Second Danieli slab caster in six months at Baosteel, P.R. of China
Cold steel mill complexe started up at VSC, Vietnam.
Major casting and rolling facilities modernization at Corus Scunthorpe (UK)
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Danieli News n.143 September 2005, Danieli Group
ALSO IN THIS ISSUE IRONMAKING 4 SUCCESSFUL CASE-HISTORY PROJECT AT ACESITA, BRAZIL. STEELMAKING 8 ACERBRAG: ARGENTINA’S MOST MODERN MINIMILL. 9 37 HEATS/DAY FOR THE DANARC EAF AT ACEROS AREQUIPA, PERU. FLAT PRODUCTS 12 EXCELLENT THICK SLAB CASTER STARTUP AT XIN YU, P.R. OF CHINA. 13 THIN SLAB CASTER EXTENDS CASTABLE STEELS RANGE AT BENXI, P.R. OF CHINA. LONG PRODUCTS 30 SECOND HIGH-CAPACITY SBQ MILL AT JIANGYIN XINGCHENG, P.R. OF CHINA. 34 MODERN BAR AND SECTION ROLLING MILLS STARTED UP AT MAGNITOGORSK, RUSSIA. AUTOMATION 38 PLATE MILL UPGRADDING AT BHILAI (SAIL), INDIA. EXTRUSION LINES 40 INNOVATIVE 32-MN EXTRUSION PRESS AT PROFERALL, ITALY.
The new 1.2-Mtpy fTSR steel complex
>Cornerstone< laying
ceremony at OMK yksa, Russia, June 11th, 2005. The cornerstone laying ceremony was opened by Mr. A. Sedykh, President of the OMK Group, who addressed a warm welcome to the authorities and the distinguished guests, testifying to the importance of this event for the City of Vyksa and the Nizhny Novgorod Region of Russia. Mr. S. Kirienko, the Delegate of the President of the Russian Federation and Supergovernor
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of the Volga Region, Mr. M. Khodyrev, the Governor of the Nizhny Novgorod Region, Mr. M. Fadeev, the President of the Russian National Railway Corporation, of Mr. A. Antonov, VP of Investments of United Metallurgical Company, Mr. G. Lavaroni, VP of Italy’s Danieli, the supplier of the steel complex equipment and technology, Mr. E. Inanc, Chairman of Gama, Turkey, the supplier of the construction package → Page 2
135 ELECTRIC ARC FURNACES 210 SECONDARY METALLURGY STATIONS 389 CONTINUOUS CASTING STRANDS FOR BLOOMS 1041 CONTINUOUS CASTING STRANDS FOR BILLETS 28 HEAVY SECTION MILLS 85 SPECIALTY STEEL AND SUPERALLOY ROLLING MILLS 266 BAR MILLS 139 WIREROD MILLS 117 SECTION MILLS 14 ENDLESS WