNOVATIVE PARTNER
TO BE FRONT RUNNERS
DaNews
DANIELI NEWS N.168
OCTOBER 2013
/ FLAT PRODUCTS
1-Mtpy large-bar mill in operation
at Henan Jiyuan, China
> 54
Successful maintenance project
at Chengdu I&S, China
> 83
Q-WIDTH technology proven
successful for slab casters > 26
Fast Learning Curve at CAASA,
Peru
> 56
The fourth-generation TSC
at Dongbu Steel, Korea
Danieli operational equipment
tailored to exploit rolling line
production capabilities
> 84
Danieli H3 wire rod line
starts at Nucor Darlington
(SC), USA
New steel grades for slab
at Yingkou. P.R. of China
> 29
> 30
Two innovations enhance flat
products rolling operations > 31
Plate / Steckel mill upgrade
at JSPL Raigarh, India
> 32
Skin-pass mill inaugurated at SAIL
Bokaro CRM III, India
> 33
Skin-pass mill commissioned at
Risse + Wilke, Germany
> 35
/ DANIELI MINIMILLS
Final Acceptance for the new
meltshop at Deacero Ramos
Arizpe, Mexico
>4
500,000-tpy PPP line at Abul
Khair Steel, Bangladesh
> 36
/ ALUMINIUM
Six strip finishing lines at Abul
Khair Steel, Bangladesh
> 38
Hot and cold rolling mills
at KUMZ, Russia
>6
Bonderizing line at Wälzholz New
Material (Taicang), China
> 39
Plate stretcher at at Dalian
Huicheng, P.R. of China
>8
/ LONG PRODUCTS
Nanshan Aluminium chooses
proven technology, again
>9
TWIN-container press
for General Extrusions, USA > 10
First coil at Taiyuan Jinxi Chunlei
Copper, China
> 11
/ IRON & STEELMAKING
Second DRI-based minimill
continues success
at Emirates Steel, UAE
> 12
> 15
Official Opening at ACM-ABS
Centre Métallurgique
> 17
Second Danieli Nano meltshop
started up at BVK, Russia
> 18
New Nano meltshop
at MTE Finance, Russia
> 19
New integrated EAF charging
system at Sohar Steel, Oman > 20
New EAF roof lifting and swivelling
system at Stefana, Italy
> 21
New VOD station
for Jisco, P.R. of China
> 21
Intense activity drives growth
at Danieli Centro Recycling > 22
Shredder launch ceremony at
Danieli China in Changsu
> 23
Benchmark FTP for Auto Scrap
Shredding at RMB, Italy
> 24
Danieli Training methodology
earns renewed trust
> 85
Bar-mill stacker in operation at
Steel of West Virginia, USA > 57
Capital equipment spare parts
supply Danieli drum shear > 86
Final Acceptance of bar mill at
Dongkuk Incheon, Korea
> 58
Technological revamping
for Steel Dynamics, USA
Commissioning of sheet piles
at Emirates Steel, UAE
> 59
// INSERT:
> 40
Final acceptance of billet and
bloom conticaster at Gerdau
SS NA (MI), USA
> 41
Final acceptance for round bloom
caster at Baotong, China
> 41
Casting of stainless steels at Xining
Special Steel, P.R. of China
> 42
> 87
Highlights AUTOMATION
/ TUBE PROCESSING
Next-Generation Cold Pilger Mill
for tube production
> 60
Heat treatment line upgrade
at Jesco, Saudi Arabia
> 62
Heavy wall-thickness tube mill
for TPI, India
> 64
New multicutter for ERW pipe
welding lines
> 65
QDrive - Medium, low and multilevel voltage drives
// 2
Q-Robot MELT / Q-Robot ZINC
How to improve operators' work
conditions
// 3
Billet conticaster modernization
at AM Dabrowa Gornicza,
Poland
// 4
Web reporting system for existing
meltshop at Hadeed, KSA
// 5
Successful Q-MOULD installation
at CMC Arizona, USA
// 5
/ HEATING SYSTEMS
Acceptance for the bloom caster
at Evraz-NKMK, Russia
> 42
India’s largest BF commissioned
at SAIL RSP
> 14
New orders from Chinese
ironmaking operations
Final acceptance for round
bloom caster at Maanshan,
P.R. of China
> 57
Ultra-low NOx walking-hearth
furnace at Hadeed, KSA
> 66
Customized furnace for Orsky
Machine-Building, Russia
> 68
Chain-track bar drawing line
at Marcegaglia Contino,
Italy
> 69
Danieli modernizing the “history”
at Volgograd Steel Works «Red
October», Russia
> 70
State-of-the-art controls for hot
strip mill, at AM Gent, Belgium // 6
Q3Intelligence BI solution at Nucor
Steel Tuscaloosa (AL), USA
// 7
QDrive symposium in India
// 8
QDrive commissioning completed
at Hoa Phat, Vietnam
// 9
E&A equipment for big bar
mill at Qilu, P.R. of China
// 10
Casting new sections of SBQ
at SeAH Besteel, Korea
> 43
/ FORGING & EXTRUSION
Finishing mill revamp at CMC
Steel South Carolina, USA
// 11
Repeat order for H3 wire rod
mill technology from Qingdao
Special I&S, China
> 44
Successful commissioning
of a seamless tubing plant
at XinXing, China
HiSECTIONPLUS
at Ferriere Nord, Italy
Danieli Garret Line Technology
at NSSMC, Japan
> 45
0.8-Mtpy bar mill for SteelAsia,
The Philippines
> 46
0.6-Mtpy bar / light section mill
for Mass Global, Jordan
> 47
> 72
// 11
Induction heating furnace
for bar mill at Sovel, Greece // 12
/ CUSTOMER SERVICE
Eelectrode arms maintenance
and overhauling package
> 74
DanJoint project accomplished
and a new order received
> 75
Merchant mill modernization
at BSRM, Bangladesh
> 48
DanJoint at Baosteel Meishan,
P.R. of China
> 76
800,000-tpy bar mill project
restarts at Lisco, Libya
> 49
Danieli Service conticasting
knowledge
Ferriere Nord (Pittini Group)
keeps working on innovation > 50
Reduced consumption of EAF
electrodes at NTS, Thailand > 80
Danieli H3 wire rod technology
ordered at AEMZ, Russia
> 51
Cost-effective, small revamping
projects with Danieli Service > 81
Inauguration for the Universal Rail
and Section Mill at Mechel’s
Chelyabinsk, Russia
> 53
MH Guide Systems technology
at Shanxi Zhongyang,
P.R. of China
> 82
New HiPROFILE at CMC Steel
Alabama, USA
// 13
HelpDesk: better response
and better service
> 78
Danieli Publicity Dept. Tel. (39) 0432.1958244
info@danieli.com
Graphic Design: Polystudio
DTP: Danieli Publicity Dept
Printing: Grafiche Filacorda, Udine
Approved by the Court of Udine
under authorization n.16
dated 21.04.83
// 14
DANEWS 168
Sustainable Entrepreneurship
in Electric Steelmaking
AN OPPORTUNITY TO DESCRIBE OUR COMMITMENT TO INNOVATION
I
nnovation should not be seen only as a
channel for new products – it must be
recognized as a corporate value. The
objective is to take advantage of the opportunities
that arise from a company’s unique appeal to
customers – in technical, social, environmental,
and therefore also in economical bases. Our “Best in Class” approach is not limited to our
technological efforts; it is also a valid description
of our cost-saving thinking and our approach to
environmental responsibilities. New ideas are not the only trigger for innovation.
It is results from efforts to bring ideas to the
market and to make them sustainable successful.
On this basis, Innovation should be understood
as an effort to address production challenges so
that everyone (employer, employees, customers
and the society) may benefit.
Analyzing our already established technologies
for electric steelmaking, it appears that we are
coming closer and closer to the theoretical
minimum limits of that production process. We will draw one step closer with our new,
patented scrap-charging concept called
“HotWind”, which provides a proven
technological concept for sustainable low-cost
conversion, one that brings greater efficiency to
the complete range of variables, such as: energies
(electric energy, natural gas), charge materials
(scrap, DRI, carbon, etc), and particularly the
reliability of the overall process and logistics. This guarantees a fast start-up for any
installation, whether it is a greenfield
development or a revamping project.
The start-up curve of average 32 heats/day
reached after one week of operation at the new
Danieli FastArc™ EAF at Ferriere Nord (Italy) is
an outstanding result of modern design, precision
manufacturing, detailed planning for
construction, and the open spirit cooperation we
share with our clients. Being aware of the importance of raw materials
for Nano-, MIDA and Mini Mill operating
results, we propose technologies that allow
maximum flexibility in the use of available raw
materials.
Now, having own line of scrap handling
equipment allows us to define the most suitable
technical strategy, from scrap yard to final
product, for every geographical area.
Also, in the field of continuous casting we can be
seen as trend setters; we are currently achieving
outstanding performances in vertical casting, as
well in round casting (including large rounds of
up to 850 mm dia), dynamic soft reduction, ultrahigh speed casting (> 6 m/min) with our
revolutionary Power Mould, an example of
continuously improving process parameters for
our endless MIDA technology. We are driven by a passion to perform: greater
productivity with less equipment, consuming less
energy, and ensuring improved product quality:
our current roster of installed meltshops proves
that we have attained these targets by working
together.
The spirit of sustainable entrepreneurship at
Danieli is not limited to a business area. It is a
shared attitude and mutual commitment that
inspires every employee. We invite all
steelmakers to be part of our passion for
continuous innovation throughout the complete
product life cycle chain!
THOMAS NARHOLZ
EVP Danieli Centro Met Swiss
3
DANIELI MINIMILLS
DANEWS
FINAL ACCEPTANCE FOR THE NEW MINIMILL
at Deacero Ramos Arizpe, Mexico
A
fter the successful startup of the
superflexible rolling mill, the first heat
for the new meltshop was executed on
March 23, 2013. This new meltshop Electric Arc Furnace, Ladle Furnace, and
conticaster- is designed to produce up to 1.5
Mtpy of billets and blooms, as well as beam
blanks up to 320x400x90 mm. It represents
the fourth minimill built and commissioned
by Danieli for Deacero in Mexico, following
the operations installed at Saltillo (600,000
tpy of bars and wire rod), and two separate
plants installed at Celaya in 1998 and in
2006, both producing about 2.3 Mtpy of
billets and 2.0 Mtpy of bars and wire rod. The new plant is designed according to the
latest technology available for steel plant
machinery and equipment. The steel meltshop is comprised of a 150-ton
FastArc™ EAF (bottom shell diameter 7.7 m;
transformer of 200 MVA; TTT 42 minutes;
max. productivity of 214 tph), a twin-type
ladle furnace, and a 6-strand caster (10/19-m
radius, outfitted for sections ranging from
130x130 to 200x240 mm).
The choice of the various systems that make
4
up the plant is directly related to the
achievement of the following high-priority
objectives: > limited investment costs,
> high-quality products,
> high productivity,
> maximum simplicity of operation,
> operational reliability, and
> maximum flexibility to meet various market
demands.
Danieli Automation supplied the electrical,
automation, and process control systems for
the whole plant.
At beginning of July, 130x130-mm billets in A529 steel were produced at a casting speed of 5 mpm. After the achievement of all the
contracted performance objectives, the Final
Acceptance Certificate was signed on July
11, 2013, with full customer satisfaction.
The plant is now proceeding with a quick
ramp-up toward first-class consistency in
operation and optimization of energy
consumption at EAF and LF, to further
increase the competitiveness on the market n
THIS IS THE
FOURTH MINIMILL
COMMISSIONED
BY DANIELI FOR
DEACERO GROUP:
A LONGSTANDING
PARTNERSHIP
CONTINUES
SUCCESSFULLY.
DANEWS 168
Deacero is a successful,
dynamic, and privately owned
company that has achieved its
growth by establishing a highly
competitive position to satisfy
the demands of the national and
international markets. The
company is an important player
among steelmakers supplying
long products, not only in
Mexico but in 20 countries
around the world. Continuous
investments in state-of-the-art
mills and plants, with their
technological improvements and
integrated production processes,
have allowed Deacero to satisfy
the continuous demands of the
sectors they serve: agricultural
products, residential and
commercial construction, and
the industrial marketplace.
Deacero has been a permanent
member of United States Green
Building Council (USGBC) since
2009 as a manufacturer of
sustainable products, and their
products achieve LEED
certification (Leadership in
Energy & Environmental Design)
for sustainable construction
projects.
5
ALUMINIUM STRIP MILLS
DANEWS
HOT AND COLD ROLLING MILLS
Al
at KUMZ, Russia
TWO CHALLENGING
PROJECTS
BEING TACKLED
BY COOPERATION,
COORDINATION,
AND INNOVATION.
T
e project under
h
execution for KUMZKamensk-Uralsky
Metallurgical Works
encompasses the engineering
and supply of an innovative,
multifunction, all-in-one
double-stand hot rolling mill
for hot plates and coils, and
cold sheets, plus an
impressive, record-breaking
6-high cold rolling mill
capable of processing wide
coils up to 2,800 mm, and
fulfilling the rising
requirements of the aviation
and transport industries.
1
2
Double-stand hot rolling mill
The mill’s planned annual
production of 240,000 tpy
will be apportioned as
170,000 tpy of HR coils,
50,000 tpy of HR plates, and
20,000 tpy of CR sheets.
This variety will be possible
thanks to the high rolling
force available at both the
rougher and the finisher
(8,000- and 6,000-t,
respectively), together with
three independent roll
coolant systems, relative
coolant application headers,
and independent fume
treatment units. The whole mill will be
6
3
managed by Danieli
Automation L1 and L2
systems. The hot rolling mill
is in an advanced design
stage, and long-lead orders
have already been
purchased. The basic civil
design, and the designs for
auxiliaries and utility systems
have been handed over for
KUMZ to proceed with the
detail designing and
construction of the
foundations. Currently the
building frames are being
erected, and scheduled to be
enclosed before the start of
winter in order to complete
the interior during the
winters months.
DANEWS 168
4
5
6
6-high cold rolling mill
There was excellence too in a performance by the KUMZ employees’ children, part of the “Raduga
- The Rainbow” Group. On July 4, KUMZ and Danieli,
along with City Officials organized a cultural event in Jesolo, Italy, where the children of KUMZ
employees presented traditional songs and dances of the Urals. The event was attended by Vladimir
Skornyakov, President of Aluminum Products
Managing Company, and Gianpietro Benedetti,
Chairman and CEO of Danieli.
1 Cold mill 3D model.
2 Hot mill 3D model.
3 Kumz and Danieli Teams
during cold mill
equipment inspection
before shipment.
4 Hot and cold mill
building under
construction.
5 Cold mill civil works
under construction.
6 First hot mill shop bays
being closed.
This will be the world’s
widest 6-high cold mill for
aluminum, and will produce
about 170,000 tpy flexibly,
ranging from the minimum
1,100 to the maximum 2,800
mm strip width. This will be
made possible by the newest
hydraulic control system for
the roll force cylinders, the
long-stroke shifting, and the
extra-wide flatness
measurement roll in a closed
loop with the coolant spray
beam headers, the bending,
shifting, and the tilting
actuators. As for the hot
section, the whole cold mill is
managed by Danieli
Automation L1 and L2
systems. The cold mill
machinery, having been
ordered previous to the hot
mill, is now fully engineered
and manufactured. Currently,
the mill civil works are being
completed for equipment
installation. To great mutual satisfaction,
all the equipment passed the
KUMZ technical inspection
successfully the first time
around, and its delivery to the
site is in progress. To design
and manufacture a hot mill
to work also as a cold mill,
and to design and
manufacture the world’s
widest 6-high high cold mill,
calls upon all the
experiences from KUMZ’s
field experience and from
Danieli’s know-how centers
(Danieli Wean United,
Danieli Fröhling, Danieli
Innoval, Danieli Automation,
Danieli Engineering, and
Danieli Hydraulics)
cooperating to achieve
excellence. In this context of close cooperation, the hot
and the cold mills are
designed to set new standards
in the aluminum industry.
Delivery of the all-in-one
“hot/cold” double-stand hot
rolling mill will start in the
first half of 2014. By that
time the 6-high cold mill
already will be producing the
whole range of alloys (series
1xxx, 2xxx, 3xxx, 5xxx, 6xxx,
7xxx, and 8xxx) of its mix n
7
ALUMINIUM STRIP MILLS
DANEWS
STRETCHED ALUMINUM PLATES
for Dalian Huicheng, P.R. of China
Al
O
n March 23rd,
2013, the hot
commissioning
process for the 60-MN
aluminum stretcher was
concluded thanks to the
Danieli Team’s efforts and
the customer’s support: a
5052F aluminum alloy was
successfully stretched,
demonstrating the capability
of the machine. This 60-MN stretcher is
designed to reach a
production capacity of
40,000 tpy with a product
mix of 2XXX, 5XXX, 6XXX
and 7XXX alloys. The main applications for
thick aluminum plates are in
transportation products,
especially in aerospace,
automotive and marine
industries. 8
DANIELI WEAN UNITED ACHIEVED
A SIGNIFICANT MILESTONE FOR ITS
STRETCHER DESIGN WITH THE FIRST
ALUMINUM PLATE STRETCHED
AT THE DALIAN HUICHENG SITE.
The range of applications
could be extended to all
sectors in which light weight
and high strength
characteristics are required.
Incoming Plate Data:
Width
1,000 - 3,600 mm
Thickness
6 - 200 mm
Length
4,000 – 25,000 mm
Max. weight 14 ton
The stretching process is
carried out as follows:
depending on plate
dimensions and maximum
plunger compensation, the
fixed head is moved into
position by a hydraulic motor
and held using pins; the
moveable head is moved by a
quick-moving cylinder. The vacuum crane charges
the plate onto fixed
supporting rollers between
the two heads. One carriage
(two for plates longer than
10 m) supports the plate in
an intermediate position and
has the effect of flattening it.
The plate is centered by side
guides and vertical rollers,
and then clamped by a
gripper. Two main stretching
cylinders exert the main
stretching force on the plate
and work until the required
stretching force for that alloy
is reached. A synchronization control
system ensures uniform
elongation for the plate,
preventing head skewing
during stretching for safety
reasons. The required
elongation varies according
to plate material, heat
treatment and the related
elastic and plastic strain
values. After stretching, the
plate is unclamped and the
centering device opens; the
plate is ready to be
discharged by vacuum crane.
The shock absorbing system
will act, with a dedicated
DANEWS 168
hydraulic circuit, in case of aluminum plate breakage,
dissipating the stretching
energy and limiting the travel
of stretching head (in one
direction) and columns plus
fixed head (in the other
direction). The hot test started with the
first stretched plate. Since
the start up, constant
improvements and finetuning were applied to the
machine in order to fulfill
the required performance
figures, according to the
EN485-3 Standard, which
defines the final tolerances
for aluminum plate.
The total number of plates
successfully stretched during
the startup phase is more
than 3,000, including the
ones for production. Up to now the machine has
stretched the hardest
aluminum grades, mainly of
6061, 7075 and 6082 alloys,
and a smaller numbers of
5052 plates.
These plates were heat
treated with mainly T651
process, but also including
some F, H112, and T451
processes, which means
solution heat treatment
followed by artificial aging.
The results obtained during
recent months confirm the
Danieli Team’s ability to face
new challenges and
successfully meet
profitability targets in the
new aluminum market
segment. The first stretched plate
represents a key event not
only for the Dalian Huicheng
project but also for other
Danieli stretcher projects n
Nanshan Aluminium
chooses proven yet advanced
technology, again
Al
CHINA’S LEADING PRIVATE
ALUMINUM STRIP PRODUCER
HAS BEEN RELYING ON DANIELI
FRÖHLING’S CUTTING
TECHNOLOGY SINCE 2003,
AND NOW WILL EXPAND
ITS PRODUCTION FACILITIES
FOR FURTHER GROWTH.
N
anshan Light Alloy Co., Ltd. was founded
in 2001, and has developed into a modern
aluminum rolling enterprise with
production space covering 328,000 sqm, with
over 1,000 people, and more than 60 sets of
production equipment of all kinds, and a total
production capacity exceeding 750,000 tpy.
Shandong Nanshan Aluminum Co., Ltd. intends
to build a modern, large, high-precision
aluminum and aluminum-alloy plate and strip
production plant in Donghai (Shandong), which
is part of the effort to diversify its product mix.
In 2003, Shandong Nanshan Aluminum and
Danieli Fröhling (DF) became partners when the
first contracts for a trimming line and a slitting
line were signed. Further orders were placed with
DF for two more high-speed trimmers in the
following years. Recently, the customer chose DF to supply another trimming line and a new
slitting line, to complete its expansion project. Slitting line The design of this new line’s is based
on experiences gathered in a large number of
similar lines supplied previously, as well as the
latest improvements in such operations. It
provides the customer with a high-end machine
able to cut strips to the closest tolerances. At the
core of the cutting process is a CNC slitting shear
that accommodates a high standard of design and
manufacturing, with pre-tensioned elements to
reduce backlash in shear adjustment, computercontrolled knife shaft positioning in closed-loop
mode, as well as an automatic clamping system
for tools. For braking, the proven DF vacuum roll
design will provide the smoothest and most
uniform tension to all individual strips. Braking
force is provided without touching the upper
surface of the material and with very low friction
on the bottom of the strip. The line will be
completed with a sophisticated packing line that
Song Changming, Vice
General Manager of
Nanshan Group, and Jörg
Schröder, DF Managing
Director.
introduces vacuum stacking and various
strapping machines, as well as film stretcher and
weighing equipment. Trimming line With its basic concept proven over
several years, and reliability at stable operation
speeds of 1,500 mpm and higher, this line is
equipped with special features to provide
precision products at maximum production,
such as:
> High-speed cropping of the out-of-tolerance
head and tail end within the line;
> Edge trimming shear with automatic
adjustment of cutting gap and immersion;
> Suction devices for side trimming scrap,
especially for high-speed applications;
> Dedicated design for the exit guide unit
downstream of the trimming shear, to establish
the shortest possible distance between cutting
and recoiling zones;
> Two recoiler outlets to manage two finished
strips at the same time (maximum speed in this
case 1,000 mpm).
Both lines will be completed with the necessary
hydraulics, automation, electrics, and other
auxiliary units. Installation and commissioning
will be supervised by our experienced staff,
which ensures a fast learning curve and optimal
fine-tuning of the plants n
9
ALUMINIUM STRIP MILLS
DANEWS
TWIN-CONTAINER PRESS
at General Extrusions, USA
for higher plant utilization
and lower energy consumption
Al
THE 23-MN PRESS,
THE FIRST
INSTALLATION OF ITS
TYPE ANYWHERE IN
THE WORLD, WILL
BE A MILESTONE
IN THE NORTH
AMERICAN MARKET,
AND WILL CONFIRM
DANIELI BREDA
AS AN INNOVATIVE
PARTNER.
10
G
eneral Extrusions Inc.
(GEi) produces
standard and
precision custom aluminum
extrusions in 3000 and 6000
series alloys.
The company is ISO-9002
certified and services
customers in the appliance,
medical equipment,
transportation, and
automotive industries,
among others.
The new press to be
installed at Youngstown
(OH) plant, according to the
contract signed in June
2013, will enable GEi to
pursue its plans for
production expansion and
cost optimization.
Featuring a dead cycle time
40% lower than the
conventional units and
requiring 44% less installed
power, the TWIN press
ensures production increases
with less energy
consumption, i.e. improved
operating margins. Further
to the 8-in. TWIN container,
the 2,600-UST press will be
equipped with the ESED:
Energy Saving Electrical
Drive and BreDanExtr
automation systems.
Among the other benefits,
this plant design also shows a limited impact concerning
installation, requiring a
minimal amount of site
excavation and a compact
footprint.
Both Danieli Breda and GEi
expect this installation to
quickly become a
benchmark for what
concerns productivity and
specific cost on the final
aluminum product n
DANEWS 168
On June 19, 2013, the Danieli Fröhling 6-high reversing mill produced
its first coil and quickly proceeded to run at the maximum speed
with the minimum exit gauge, all within gauge and shape guarantee tolerances.
First coil rolled
at Taiyuan Jinxi Chunlei Copper, P.R. of China
T
he coil produced was
CuZn 35 with a width of
420 mm and rolled from
0.25 to 0.155 mm in two
passes at speeds up to 450
mpm. It met all of the shape,
gauge, and quality
requirements of the contract.
By the time the third coil had
been rolled the mill had
achieved maximum speed of
600 mpm; the minimum exit
gauge of 50 µm was achieved
shortly after, all within gauge
and shape guarantee tolerance.
Danieli Fröhling received this
order from Chunlei following
their successful project for a
20-high mill supplied in the
mid 1990s, and to make sure
that everything ran smoothly
the same site supervisor was
assigned for the installation
and commissioning phases of
this 6-high mill. The mill stand
was supplied fully assembled
from the Danieli Fröhling
workshops in Germany, with
local supply from Danieli China
for the auxiliary equipment and
gearboxes. The electrical and
automation system was
provided by Danieli Automation.
Equipment control functions
The mill can operate in fully
automatic or semi-automatic
modes, with limited operator
intervention. All the necessary
permissive signals and
interlocks are provided for safe
operation. Drive and motor
controls include highly
accurate mill speed master,
reel tension control and
automatic slowdown control.
Hydraulic Gap Control (HGC)
The hydraulic screw-down
cylinders are arranged in the
upper mill housing. The
positioning of the screw-down
cylinders is done via
independent hydraulic servovalves. The roll-gap positioning
is measured by high-precision
linear position transducers on
each cylinder.
Strip thickness control (AGC)
Several thickness control
modes are used to achieve
reproducible, smallest
thickness tolerances, using
high-precision strip thickness
and strip speed measurement:
feed-forward control, feed-back
control, mass-flow control.
Strip flatness control (AFC)
Strip flatness control is based
on the following actuators:
bending control of WR and IR,
dynamic and differential
shifting control of IR, tilting
control, roll coolant control.
The flatness control package is
based on an extended “Least
Mean Square Algorithm” for a
perfect assignment of shape
errors to the mechanical
actuators of the rolling mill. In addition to this optimized
'job sharing' between the
mechanical actuators, the
flatness control concept
comprises several advanced
features like “Coolant Support”
functionality. Essential
highlights of the equipment
supplied that makes it
advantageous are:
> Direct measurement of strip
entry- and exit tension for
improved strip tension and
gauge control;
> Symmetrical positive and
negative WR and IR bending;
> Differential and dynamic IR
shifting;
> Vibration suppressive design;
> Easy maintenance and
minimal downtime;
> Short roll-changing times;
> Plate filter for highest-quality
rolling oil filtering; > Auto centering of the coil at
decoiler;
> 3M® Squeegee roll strip
wiping system;
> Level 2 adaptive scheduling
model n
First coil! From left: Song Yinghui,
Project Manager Chunlei; Ralf Pütter,
Rolling Process Specialist DF; Pei Tongwei, main operator Chunlei;
Wolfgang Rathmann, Senior
Commissioning Supervisor, DF.
Main processing parameters of the mill
Typical material grades
Copper: C10200, C11000, C12000, …
Copper alloys: C19210, C19400, C 26000,
C26200, C26800, C27000, C70250, …
Material condition
CR and soft annealed or CR only, non-sticking,
straight wound, edge trimmed
Strip width
300 - 430 mm
Initial / Final strip thickness
Max. 1.50 mm / 0.05 - 1.20 mm
Max. coil weight
6,000 kg
Max. roll force
4,000 kN (Nominal 3,600 kN)
Rolling speed
600 mpm
11
IRON & STEELMAKING
DANEWS
SECOND DRI-BASED MINIMILL
CONFIRMS SUCCESSFUL PERFORMANCES
at Emirates Steel, UAE
E
mirates Steel plants in Abu Dhabi are
in full operating mode now,
establishing new records for successful
performance. Both integrated steel plants -namely, Phase 1
in operation since the end of 2009, and
Phase 2 since the beginning of 2011- are
running with very stable performances that
maintain high levels of productivity, and
representing remarkable accomplishments. On May 12, 2013, the Phase 2 EAF safely
achieved 38 heats per day with 5,565 tons of
molten steel, while the conticaster reached
37 heats per day with 5,466 tons of semifinished product cast (melting Energiron Hot
DRI at 94% met - C 2.3%), as announced by
Paolo Razza, the ES Steelmaking Plant
Manager. The conticaster output has
achieved peaks above 230 tph, with 227 tph
average, well above the design concept of
197 tph; these data prove the reliability of
the installed technology, entirely supplied by
Danieli, and the fine tuning process carried
out by the ES team.
Even so, a critical factor that contributed
Production
ramp-up and very
stable operational
conditions make
Emirates Steel’s
minimill No.2
the benchmark
in DRI-based
minimill plants.
Cumulative production in 1 year of operation (15 Aug 2012 – 15 Aug 2013), 1,619,388 t of hot DRI.
1600
Cumulative production (t*1000)
1400
1200
1000
800
600
400
200
0
Au
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No
J
De
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Ma
Ap
A
Jul
Ma
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c 2 an 2 ebr
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12
significantly to this smooth operation of the
meltshop certainly has been the perfect
integration with the upstream DR plants.
These high performing Energiron plants,
which direct reduction technology has been
developed jointly by Danieli and Tenova
HYL, show the ability to feed two EAFs
continuously with high-quality hot DRI,
regardless of the quality of the raw material.
In this way the plant manager is able to seek
a significant cost reduction easily by choosing
the most economic pellet according to the
market conditions, without ever overlooking
the primary importance of the finished
product quality. The latest production record
achieved by the Phase 2 Energiron DRP at
the beginning of August, when the nominal
design capacity of 1.6 Mtpy has been
reached after 12 months of production,
further confirms the increasing reliability of Energiron plants with external reformer as well.
These excellent results will be improved
further with the forthcoming capacity
enhancement of both direct reduction plants.
With a marginal capital investment, each
plant will reach production capacity of 2
Mtpy, putting the entire plant at 4.0 Mtpy of hot DRI capability n
DANEWS 168
View of the second
Energiron DR plant at the
minimill complex in
Mussaffah, which
together with the first DRI
plant in operation there
since 2009, will enable
Emirates Steel to reach a
total production capacity
of up to 3 Mtpy for
structural steel long
products.
13
IRON & STEELMAKING
DANEWS
INDIA’S LARGEST BLAST FURNACE
(8,000 THM PER DAY) COMMISSIONED
at SAIL Rourkela Steel Plant
S.S. Verma, ED Projects, SAIL RSP, and P. Zonneveld,
Managing Director, Danieli
Corus, cutting the ribbon.
R
ecently Danieli Corus commissioned
the greenfield Blast Furnace No. 5
built for SAIL (Steel Authority of India
Limited) at their Rourkela Steel Plant. This
ironmaking vessel was built by a consortium
consisting of Danieli Corus and Tata Projects
Limited, and currently stands as India’s
largest blast furnace. The first hot metal was
tapped after 27 hours. It is a noteworthy
accomplishment for Danieli Corus to have
built the largest operating blast furnace,
according to the “Hoogovens” philosophy, in
this important market. While the furnace is
named after the Hindu goddess Durga, it was
based on European technology and designed
to European standards. It was built to
produce around 8,000 tons of hot metal per
day for a 20-year campaign, and is part of a
1.75-million Euro expansion program at the
Rourkela Steel Plant. 14
DANEWS 168
New orders for Danieli
Corus from Chinese
ironmaking operations
anieli Corus was awarded
an assignment to replace
three sublance systems
at the 180-t converters of the
No. 1 Steel Making Plant
operated by Shagang I&S
(Group) Co., Ltd. The scope of
this project includes design,
supply of sublance equipment
and technical services. The
equipment components will be
manufactured in both The
Netherlands and China.
Delivery is scheduled for
December 2013, with
installation and commissioning
expected to take place in early 2014.
D
A “pooja” was performed as part of the
commissioning of Blast Furnace No. 5
(“Durga”) -according to Hindu tradition,
coconuts were cracked and the contents
sprinkled over the furnace’s shell to honor
Durga, the goddess of energy and creation.
This is the fourth greenfield blast furnace
project completed by Danieli Corus in India
and based on the Hoogovens philosophy.
Previously, three smaller blast furnaces were
built for private companies, among which the
one operated by Jindal Steel & Power Ltd.
has been India’s best performing blast
furnace over the past years. In addition,
Danieli Corus has executed substantial
revamp and repair projects on the blast
furnaces operated by Tata Steel at its
Jamshedpur plant. An order for a fifth
greenfield project in India was received from
the mining company NMDC in 2011. This company is diversifying into the steel
industry and developing a new integrated
plant at Nagarnar. Currently, Danieli Corus is building the blast furnace there, which will be larger than the “Durga” furnace now operating at Rourkela. This upcoming
furnace is expected to be commissioned in 2015 n
These three sublance systems
are intended to replace three
existing systems originaly
supplied by competing
European firms, the
performance of which has been
unsatisfactory for the
steelmaker. On other
converters, Shagang uses
Danieli Corus sublances that
were supplied earlier, achieving
excellent results. This fact
reinforces Danieli Corus’s
global leadership for BOF
process control systems. With
more than 110 references for
sublance systems, especially
operating with the StaticDynamic Process Control Model
for BOF steelmaking, Danieli
Corus's track record and
experience in BOF Process
Control Systems is unrivaled.
With this experience, Danieli
Corus has developed systems
for fully automatic steelmaking
capability, from charge to tap.
The possibility of producing
steel at the touch of a single
button makes the system
unique in the global steel
industry.
Danieli Corus has received a
repeat order from Pangang
Xichang Steel & Vanadium Co.,
Ltd. for the design and supply
of a third hot-metal
desulphurization system for
their steelmaking plant. This system will be based on
co-injection of magnesium and
lime. Equipment delivery is
scheduled for December 2013,
installation and commissioning
activities are expected to take
place in early 2014 n
15
IRON & STEELMAKING
DANEWS
ON JUNE 25, 2013,
A CONFERENCE ATTENDED
BY NUMEROUS
CUSTOMERS OF ABS
AND END-USERS
OF ITS MAIN PRODUCTS
CELEBRATED THE
OPENING OF THE NEW
ABS’ R&D CENTER
IN METZ, FRANCE.
16
DANEWS 168
OFFICIAL OPENING AT
ACM-ABS CENTRE MÉTALLURGIQUE
IN METZ, FRANCE
W
ith this significant investment,
ABS, the steelmaking division of Danieli Group, reaffirmed its
dedication to constant innovation and front
running spirit, as in the best tradition of the
Group. The effort to innovate is ABS’ answer
to the European engineering steels market, a market that still is far from a full recovery.
ABS Centre Métallurgique is an investment
that created a 2,500-sqm laboratory,
equipped with the best technologies for
analyzing and simulating products and
processes, guided by engineers and
technicians with a deep metallurgic
knowledge. The selection of Metz is due to
its location in the center of Europe, in order
to be closer to the customers, as well as to
the tradition and knowledge of the
metallurgical sciences native to that region,
in order to enhance the chances of
cooperation with the best institutions for research and development.
ACM is divided in two main divisions:
process research and product research. Every division cooperates with ABS for the
innovation and competitiveness of the
steelmaking division, with all Danieli product
line divisions supporting of innovation; and
with customers along the supply chain of steel processing, including the prospect of independent partnership at customer’s
service.
The main fields of activity will cover the following areas:
> Mechanical: mechanical, fatigue and
machining properties of steel and the
influence of manufacturing processes on components’ behavior;
On June 25, 2013, a conference
attended by
numerous customers
and end-users of the
main markets of
ABS celebrated the
opening of the new
ABS’ R&D center in Metz, France. Since its establishment, ACM has counted
on a comprehensive and state-of-the-art array
of equipment for: fatigue testing and DRX
equipment, mechanical testing, machining
and machinability equipment, metallographic
characterization, optical cleanliness
assessment, electron microscopy, plastodilatometry, chemical composition
determination, heat treatment, ultrasonic
immmersion, and a full range of software for image analysis and process simulation of rolling, forging, heat treatment, cooling,
and ingot and continuous casting of steel.
> Manufacturing processes: Investigation of manufacturing processes, especially
rolling, forging, and heat treatment;
In order to guaranty the reliability of the new
lab’s results and, moreover, to have tools
allowing it to reduce the development time,
ACM this year started the process of ISO
accreditation by setting up all requirements
to gain ISO TS 16949 quality certification in
2014. In 2015, the ISO 14001 accreditation
for environmental protection will complete
the panel n
> Steelmaking: investigation and
optimization of steelmaking processes from scrap to cast product.
Alessandro Trivillin, CEO of ABS, and Pascal
Daguier, Director, Research Manager of ACM,
giving their speech at the Opening Ceremony.
> Metallurgical: comprehension of
metallurgical mechanisms, steel design and characterization;
17
IRON & STEELMAKING
DANEWS
SECOND DANIELI
NANO MELTSHOP IN RUSSIA
started up at BVK in Chelyabinsk
THE NEW FOUNDRY,
BASED ON THE
DANIELI NANO
MELTSHOP
CONCEPT, STARTED
UP SUCCESSFULLY
ON MAY 29, 2013,
AND FOLLOWS THE
FIRST ONE
COMMISSIONED IN
2012 AT KULEBAKY,
FOR RUSPOLYMET
SPECIAL STEELS.
1
2
3
4
VK LLC is a new joint
venture between Italy’s
Cividale Group, one of
Europe’s largest foundries, and
Konar, one the most important
producers of fittings and valves
in Russia, based in
Chelyabinsk. Designed to
produce 25,000 tpy of ingots,
blooms and stampings, the
B
1
2
3
4
18
Electric Arc Furnace
Ladle Furnace
Vacuum Degasser
Ingot casting.
DANEWS 168
New Nano meltshop
for specialty and stainless steels
at MTE Finance, Russia
meltshop basically consists of a
20-t electric arc furnace (fitted
with the latest Danieli
FastArcTM technology), a ladle
furnace with inert roof and a
single-tank / single-cover
VD/VOD station, equipped with
dry mechanical pump.
The EAF is part of the new
generation of Danieli EAF Nano
series, specifically designed for
small heat sizes and low
annual production volumes. To optimize the melting
process and the energy
consumption by use of
chemical energy sources, a
Robox consumable slag door
lance is provided and fully
integrated in the process model of the automation
system. The LF follows the
same Nano philosophy. It is designed to reduce all
necessary maintenance, and is
fully equipped with necessary
auxiliaries. The vacuum
degassing and oxygen
decarburization (VD/VOD)
station is designed to treat the
entire range of high-alloy
carbon steels, and martensitic,
austenitic, and duplex stainless
steels necessary for BVK to solidify its market-leading
quality standards. The vacuum pump is a dry
mechanical type operation,
with suction capacity of
approx. 44,000 m3/h, textile
filter, and dust separator to
remove dust coming from the
process.
The vacuum station is
equipped with supersonic
oxygen lance, splash shield,
under vacuum hopper,
automatic sampler, and wire
feeder. First results obtained
anticipate a fast plant
commissioning and a
successful project conclusion n
5
7
3
8
2
4
10
11
9
6
1
MTE Finance Group
awarded a contract to
Danieli to supply a
complete meltshop, to produce up to
115,000 tpy of liquid steel. It’s part of a
program to modernize the steelmaking site at
Azov, near Rostov. The renovation of the steel
complex will benefit from the long tradition
of high-quality metallurgical industry in the
Rostov district, and from the plant’s strategic 1
location. The new facilities will include all
technological process equipment for melting
and refining of high-quality special and
stainless steel to be cast as ingots and blanks.
The main plant units are:
> A 16-t EAF with a spout-tapping device,
powered via an 18 MVA transformer;
> A 16-t ladle furnace with a high heating
rate for the highest flexibility on product mix;
> A single-tank vacuum degassing station
(VD/VOD), with mechanical vacuum pump;
> A integrated material handling system for
Fe-alloys and coarse material;
> A Fume Treatment Plant with capacity of over 300,000 Nm3/h;
> EOT cranes for ladle and ingots handling
with 400/80 kN capacity;
> A closed-circuit water treatment plant for
cooling of the newly installed equipment.
When completed, the new project will
estabilish a vertically integrated production
sequence for specialty steel ingots, to fully
exploit the capabilities of the newly installed
Danieli Breda integrated open-die forging
plant. The implementation of a meltshop
dedicated to such specific products will
provide benefits in term of process
optimization on niche products; reduction of WIP and stocks; full control of the quality,
from scrap to final product; reduction of total
OPEX; internal recirculation of valuable
process scrap; possibility of hot charging of
ingots to the forging cycle. The improved
plant performance that results will allow MTE
Finance to meet the needs of both domestic
and international markets, competitively, with
significant reductions in energy and labor
costs, and to create an environmentally
friendly production process n
1
2
3
4
5
6
7
8
9
Scrap yard
Electric Arc Furnace
Ladle Furnace
Vacuum Degasser
Ingot casting car
Scrap bucket transfer car
Ladle refractory
removal area
Ladle slag removal
area
Ladle relining station
10 Ladle drying and
preheating station
11 Additives storage and
charging system
Ivan Reshetnikov, MTE
Finance General Director
(right) and Paolo Burin,
Danieli Executive Manager
Sales Steelmaking, signing
the contract.
19
IRON & STEELMAKING
DANEWS
NEW INTEGRATED
EAF CHARGING SYSTEM
at Sohar Steel, Oman
THIS NEW CHARGING
SYSTEM COMBINES
CONTINUOUS
FEEDING FOR BOTH
DRI AND HBI
TO FURNACE
WITH DANIELI’S
INNOVATIVE ISAC™
SYSTEM FOR
CONTINUOUS
DELIVERY OF
SHREDDED SCRAP,
TO ESTABLISH
THE GREATEST
FLEXIBILITY FOR RAW
MATERIAL SELECTION
AND TO INCREASE
PRODUCTIVITY,
WHILE LOWERING
PRODUCTION COSTS.
A
Danieli Integrated
Shredded scrap
Automatic Charging
(ISAC™) system will be
installed at the Sohar
meltshop in Port of Sohar to
feed a new Danieli 75-t
FastArc™ electric arc
furnace, ordered in 2012.
The system is a new process
solution for charging
shredded material into the
EAF, and results from
merging the know-how of
Danieli Centro Met for steel
meltshops, Danieli Procome
Iberica for material handling
systems, and Danieli Centro
Recycling for scrap
shredding plants. The system
combines single bucket and
continuous charging for
20
G
Closed scrap bay
A
Free space for DRI/HBI
charging into bucket
F
Closed scrap bay
B
Shredded scrap
belt conveyor
E
C RELINING STATION
C
DRI/HBI/Lime
belt conveyor
A Danieli new EAF
B Shredded scrap charging
C Shredded scrap buffer storage
D DRI/HBI charging
E DRI/HBI storage silos
F Common conveyor
G EAF feeding from 5th hole
D
X
X
scrap to the EAF closed roof
by means of a special
conveyor, with a dedicated
melting profile and chemical
energy optimization program
In this way, the scrap density
in the bucket is managed
dynamically, without
impacting the standard
furnace design or the linked
equipment (i.e. bucket, shell
etc). The EAF is charged at
the beginning of the heat
with one bucket of scrap;
then, the melting process
begins and with precise
timing, determined by the
automation system, the
ISAC™ system starts to feed
shredded material through
the fifth hole to complete
the charge required. The
ISAC™ system provides a
complete and accurate
indication of the quantity of
material delivered to the
EAF by dedicated special
weighing systems on the
handling equipment. This
indication, plus the weighing
of the scrap bucket, provides
complete information for the
material charged into the
EAF. The ISAC™ system is
extremely beneficial for the
EAF melting process,
ensuring:
> an increase in melting
process yield, thanks to the
higher quality charge;
> a reduction of energy
losses, due to the fewer roof
openings;
> an increased in EAF
productivity with the same
Power-On factors, thanks to the reduced Power-Off
period. At Sohar Steel this
will improve EAF
productivity from 92 to 105 tph (+14%). The ISAC™ system is
integrated with a new
Danieli material handling
system for DRI/HBI
continuous feeding, allowing
the customer to select a wide
range of raw material for
charging and the highest
process flexibility, to lower
production cost an
d enhance plant profitability.
The ISAC™ system and the
DRI/HBI feeding system will come on stream during
spring 2014 n
DANEWS 168
New roof lifting
and swiveling
system for the
140-t EAF
at Stefana
Ospitaletto, Italy
ANOTHER INNOVATIVE VD/VOD PROJECT IN CHINA, FOLLOWING THE
SECONDARY METALLURGY STATION INSTALLED AT XINING SPECIAL STEEL.
NEW VOD STATION
for Jisco, P.R. of China
The new equipment will make possible a production increase, with safer operating
conditions and less
maintenance requirements.
his upgrade project for the 20+ years-old
Danieli EAF, to install a new design roof lifting and
swiveling system, aims to
increase production by fully
exploiting the 135/162 MVA
transformer, a condition
currently prevented by the
design restrictions of the
existing system. In this
respect the new system is
designed so as to allow the
use of larger electrodes (from
24 to 28 in.), and the
consequent increased loads
on the superstructure by
heavier electrode masts and
arms. At that time the EAF
transformer will run at the
maximum power of over 120
MW by raising the electrode
current up to 78 kA. As a
result of these design
changes, maximum EAF
productivity will be achieved.
Since the design will
accommodate the existing
hydraulic cylinders and
superstructure, with no
modification, the system will
be installed on site quickly
during a scheduled
maintenance stoppage,
without impacting the EAF
production. The startup of
the new unit is planned for
summer 2013 n
T
T
he vacuum degasser ordered in May
2013 will complete the stainless
steel production plant that JiscoJiuquan Iron & Steel Co. operates in
Jiayuguan (Gansu Province). The VOD will
be dedicated mainly to producing stainless
steel grades with ultra-low carbon and
nitrogen content (C+N < 200 ppm), and its
innovative features will allow a dramatic
increase to the productivity rates for these
steel grades. Ladle capacity, with new
refractory material, will be 105 t, with
1,200 mm freeboard. The VOD design is a
double tank-double cover type, equipped
with a five-stage vacuum pump with steam
ejectors and water ring pumps, with a
suction capability of 450 kg/h. The
innovative design of the pump will allow
Jisco to perform treatment under vacuum,
at different vacuum levels in both tanks at
the same time. Danieli was assigned an
extremely demanding task: Jisco requested
an operation capable of sequencing at least
three ladles to the caster in around 240
minutes. The AOD converter is delivering
ladles to the VOD every 50 to 60 minutes,
and the slab caster downstream the VOD
has a casting time around 45 minutes.
A usual VOD station design would need
two independent vacuum pumps to fulfill
this requirement. Danieli decided instead
to offer its new vacuum pump design that
will allow the operators to reach the target
required, saving on investment costs and
reducing steam consumption.
Danieli will supply all the technological
equipment, including the vacuum pump.
The tanks and the covers that will be
manufactured in Danieli China’s
workshops in Changshu, while the critical
control equipment will be supplied directly
from Europe, thus enabling Danieli to
deliver its traditional, high-quality supply
standards n
From left: Cao Shihai, Deputy Manager of Tian Feng
Stainless Steel Co.; Tian Hai, Vice Manager of Import and
Export Trading Co. of Jisco; Giulio Pretini, Manager, Sales,
Steelmaking, Danieli.
21
IRON & STEELMAKING
DANEWS
INTENSE ACTIVITY DRIVES GROWTH
at Danieli Centro Recycling
This year will
undoubtedly be
memorable for
Danieli Centro
Recycling.
The acquisition of
Riverside Products,
Inc., in USA brings
a third major global
brand to the product
portfolio, and
significantly
strengthens the
service capability
and capacity
of the division.
During the same
period, Danieli
Lynxs secured the
order for the world’s
largest aluminum
recycling and
shredding plant,
whilst Danieli
Henschel achieved
notable new
machine orders in
the UK, Belarus,
Middle East, China,
and Australia.
22
I
n April 2013, Riverside
Products became part of
Danieli Centro
Recycling. Now renamed
Danieli Riverside, the
company has been actively
supplying highly engineered
scrap shredder rotors and
wear parts to the metals
recycling industry worldwide
for more than 50 years. Its
reputation for engineering
excellence and the number
of patents it holds was a
decisive factor behind the
acquisition. Innovative rotor
designs developed by Danieli
Riverside will be
incorporated into specialty
shredder applications offered
by Danieli Lynxs. Spring
2013 saw Danieli Lynxs
awarded the contract to
construct three shredding
and separation lines for the
world’s largest aluminum
recycling plant, under
construction in Germany.
The client, a prominent
supplier of aluminum sheet
to the automotive industry,
chose Danieli Lynxs due its
superior technology and
flexibility in design. Fasttrack manufacturing will
allow installation of the first
shredding line to begin in
January 2014, with handover
of the complete plant
scheduled for third quarter
2014. The integration of
Danieli Henschel over the
past 12 months has brought
new processing synergies for
steelmaking customers of
Danieli and Danieli Lynxs.
In Australia, Sell & Parker
(Pty) Ltd. chose Danieli
Henschel as its preferred
supplier for a new CIB
1400-10L static hydraulic
shear to complement a
DANEWS 168
3,000-kW Danieli Lynxs
shredder installed and
operating at their Sydney
processing facility since
2002. Similarly, NatSteel Holdings
in Singapore and United
Steel Industrial Co. (Kuwait
Steel) appreciated the
importance of their long
association with Danieli
when deciding on the
supplier of, respectively, new
CIB 1400-10L and CIB
1250-10L static hydraulic
shears. The prominence of
Danieli Henschel as one of
the world’s foremost
suppliers of large hydraulic
shears brought further orders
from Enablelink, UK and
Belvtormet in Minsk,
Belarus. As part of a new
Nanomill project awarded by
Arabian Gulf Steel (Taybah),
Danieli Lynxs will supply a
1,050-kW DCR 1822
shredder and Danieli
Henschel a CIB 1000-8L
static hydraulic shear. As one
of the world’s leading
technology companies,
Danieli brings new solutions
to all its product lines.
During Spring 2014, a
1,050-kW DCR 1822 scrap
shredder plant was
commissioned by Danieli
Lynxs for Metales de
Navarra, S.A. (Medenasa),
Pamplona, Spain. The main
shredder motor represents
the world’s first application
of a low-voltage inverter
drive for this type of
equipment. The technology
was developed exclusively by
Danieli Automation and
provides significant savings
in total energy costs. The
perennial problem of power
supply ‘flicker’ is overcome
and significantly smaller
demands are made upon the
incoming power supply.
Other notable project
completions in this period
have been the 1,500-kW
DCR1827 shredder plant
with advanced TOC Fume
Treatment for RMB SpA,
Brescia, Italy, and the 1,050kW shredder plant for Mag
Ferum, Nowy Sacz, Poland n
DCR6290 shredder launch ceremony
at Danieli China in Changsu (DCS)
O
n May 29, 2013, in parallel with
the BIR convention held in
Shanghai, an event was organized
at DCS to present the newly finished
DCR 6290 scrap shredder to a selected
group of potential customers. During the plant tour, the guests were
shown the excellent level of product
Li Jun, EVP of Danieli
China, delivering the
welcome speech.
The general secretary of
CAMU, Li Shubin, the
EVP of Danieli China Li
Jun, and the VP Global
Sales of DCR, Andreas
manufacturing and of production
management available at DCS.
The guests expressed a deep interest in the
advanced technical points of the shredder
(e.g. the unique base section design, spider
rotor with cap, hydraulic fasten unit,
appropriately sized wearing parts, etc.) and of downstream systems. Such interest makes
us confident that a broad market appreciation
will be shown, and will be pursued through
dedicated visits and discussions.
Further to the positive responses of guests at DCS, leaders of the China Association of Metal Scrap Utilization (CAMU) that
attended the ceremony stated their belief
that the launch of the new shredder well
represents the commitment of Danieli to the Chinese metal recycling industry, and will lead the market demand for green
recycling technology n
Zoellner, cutting the
ribbon to unveil the
brand-new shredder
together.
Qin Linsheng, Vice
Chairman of CAMU, and
Davide Braga, Sales
Manager of DCR propose
the toast to the guests.
23
DA N
BENCHMARK PERFORMANCES
FOR AUTO SCRAP
SHREDDING FUME TREATMENT
I
EL
EL
DANEWS
TE
IRON & STEELMAKING
I GR EN S
E
at RMB Brescia, Italy
A new Danieli-patented system
for gas cleaning and controlling
Volatile Organic Compounds
(VOC) emissions was
commissioned successfully
this past March.
6
The innovative solutions
achieved all the project targets,
with total VOC emissions lower
than 5 mg/Nm3, advancing this
new technology as the new
benchmark for dedusting
systems for automotive recycling
4
2
T
he shredder at RMB treats a mixed
charge of scrap, including compacted
vehicles; for this reason a need was
identified for a fume-treatment plant to treat
the Volatile Organic Compounds (VOD). It should be noted that the abatement of
VOC has become mandatory only recently in
the car recycling industry, and this
requirement involves other pollutants, too.
One suitable technology for VOC control is
oxidation at high temperature, but this
method is not economically viable in this
case because the VOC concentration is so
low that it cannot support the selfcombustion of VOC, thus external fuel must
be used to increase the fume temperature to
approx. 900 °C.
It is not possible to treat the air directly with
a bed of activated carbon due to the risk of
water vapor condensation from the pretreatment stage involving a wet scrubber
(which is necessary for dust abatement). Dry
pre-treatment with a bag filter is not feasible
due to the potential fire hazard (flying
burning materials must be quenched with
the water sprayed in the scrubber).
The Danieli technology involves controlling
VOC with a bed of activated carbon and
processing the primary air flow from the
24
5
3
1
Pollutants Target Measured
values values
(mg/Nm3)
(mg/Nm3)
Dust content
10
4.5
Oil mists
10
3
∑ Cr, Co, Cd, Ni, As
1
0.1
∑ Pb, Mn, Cu, V, Sn
5
0.5
HCl
10
1
HF
2
0.2
H
0.01
0.001
PCB
0.1
0.001v
VOC
30
5
1 Active carbon boxes
2 Cyclone
3 Demister and scrubber
4 Bag filter
5 Burner
6 Stack - Fan
Target values of the fume
treatment plant, expressed
as pollutants at chimney,
compared with the
measured values.
DANEWS 168
Danieli fume treatment
technology with bed of
activated carbon to control
VOC at RMB, Brescia, Italy.
shredder, together with a secondary flow
coming from the air separation equipment
installed at the fluff separator. The primary
fumes are dedusted with a cyclone and then
with a wet scrubber. The secondary flow is
pre-filtered with a bag filter and heated by an
external fuel burner prior to mixing with the
primary air flow (from the shredder). The
temperature of the mixed flow is higher than
ambient temperature, thus the risk of
condensation in the carbon bed is prevented. The advantage of this technology is that a
free flame can be safely used to heat only the
secondary flow of air, which does not contain
VOC. The flow rate of air treated by the
activated carbon bed does not increase
significantly because the secondary flow is
only one fifth (approx.) of the primary flow. The combination of the two lines (primary
flow from the shredder and secondary flow
from air separation unit) is economically
advantageous because it allows using only
one induced draft fan and one stack instead
of two, as it would be required with two
independent lines. The project was successful and all the targets
have been reached, with total volatile organic
compounds lower than 5 mg/Nm3. Due to the innovative solution this
technology will become the new benchmark
for dedusting systems for the car recycling
industry n
25
FLAT PRODUCTS
DANEWS
Q-WIDTH TECHNOLOGY:
PROVEN SUCCESS FOR HIGHER-FLEXIBILITY
SLAB CASTING OPERATIONS
Danieli developed
the “3Q” process
technologies suite
to address three
critical principles:
delivering highest
product Quality, in the required
Quantity, with the Quickness of response
required for today’s
casting machines.
Q
-WIDTH is a
combined
mechanical and
software solution that makes
it possible to change the slab
width without interrupting
the operation of the slab
caster, thereby providing the
caster operator with
maximum operational
flexibility in line with
customer requirements and
the production schedule.
It is well known that proper
control of the taper minimizes
the risk of excessive narrow
side bulging and depressions
in the slab corner area,
which ultimately will lead to
product down-grades or even
rejections. Q-WIDTH
addresses these issues by
continuously adjusting the
narrow-side taper according
to slab width, casting speed,
steel chemistry, and super
heat. Hence, Q-WIDTH
ensures high-product quality,
26
whilst maximizing caster
availability. Q-WIDTH
utilizes state-of-the-art
technology to achieve the
narrow-face taper and
position accuracy required.
The electro-mechanical
system consists of a highcapacity roller screw jack in
each adjustment ram, fitted
with a gearbox to drive the
narrow-side assembly
forward and back. A position
transducer, inside the roller
screw, and an encoder on the
gearbox provide the accurate
position measurement of the
narrow side assembly. The
drive comes from an electric
motor fitted to it, positioned
either off the mold or
integrated into the mold.
This arrangement guarantees
that the system will not be
affected by any mechanical
backlash and, as the system
is equipped with a stationary
braking device, any
movements cannot take
place if not requested by Q-WIDTH. Compared to a
hydraulic system, QWIDTH has the advantage
of not losing its position even
in the event of a power or
electrical failure. During a
slab width changes, the
control software will conduct
real-time calculations of the
optimal narrow-side taper,
considering casting speed,
narrow-side width adjustment
speed, and narrow-side width
adjustment acceleration.
Based on this calculation the
movement of the mold
narrow faces is a combination
of translation and rotation,
which eliminates the risk of
an air gap between the slab
shell and the mold narrow
side copper plates. QWIDTH is a proven
technology, as testified by the
results recently achieved
during performance
guarantee tests at Tangshan,
P.R. of China, and
ArcelorMittal Tubarão, Brazil,
where a width change of up
to 300 mm was achieved in a
single step. Q-WIDTH can
be applied to new casting
machines or retrofitted to
both conventional slab
casters and thin slab casters,
working in a typical range of
casting speeds from 0.5 - 7.0
mpm. Since there is no
limitation for casting speed,
the width change can be
operated in any condition
that allows optimizing the
tapered slab length. The
project payback period is
typically less than 12 months,
with the following anticipated
benefits:
> Increased flexibility in
satisfying the production
schedule;
> Improved slab quality and
shape;
> High-speed width change,
reducing downstream yield
loss;
> Reduced machine down
time; and
> Reduced potential for
breakouts n
THE COMPREHENSIVE RANGE OF 3Q TECHNOLOGICAL PACKAGES
> Q-LEVEL+ for accurate mold level control
system;
> Q-MAP for mold thermal monitoring system;
> Q-INMO+ highest quality, low maintenance
hydraulic oscillator;
> Q-COOL the high-efficiency dynamic
secondary cooling technology;
> Q-CORE for dynamic soft reduction;
> Q-WIDTH mold width adjustment system;
> Q-PULSE the innovative system for liquid pool
end point measurement;
> Q-MIX model calculates in real time the
chemistry of the steel;
> Q-MOD monitors the mold oscillator movement
performance during production;
> Q-OPTIMUM is Danieli’s unique segment
design, to deliver the ultimate in operational
performance, with reduced maintenance.
> Q-ART is a computer-based cast product
quality assessment system
> Q-ROLL is based on long-standing experience
in caster operation and maintenance;
> Q-CUT maximizes the quantities of prime quality slabs.
DANEWS 168
1 Typical Q-Width assembly.
2 Narrow faceplate movement
position during 50-mm width
decrease and increase.
3 Schematic diagram of QWidth equipment fitted to the
mold.
4 Example of MWA tests
performed at Tangshan, P.R.
of China, and ArcelorMittal
Tubarão, Brazil. Width
increase and decrease (per
strand).
1
2
Motor 1
Right top
Motor 3
Left top
Reduction
gear
Number of MWA test
Resolver brake
90
80
70
60
50
40
30
20
10
0
85
52
45
32 34
21 23
16
TOTAL
3
11 14
12
3 2
INCREASE DECREASE
Motor 2
Right bottom
Strand 1
Strand 2
74
4 5
4 4
6 3
INCREASE DECREASE INCREASE DECREASE INCREASE DECREASE INCREASE DECREASE
0-49 mm
60-99 mm
100-199 mm
200-300 mm
Motor 4
Left bottom
4
27
FLAT PRODUCTS
DANEWS
WITHIN THE LONG-TERM
COOPERATION
ESTABLISHED BETWEEN
DONGBU AND DANIELI,
THE PAPER “UPGRADE
TO FOURTH GENERATION
OF THIN SLAB CASTER”
WAS JOINTLY PRESENTED
AT THE AISTECH2013
CONFERENCE
IN PITTSBURGH (PA).
28
DANEWS 168
SUCCESSFUL STARTUP OF THE
FOUTH-GENERATION THIN SLAB CASTER
at Dongbu Steel, Korea
SAE1008M (LC) - 4.3%
SPHC (LC) - 42.7%
SPHT2 (LC) - 2.4%
SPHT3 (LC-HSLA) - 2.4%
API X52 (LC-HSLA) - 0.9%
SS400 (MC) - 17.7%
API J55 (MC) - 2.0%
SS490 (MC-HSLA) - 1.3%
JS 45C (HC) - 0.7%
SPECIAL STEEL (HS, VAG) - 18.9%
CHECKER PLATE - 6.7%
T
he steps performed in this machine
modification, as well as the final
results achieved by Dongbu Steel,
were jointly exhibited as the accomplishments
of the high-speed casting and high quality
targets, a model for fast and reliable caster
upgrades and tuning of the fourth generation
fTSC. Danieli’s technological packages were
fundamental to achieving the production
targets, as well as the highest-quality products.
In particular, two of these packages were
further developed specifically for the Dongbu
project: the Mould Breakout Prevention
System with Thermal Mapping (Q-MAP),
and the Advanced Mould Level Control (QLevel+). The Q-MAP mapping viewer was
improved and the algorithms for faster and
more reliable detection of defects were
further developed, customized to address
specific customer demands. Furthermore,
the Q-Level+ was successfully implemented
for highly accurate performances in mold
level control and level diagnostics at
The paper describes
the achievements of the latest Danieli
TSC technology and testifies to the
fact that hard work,
flexibility, and a cooperative spirit,
are the keys to
achieving high-end
results and customer
satisfaction.
Kwang Yeol Kim, VP of Dongbu,
Superintendent of Hot Rolling Mills,
Dangjin Works; Yoon Jae Lee,
Technical Director, Danieli Davy
Distington.
maximum casting speed, and even adopting
double sensor (radioactive and eddy current
type) monitoring. The two Danieli fTSCflexible Thin Slab Casters commissioned in
2009 are currently producing a wide variety
of steel grades, spanning from low-carbon
grades for high-quality galvanized products
(Dongbu Steel is the market leader in Korea
for cold rolled products), to API J55 for
casing and X70 grades for pipe applications.
High-carbon grades are produced in a range
of carbon contents, from 0.35% to 0.85%.
Depending on market demand, the hot
complex exceeds 190,000 - 200,000 tons per month of HR coils produced, smoothly,
and with the highest quality standards.
Dongbu Steel previously expressed its
satisfaction to Danieli, highlighting the attainment of the targets that were the result of the mutual cooperation between both parties. And co-operation still
continues, targeting more and more new
achievements n
29
FLAT PRODUCTS
DANEWS
COMMISSIONING OF NEW STEEL GRADES
FOR 350-MM THICK SLABS
at Yingkou. P.R. of China
P
roducers of steel
plate face an
increasing demand
for high-quality, highthickness plate products.
The Yingkou slab caster, with its 11-m radius and the
ability to cast slabs from 250 up to 350 mm thick, was designed to match this
requirement. Currently the
caster is in the tuning phase,
in order to solidify the
achievement of defect-free
products that can be rolled
without prior conditioning.
To address the market’s
expectations, priority was
given to the production of the highest thickness (350 mm) and the widest
dimensions (2,000 - 2,200 mm.)
The product mix consists of about 80% of mediumcarbon and medium-carbon
HSLA steel grades, a small
amount of special steel
grades, and about 18% of
high-carbon grades.
Of particular interest among
the medium-carbon steel
grades is the casting of
boron-added steel grades. It is well known that steels
grades with boron addition
are extremely sensitive to
cracking. Particular attention
has to be paid to corner
cracks. It is crucial to
prevent edge temperatures
from falling into ranges in
which there is a reduction of ductility of the material,
thereby promoting crack
formation. The application of the proper cooling strategy
is fundamental to obtaining a product free from defects.
For the secondary cooling
system of the Yingkou caster,
each loop is capable of
30
1
2
1 Internal quality achieved
in terms of cracks and
segregation is at the
highest level.
2 Inspected slab of MC B-added slab of 350
mm thickness, no
subsurface defects
found.
3 Dimensional tolerances
are easily within
contractual limits, in
particular the bulging of the narrow face is less
than 4 mm, a critical
point for the high
thickness slabs.
3
independent flow control for
each width, ensuring in this
way proper temperature for
any casting condition. As result of tuning activities
it has been possible to obtain
medium-carbon boron-added
slabs free from surface
defects.
Dimensional tolerances are
easily within contractual
limits, in particular the
bulging of the narrow face, a critical point for the high
thickness slabs, is less than 4 mm.
Another fundamental aspect
to consider when producing
slabs for plate applications is
the internal quality. Applying
soft reduction in the correct
position is a critical point to
achieve the required internal
soundness. Soft reduction
and secondary cooling are
controlled by a mathematical
model calculating
temperature across the slab
width, regulating water flow
and soft reduction end point.
To verify accuracy and tune
the model when necessary, a great contribution is made
by the Danieli Q-Pulse
system (patent pending) that detects and confirms
the end of the liquid cone. In terms of cracks and
segregation, the internal
quality is at the highest level.
Production tuning activities
are still in progress but
results obtained up to now
prove the Yingkou caster
capable of meeting the most
demanding requests in thick
slab casting n
DANEWS 168
Hot strip mill innovations
to enhance rolling operations
in North America
New guillotine-type crop shear for transfer bar
A SUCCESSFUL
HOT STRIP MILL
UPGRADE PROJECT
IN THE USA
PRESENTED
AN OPPORTUNITY
TO DEVELOP TWO
INNOVATIVE
SOLUTIONS,
FOR TRANSFER BAR
CUTTING AND FOR
THE WORLD’S FIRST
AUTOMATIC
SAMPLING STATION,
MAKING IT POSSIBLE
TO EXTEND THE
MILL’S PRODUCT
RANGE TO INCLUDE
HIGH-STRENGTH /
HIGH-THICKNESS
PRODUCTS.
From top: Guillotine shear preassembled at Danieli’s workshops.
Saw-type sampling station preassembled at the Danieli
workshop, and in operation in line.
The shear operates in conjunction with an existing rotary drum crop shear so as to increase the range of products cut up to 3 in. transfer bar thickness for API X80 grade
strip. This will make it possible for the hot
strip mill to process high-strength, 1-in. thick
API X80 line pipe grades, while maintaining
the ability to process all of the current product
mix.
The transfer bars range in size from 1.5 to 3 in. in thickness, and 24 to 78 in, in width,
and have a minimum temperature of 900 °C.
The guillotine shear squares off the head end
of the transfer bar to improve its inlet into
the finishing mill. The shear is a down-cut
lever design with hydraulic actuators,
designed with a hydraulic synchronization
system. Hydraulic synchronization of the two
sides of the shear is performed through a
closed-loop control using the hydraulic
cylinder linear transducer signals. The entry
pinch roll is provided to clamp the transfer
bar during threading and cutting,
respectively. The machine is completed with
entry pinch rolls and knife-changing
mechanisms for quick removal and
replacement of shear knives and pinch rolls.
World’s first automatic sampling station
for API X80, 1-in. strip thickness
The new automatic sampling station area
consists of a coil loading station, coil transfer
car, unbanding machine, saw disk-type shear
with peeler, circumferential and radial
strapping machines, coil removable station
and scrap and sample evacuation equipment.
This new, compact machine is able to cut
scraps and samples from high-resistance coils
of 0.31 to 1 in. thick and 24 to 78-in. wide
strip, in semi-automatic mode, consistently
reducing the complete cycle time.
The cutting is done by a carbide-tipped saw
disk. Samples are collected in automatic
mode in a movable basket in an ordinate
sequence. The performance test was
completed successfully, confirming the
soundness of Danieli’s innovative concept for both the guillotine shear and the saw-type
sampling station n
31
FLAT PRODUCTS
DANEWS
PLATE / STECKEL MILL UPGRADE TO ACHIEVE
BETTER QUALITY AND HIGHER PRODUCTIVITY
at JSPL Raigarh, India
On July 25, 2013,
Jindal Steel and
Power Ltd. and
Danieli agreed to
a contract for the
supply of design,
engineering, and
equipment supply
to upgrade the
existing JSPL
plate/Steckel mill
plant, a project that
will increase the
finished product
quality as well as
the mill capacity
from its current
production to
1.2 Mtpy.
J
indal Steel and Power Ltd.
(JSPL) is one of India's
largest steel producers,
with a significant presence in
mining, power generation and
infrastructure sectors. JSPL
has a steelmaking plant at
Raigarh, Chhattisgarh, that
features downstream a thick
slab caster and a plate/Steckel
mill to produce 3.5 m wide
plates and coils of 3 m width.
This is an old plate/Steckel mill
that has been relocated to
Raigarh, starting its current
commercial production in April
2007 and having an actual
production capacity of 1 Mtpy.
32
Project features
To ensure the productivity,
reliability, consistency and the
satisfactory operation of the
existing plant, the main
objectives of the revamp are:
> Supply new drive motors (2 x
7,500 HP) with base frames
and bearings for the 4-high
finishing Steckel mill stand,
and relocated existing drive
motors (2 x 5,000 HP) with
base frames and bearings to
the 2-high mill.
> General refurbishment of the
4-high mill stand to
accommodate new mill entry
and delivery strippers and
guides, new WR heavy bending
system, existing HAGC with
new servo valves and built-in
electronics, new roll bite
lubrication system, new WR
Thermal Crown Control (RTC),
new dust suppression system,
new on-board descaling
system, and intermediate
laminar cooling.
> Implementation of Danieli’s
patented fully automatic
Accelerated Cooling system, to operate according to the
laminar-flow principle with lowpressure water to cool the strip
/ plates coming from the mill,
and also to improve the
mechanical characteristics of the thermo-mechanical
rolled plates. An edge-masking
function is provided to prevent
plate edge overcooling.
> Installation of a powerful
Danieli downcoiler, customdesigned to coil 25.4x2, 500mm strip in API X80 grade,
matching the extreme rolling
conditions and the demanding
requirements of coiling speed
and strip formation for those
oil-and-gas products. Three
wrapper rolls provide excellent
tension control to prevent
telescoping coils.
> Addition of a complete coil
handling system with in-line
facilities (such as
circumferential and radial
strapping machine, weighing
and marking machine) as well
as off-line sample collecting
and inspection line. > Implementation of a new
automation system for the mill
zone and for the new
equipment, provided by Danieli
Automation.
expertise with revamp projects,
encompassing the ability to
analyze all the requirements
and the possible critical
aspects, and to customize and
optimize the proposal, also
respecting the need to
minimize the
intervention/modification and
the plant shutdown. So, it
should reiterate the increasing
confidence shared by flatproducts producers worldwide
in Danieli’s reliability, including
the Indian market, where
previous interesting and
challenging upgrade projects
(Bokaro hot strip mill, and
JSPL Raigarh plate / Steckel
mill at glance) have been
awarded to Danieli during
recent years, beyond turnkey
complete plants like NMDC’s
QSP-2 and SAIL RSP’s plate mill n
The proposed solution thus
incorporates optimal plant
configuration and layout, taking
full advantage of the rationality
of material handling in the
plant. In fact, this order
confirms the Danieli team’s
Saroj Jain, President
(Projects) of JSPL and
Matteo Bulfone, Product
Manager of Danieli Wean
United, exchanging
contract documents.
Right: The 4-high finishing
Steckel mill stand as it is
now, before the upgrade.
DANEWS 168
DANIELI SKIN-PASS MILL INAUGURATED
at SAIL Bokaro CRM III, India
T
his state-of-the-art skin-pass mill -the
first unit to be inaugurated at the
Bokaro CRM-III complex- will
process about 860,000 tpy of cold rolled
annealed coils (strip thickness of 0.25 to 2.0
mm; strip width of 800 to 1600 mm) at a
maximum speed of 1,200 mpm in a wide
spectrum of grades (CQ, DQ, DDQ, EDDQ,
HSLA, IF, BH, etc., with yield strengths
from 140 to 400 N/mm2) targeting the
automotive, white goods, and appliance
sectors. This SPM will be able to process
very soft materials, like IF grades, and very
high-strength steels with the necessary
elongation, hardness, flatness and strip
roughness standards required mainly for
automotive applications. Designed as an
elevated mill structure with strip flow from
left to right, it consists mainly of the
following equipment:
> Entry section, including walking-beam
conveyors, downcoilers, coil cars, coilpreparation station, payoff reel with pup coil
removal system, entry bridle unit, automatic
de-bander, etc.
> Mill stand equipment consisting of mill
stand with rolls, chocks and bearings,
bending blocks, quick work-roll changing
device, hydraulic wedge for pass-line
ON JANUARY 18,
2013, C.S. VERMA,
CHAIRMAN OF
STEEL AUTHORITY
OF INDIA LTD.,
INAUGURATED
INDIA’S MOST
ADVANCED SKINPASS MILL,
A STATE-OF-THEART LINE SUPPLIED
BY DANIELI FOR THE
1.2-MTPY CRM III
NEW COLD ROLLING
MILL COMPLEX.
adjustment, backup roll-change system, wet
skin-passing headers and nozzles, anti-crimp
roll, cobble guards, roll polishing device, etc.
> Delivery section consisting of strip blow-off
unit, thickness gauge, shapemeter roll,
hydraulic shear, electrostatic oiler unit,
tension reel, belt wrapper, exit coil car,
banding machine, and exit walking-beam
conveyor system.
Danieli’s scope of supply also included all the
auxiliary systems (hydraulic, pneumatic,
lubrication, fume and dust extract systems,
etc.) and complete electrical and automation
systems, which were implemented by Danieli
Automation n
From left: T. Suresh, Director, Projects, SAIL; H.S. Pathi,
Director, Personnel, SAIL; S.S. Mohanty, Director, Technical,
SAIL; C.S. Verma, Chairman, SAIL; A. Maitra, CEO, BSL;
Umesh Kumar, ED (Projects), BSL.
33
FLAT PRODUCTS
34
DANEWS
DANEWS 168
FINAL ACCEPTANCE FOR SKIN-PASS MILL
at Risse + Wilke, Germany
T
he Ruhr area is known as the
birthplace of the cold rolling industry
in Germany, and 10% of Germany’s
total cold-rolled steel strip output is supplied
by Risse + Wilke, located at Iserlohn in the
heart of the Ruhr region. The company has
about 350 employees, with an annual turnover
of 160M Euro. 45% of the output is dedicated
to the automotive industry, and the remaining
55% to a wide selection of applications for
other customers. An example of the company’s
special products with unique features are
ultra-hard saw blades, supplied to Brazil for
large chainsaws used to harvest lumber, or to
Italian stone quarries for saws to cut marble
blocks. Most of these products get a final CR
pass on the new DF skin-pass mill, designed
for steel grades ranging from carbon steel up
to high-strength microalloyed steel, at a
maximum strip width of 820 mm and strip
thickness between 0.2 mm and 6.0 mm. The mill is a combined 2-high / 4-high
configuration, for strip elongation and
reduction ranging from 0.2% and 15%, using
either a 2-high or 4-high roll stack. Special
constraints for the equipment design have
been followed closely, together with the
customer, as the new mill was installed in an
existing building and infrastructure.
Special features of the mill
> Top-mounted HAGC cylinders with low
hysteresis for highly dynamic roll-gap
adjustment and thickness control. > 4-high work rolls equipped with positive
and negative roll bending to allow a wide
product mix at a reduced number of different roll crowns.
IN MAY 2013
RISSE + WILKE
SIGNED THE FINAL
ACCEPTANCE
CERTIFICATE FOR
THE 2-HIGH/ 4-HIGH
SKIN-PASS MILL.
THE EVENT MARKED
THE SUCCESSFUL
COMPLETION
OF THE LARGEST
INVESTMENT
IN THE HISTORY OF
RISSE + WILKE’S.
THIS PROJECT ONCE
AGAIN SHOWS THE
STRONG MARKET
POSITION OF
DANIELI FRÖHLING
FOR NARROW
SPECIAL STEEL
ROLLING MILLS
> Twin-drive gearbox for separately
controlled top and bottom rolls.
> Dry rolling and minimum lubrication
rolling mode. The minimum lubrication uses
a special design for constant, reproducible
application of very low quantities of oil onto
the surface of the strip. The system uses
pressurized air to atomize the lubrication fluid
to the smallest drops. Additionally, the air
builds up a channel to avoid fluid particles
splashing to surrounding areas.
> Roll polishing units, using DF innovative
design for dry and wet polishing. For dry
polishing the dust particles are vacuum
exhausted and air cleaned by a highefficiency cyclone filter.
> Completely enclosed housing for the core
equipment, for increased safety at work and
compliance with the strict German noise and
fume emission regulations.
> Fully automated manipulator to remove
pup coils from the payoff reel, for fast coil
change sequence and high yield.
The mill is equipped with AC drives of a total installed power of 1.6 MW. Special
attention is paid to sustainable, energyefficient design by net regenerative drives
with minimized harmonic feedback and
adjustable reactive power compensation, as
well as to motors of the highest efficiency.
The automation system provides a state-ofthe art, real-time control system with
automatic thickness / elongation control and additional strip profile measurement.
The line was officially inaugurated during
this past spring, and since then has been
operating at full production n
35
FLAT PRODUCTS
DANEWS
NEW 500,000-TPY PUSH-PULL PICKLING LINE
at Abul Khair Steel, Bangladesh
O
n June 13, 2013, Danieli India Ltd.
signed a contract with Abul Khair
Strip Processing Ltd. for design,
engineering, supply, and installation of a
500,000-tpy push-pull and semi-continuous
pickling line, to be installed at the Abul
Khair Steel facility in Kadamrasul, Sitakund,
Chittagong.
This new push-pull/semi-continuous pickling
line is one part of a strategic capacity
expansion project by Abul Khair for its flat
product production facilities.
Danieli is responsible for supplying the
entire mechanical, electrical and control
systems. According to its well-proven
strategy, Danieli will manufacture the
mechanical equipment at its own workshops
in Italy, Thailand, China, and India. The first
coil from this line will be produced within
10.5 months of the contract’s effective date.
The line will treat low-carbon steels with
max. UTS of 550 N/mm2, and YS of 170 to
400 N/mm2, at max. process speed of 200
mpm. Strip thickness and width will range
from 0.8 to 4 mm, and from 800 to 1,270
mm, respectively. This state-of-the-art PPPL
will have a double-pass entry section, a
stitcher for semi-continuous operation to
process thinner strips, a Danieli Turboflow®
acid-pickling section, side trimming, and
recoiling. The electrical and automation
system supplied by Danieli Automation will
be based on state-of-the-art technology and
widely accepted industry standards in order
to ensure reliability, user-friendliness and
ease of maintenance. Easy line diagnostics
36
PPPL TECHNOLOGY
HIGHLIGHTS
> ECONOMICAL
PLANT SIZE FROM
1.0 MTPY DOWN
TO 0.25 MTPY.
> ABILITY TO
PROCESS MUCH
HEAVIER GAUGES
COMPARED
TO CONTINUOUS
LINES, UP TO
16.0 MM.
> HIGHER
FLEXIBILITY IN
OPERATION
COMPARED WITH A
CONTINUOUS LINE.
Photograph of the contract
signing on June 13, 2013,
at Chittagong. From left:
Wazad and Mukesh
Aggarwal from Abul Khair,
Sanat Bhaumik,
Massimiliano Svetina,
Sudipta Ray and Siddartha
Banerjee from Danieli.
will be an integral part of the overall system
architecture design, providing the operators
with information needed to take quick and
decisive action. From the main pulpit on the
HMI screen, all the machine operations and
set-up values can be monitored and
supervised by the operator, which helps to
simplify operation of the line.
This plant is expected to be processing strips
by the middle of 2014, estabilishing a new
benchmark for Danieli in the market of such
push-pull pickling lines in Bangladesh and
neighboring countries. One of the main
highlights of the line will be its ability to
process ultra-thin hot rolled strips down to
0.8 mm. With production of thinner and
thinner hot rolled strips by modern thin slab
casting and rolling plants, demands for such
innovative push-pull/semi-continuous
pickling lines will continue to rise from
customers in the steel sector. Such lines will supply not only pickled coils to cold
rolling mills but a large number of HRPO
coils to hot skin pass mills for skin-passed
HRPO coils n
DANEWS 168
37
FLAT PRODUCTS
DANEWS
ORDER FOR SIX STRIP FINISHING LINES
from Abul Khair Steel, Bangladesh
Main data of the five recoiling lines
Material
CR LC steel coils
Thickness
0.09 - 0.4 mm (for line nos. 1 &2);
0.20 - 1.0 mm (for line nos. 3 & 4);
0.25 - 2.5 mm (for line no.5)
Width
650 to 1,250 mm
Coil data
ID: 508 mm, OD: 2,000 mm (max)
Weight: max 25 t, PIW: max 20 kg/mm
Line speed
600 mpm max
Line functions
Uncoiling, edge trimming, top and
bottom side inspection, coiling, coil
strapping and weighing, spool loading /
unloading, etc.
Main data of the cut-to-length line
A
bul Khair Strip Processing Limited
(AKSPL) is a newly established metal
strip finishing plant for the AK Group
in Bangladesh, planned to produce a wide
range of steel products like very thin coldrolled coils, galvanized plain and corrugated
sheets, color-coated plain and formed sheets,
etc. Because the minimum thickness of coldrolled or galvanized sheets will be as low as
0.09 mm (90 µm), AKSPL needed very
special finishing line equipment to ensure
proper edge trimming at very high speeds (600
mpm), shearing and producing the finished
coils / sheets without any scratch marks on
the strip surfaces. Being impressed with the
Contract signing on August 23, 2013. From left, from
Abul Khair: Zakir Ahmed Suman, Deputy Manager,
Supply Chain Management, Mukesh Aggarwal,
Deputy General Manager Flat Project, A.N.M. Wazed
Ali, General Manager, Supply Chain Function; for
Danieli China DNF BU: Zhang Chang, EVP, and
Huang Zhenyan, Sales Manager.
38
Abul Khair Steel
Limited is an
affiliate of AK
Group, which is a
one of the largest
Bangladeshi
industrial
conglomerates. AK Group was
established in 1953
by Abul Khair, a pioneer in the
private industrial
sector. The markets
served by this
conglomerate
include cement,
steel, consumer
goods, tobacco, food products, etc.
Material
LC steel coils, cold rolled,
galvanized and color-coated
Thickness
0.2 to 2.0 mm
Width
750 to 1250 mm
Coil data
ID: 508 mm, OD: 2,000 mm (max),
Weight: max 25 t, PIW: max 20 kg/mm
Line speed
100 mpm max
Line functions
Uncoiling, leveling by 6-high, 21-roll
leveler, shearing by double eccentric
flying shear, stacker for 4-m-long sheets
state-of-the-art equipment proposed, AKSPL
selected Danieli to supply these finishing
lines. On August 23, 2013 Danieli AKV
China signed a contract with AKSPL
covering the design, engineering, supply, and installation of six finishing lines (five
recoiling lines and a cut-to-length line) to be installed at its flat-rolling facility in
Kadamrasul, Sitakund, Chittagong. The contract for these state-of-the-art
finishing lines is one step of a strategic
capacity expansion project for Abul Khair at its flat-product facilities in Chittagong.
Danieli is responsible for the entire supply of the mechanical, electrical and
control systems. As per Danieli’s well-known
strategy, manufacturing of all mechanical
equipment will be done in Danieli workshops in China. The first two recoiling
lines and the cut-to-length line are expected
to be operational by the third quarter of 2014, creating a landmark for Danieli in the market of such finishing lines in Bangladesh and India n
DANEWS 168
New bonderizing line
at Wälzholz New Material (Taicang), P.R. of China
THIS IS ANOTHER
“HALF TURNKEY”
PROJECT
ASSIGNED TO
DANIELI CHINA.
n June 17, 2013,
Wälzholz New Material
(Taicang) Co., Ltd. and
Danieli China signed an order
for installing a new bonderizing
line at its production site in
Taicang, Jiangsu Province. The
scope of the contract covers
the design, manufacturing,
installation, and commissioning
of the strip processing line, a
process also known as
phosphating or phosphatizing.
Wälzholz New Material
(Taicang) Co., Ltd. is a wholly
owned subsidiary of Germany’s
CDW Group. At CDW more than
180 years of experience in
working with steel is combined
with modern technology. Today
the company is a marketleading supplier of steel
products for complex
applications, worldwide.
Bonderized steel strip has
some excellent properties: it is
capable of extreme metal
forming with minimal drawing
steps and without intermediate
annealing, for all end products. The new bonderizing line will
be designed to produce 650mm wide cold-rolled steel strip.
The line’s process technology
includes a travelling shear to
cut off the stitches without
stopping the line. The finished
strip can be recoiled either to
the top or the bottom. This line
O
is part of the second-phase
expansion project at WNM, by
which the customer aims to
produce 70,000 tpy of treated
material. The contract shows
the confidence of an
internationally renowned
customer in Danieli China
regarding the high-quality
engineering / manufacturing,
and fast, reliable execution of
the project. It also opens the
door to future cooperation
between the two companies
worldwide n
Top: Waelzholz New Material (Taicang)
worksite. Left: Juergen Jentsch (right),
General Manager of Waelzholz New
Material (Taicang) and Zhang Chang,
EVP Danieli China Nonferrous
Business Unit, shake hands after
signing the contract.
39
LONG PRODUCTS
MA STEEL
DANEWS
FINAL ACCEPTANCE FOR ROUND BLOOM CASTER
at Maanshan, P.R. of China
I
n May 2013, Danieli successfully
completed the performance tests on the
conticaster for round blooms, and the
Final Acceptance Certificate was released
with the mutual satisfaction of the
equipment builder and the customer. The
15-m radius, five-strand caster is designed to
produce up to 800,000 tpy of 380-, 450-, and
600-mm blooms in high-quality carbon and
alloyed engineering steels.
The caster is fed with liquid steel from 120-t
ladles, and features all the technological
packages needed to achieve top-level quality
products. Around 50% of the output is used
to produce railcar wheels, while the
remainder goes toward fabrication of rings,
pipes, spring, tire cord, and bearings. An example of the excellent quality results
achieved is presented in the following table, concerning six heats of C50Mn train
wheel steel n
1
2
3
Equiaxial
zone
Max. difference
of C content
Carbon
segregation
Guarantee
figure ≥ 55 %
0.03 max.
≤ 1.06
heat 1
60%
0.03
1.04
heat 2
56%
0.03
1.00
heat 3
56%
0.03
1.05
heat 4
55%
0.02
1.05
heat 5
56%
0.02
1.02
heat 6
55%
0.01
0.96
40
1 Macroetch of a 380 mm round bloom, steel grade 16Mn.
2 Macroetch of a 600 mm round bloom, steel grade IDC35E.
3 Example of the excellent quality results achieved for the steel grade
C50Mn.
DANEWS 168
Final acceptance
of billet and bloom
conticaster
at Gerdau SS NA
(MI), USA
Final acceptance for the new
conticaster
for large round blooms
T
FOLLOWING
AN EXCELLENT
STARTUP,
THE PROVISIONAL
ACCEPTANCE WAS
RELEASED IN JUST
FIVE DAYS, ONLY
29 DAYS AFTER
THE FIRST HEATS
OF ALL GRADES FOR
ALL SECTIONS WERE
SUCCESSFULLY
TESTED AND
APPROVED.
his new four-strand,
10-m radius caster
(already ready for
expansion with the
addition of a fifth strand),
is capable of casting 6-in.
and 7-in. round billets of
254- and 325-mm
diameter. It started
operation in November
2012, and the Final
Acceptance Certificate was
signed, with total customer
satisfaction, on May 13,
2013. This successful
accomplishment represents
another advancement for
both Danieli and Gerdau.
Phase 2 of the project
began in August and
includes installation of a new twin-tank vacuum
degasser (VD) station with
a mechanical pump
system, and a conversion of the existing VAD, for
service as a ladle furnace n
Souvenir photo after signing the FAC.
From left: L. Pontoni, Danieli
Erection & Commissioning Engineer;
U. Pupp, Engineering Manager;
K. El-Rassi, and C. Andre, Meltshop
Sr. Process Engineers, for Gerdau.
at Baosteel Nantong, P.R. of China
T
he great spirit of cooperation and
teamwork established
between the Danieli and
Baosteel teams have been
vital to the success achieved
in the challenging task of
bringing this new
conticastrer to its full
performance capability.
In fact, only 29 days after
the first heat all grades for all
sections had been tested and
approved. As a result of this
remarkable work, the Final
Acceptance Certificate was
released on February 27,
2013, with mutual
satisfaction. The four-strand caster
produces 300-, 370-, 430mm round blooms in lowand medium-carbon and
alloyed steels, for final
applications in tubing and
casing, tubes for highpressure boilers, machinery,
gas cylinders, petrochemical,
and pipeline applications n
Signing of the FAC, from left: Chen Kaijun, Baosteel Commercial Manager of
Engineering Equipment Dept.; Gu Wen Bin, Baotong Assistant General Manager;
Marco Cozzarolo, Danieli Project Manager; Li Bin, Baotong Director of Steel
Making Plant.
41
LONG PRODUCTS
DANEWS
FINAL ACCEPTANCE
FOR THE REVAMPED
BLOOM CASTER
FOR RAIL QUALITY
at Evraz-NKMK, Russia
Casting of stainless
steel grades
at Xining Special Steel,
P.R. of China
Xining’s main
objective is to replace
the ingot-casting
route by progressively
adding stainless
steels to the product
mix of the new bloom
conticaster, supplied
by Danieli.
IT IS THE FIRST
CASTER FOR THESE
FINISHED PRODUCTS
INCLUDING SOFT
REDUCTION
TECHNOLOGY
O
n May 24, 2013 Evraz
Consolidated West
Siberian Metallurgical
Plant and Danieli signed the
Final Acceptance Certificate
for the revamped No.1 largebloom conticaster at the
Novokutnetsk facility. The
caster is producing highquality blooms of 300x360
mm, in low- and mediumcarbon grades, and rail steel,
the latter representing more
than 90% of the caster’s
output. The successful
42
performance tests were
executed for all the grade
families and proved that the
strand productivity increased
by about 40% compared to
the original configuration,
reaching an average
production rate of 140 tph. At the same time, the quality
of the blooms showed a
significant improvement for
center porosity, axial
segregation, and equiaxial
zone, if compared with the
results that could be obtained
prior to the revamp. The
performance tests also
exhibited a total absence of
internal cracks (both axial and
corner), no white band, and
no edge contamination. The
surface quality exceeded all
the required standards and product dimensions were
within the required ranges n
Top: Detail of the new withdrawal and
straightening units.
Right: Top view of the old W&S area.
X
ining Company, located
in the Qinghai Province,
is among the most
qualified producers of special
steels in China, and over the
coming months it will startup a
Danieli conticaster for large
blooms of special engineering
and tool steels. Recently, a
decision was taken to add
stainless steels to the
conticaster product mix, in
order to progressively replace
the current production of
stainless steel ingots.
Consequently, an additional
contract was placed with
Danieli to supply the further
equipment needed for those
new products. The original
three-strand caster features a
16.5-m main radius, and the
cast sizes are 250x280 and
410x530 mm, whereas ferritic
and martensitic stainless steel
grades will be cast in the
250x280 mm bloom size only.
Customized arrangements have
been made for the design of
the caster equipment,
specifically for stainless
grades, such as new molds
with different taper values, new secondary cooling spraying
nozzles, different position of F-EMS (Final Electromagnetic
Stirrer), and specific solutions
to avoid excessive friction of
the bloom in the runout area,
detrimental to the bloom
surface quality and subsequent
processes. The commissioning
of the new equipment is
planned for Spring 2014 n
DANEWS 168
CASTING NEW SECTIONS OF SBQ
AT SEAH BESTEEL, KOREA
S
eAH Besteel, a
steelmaker that
specializes in
engineering and automotive
SBQ grades, assigned a
contract to Danieli for the
supply of three new round
formats - 150, 170, 210
mm - to be produced on
the existing Danieli billet
conticaster No. 3. This
caster, originally supplied in
2011, followed the two
other billet casters and a
bloom caster from Danieli which are currently in
production at Gunsan-si
Works, solidifying the longterm partnership
established between
Danieli and SeAH Besteel.
The five-strand No. 3
caster features a 9-m
radius, with a 150-t ladle
capacity. It was originally
arranged to cast 130, 160,
and 180-mm square billets,
and 200-mm round billets.
The machine was equipped
with advanced facilities to
cope with the more and
more demanding customers
in the special steel
business, including a mold
and final EMS system, airmist cooling, and an
advanced automation and
process control system. A critical factor for the
success of this project will
be the very short period
required for delivery -less
than five months- which will
allow SeAH to be very
responsive in marketing its
new products n
43
LONG PRODUCTS
DANEWS
Repeated orders for H3 wire rod mill technology
from Qingdao Special I&S, P.R. of China
Contract signing ceremony with,
from left: Hu Naizhi, Plant
Director of WRM #2, Jiang Gong,
President of Imp. & Exp.
Company of QDIS, Antonello
Colussi, EVP, Danieli China,
with managers and executives
of both companies looking on.
There has been a high level of activity for the
Danieli Group in China’s wire rod mills market: in
addition to the new assignment from Qingdao,
some prestigious orders have been recorded from
Yunnan Yuxi Xianfu Steel Rolling, and
Shangdong Guangfu Group, and new plants have
been started up successfully at Shanxi Jianbang,
Jiangyin XingCheng and Tianjin Metallurgy Group
Zhasan Youfa.
Q
ingdao’s new twin wire rod mills were
assigned to Danieli on June 24,
2013. Its primary products will be
tire cord and high-carbon steels grades, at a
rated capacity of 500,000-tpy. The state-ofthe-art plant will be installed at Qingdao, in
Jiaonan, and outfitted with all of Danieli’s
latest technologies for rolling, on-line
processing, and heat-treatment of wire rod.
This list will include the LTR-Low
Temperature Rolling and UFG-Ultra Fine
Grain rolling processes. The project basically
foresees two rolling mills, each made up of
16 H/V alternate stands.
The new design for the mill outlet includes
a wire rod line with two-pass wire rod
44
Following previous
mills supplied in
2001 and 2003,
Qingdao
once again
turns to Danieli
for its twin
high-speed plant
lines 2 and 3.
pre-finishing equipment, eight-stand prefinishing block, DSC-Danieli Structure
Control System, including water cooling lines
and CCW-Controlled Cooling Conveyors,
four-stand TMB-Twin Module Block® highspeed finishing blocks, and OFB-Oil Film
Bearing loop laying heads.
Sund Birsta will supply the entire finishing
end, from the reforming tube with distributor
and Easy-down systems for perfect coil
formation, to the SundCo-V vertical coil
collecting station and the horizontal coil
transporting, tying, and final collecting
system.
The product range starts with 150-mm
conticast square billets, anticipating finished
products from 5 to 16 mm dia wire rod, in
coils weighing up 2,050 kg.
Danieli Automation will supply the
automation and process control systems
for the main equipment, including two
Hi-PROFILE laser gauges for rolled stock
dimensional control.
The startup of the twin lines is scheduled for
the end of 2014 n
DANEWS 168
DANIELI GARRET LINE TECHNOLOGY
at NSSMC, Japan
To upgrade
the finishing end
of the rolling mill
at the Muroran
Works, Nippon
Steel & Sumitomo
Metal Corporation
are relying
on the world’s
leader in bar
coiling technology,
with 123 machines
installed for
60 customers
worldwide.
Assembly of high-tech Garret
coilers at Morgårdshammar
workshops at Smedjebackens,
Sweden. These machines ensure
accurate product control,
and produce scratch-free
material at the highest possible
speeds and coil weights.
n April 2013 Danieli
Morgårdshammar, Sweden,
was chosen to supply two
new coilers that will be
integrated into an existing
rolling mill at the Muroran
Works, to improve the product
quality and productivity of the
line. Most of the products
made by the Muroran Works
are intended for automobilerelated applications.
Particularly, they are used for
important safety-related parts
that require the highest levels
of strength and durability. To
achieve such critical targets,
Morgårdshammar developed
a unique coiler design, based
on its over 45-year experience
in designing and
manufacturing plants and
equipment able to ensure
accurate product control,
and to produce scratch-free
material at the highest possible
speeds and coil weights.
With the NSSMC order, our
reference list now tops 120
coilers, with 44 units supplied
just in the last 10 years n
I
45
LONG PRODUCTS
DANEWS
NEW 800,000-TPY HIGH-SPEED BAR MILL
for SteelAsia Manufacturing Corp.,The Philippines
3
4
5
2
1
3
6
1 Reheating furnace
2 16-stand roughing and
intermediate mill
3 Six-pass finishing blocks
4 Double Twin Channel
system
5 90x10 m cooling bed
6 Cold finishing services
“We’re raising
the bar” is
SteelAsia’s motto,
in reference
to the level of its
performance
standards.
Simply put,
it means doing
things better.
True to this
statement of
purpose, SteelAsia
selected Danieli
to supply
a new flexible bar
mill.
Souvenir photo at the contract
signing ceremony. From right:
Leslie Corker, Project Manager,
SteelAsia; Tony Lorenzana, COO
of SteelAsia; Benjamin Yao,
President of SteelAsia; Franco
Alzetta, COO of Danieli; Andrea
Nardone, VP Danieli; Carlo
Pagano, Director Sales, Danieli.
Left: handshake between
Benjamin Yao and Franco Alzetta.
46
E
stablished in 1965, the private
company known now as SteelAsia is
the largest steel bar manufacturer in
The Philippines, with a capacity of 1.75
Mtpy, and it supplies rebar to around 70% of
the infrastructure and critical building
projects in that country. Continuing with its
modernization program, SteelAsia selected
Danieli to supply a new flexible bar mill with
a design capacity of 800,000 tpy.
The product range will be 8- to 36-mm
rebars produced at rates of up to 120 tph,
starting from 130- and 165-mm billets. The
16-stand mill -entirely made up of SHSPLUS
housingless stands, plus two 6-pass finishing
blocks- will use a two-strand slit- rolling
system to produce 8, 10, 12 and 16- mm
rebars at finishing speeds of up to 29 mps.
Souvenir photo at the contract signing ceremony. From right:
Leslie Corker, Project Manager, SteelAsia; Tony Lorenzana,
COO of SteelAsia; Benjamin Yao, President of SteelAsia;
Franco Alzetta, COO of Danieli; Andrea Nardone, VP Danieli;
Carlo Pagano, Director Sales, Danieli.
Left: handshake between Benjamin Yao and Franco Alzetta.
The supply also will include on-line QTB
for the Quenching and Tempering process
of deformed bars, double HTC-High speed
Twin Channel systems, and a 90x10 m
cooling bed. Associated cold cutting-tolength, automatic bar counting and bundling
(up to 2,500 kg) forming, tying and collecting
services complete the rolling mill. Danieli
Automation will supply the Level 1 and Level
2 equipment automation and process control
systems. Plant startup is scheduled for the
first half of 2015 n
DANEWS 168
FOLLOWING A MINIMILL PROJECT IN 2011, MASS GLOBAL INVESTMENT ONCE AGAIN
RELIES ON DANIELI GROUP’S TECHNOLOGY FOR ITS EXPANSION PROJECT
New 600,000-tpy flexible bar / light section mill
for Mass Global Investment, Jordan
his new flexible mill will be designed to
produce 600,000 tpy of bar and light
section. The 18-stand continuous rolling
mill will be made up entirely of SHS housingless
stands in H, V and H/V arrangements.
The rolling mill being supplied also will include
automatic quick-changing facilities in the prefinishing and finishing stands in order to
establish the production flexibility and the
shorter size/section changing times required to
respond quickly, and competitively, to market
demand. The bar finishing facilities will feature
a 90-m-long cooling bed fitted with water-spray
cooling, start/stop-type in-line straightening and
cut-to-length services, a 24-m-long single-head
magnetic stacker, plus bundling, tying, and
collecting facilities.
The extremely wide range of products will
include rebars from 16 to 40 mm dia, plain
rounds from 20 to 40 mm dia, squares from
20 to 40 mm, equal angles from 30x4 to
100x12 mm, flats from 40x5 to 100x10 mm,
channels from 40x20 to 100x50 mm, and tees
from 30 to 50 mm. A 120-tph walking-hearth
furnace supplied by Danieli Centro Combustion
will reheat billets and feed the material
to the rolling mill. Danieli Automation will supply
the electrical, automation, and process control
systems. Plant startup is scheduled for the end
of 2014 n
T
Handshake between Ahmad I. Saleh, President of Mass
Global Investment (right) and Paolo Baldo, VP Key Account
Management, Danieli, after contract signature.
47
LONG PRODUCTS
DANEWS
New merchant mill modernization
at BSRM, Bangladesh
T
IN ORDER TO
MAINTAIN ITS
LEADING POSITION
IN THE
BANGLADESHI STEEL
MARKET, BSRM
WILL CONTINUE
EXPANDING WITH
A PROGRAM
TO REBUILD
A 450,000-TPY
ROLLING MILL
AT CHITTAGONG,
INCLUDING NEW
INVESTMENTS IN
DANIELI’S
INNOVATIVE
TECHNOLOGY
AND EQUIPMENT.
he new contract that was signed in
April will be carried out as a two-stage
project that aims to increase plant
production capacity to over 1 Mtpy,
expanding the product range, and improving
the finished product quality. Further targets
are to reduce current product change-over
times and downtime, and possibly to recover
and reuse the mechanical and electrical
equipment for the new working conditions.
Because of this the supply includes 20 rolling
mill stands (of which 10 with be SHS type
and 10 will be re-utilized and adapted to the
new rolling condition), a QTB water
quenching system for reinforced bars, a
66x7-m walking-beam cooling bed with a
water-cooling system for forced bar cooling,
and a multi-strand straightener with
associated cold cutting-to- length facilities.
An automatic counting / bundling / stacking
station with associated finishing, and final
collecting systems for bundles and stacks,
also will be included. Danieli Automation
will supply the electricals and the advanced
automation system. A water-treatment plant
from Danieli Engineering is included in the
supply, too.
In the first stage, starting from 130-, 160and 170-mm square billets, the plant will
produce rebars from 8 to 50 mm, channels
up to 125x65 mm, and equal angles from
25x3 to 100x12 mm.
In the second stage the product mix will
be extended to rounds up to 65 mm, flats
up to 100x15 mm, unequal angles from
1 20-pass rolling mill
with new SHS stands
2 QTB water quenching system
3 66x7 m cooling bed
4 Multistrand straightener
and cutting to length
5 Automatic counting / bundling /
stacking station
6 Water treatment plant
From left: E. Francescatto, Area Sales Manager, Danieli;
F. Mulinaris, EVP, Danieli; Aameir Alihussain, Managing
Director, BSRM; F. Albanese, Sales Engineer, Danieli.
30x20x3 to 100x75x12 mm, and Tee profiles
up to 50 mm. One detail worth mentioning is
that BSRM will produce small rebars with
the Danieli 5-strand slitting system (5x8 mm)
- a world’s first! Development work is
expected to begin soon, and startup
of the redesigned rolling mill is scheduled
for the end of 2014 n
5
2
3
1
4
6
48
DANEWS 168
800,000-TPY HIGH-SPEED
BAR MILL PROJECT RESTARTS
at Lisco, Libya
E
stablished in 1979, the
Libyan Iron and Steel
Company is one of the
largest industrial companies
in Libya, designed to
produce 1,324,000 ton of
liquid steel annually. The
company is situated near the
coastal city of Misurata,
about 210 km east of Tripoli,
on site covering 1,200
hectares. Since its
establishment, Lisco has
pursued a policy of
continuous facilities
improvement by upgrading
existing plants and
introducing new production
lines, with the dual aim of
meeting increasing domestic
demand and diversifying its
product mix, to increase its
share of overseas markets.
Following this focused
vision, two major upgrade
projects were assigned to
Danieli Group: the twostrand wire rod mill in 1995,
and the high-speed bar mill
in 2008. During the
fulfillment of the latter
project, Lisco chose Danieli
Morgårdshammar to supply a
new 800,000-tpy high-speed
rolling mill to produce 8 to
40-mm-dia deformed bars, a
contract assigned on a
complete turnkey supply
basis.
Due to Libyan revolution in
2011, work that had been
underway was abruptly
stopped and, consequently,
all the related activities. In
early 2012, immediately
after the conclusion of the
hostilities in the country,
Danieli was ready to restart
the project, demonstrating
its strong, continuous and
proactive customer support.
To this end, the Lisco and
From left: Ali A. Sasi, General Manager Expansion Lisco; Dr. M.A Elfigih,
Chairman of Lisco; F. Roman, EVP TK Projects Danieli; Eng. Nagi M. Abunaama,
Director Technical Affairs, Lisco; Marai Almalki, Legal Manager, Lisco.
Bottom: M.A. Elfigih, (left) and F. Roman, sign the contract reinstatement.
Danieli teams started again
with a thorough review of
the actual status of the
works, plants and
equipment, and planned the
resumption of the project.
Thanks to a strong effort by
both teams, even in a stilldifficult situation, the parties
were able to finalize a
contract reinstatement that
was signed on May 30, 2013.
This allowed a prompt kick-
off of the project,
representing one of the first
major jobs started in Libya
after the revolution.
The new plant’s main
highlights will be the high
production capacity and the
very high-speed finishing for
small-size bars, to be
delivered through the
Double Twin-Channel
system to the cooling bed at
up to 37 mps.
To this end, the revised plant
layout is arranged as a 16stand continuous mill plus
two 6-pass, high-speed twistfree finishing blocks, fed by
two- strand slit-rolled stock
coming from the upstream
intermediate mill.
In this way, smaller bar sizes
will be produced on two
strands at very high speeds,
fully exploiting the mill's
capacity for the entire
product range (over 140 tph
already with 10-mm and
larger-dia bars).
On-line water quenching
and self-tempering of rebars
will be performed by two
QTB lines, located at the
finishing blocks’ delivery
side.
Danieli Automation will
supply electrical and fully
integrated automation
systems, while Danieli
Centro Combustion will
supply the 150-tph walkinghearth reheating furnace.
The complete turnkey supply
will include all auxiliary
plants and systems, auxiliary
equipment, cranes and
transport devices, buildings,
civil works and general
coordination by Danieli
Engineering. The project
completion, followed by
commencement of the
commercial production at
the plant, is planned within
first half of 2014.
The successful conclusion
of the challenging course
described here reconfirms
the strategic commercial
relationship between Lisco
and Danieli, one that will
guide further technical and
commercial resources to
support this very important
customer n
49
LONG PRODUCTS
DANEWS
Ferriere Nord (Pittini Group)
keeps working on innovation:
EWR®, SHSPLUS, Spooler
An extensive restructuring program
will bring Danieli’s latestgeneration rolling technology to the
existing bar mill, increasing
efficiency and reducing operational
and maintenance costs across the
entire operation thanks to the
simplified, standardized
engineering of the equipment
produced by the Danieli Long
Products Division.
T
he existing bar mill will be rebuilt with
newly designed SHSPLUS stands, the
EWR® - Endless Welding Rolling
system, and a newly designed bar spoolers that
will deliver the heaviest, compact coils ever
produced. Following the successful startup of
the new EAF and the completion of the wire
rod mill in January 2013, Ferriere Nord
decided to implement the latest Danieli
technology to upgrade its existing bar mill,
making considerable structural changes in
different technological areas, such as:
> Adding 20 SHSPLUS new generation
housingless stands (for a total of 42, including
the spare units for changes in production) for
billets up to 170 mm square, to feed the
existing HTC-High Speed Twin Channel line
supplied earlier by Danieli. The intention of
this part of the plant improvement is to reduce
the maintenance costs and mechanical failures;
> Installation of a new billet EWR®-Endless
Welding Rolling line- for continuous billet
rolling with no time gaps between charged
materials, and the associated front/back ends,
for uninterrupted production of bars and barsin-coils;
> Installation of two, new-generation spooler
units to produce compact heavy coils, with
new water-cooling boxes placed along the line.
Electrical and automation systems for the
entire installation will be supplied by Danieli
Automation.
The plant will be in operation by Q1 of 2014.
Thanks to this new project, Ferriere Nord will
be first in the world producing these heaviest
coils with the EWR® system, further
establishing its leadership in the production
of concrete reinforcing bar products n
50
DANEWS 168
DANIELI H3 WIRE ROD TECHNOLOGY ORDERED
at AEMZ, Russia
The ultra-modern,
600,000-tpy wire
rod mill for AEMZAbinsk Electric
Steel Works will
incorporate all
Danieli’s latest
technological
innovations for
high-speed rolling
and on-line heat
treating of superiorquality wire rod
products.
n March 30, 2013
-the day of the plant’s
third anniversary- AEMZ
selected Danieli as sole
supplier for a new 600,000tpy, high-tech rolling mill that
will be installed at Abinsk,
Krasnodar Region, to produce
wire rods in commercial and
engineering steel grades.
AEMZ started its business in
2010 and the geographical
location and transportation
infrastructures (motor and
railway transport, port of
Novorossiysk) make its products
attractive for the entire
Southern Federal District. The
new plant will produce a wide
range of steel grades, such as
tire cord, low-, medium-, and
high-carbon, microalloyed and
reinforcement grades, spring
steel, bearing steel, welding
O
wire, and CHQ grades. The
finished product sizes will
range from 5.5 to 25-mm-dia.
wire rod and 6 to 16-mm-dia.
deformed wire rod in coils
weighing up to 2.0 ton. The
starting material will be
150x150-mm billets in lengths
of 12,000 mm, and weights up
to approximately 2,050 kg.
The new plant will be
comprised of a 150-tph Danieli
Centro Combustion walkingbeam reheating furnace
equipped with the latest
generation flat MAB flameless
burners -that will ensure ultralow NOx emission below 150
mg/Nm3, 16 SHS housingless
stands in H and V
configuration, on-line water
cooling boxes, an H3 (High
productivity, High efficiency,
and High quality) 110-mps
wire rod production line with a
two-pass wire rod pre-finishing
unit, 10-stand pre-finishing
block, DSC-Danieli Structure
Control system including QTRWire Rod Quenching system
and CCW-Controlled Cooling
Conveyor, OFB-Oil Film Bearing
loop-laying head, RRT-Rotary
Reforming Tube and EasyDown system for perfect coil
formation. Sund Birsta (a
Danieli Group company and
global leader in its field) will
supply a Sundco V/H system
for finishing wire rod coils.
With this new project, Danieli
confirms its leadership in the
production of rolling mills for
long products, following
successes with similar plants in
operation at MMK and
Berezovsky, Shandong Laigang
Yonfeng, Angang Steel,
Xincheng, and Tianjin in the
P.R of China, and Ferriere Nord
in Italy. It also anticipates the
next such plants to come into
operation in the CIS countries,
at the Severstal Balakovo
Works in 2013 and BMZ in
2014.
At AEMZ, Danieli Automation
will supply all the electricals
and the Level 2 automation
system for the whole plant,
including its new QDrive
solution of MV drive for highspeed finishing block, and HiPROFILElite and Hi-SECTION
measuring devices for in-line
tracking and product
monitoring. Also part of the
supply will be a Danieli CMSConditioning Monitoring
System, to improve equipment
efficiency and reduce
maintenance costs through
continuous equipment status
monitoring and diagnostic
information. The startup of the
new AEMZ plant is scheduled
for the beginning of 2015 n
Handshake between
D. Homchenkhov (right),
AEMZ General Director,
and L. Tambosco, EVP,
Danieli Bar & Wire Rod
Mills, after signing the
contract for the wire rod
mill. Attending the
ceremony were, standing,
from left: A. Eremin and
A. Londero for Danieli,
and S. Danilenko, S. Volos,
M. Zhigarev, and
V. Luchinets for AEMZ.
51
LONG PRODUCTS
52
DANEWS
DANEWS 168
OPENING CEREMONY FOR MECHEL’S CHELYABINSK
1.1-MTPY UNIVERSAL RAIL AND SECTION MILL
The Russian plant is designed to produce
100-m long in-line heat treated rails
ON JULY 16,
IN THE PRESENCE
OF THE RUSSIAN
FEDERATION PRIME
MINISTER, DMITRY
A. MEDVEDEV,
THE OPENING
CEREMONY FOR
THIS NEW
UNIVERSAL RAIL
AND SECTION MILL
TOOK PLACE,
ALONG WITH
A CELEBRATION
OF THE 70TH
ANNIVERSARY OF
THE FIRST HEAT
AT THE
CHELYABINSK
METALLURGICAL
PLANT.
L
ocal, regional, and state authorities,
as well as representatives of steel,
administration and finance sectors,
have been impressed with this huge facility,
which extends more than 1.3 km long, as
well as with the plant systems and the
equipment supplied there.
Appreciation was expressed by the Mechel
and Danieli executives for the cooperation
demonstrated by the project and the
commissioning teams, and the example they
have set for an integrated partnership.
Danieli also honored the Mechel group’s
innovative approach to steelmaking and to
infrastructure development in the Russian
Federation. The commissioning of the
Universal Rail and Section Mill supplied to
ChMK to produce up to 1.1 Mtpy of 100-mlong hardened rails, up to 600-mm-wide
parallel flange beams, structural shapes, and
sheet piles, started in April 2013 with the hot
rolling area and the structural shapes
finishing end, and then moved forward to
include the rail finishing end.
The project featured a 240-tph Danieli
Centro Combustion walking-beam reheating
furnace for blooms and beam blanks. The hot
rolling area is comprised of an existing breakdown mill stand, a new break-down mill
stand, an UFR-Ultra Flexible Reversing mill
with three close-coupled stands, and a
separate Universal Finishing stand using
SCC-Stand Core Concept super-heavy duty
design to perform the PSP-Profile Sizing
Process. Downstream from the Universal
Finishing stand, the in-line Rail Head
Hardening (RH2) system developed by
Danieli will be used to manufacture
premium-quality rails. Such rails, featuring
high fatigue- and wear-resistance and highimpact strength for very low temperature
applications, will be supplied to the Russian
Railways OAO for the upgrade of existing
tracks as well as the construction of new
railways all over the country.
Further downstream, the dedicated cooling
bed and the Horizontal/Vertical roller
straightening line facilities are provided,
respectively, for rail and for cold processing
and finishing of structural shapes.
The finishing end for structural shapes
includes cold sawing, automatic stacking,
and collecting facilities.
The rail finishing end is provided with endstraightening presses, a Non-Destructive Test
center, sawing and drilling units, final
inspection, collecting stations, and special
overhead cranes for final handling of 100-mlong rails.
Danieli Automation supplied the associated
electrical and the automation system, too.
Also included in the Danieli supply were two
water treatment plants, a workshop and rollshop facilities, and a laboratory n
53
LONG PRODUCTS
DANEWS
1-MTPY LARGE-BAR MILL STARTS OPERATION
at Henan Jiyuan, P.R. of China
1
T
The cooperation
between Danieli and
Henan Jiyuan I&S
Group began in 2007 with
the supply of a 600,000 tpy
bar-in-coil mill, and now
includes another significant
achievement following the
succesful startup of the new
large-bar mill designed to
produce 1 million tpy of
high-quality steel bars.
The first bar was rolled on
June 20, 2013, less than 19
months after the contract’s
launch date. The official
ceremony held on July 10
included participation from
54
important members of the
local government, as the
Henan provincial Vicegovernor Mr. Wang Tie, and
from the Italian Embassy
Economic Counsellor, Mr.
Livio Spadavecchia.
The plant -a complete rolling
mill, including reversing
roughing stand (BDMBreakDown Mill), 8-stand
continuous finishing mill,
hydraulic shear with 1,500-t
cutting capacity, and
collection facilities that
allow quick bar removal at
high temperature for slow
cooling (a critical step for
DANEWS 168
2
3
special steel production) incorporates Danieli’s most
up-to-date large bar mill
technology and equipment.
The installation produces
round bars up to 300 mm
and square billets up to 240
mm for the automotive,
machinery and equipments,
railway and power generation
industries.
This project was
implemented by Danieli
Italy, Danieli China, and
Danieli Automation as the
main suppliers of equipment,
engineering, automation, and
process control systems n
1 The first billet is rolled
by the reversing break
down mill.
2 The continuous finishing
mill is made of eight
Danieli Star Housingless
stands.
3 Collecting table for slow
cooling with first rolled
specialty steel bars.
This new rolling mill is the core element
of Henan Jiyuan’s 12th five-year plan
to achieve total production capacity
of 4 million tpy, becoming one
of the largest producers in central China’s
Henan province. Demand for large bar
products is expanding in China,
and Danieli confirms its leadership in the
design of such plants, with nine orders
acquired in less than two years.
GUOTAI
55
LONG PRODUCTS
DANEWS
FAST LEARNING CURVE
at CAASA, Peru
J
ust three months after
rolling the first billet on
April 12, 2013, the new
high-speed rolling mill at
Corporacion Aceros
Arequipa’s plant in Pisco,
has test-run all the products
successfully. Various sections
(e.g., rebar 6 mm, 8 mm,
3/8-in., ½-in., etc.) have
been produced smoothly and
successfully on the Double
Twin Channel line, with
stable and constant process
speeds of up to 35 mps
More than 40,000 tons have
been rolled during the first
month of operation and over
120,000 t in the first three
months, surpassing the
56
ANOTHER SUCCESS
WITH HIGH-SPEED
BAR MILLS:
THE DANIELI
STARTUP TEAM
SET ANOTHER GOAL
AND STRENGTHENS
THE COOPERATION
BETWEEN THE TWO
COMPANIES.
contracted monthly
production program, with
the customer’s full
satisfaction.
This target has been
achieved thanks to the full
and strong co-operation
between the CAASA and
Danieli teams. The next step
for the high-speed bar mill
will be to install and start the
new QTB quenching line.
That QTB line will treat
rebars from 6.35 to 32 mm
at operating speeds of up to
14 mps, producing rebar
with high mechanical
properties, good weldability,
and high ductility, starting
from common, low-carbon
steel without the use of
microalloyed steels, for
substantial production cost
savings. The installation is
scheduled for the end of
this year, in order to give
customer more flexibility
in quenched rebar
production, aiming for high
efficiency and productivity,
and the best quality rolled
bars and sections n
Augusto Cornejo, Plant Manager of
CAASA, and Emanuel Roiatti, Danieli
Site Manager, with the joint CAASA
and Danieli Team that carried out the
plant startup and commissioning.
DANEWS 168
New bar-mill stacker
operating now
at Steel of West
Virginia, USA
DANIELI H3 WIRE ROD
SPECIALTY STEEL MILL
STARTS SUCCESSFULLY
at Nucor Darlington
A
From the good results in P.R. of China to the
new line installed at Nucor Darlington, these
H3 wire rod lines will be the benchmark for
high-speed, high-efficiency, and high-quality
wire rod production.
100-tph automatic “Winstack”
stacking station has been operating
at the SWV No. 2 bar mill in
Huntington, since January 20, 2013, when
the Provisional Acceptance Certificate was
released. The 16-m-long, magnetic stacker
is designed to process over 100 products in
regular stacks weighing of up to 500 kg/m.
The option to extend the system’s handling
capability up to 80 ft. has been provided, to
increase its overall productivity. Danieli
Automation supplied all the electricals and
the automation system for the new finishing
area. With this stacking machine, 136
Winstack stations have been installed
worldwide since 1970, confirming Danieli
Morgårdshammar’s absolute leadership
in this field n
(SC), USA
R
iding the wave of the
success that resulted from
a series of orders in P.R of
China, and the installations and
successful startups that followed,
this upgrade to the No. 2 rolling
mill at Darlington benefitted
from an especially positive legacy
that continued with the
installation and the fast startup
of the 6-stand roughing mill on
May 30, 2013. A few of days
later, the first bars were tested
and produced through the bar-incoil line. The installation
schedule has been fully
observed, and the new wire rod
line started operations at the
beginning of September 2013 n
57
LONG PRODUCTS
DANEWS
Final Acceptance
of the 1-Mtpy high-speed bar mill
at Dongkuk Incheon, Korea
O
n May 14, 2013
Dongkuk released
the Final Acceptance
Certificate for the ultramodern high-speed rolling
mill for rebars built by
Danieli and installed at
Incheon Works. The mill
has an output capacity of
1,000,000 tpy for 10- to 57mm dia rebars, but currently,
the main products are D10,
D22 and D25, while the
remaining diameters are less
frequently produced due to
market conditions.
The mill has shown an
impressive, fast learning
curve, and lately the
production has surpassed
650,000 t rolled, aiming
toward full production
capacity within the end
of the 2013 n
900
90
83.353
Production
on three shifts
started on Sep. 4
Monthly production (ton*1,000)
800
H
700
63.216
57.266
56.931
49.243
August
dedicated to
Performance Tests
(4 sizes)
50
40
J
30
20
June and July
dedicated to
Hot Commissioning
500
J
400
300
Top, left: the 17-stand
continuous mill.
Right: The cooling bed,
equipped with HTC-Highspeed Twin Channel
system.
Left: the impressive
Learning Curve recorded
in the first 12 months
of operation.
200
16.008
10.050
10
600
Progressive production (ton*1,000)
Hot Commissioning
and Performance
Tests performed on
a daily single shift
76.845
75.352
Monthly avg. target considering
1.0 Mtpy of mill productivity
60
83.333
80.811 79.712
79.094
80
70
85.315
100
1.615
0
June
August
October
December
Month
58
February
April
June
0
monthly average
target
Monthly production
Cumulative production
COMMISSIONING OF SHEET PILES
at Emirates Steel, UAE
E
mirates Steel has been increasing its
product selection on a continuing basis,
and as of today more than 140 different
types and sizes of beams, columns, and
channels have been rolled.
Now, Zed piles (EZ 18) represent the latest
production challenge. The combined ES and
Danieli team is completing the commissioning
program for this product using the latest
available technologies available in this product
segment, and together are establishing new
standards for rolling sheet piles: for the first time
anywhere in the world it will be possible to roll
EZ18 with only one BreakDown Mill plus the
three-stand UFR finishing mill. Based on the
successful preliminary tests, we are confident
that the commissioning of EZ 18 will be
completed soon.
This represents only the latest challenge that
Emirates Steel and Danieli teams have addressed
successfully, thanks to their collaborative spirit,
professional approach, and mutual efforts n
ROLLING OF EZ18 SHEET PILES WITH ONLY ONE BDMBREAKDOWN MILL STAND PLUS UFR-ULTRA FLEXIBLE
REVERSING FINISHING MILL WILL BE A FIRST-OF-ITSKIND ACHIEVEMENT, AND JUST THE LATEST OF THE
CHALLENGES SUCCESSFULLY OVERCOME THROUGHOUT
THIS PROJECT.
59
TUBE PROCESSING
DANEWS
NEXT-GENERATION COLD PILGER MILL
for tube production
O
vercapacity is quickly becoming the
rule in the actual market situation,
especially where commodities are
concerned. The pressure on pricing is
increased daily by new producers settled in
BRIC countries. Simultaneously, new
opportunities are arising for producers of
highly specialized niche products.
In such a challenging market situation it is
fundamental for equipment designers and
manufacturers to completely change their
approach to customer requirements and in
particular understand the necessities not only
of tube producers but also of tube end-users by
anticipating market trends and developing new
innovative technological solutions.
A major challenge in the energy market is
increasing tube operating temperature in
power plants in order to increase process
efficiency. Consequently, more sophisticated
stainless steel grades (duplex and super
duplex) are needed. Aerospace applications
demand a large amount of non ferrous metal
tubes (aluminum 2024 and 7075 alloys, nickel
alloys and titanium alloys). In larger countries
such as P.R. of China and India, the growing
population and changing life style tends to
increase energy demand and consumption,
therefore the installation of new nuclear power
plants is seriously considered as the most
realistic and reasonable option available thus
new fuel complexes for zirconium tube
production are planned. In some applications,
e.g. OCTG submersible pumps, mechanical
tubes with extremely tight geometrical
tolerances are requested as a starting material
for the production of equipment components.
The production of such a wide range of
different products is possible only using tube
Cold Pilger Mill technology now available in
Danieli thanks also to cooperation established
in 2010 with JSC Institute Tsvetmetobrabotka
which combines respective know-how and
experience in tube cold rolling.
The target of this ambitious R&D project plans
to answer two fundamental requests arriving
from tube producers:
60
Mill data
Number
2 (Left / Right)
Type
Lever
Stand/cassette type
2 and 3 rolls; 2 and 3 rollers
Finished tubes
OD 4-24 mm
WT 0.2-2 mm, with 2 and 3 rolls
WT 0.12-2 mm, with 2 and 3 rollers
Length 3-8 m
Finished tube type
Ultra-thin wall thickness, round, square and hexagon
Detail of a Extreme Performance Cold
Pilger Mill equipped with movable
stand and cassette with lever-type
synchronization; the optimal solution
for the production of ultra-thin wall
precision tubes.
To maximize product-mix flexibility,
interchangeable stands with two
or three rolls/rollers may be used
to produce round, square or hexagonal
high-precision tubes.
> Accessibility of new innovative state-of-theart Cold Pilger Mills at a reasonable price;
> Accessible solutions to increase the
performance of existing Cold Pilger Mills with
limited investment costs.
Nowadays thousands of Cold Pilger Mills are
installed worldwide and hundreds of tube
producers are using the technology considered
fundamental for some specific materials and
especially when demands for tube quality are
key. The majority of these Cold Pilger Mills
were installed in traditional tube producer
countries before the 1980’s; therefore some of
these machines are now technically or
economically obsolete.
To compete on the global market means tube
producers need to seriously consider whether
advantages of new technologies now available
DANEWS 168
Three families of
Cold Pilger Mills
for rolling highly
sophisticated
materials for
critical applications
are now available
in three different
configurations:
"Quarto" for
difficult to roll
materials, "Duo"
for ductile
materials
and "Lever” for
ultra-thin wall
tubes, all with
a common
interface.
justify an investment into new equipment or
whether revamping existing ones is a more
viable option.
Danieli’s line of approach is to assist tube
producers in understanding their specific
needs and develop custom-built solutions in a
spirit of teamwork to offer a win-win
partnership. Several options are available to
maximize or increase productivity:
> Using a continuous Cold Pilger Mill instead
of a non-continuous one;
> Using a roll-type Cold Pilger Mill instead of
a roller one,
> Changing the feed and turn section of an
existing mill,
> Changing the roll path (roll and mandrel
design, number of feeds and turns per stroke,
feeding per stroke),
> Changing the product mix (increasing OD
and WT range).
Several options are available to increase
produced tube quality:
> Increase stand rigidity using a different stand
design;
> Increase feeding and turning section
precision.
All these options are already available from
Danieli but need to be evaluated by the
customer together with the specialist to ensure
the right solution is selected.
An additional benefit of working with Danieli
Centro Tube is the possibility to develop
vertically integrated projects including stainless
steel tube extrusion (Danieli Breda), tube cold
rolling, bright annealing (Danieli Olivotto
Ferrè) and tube finishing.
Examples of this approach are the two Cold
Pilger Mills for nuclear applications developed
for a Russian customer which are now under
testing in our workshop. In this project cuttingedge technology, know-how and experience in
cold forming is utilized to produce ultra-thin
stainless steel seamless precision tubes.
To maximize product mix flexibility
interchangeable stands with two or three
rolls/rollers can be used to produce highprecision round, square, or hexagonal tubes n
61
TUBE PROCESSING
DANEWS
1 Straightening machine exit area
2 Hardening and tempering
furnaces
3 Quenching head
4 Quenching tank
5 Sample cut-off and exit area
1
2
4
3
5
62
DANEWS 168
HEAT-TREATMENT LINE UPGRADE
FOR THE 16” SEAMLESS PIPE MILL
at Jesco, Saudi Arabia
A NEW CONTRACT TO UPGRADE
THE TUBE HEAT-TREATMENT LINE (HTL)
IN OPERATION FOR THE MIDDLE EAST’S
FIRST SEAMLESS PIPE MILL AT JUBAIL
INDUSTRIAL CITY RECONFIRMS
THE EXCELLENT COOPERATION
ESTABLISHED BETWEEN DANIEL
AND JUBAIL ENERGY SERVICES CO.
production size range.
The capacity will be
increased by approximately
+35%, however.
HTL upgrade description
D
emand for seamless
tubular products
continues to rise, as
demonstrated by the growth
in orders assigned to Jesco,
and the buyers’ increasing
demands for heat-treated
pipes and higher grades also
has had a significant
influence on the company’s
decision to boost HTL
production capacity, even
though the line (part of the
original turnkey contract)
had only just been
successfully commissioned
in 2010. Danieli’s design
offers fewer modifications /
replacements to equipment
in this project, and so the
upgrade will have no impact
either on operating time or
Although the main target of
Jesco’s contract was to
increase production capacity,
the project also was
developed to improve the
flexibility of the HTL,
meaning, to allow quick
tube-size changeovers.
Several areas of the line will
be subjected to upgrade /
modifications:
HTL production capacity
increase will include:
> Modifications to the
straightening machine exitside handling system and a
software upgrade to reduce
the tube-straightening cycle
time;
> Installation of additional
burners (hardening,
tempering furnaces);
> Re-distribution of preheating zones capacity
(hardening, tempering
furnaces);
> New quenching head
configuration: installation of
a fourth module and redistribution of quenching
capacity modules.
HTL flexibility improvements
will include:
> Installation of a quenching
tank by-pass system: a chaintype frame, including quick
connecting/disconnecting
system;
> Re-location of the sample
cutting saw (off-line) and
installation of a new tube-
collecting cradle.
The design concept for these
upgrade solutions was based
largely on the objective of
limiting installation and
commissioning activities,
thus avoiding any
unscheduled plant
shutdowns. Installation of
new equipment is expected
to commence during the
plant’s annual shutdown and
weekly maintenance
activities n
63
TUBE PROCESSING
DANEWS
HEAVY-DUTY, THICK-WALL TUBE MILL
for TPI, India
D
anieli W+K delivered a new specialty
rolling mill to Tube Products of India
(TPI), located in Chennai, and
designed to produce precision tubes in hightensile strength materials, with diameters
ranging from 2.5 to 7 in. and a maximum wall
thickness of 0.5 in. The challenge for Danieli
W+K was to design a customized special
tube mill because the line will produce
mainly precision tubes for hydraulic cylinders
used for earthmoving and construction
machines, and hollow sections for steel
construction. The complete line consists of a
fully automatic strip preparation section, a
forming, welding and sizing section, and a
newly developed flying saw -the multi-cut.
The finishing line, also provided by Danieli
W+K, consists of a run-out section, sample
tube-cutting device, and an integrated flushout station to flush out the inside scarf. A
chopper to cut the inside scarf and a blowout station is incorporated into the flushing
station. The system also is equipped with an
automatic bundle station and a magnetic
portal packaging device for assembling
hexagonal and rectangular bundles of round
tubes and hollow sections.
The enhanced multi-cutter consists of two
individually driven saw blades on an orbital
rotation system that enables it to cut in two
64
The complete line
consists of a fully
automatic strip
preparation
section, a forming,
welding and sizing
section, and a
newly developed
flying saw -the
multi-cut.
Forming stands section
of an ERW line for
precision tubes.
Workshop assembly of a
Multicutter for maximum
pipe OD 220 mm.
modes: one is the HSS saw blade for tubes
ranging from 2.5 to 3.5 in., and another is the
two-mode system consisting of two tungstencarbide saw blades to cut round and
rectangular sections up to 7in. The saw blade
drives are water-cooled and well protected
against the particular environmental
conditions. Special gearbox design and
patented clamping devices guarantee almost
vibration-free cutting and long life for saw
blades. With this new line TPI plans to
penetrate new market segments, and in
particular the market for thick-walled-tubes
for special applications.
Production is scheduled to commence in
March 2014 n
DANEWS 168
Danieli W+K’s successful
development of a new
multicutter for ERW pipe
welding lines
T
he machine produces almost burr-free cuts
of pipes between 60 and 220 mm OD,
with WT between 1.0 and 14.0 mm at a
maximum tensile strength of up to 850 N/mm².
The new Multicutter is distinguished by the
fastest tool change-over, high protection classes
for the AC servomotors, extremely short cutting
cycles, excellent quality of the cut, and
automatic process optimization by the newly
developed control system. Depending upon the
pipes and profiles to be cut, the Multicutter can
be operated either with one saw blade (HSS) or
with two saw blades (TC tipped). The single-saw
blade cutting mode is selected for pipes up to
100 mm OD and up to 5 mm WT. In this cutting
mode it is guaranteed that the inside scarf is cut
as well. The two-saw blade cutting mode is used
to cut profiles and pipes of more than 90 mm
OD, and guarantees high cutting speeds, high
performance, and a high-quality, low-burr cut.
Also, Danieli W+K has developed a new
special clamping system that ensures tight
clamping of the pipes and profiles during the
cutting process. The clamping units are mounted
to both sides, close to the saw blade at a
maximum distance of 10 mm. This reduces any
vibrations during the cut-off process, thereby
achieving longer service life for the saw blades.
All motors in the working area of the saw are
water-cooled and in the highest protection class
to guard the motors safely against emulsion, dust
or chips. Special attention should be given to the
easy access for the operator when exchanging the
clamping tools and saw blades. For this purpose,
the exit-clamping unit is locked hydraulically.
The unique design of Danieli W+K’s new
Multicutter allows for easy integration into
existing pipe welding lines n
65
HEATING SYSTEMS
DANEWS
NEW GENERATION ULTRA-LOW NOx
WALKING-HEARTH FURNACE
at Hadeed, Saudi Arabia
I
n 2009, Sabic Hadeed contracted
Danieli to supply a second wire rod line,
similar to the one commissioned in
2004. The new line features a Danieli Centro
Combustion (DCC) heating furnace that
duplicates the one supplied in 2004, i.e. a
walking-hearth type furnace (radiant-roof
type) with a maximum production rate of 120
tph. The 25-long, 14.8-m wide furnace heats
130- and 150-mm billets in lengths ranging
from 8.8 to 14 m. The furnace is equipped
with four moveable and five fixed hearths.
Considering the predominant maximum
billet width, it is also equipped solely with
radiant burners to ensure uniform thermal
feedstock heating, and discharging
temperatures ranging from 1,050 to 1,150
°C. Burners are fed with natural gas and air
preheated from 400 to 450 °C via a central
recuperator installed in the waste-gas flue.
During the five-year period between the two
orders, Saudi Arabia introduced stricter limits
on pollutant emissions: in particular, the
allowance for nitrogen oxides has been
reduced from 86 g/GJ to 43 g/GJ (based on
gross calorific values), corresponding
respectively to 260 and 130 mg/Nm3 @ 3%
02, considering wet waste gas.
However, DCC’s R&D department has made
considerable advances since 2006, especially
in the field of combustion, and two new
types of radiant burners designed and tested
for the new Hadeed furnace guarantee NOx
emissions lower than 100 mg/Nm3 @ 3% 02
with a furnace chamber temperature of
1,250 °C, fed with combustion air preheated
to 450 °C, and requiring use of flameless
combustion. The following burners are
installed on the furnace roof:
> Pre-heating zone: 27 RAD-FL6 burners
(three rows of nine), with maximum power
of 610 Mcal/h;
> Heating zone: 27 RAD-FL6 burners
( three rows of nine), with maximum power
of 750 Mcal/h;
> Equalizing zone, right and left: 15 + 15
(on three rows) RAD-VGL4 ULNOx burners
66
LIMITATIONS
TO NOx
CONCENTRATIONS
IN EXHAUST FUMES
ESTABLISHED
BY NATIONAL
AND INTERNATIONAL
REGULATIONS
IMPOSE
A REQUIREMENT
FOR SUBSTANTIAL
REDESIGN
OF NEW BURNERS.
Tests in the DCC Lab: RAD-FL6 in flame mode (top) and
in flameless mode (middle).
Zone 1 Shortening: RAD-FL6 burner in flameless mode
in the third row (first two rows switched off).
THE CHALLENGE
IS TO ACHIEVE
OPTIMAL
EFFICIENCY
AND AT THE SAME
TIME TO ENSURE
THAT EMISSIONS
PRODUCED REMAIN
WITHIN THE SET
RESTRICTIONS.
DANIELI CENTRO
COMBUSTION
ACCOMPLISHED
THIS TASK IN ITS
DEVELOPMENT
OF THE REHEATING
FURNACE FOR
HADEED’S NEW
WIRE ROD MILL.
DANEWS 168
Customer inspection at DCC’s R&D center. From left:
C. Iernetich (DMH); D. Astesiano (DCC - R&D); Tawfeek
Shammasi, Hadeed Environmental Dept.; M. Rocca (DCC).
with maximum power of 200 Mcal/h.
Each zone is equipped with a single airfeeding line and two gas-supply lines, one
dedicated to the flame mode function, the
other to the flameless mode. Once the
combustion zone reaches automatic ignition
temperature (800-850 °C), gas flame
alimentation closes automatically and
switches over to flameless mode. Registered
toxic waste, and NOx emissions in particular,
are extremely low and the percentage of
unburned hydrocarbons (CO) is virtually nil.
In the preheating zone there is an option to
switch off first- and second-row burners
according to thermal request in the zone, and
to further reduce fuel consumption when the
furnace is functioning in low production mode.
Furnace performance tests were carried out
from March to April 2013, with extremely
successful results:
> Specific consumption: 219 kcal/Nm3 against
242 kcal/Nm3 of contractual requirements,
discharging temperatures of 1,050 °C with
150-mm billets;
> Billet temperature uniformity: DeltaT less
than 10 °C on the section and less than
15 °C on the length; contract requirements
of 25 and 30 °C, respectively.
> Scale loss: 0.55% on total weight with
150-mm billets discharged at 1,150 °C
compared to 0.7% in the contract.
The outstanding performance regarding
nitrogen oxides must be highlighted, too.
Considering the limit of 43 g/GJ @ 3% 02,
29 g/GJ (equal to 93 mg/Nm3) was recorded
in flameless mode, that is 33% less than the
guaranteed limit -- also considering billet
discharging temperature of 1,150 °C.
In flame mode this value was 63 g/GJ
equivalent to 202 mg/Nm3.
By way of comparison, the furnace installed
in 2004, at a billet discharging temperature
of 1,050 °C, produced NOx emissions
of 61 g/GJ, equivalent of 194 mg/Nm3 n
67
HEATING SYSTEMS
DANEWS
CUSTOMIZED FURNACE
for Orsky Machine-Building Plant, Russia
The Orsky Machine Building Plant
(TMK Group) in Orsk produces
a wide range of forged parts and drill
pipe joints, supplied to both Russian
and foreign consumers.
It is the only plant in Russia authorized
by the American Petroleum Institute
to manufacture drill pipe joints
in compliance with the API Spec 7
international standard.
68
Maximum productivity
3 tph
Residence time in furnace
6.2 h
Total cycle time
7.2 h
Gas consumption
at maximum capacity
200 Nm3/h
the roof, promoting high
waste-gas recirculation, and
heat exchange. After heating
and soaking at a temperature
of 860 °C, the treated parts
pass through the controlled
cooling phase, which reduces
the temperature down to
approximately 600 °C before
transfer into the forced-air
cooling chamber. The forced-air
cooling chamber is equipped
with two recirculating
centrifugal fans (located on the
roof) and one injection of cool
ambient-air deriving from a
third fan managed by an
independent temperaturecontrol loop. Material
temperature is lowered to
approximately 300 °C before
transfer to the final waterspray cooling chamber. This
strategy, combined with
appropriate fan management,
ensures temperature control at
any point on the material within
a range of less than ±5 °C n
Core temperature trend for a 30-mm forged component
900
800
700
710
832 842 846 852 856
788 814
736 762
620
600
520
500
420
400
310
300
200
200
Furnace recorded temperature
Core recorded temperature
Theoretical interpolated avg. temperature
100
0
30
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
itself is equipped with 26
burners (80 kW each) for
material heating. The furnace
is divided into 10 control
zones, each of which is
outfitted with independent
temperature loop monitoring
and control. The last four
zones also are equipped with
cooling systems (fed by
combustion air) in order to
perform smooth, combined
heating / cooling control
during the final portion of the
thermal recipe (soaking and
cooling phases). Temperature
uniformity and optimized heat
transmission in the furnace
heating and soaking chamber
are guaranteed by eight
centrifugal fans located on
Performances achieved
Temperature (°C)
I
n June 2013 Danieli
Olivotto Ferrè successfully
commissioned the
annealing line installed there
recently to treat forged
parts/tool joints. The fully
automatic line includes a rollerhearth annealing furnace, a
roller-hearth air-cooling
chamber, a roller-hearth watercooling chamber, and a
complete handling system for
loading / unloading forged parts
for treatment in a special
basket. The annealing furnace
Time (min)
DANEWS 168
HOT & COLD PROCESSING
DANEWS
Chain-track bar drawing line in full operation
at Marcegaglia Contino, Italy
he Marcegaglia plant in
Contino (Mantova) is one
of Italy’s top three
producers of cold-drawn steel
bars. The plant owners decided
to increase their output by
investing in a new, high-speed
chain-track drawing plant,
chosen over the alternative of a
traditional cam-based drawing
line. Processing bar diameters
up to a finished size of 28 mm,
this new line is now in full
operation, capable of a 180-
T
mpm maximum speed, which
is 50 per cent higher than the
best previous drawing
technology available on the
market.
With a bar length tolerance
of 0/+1 mm and up to 48 bars
drawn per minute, cut to
length, and chamfered, the
Danieli chain-track technology
is yet again proving to be the
winning solution for maximum
productivity, with best finished
product quality n
Marcegaglia Open Day - June 7, 2013
Souvenir photo at the end of plant tour. From left: G. Dorscheid, SaarBlankstahl; D. Meyer, Steeltec; M. Liedlich, Deutsche Edelstahlwerke;
I. Robin, Deutsche Edelstahlwerke; E. Christau, Bessey Präzisionsstahl;
S. Liebetanz, Stahlwerk Ergste Westig; E. Sittaro, Danieli; A. Sieber,
Steeltec; P. Rüdiger, Danieli; E. Ceresetti, Plant Director, Marcegaglia
Contino, G. Pasquali, Production Engineer, Marcegaglia Contino.
T
he chain-track technology is usually associated
with the drawing of copper tubes. More and more,
the chain track is used to draw solid steel too, since
this type of drawing has significant advantages compared
to the cam-driven machines. In recent years Danieli has
delivered only chain tracks for drawing of steel.
Now, customers are showing a greater interest in the
chain-track technology. With the kind permission
of Marcegaglia Contino, a Danieli chain-track line
in operation could be demonstrated to technical,
production, and maintenance managers from Germany
and Switzerland. All the participants were very impressed
with the speed, quiet running, and bar length tolerances
achieved by the Marcegaglia drawing line n
69
HOT & COLD PROCESSING
DANEWS
DANIELI MODERNIZING THE “HISTORY”
OF SPECIAL STEEL PRODUCTION IN RUSSIA
at Volgograd Steel Works «Red October»
Danieli Breda open-die forging
complex
The first stage of this program has been
contracted to Danieli Breda. It calls for
a new forging complex based on a 25-MN
push-down open-die forging press integrated
with a 20-t rail-bound manipulator and a
20-t diesel mobile manipulator.
Thanks to the Danforge® automation system,
the plant will process ingots of high-quality
alloys, such as tool steel, HS steel, stainless
steel, Ni-based, and titanium grades, with
maximum efficiency and reliability toward an
average production target of 35 ktpy. The
new forging plant will commence production
in Q1 of 2014.
Equipped with advanced features for opendie forging technology, developed earlier by
Danieli Breda, it will ensure a wider product
mix for the customer, increasing production
quality in order to match the demands of an
70
even more challenging and competitive
market. Danieli and Red October also are
cooperating to optimize plant layout.
The first step of this task already started with
the award of a contract for existing forging
plant modernization. In that project the
target is to optimize the hammers shop by
removing the outdated steam drive and
converting the power supply to a modern,
centralized unit to drive a group of hammers
ranging from 20 to 50 kJ. The project will be
in operation before the end of the year.
Fume Treatment Plants
Danieli Environment was selected as sole
technology supplier to design, manufacture,
and supply the new fume treatment plant
(FTP) for the steel meltshop, to control
fumes and dust emissions from the primary
and secondary lines of the 200-t electric arc
Dmitry Petrovitch Gerasimenko,
Executive General Director of
JSC Volgograd Steel Works "Krasny
Oktyabr", and Franco Alzetta, COO
and Member of the Board Danieli,
signing the contract for the plant
modernization project.
DANEWS 168
Volgograd Steel Works
«Red October» has always
been a leader in metal
industry. The mill is
considered to be Russia’s
largest producer of highquality special steel grades
for the automotive industry
and aircraft producers, and
for chemical, oil and
power engineering
programs. The mill was
established in 1897.
Production capacities
increased and new steel
grades were adopted up
to 1941. Almost destroyed
during WW2, it was fully
restored, and by 1949 the
production had increased
to its pre-War volume.
By 1986 the Mill had a
production capacity of 2
Mt of liquid steel, with the
ability to produce about
500 steel grades
according to the main
international standards.
In summer 2013
Volgograd Steel Works
decided to proceed with
a modernization project
for its meltshop, forging
complex, and finishing
lines, with the target of
minimizing meltshop
emissions, reducing
production costs, and
improving product quality.
L1 and L2) systems. Also included in the
supply will be a dust separator and textile
filter (to remove the dust coming from
process gas), all necessary shut-off and
control valves, spectrometer-type gas
analyzer, and a hydraulically-actuated
vacuum switch to serve both the vacuum
tank for degassing and the vacuum ingot
chambers, managed with same dry pump
system. Startup of the new mechanical dry
pump is scheduled for the end of 2014.
New bar straightening
and peeling plant
furnace and ladle furnace.
The design of these new facilities will ensure
high-efficiency fume capture and fume
filtration, as well easy maintenance and long
service life for the components.
A thorough design was required to comply
with the space limitations and other
constraints of the site, and to minimize
meltshop shut-down required for the
installation. The FTP will treat about 80,000
Nm3/h at 1,100 °C as EAF primary off-gas
extraction and 2.75 Mm3/h of secondary
fumes, ensuring a dust content emission at
the stack of less than 10 mg/Nm3, with noise
levels less than 85 dB(A) at the stack outlet
(less than 45 dB(A) at 300 m distance from
the stack). FTP technology is based on pulsejet filters to guarantee high filtration
efficiency, low pressure drop, and limited
consumption of compressed air. Bag cleaning
is controlled electronically and can be
programmed with the bag compartments online or off-line. The bags can be replaced
without entering the filter, thus occupational
health and safety are not compromised.
Danieli Centro Maskin will delivery a new
peeling plant to process hot-rolled bars up
to 250 mm in diameter and 6,500 mm long.
This system will be installed downstream
from the straightening machine for large bars
supplied in 2004. Bars will be prestraightened on a new Danieli RL250 tworoll straightening machine (one of the largest
such machines in the world) in-line with the
new peeling machine, all with fully automatic
settings/adjustment and recipe programming
systems for maximum production flexibility.
Processing a wide range of steel grades,
including nickel alloys, bearing steels, and
stainless steels, this high-performance plant
will be capable of producing up to 90 tph of
100% surface defect-free material with
excellent h9 dimensional tolerance. The very
tight dimensional tolerance combined with
the bar straightness of 1 mm/m and defectfree surface will allow the Volgograd
Steelworks to supply all specialty engineering
customers in Russia and abroad where only
the very highest bar quality standards are
acceptable, as guaranteed by the best Danieli
cold-finishing technology developed over
more than 50 years n
Mechanical dry pump system
for vacuum degasser
Danieli Centro Met will supply a new
mechanical dry pump system to replace the
existing steam ejectors vacuum pump serving
the VD/VOD unit. Mechanical
dry pump systems offer the same
performances as the steam ejectors vacuum
pump, but without the active costs for steam,
steam generation plant, and maintenance.
The number of mechanical dry pump
installations is rising, and Danieli is further
solidifying its leadership in the field thanks
to the stable results achieved in numerous
reliable solutions developed worldwide.
These results are supported by the
continuous development of the metallurgical
process target and control philosophy, and
the complete automation control (including
71
FORGING & EXTRUSION
DANEWS
SUCCESSFUL COMMISSIONING
OF A SEAMLESS TUBING PLANT
at XinXing, P.R. of China
1
B
oth XinXing and Danieli Breda teams
involved in the commissioning of this
plant proved to be particularly skilled,
and the startup was conducted smoothly and
with very good performances in terms of time
and quality, leading to the release of the Final
Acceptance Certificate with mutual
satisfaction. The core technological
equipment supplied by Danieli Breda
included the 25-MN expander press, where
72
WITH THE PERFORMANCE TEST
OF THE 60-MN EXTRUSION PRESS
CARRIED OUT IN APRIL 2013, DANIELI
BREDA SUCCESSFULLY COMPLETED
THE STARTUP OF THE SEAMLESS
TUBING PLANT AT XINXING PIPES,
LOCATED IN HANDAN.
DANEWS 168
1 Overall view of the extrusion plant.
2 Xing Derun, Plant and Production
Manager, XinXing Pipes, with the
joint Team that carried out the
plant commissioning.
3 The 60-MN extrusion press.
4 Wang Li Hui, XinXing Pipes,
and Domenico Samele, Site
Manager, Danieli Breda.
2
3
XinXing Special Steel Pipes
has a production capacity
of 180,000 tpy of bimetal
composite pipes and highalloy steel pipes and other
high-end seamless steel pipes,
widely used in power
generation, petrochemical,
chemical industry, etc.
the billet is upset and the pre-hole is
expanded to a value higher than the final
diameter of the pipe to be produced.
The downstream 60-MN extrusion press
-the heart of the process- is equipped with
an active piercer, and forms the expanded
billet into the hot finished tubes.
The extrusion process requirements are very
demanding, with total extrusion times of less
than 5 seconds, and product exit speed of 2
4
to 8 mps. This means that extrusion speeds
between 50 and 300 mmps are required
(with a tolernace of ±3% extrusion speed
variation during one push at 300 mmps).
The new plant is designed to produce pipes
of different diameters and lengths
with a targeted production capacity of
50,000 tpy, and a product mix that includes
plain quality special steel grades and double
metal pipes n
73
CUSTOMER SERVICE
DANEWS
MAINTENANCE AND OVERHAULING PACKAGE
FOR DANIELI SERVICE EAF/LF'S ELECTRODE ARMS
The electrode arms
are one of the most
critical components
of the meltshop area, and
must be monitored
constantly and maintained
to avoid possible accidents
and unscheduled plant
stoppages. These
components must be always
available in stock and ready
to be installed in case of an
emergency. Accordingly,
Danieli is supporting its
customers with a specific
“Electrode Arms Package,”
in which we analyze the arm
condition and, if needed,
overhaul the arms, drastically
74
reducing the costs of
replacing the equipment
with a new set of arms.
This package is now
proposed as an option to new
spare parts arms supply, or to
customers who seeking to
optimize costs by rotating
and refurbishing the present
sets of arms. The first part of
the package consists of an
annual specialized arms
survey, in which we monitor
the condition of the arms to
define the maintenance
plan, and agree to a
customized overhauling
program to restore the
complete arm condition.
DANEWS 168
According to the above
analysis, specialized actions
will be planned directly onsite, such as:
> Bimetallic plates
machining;
> Arms tail machining;
> Pusher refurbishing;
> Other updates.
In case this approach is
determinated to be
insufficient, a complete arm
overhauling will be carried
out in Danieli workshops,
where we complete the
following:
> Cleaning, disassembling,
and shot blasting;
> Inspection to identify any
possible defects in the arm
structure or welding damage;
> Bimetallic plates
replacement and checks;
> Power cables connecting
area inspection and possible
machining;
> Endoscopic internal
inspection and flushing;
> Final pressure test and
painting;
> Components reassembly.
The Electrode Arms Package
is tailored to the customer’s
needs and maintenance
policy, and aimed at
preventing the more invasive
-and expensive- action of
complete electrode arms
overhauling, that thus
becomes the very last solution
to the problem. These
services improve the
electrode arms service life,
saving money and time,
needing just a simple
scheduling to check the
proper arms condition and
to replace any worn critical
parts n
After the successful startup of DanJoint spindles at their hot strip
mill, Thailand’s Sahaviryia Steel Industries (SSI) confirmed its
confidence in DanJoint technology with another order for spindle
supply and HRM stand powertrain upgrading.
DanJoint project accomplished
and a new order received
High-performance,
oil-lubricated gear
spindles were
commissioned successfully
for stand F7 during the
December shutdown at SSI
in Bangsaphan. During that
period from December 16 to
28, the following activities
were accomplished:
> The existing greaselubricated spindles were
removed from the stand,
> The pinion stand was
dismantled and the two
pinions shipped to Danieli
Thailand, where the existing
drive-side hubs that were
shrunken on the pinion shafts
were removed. The new driveside hubs for the new spindles
were installed on the existing
pinions, and properly secured
in place;
> The pinions with the new
hubs were shipped back to SSI
and installed in the existing
pinion stand housing;
> A new oil-collecting tank
was installed and grouted on
the foundation;
> New spindles were installed,
and then cold- and hot-tested;
> Properly adjusting all
lubrication parameters and
recording all technological
working parameters completed
the commissioning.
All activities were properly
scheduled and carried out in
order to complete all actions
within the planned shutdown.
Then, a new order was
discussed, concerning new oillubricated spindles for stand
F6. During one year of work for
finishing stand F7 with the
new DanJoint oil-lubricated
gear spindles, SSI had the
opportunity to verify all the
advantages of DanJoint
technology:
> Drastic reduction of
damages typical for gears with
grease lubrication (like pitting,
abrasion wear, bonding and
fusion),
> High efficiency in terms
of power transmission,
> Low friction between contact
surfaces,
> Increased lifetime of geared
elements, and
> Main economic advantages
(“easy maintenance” design
concept to reduce operating
costs, drastic reduction of
lubricant consumption and
relevant storage costs, no risk
of human error during
lubrication that may cause
equipment failure, no need
for lubrication maintenance
personnel).
All these reasons convinced
SSI to also replace the
spindles of finishing stand
F6 with the DanJoint oillubricated gear spindles n
Souvenir photo after successful
conclusion of the DanJoint installation.
From left: P. Bootsri (S.MMD),
M. Rugo (Sr. Engineer, DS),
T. Khaengkhan (S.MMD), M. Rovere
(Sales Mgr., Danieli Thailand),
M. Persoglia (Mechanical Engineer, DS).
75
CUSTOMER SERVICE
Baosteel Meishan reconfirms trust in Danieli technology
for high-torque transmission drives
DANJOINT FOR VERTICAL EDGER
In July 2013 Danieli
Service was assigned
a critical order by
Baosteel Meishan, China,
relating to the cardan
spindles for the edger main
drive. The reversing roughing
stand and the edger were
originally designed and built
by a reputed local producer;
recently, cracks appeared in
the key seat at the interface
between the roll side hub
and the spindle yoke. Then,
DanJoint was requested to
analyze the issue and to
propose a new solution to
the problem. Highlights of
the new design are as
follows:
> In order to increase the
service factor, newly
designed spindles feature an
increased size, from 700- to
900-mm rotation diameter;
> Cast yokes were replaced
by forged yokes, made in
HS, Q&T steel;
> Different materials and
designs for yoke and flange
frontal teeth were installed,
to achieve better
performance and longer
service life;
> Very high performance,
case-hardening steel was
used for the cross, in order
to achieve high quenching
effects and high surface
hardness at the surface in
contact with bearing rollers;
> Newly designed cardan
joint, with toothed-type
serration to replace the
keyed connection, thus
avoiding dangerous stress
concentration at the key seat;
> An advanced bearing
design was adopted that
includes inner and outer
rings to prevent yokes and
76
Top: detail of the existing spindles that
shows critical details at the key seat.
Bottom: FEM analysis showing how
the heavy torque load creates heavy
stresses in the key seat that induce
cracks on the spindle flanges.
crosses from any scratches
due to possible overloads or
cobbles;
> Customized maintenance
tools were selected for the
specific application, to be
delivered along with use and
maintenance manuals;
> An optimized grease
lubrication system was
chosen, for more effective
and ergonomic;
> All spindle items are
forged and compliant with
the strictest European
quality standards.
The new order includes two
new 900 S spindles
Souvenir photo at the contract signing, involving Mr. Yang Rui, Meishan Import &
Export Co. Director; Mr. I. Picco, Area Manager, Sales, Danieli Service; and Mr.
Wu Suo Tuan, Meishan HSM Plant Chief Engineer.
DANEWS
FRUITFUL COLLABORATION
DANIELI SERVICE HSM'S
KEY SPARE PARTS SUPPLIES
CONVINCE HIGH-PROFILE
CUSTOMER
MILL STAND
complete with serratedflange frontal teeth on the
drive side and roll side hubs
and one spare spindle.
The new design has been
calculated both for pulsating
and reversing loads and to
ensure high service and
safety factors for the spindle
and all the related
components. This important
order highlights DanJoint’s
competence in heavy-duty
drives for rolling mills, and
confirms Danieli’s longlasting, satisfactory
relationship established
with Baosteel n
In November 2009 Danieli was awarded a contract to supply
equipment and service for a complete 1,780-mm hot strip mill
with a capacity of 4.0 Mtpy of HRC.
Two contracts were awarded to Danieli Service to supply
HAGC, bending blocks, shifting devices, and DanJoint geared
spindles for finishing stands F1-F7.
At the end of 2012 another order was assigned to Danieli
Service, to supply additional HAGC and geared spindles
DanJoint for finishing stands. The quality of the equipment
and the project execution capabilities shown by Danieli Service
were so well appreciated that the customer asked
us also to supply the spindles for the No. 1 vertical edger,
modified according to Danieli’s know-how.
Danieli Service is providing good service and support
to the Meishan hot strip mill and Baosteel Group, and the
target is to continue this cooperation for several more years.
PASS LINE
Baosteel delegation visiting Danieli HQ.
Friendly handshake between Mr. Wang Qiang Min, VP, Baosteel,
and Mr. M. Di Giacomo, Danieli EVP, Danieli Service.
77
CUSTOMER SERVICE
MOLD COPPER TUBE CONDITION MONITORING SERVICE
FOR UNINTERRUPTED CASTING QUALITY
Danieli Service casting knowledge
The ability to analyze
the state of wear of
the copper tubes
during their operating life,
and also to check the correct
taper at delivery time, is
essential in order to ensure
consistent cast product
quality. Danieli has
developed a new laser
instrument to compare
different measurements
made during a copper tube
lifecycle, providing the
ability to monitor the
progress of wear related to
this core element of the
continuous casting machine.
The instrument is useful for
testing the copper tube’s
dimensions and geometry,
either before the tube is put
into service or during
operation, to check its wear.
In both cases, when the
measurements do not
comply with the
requirements, or the wear
could be too much, the tube
could be preventively
replaced to avoid product
quality problems. The
instrument, which requires a
single operator, both in the
workshop and on the casting
78
1,995 casting strands designed,
manufactured, and put in
operation worldwide are the solid
basis on which stands our process
knowledge for casting steel.
This is what customers gain from
our consultation on molds’
> copper tubes
> and copper plates
condition monitoring
and operations setup support.
DANEWS
1 Main characteristics of laser-based copper tube section measurement tool.
Measuring range
Square sections: from 130 mm to 160 mm;
Copper tube length: from 780 mm to 1000 mm
Accuracy
± 0.01 mm on tube side; ± 0.5 mm on tube length
Resolution
± 0.005 mm on tube side; ± 0.2 mm on tube length
Repeatability
± 0.01 mm on tube side; ± 0.5 mm on tube length
2
floor, is comprised of a
handle equipped with a
control panel at one end; on
the other end is a rotating
measuring head with a
double laser sensor that
detects the internal
dimensions and geometry of
the copper tube.
Using wireless technology
the tool moves all the
collected data to a portable
PC equipped with dedicated
software to visualize the
measurements of mold taper,
shape, and squareness, in
the form of graphs and
tables.
Moreover, at any time these
values can be compared with
those related to the design
drawings loaded in the
software. Loading the
measurements related to a
copper tube in the Q-mold
package, a historical
database could be created
with all significant data
belonging to a single copper
tube n
2-3 Danieli Service
technicians support
for mould
maintenance and
monitoring of copper
tube’s wearing and
working conditions.
3
4 Example of inner-outer bow / left-right measurements: meniscus wear is shown,
the report grants to act process setup adjustments as to preserve casting
quality.
X profile
Y profile
79
CUSTOMER SERVICE
DANIELI SERVICE REDUCES
EAF ELECTRODE CONSUMPTION
at NTS, Thailand
1
Technical support
agreement
once again
demonstrates
the Group’s
commitment to be
a reliable partner
for on-site
customer support.
NTS, a company of Tata Steel Group
in Thailand, and Danieli Service
signed a six-month service contract
agreement for the supply of technical support
in order to reduce EAF graphite electrode
consumption. The project started in February
2013 with the arrival of Danieli Service
specialists to conduct a technical site survey,
and to provide practical advice for the
optimization of three major components of
the EAF:
> Danieli Melting Profile;
> Danieli HiRegPLUS electrode regulation
systems;
> Danieli More injection system.
Not only has the intervention achieved an 8%
reduction of electrode consumption, but also
helped to cut electrical energy consumption
by a remarkable margin, with no machine
revamping, to the full satisfaction of the
customer. Danieli specialists will continue to
provide technical support remotely from
Danieli Thailand headquarters, and to give
advice on activities through periodic site
surveys n
%MgO
Chart of saturation isotherm
4
1-2 View of EAF and detail
of the calibration of
flow meter for
electrode cooling.
3 Implementing HiReg
harmonic analyzer and
HiRegPLUS electrical
regulation.
4 Slag analysis and
adaptation for good
slag foaming.
80
20
18
16
14
12
10
8
6
4
2
0
MgO-FeO and
2CaO-SiO2
saturation
liquid
phase
2CaO-SiO2
saturation
10
20
3
EAF main data
MgO-FeO
saturation
0
2
30
%FeO
40
Type
Full platform, AC, EBT
Shell diameter
5,900 mm
Transformer capacity
72 MVA
Tapped steel
75 t
Electrode regulation
Danieli HiRegPLUS
Burners
6
Oxygen lances
3 x 2,000 Nm3/min
50
EAF Performance
Mar-13
Apr-13
May-13
Jun-13
Electrode consumption (kg/ton)
1.82
1.75
1.66
1.67
Electrical energy consumption (kWh/ton)
386
398
398
378
Average Power-On time (min)
39
39
39
39
Average oxygen consumption (Nm /ton)
34
34
34
34
Average production (ton, on-peak)
44,000
44,000
44,000
44,000
3
DANEWS
Cost-effective revamping projects
by Danieli Service
In a period of global
financial straits that
continues to have
consequences for the steel
market, revamping projects
are often the best solution
for many steelmakers to
improve productivity and
quality while saving on
investments in new
technology.
Following this perspective,
Danieli Service acquired two
new orders to revamp
existing bar mills, at Aceros
Alfa, Honduras, and at Abul
Khair, Bangladesh.
Aceros Alfa, Honduras
This revamping project
developed for Aceros Alfa is
the first step of a two-phase
program that will upgrade
the rolling mill production
capacity, from 25 to 60 tph,
and increase the plant’s
functionality without
completely changing the
existing configuration. In this
first phase, the layout of the
plant will be modified to
produce squares and angles
as well. The modifications
include the supply of two
new gearboxes for stands
No. 7 and No. 8, with a new
crop shear between the two
stands; in the finishing mill,
two new stands, No. 11 and
No. 13, will be supplied. In
the finishing area, a new
cold shear will be installed.
Abul Khair, Bangladesh
The project for Abul Khair
will introduce some
important changes in the
actual plant configuration:
with the installation of two
new roughing stands prior to
the existing rolling mill, the
maximum billet size will
increase from 130x130 up to
160x160 mm. In the
finishing mill, new guides
and conveyors will be
supplied, in order to perform
the four-strand slitting. The
installation of a new water
quenching line will improve
the material properties; the
QTB is already designed for
a future five-strand slitting
configuration.
Souvenir photo after successful conclusion of the technical meeting, from
left: Mr. L. Zampa (Senior Engineer, Danieli Service), Mr. A.J. Kattan
(Aceros Alfa owner), Mr. E. Guarini (Danieli Service Mgr. South America),
Mr. E. Kattan (Aceros Alfa Director) and Mr. M. Odorico (Senior Engineer
Technical Assistance, Danieli Service).
These two projects will
require strong cooperation
between Danieli Service and
customers, to provide the
best solutions for a proper
integration of the new
machines in the existing
layouts; in order to obtain
the best results possible, the
teamwork approach taken by
Danieli Service will be the
most important factor for
success n
Aceros Alfa rolling mill revamping project:
Existing equipment
New equipment - Danieli supply
New equipment - Manufacturing
at the customer direction.
81
CUSTOMER SERVICE
MH GUIDE SYSTEMS TECHNOLOGY
at Shanxi Zhongyang Steel, P.R. of China
Left: souvenir photo at the
contract signing ceremony,
with Bao Qing Wang, Steel
Rolling Factory Director;
Bai Junhong, Rolling
Guides Sales Supervisor,
Danieli China; Qi Jun Ying;
S. Capra, Product
Responsible, MH Guide
Systems.
On September 30, 2011 Shanxi
Zhongyang Steel assigned an important
contract to Danieli for modernization of
its obsolete bar mill to the current 700,000 tpy
capacity, with the update to high-quality
production bar mill. After that contract the
customer decided to continue its collaboration
with Danieli for special guide systems, trusting in
the quality of our products and our experience,
as well as in our assistance. Then, the contract
signed with Danieli China covers the supply of
guides for a half-year production (especially for
the 4-slitting process). In order to certify the
global quality of our guide systems, Shanxi
Zhongyang Steel visited Danieli Austria
workshops, where the guides are manufactured.
During the visit, the customer stressed the
importance and desire to work with quality
products made according to European standards,
such as those made in Danieli Austria. The visit
was extremely satisfactory and the customer
expressed again an appreciation for the quality
and professionalism on our guide system
products department n
82
Right: Shanxi Zhongyang
delegation visiting MH
Guides manufacturing
center at Danieli Austria.
Yuan Yu Ping, VP Shanxi
Zhongyang; S. Capra,
Product Responsible,
Danieli MH Guide Systems;
Qi Jun Ying, Intl. Dept.
Manager; S. Bergamasco,
Operation Manager, Danieli
Austria.
DANEWS
Successful maintenance project
at Chengdu Iron & Steel, P.R. of China
CHENGDU I&S, PAN GANG
GROUP, RECOGNIZES DANIELI
SERVICE CHINA AS A RELIABLE
PARTNER FOR ADVISORY
SERVICE FOR IN-HOUSE CAPITAL
EQUIPMENT MAINTENANCE.
Pangang Group Chengdu I&S Co. is
an important source of construction
steel in Sichuan Province. As of
March 2013, the imported wire rod mill
equipment has been running continuously
for nearly four years. As part of a preventivemaintenance program, the steelmaker
organized an annual maintenance schedule,
and urgently requested Danieli Service to
visit to the production site and provide
advisory services. Danieli Service responded
positively, organizing a squad of experienced
professional and technical personnel that
hurried to the customer’s site, and delivered
high-level technical support to ensure that
the client would complete all maintenance
tasks within the stipulated time.
The main maintenance activities were carried
out on critical components of Danieli
equipment of the WR mill, namely:
> 8-pass DWB wire rod block;
> 4-pass TMB high-speed finishing block;
> Oil-film bearing-type loop laying head;
> Shear.
Key aspects of Danieli technicians’ support
have included:
> Equipment inspection on site
> Analysis of the issues with the customer
> Fix detailed maintenance actions
> Refurbishment on-site
> Final check of the equipment startup
> Detailed plan for effective solution to the
customer’s spare parts shortage problems.
Once more, Danieli Service confirms
its role as a valuable resource for qualified
technical support and 24/7 troubleshooting
capabilities n
Although the customer planned a three-week maintenance
period for this wire rod line, Danieli completed all the
activities, one week earlier than originally planned.
For any refurbishment project, Danieli China is completely
self-sufficient thanks to its state-of-the-art workshops that
support customers on a 24/7 basis.
Customer compliments Danieli Team:
...Allow me to express my sincere thanks to your company, who attached
great importance to the WRM annual maintenance, actively preparing for
the deployment of manpower in this busy schedule, and sent three
comrades to our factory for tracking and technical guidance! The three
comrades arrived at the scene and went to work immediately. They give up
the rest of their holidays to work alongside our on-site personnel. The
atmosphere of cooperation was very smooth and pleasant. Your company
gave full technical support for equipment inspection and installation, and
enhanced our understanding of the equipment. Therefore, for this
technical support we express thanks to your company! I hope we may
work together again in the future to help each other, learn from each
other, for mutual benefit and to seek common development, working
together and achieving better results.
Pan Gang Group Chengdu Iron & Steel Co., Ltd and Wire Plant
CUSTOMER SERVICE
DANIELI OPERATIONAL EQUIPMENT
adapted to exploit rolling line
production capabilities
Customized Danieli Service operating
equipment is the reliable foundation
on which to build production flexibility,
so as to satisfy the increasingly strict
market standards for a wide product mix
availability, and a fast response to any
supply request.
Successful workshop
tests and inspections
were carried out for
two new cartridge stands at
the Hadeed rolling mill.
Both stands were
successfully tested in the
Danieli workshop under
direct supervision of Hadeed's
Roll Shop Long Products
Superintendent: every
critical component and every
alignment measure was
checked and approved by the
customer. Additional tests
were required by the
customer during an
inspection visit, such as dyepenetrant inspection on the
chocks. Particular care was
84
taken to set the correct
alignment between the rolls
and the rest bar, so as to
minimize the effect of the
wear on the guides and to
align the stand perfectly;
additional improvements
have been added to the
cartridge stands in order to
optimize the customer’s
workshop activities n
Snapshot of the commissioning stage
in Danieli HQ workshops. Friendly
handshake after successful test
conclusion, in the presence
of Mr. Khalid Al-Suhail (roll shop
superintendent of the long product
plants, Hadee), Mr. K. Emam (Danieli
Service Area Mgr.), Mr. S. Lucchetta,
(Project Mgr., DS) and Mr. L. Zampa
(Senior Engineer, DS).
ELIAL
I
N
DA IGIN ARTS
OR ARE P THS
SP RENG
ST
> Flexible supply structure,
offering:
- LTSA Long-Term Service
Agreement to minimize
delivery time and spares
storage requirements.
- Emergency spare
assistance as a troubleshooting service.
- Spares, for preventive
maintenance.
- Capital parts spares
contracts, to reduce repair
time.
> Plant engineering and
startup, maintaining
continuous feedback, and
able to lead continuous
improvement on spare
selection and
manufacturing.
> Spares implemented
by a new solution in order
to improve equipment
performances.
> Maintains equipment
value through the years.
> Danieli proprietary brand
technological products.
> Consulting service to
optimize spares
management to avoid
hidden production costs.
> Warranty
> Asset preservation
> Enhance the value
of equipment
> Reduce inventory n
DANEWS
Danieli Training earns renewed trust
thanks to its learning methodology
AS A RESULT OF THE LONGSTANDING PARTNERSHIP
WITH ITS CLIENTS,
CONTINUING
AFTER PLANT STARTUP,
DANIELI HAS RECEIVED
TWO IMPORTANT ORDERS
FOR TRAINING ACTIVITIES.
Following the conclusion of three
customized training projects for their
engineers, during which Danieli
provided 150 man/days of training in
classroom and selected similar plants,
for a total of 990 trainee/days, Saudi Iron
& Steel Company (Hadeed), the largest steel
producer in Saudi Arabia (fully controlled by
Sabic) placed an open order with Danieli
Service for future training packages
that will cover all the disciplines and
technological areas.
This will allow Sabic to place orders
immediately, to cover their training needs,
and will guarantee the immediate
programming of the training, as all terms and
conditions have already been defined.
In June 2013 EZZ Dekheila placed an order
for a complete training package for its
engineers and supervisors. A detailed training
program (total duration, 35 weeks) was
designed to include theoretical and practical
courses to cover each plant area for a total
of 175 instructor man/days and 1,050
trainee/days.
The entire training program was developed
for different groups:
>
>
>
>
>
Rolling mill for long products,
Meltshop area,
Slab caster,
Rolling mill for flat hot products,
Academy training for plant managers.
Each course will consist of theoretical
classroom lessons and training at similar
plants n
85
CUSTOMER SERVICE
Capital equipment spare parts supply
Danieli drum shear
Danieli designed and manufactured
a complete drum shear cassette to be
installed in an existing hot-strip mill.
The shear cassette underwent the final tests at
Danieli workshops, in the presence of one official
from the customer. Special tools designed to
simulate the operational dynamics are used to
guarantee the cassette performance. The testing
plan, as agreed with customer’s maintenance
and production staff, included rotating drums
to measure the main gear action path, knives
clamping/unclamping, and knife-gap adjustment.
All the structured testing sequences have been
performed and completed successfully, and
the signature of the dispatch clearance
certificate gave a green light for packing
and transport to the plant. The shear is designed
to cutting/chopping strips of API pipe grades,
HSLA, and carbon steels in the thickness range
from 25 to 40 mm. The supply also includes
Danieli manufactured knives in DanCut 510.
As part of the sales contract, Danieli Service also
will provide advisory service for the first
installation of the cassette into the rolling mill,
to follow the cold and hot commissioning up to
full customer satisfaction n
For capital equipment spare parts,
Danieli Service carries out in-house
functional tests, sharing results and
final commissioning with the customer.
This approach guarantees both
a dramatically reduced installation
and on-site testing period, as well
as a truly "ready to go" startup.
86
DANEWS
TECHNOLOGICAL REVAMPING
DANIELI KOHLER
NON-CONTACT EDGE
BAFFLES FOR HDGL
AIR KNIVES:
STRIP-COATING
QUALITY WITH
MINIMAL CAPITAL
INVESTMENT.
Today's steel
industry has a
limited need and
capability for expansion,
which makes it extremely
important to improve
product quality with minimal
capital investment. Steel
Dynamics, Inc. of Butler
(Indiana) has two galvanizing
lines whose pot areas are
identical except for the style
of wiping equipment
supplied by Danieli Kohler's
predecessor, Kohler Coating
Machinery Corporation.
CGL1 is used to coat
heavier-gauge materials,
mostly hot rolled product,
while CGL2 is for lightergauge cold rolled product.
Due to the combination of
low line speed and heavy
coating weight SDI
experienced edge
overcoating on CGL1, which
was the source of customer
complaints. SDI approached
Danieli Kohler to make a
proposal for Danieli Kohler's
NTLT non-contact edge
baffle for CGL1.
In conjunction with Danieli
Service, Danieli Kohler
analyzed the request and
suggested including CGL2
as well, even though that
line had shown no problems
with edge overcoating, thus
taking advantage of a
common design and shared
maintenance strategy, and
standby equipment, which
made the proposal
economically attractive. The
system improves zinc coating
uniformity by avoiding air
turbulence generated by
opposing knives’ airflow
crossing at the strip edge,
and reduces noise. A
dedicated automation
control system dynamically
controls the baffle position,
referring to the non-contact
strip position sensor, and
the dedicated automation
is interfaced to the line
automation. Maintenance
software tools are anticipated
to help calibrate and
diagnose the
mechanical/electrical
system.
The design is tailored and
focused to supply preassembled and precommissioned components
for an easy
and quick installation
and commissioning at site n
5
Danieli Kohler edge baffle
equipment:
1 Baffle plate.
2 Edge baffle mechatronics
drive.
3 Sensor for strip position.
4 Elevator positioner
(existing).
5 Tomahawak mechanism
(for maintenance).
4
2
3
1
Quality for galvanized
strip production
for Steel Dynamics, USA
DANIELI
THE
RELIABLE
INNOVATIVE
PARTNER
TO BE
FRONT
RUNNERS
Worldwide Offices
and Service Centers
Danieli
Headquarters
Worldwide
Danieli Companies
Via Nazionale, 41
33042 Buttrio (UD) Italy
Tel (39) 0432.1958111
Fax (39) 0432.1958289
info@germany.danieli.com
Tel (49) 208.3780000
info@spain.danieli.com
Tel (34) 94.4872800
info@brazil.danieli.com
Tel (55) 11.35085900
info@russia.danieli.com
Tel (7) 351.2674632
info@japan.danieli.com
Tel (81) 45.6517077
info@russia.danieli.com
Tel (7) 903.6001990
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Tel (1) 724.7785400
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Tel (52) 81.83781055
info@ukraine.danieli.com
Tel (38) 056.7904301
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Tel (41) 61.8368310
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Tel (43) 4232.51440.6101
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Tel (86) 10.58082828
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Tel (20) 2.26379229
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Tel (90) 232.4355577
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Tel (46) 240.668500
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Tel (86) 512.52267088
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Tel (971) 2.6812268
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Tel (886) 7.3358655
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Tel (44) 114.2800300
infodfe@thailand.danieli.com
Tel (66) 38.955888
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Tel (966) 3.8993145
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Tel (66) 2.6933520
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Tel (33) 1.49722269
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Tel (7) 495.9819073
info@korea.danieli.com
Tel (82) 2.5626622
www.danieli.com
info@danieli.com
88
Danieli Centro Tube seamless
pipe plants are equipped with
cone-type piercing mills,
original FQM™-Fine Quality
Mill (3-roll retained mandrel
mill) and sizing/stretch
reducing mill to roll tubes with
close dimensional tolerances.
DANIELI CENTRO TUBE,
SEAMLESS PIPE TECHNOLOGY
TO PRODUCE
UP TO 28” DIA API GR 1 TO 5
AND UP TO 160 PIECES/HOUR
Since 2004 Danieli Centro Tube designed and built
12
Seamless pipe plants
1914 / 2014
Seamless Pipe Plants
DANIELI
CENTURY
DANIELI THE RELIABLE
INNOVATIVE PARTNER
TO BE FRONT RUNNERS
800 -MM ROUND BLOOMS
IN SPECIAL ENGINEERING STEELS
CAST ON A 5-STRAND CASTER
at Laiwu Steel Co. Ltd. PR of China
MORE THAN
20,000 TONS
OF BLOOMS
IN SECTIONS
OF 500-650-800 MM
PRODUCED
IN JUST ONE MONTH
AFTER
THE FIRST HEAT
This is the only Continuous Casting Machine in the world that features five strands and 16.5-m radius,
equipped with all the most advanced technological packages, and designed for the production of demanding
steel grades such as automotive, spring, free-cutting, bearing, and gear steel.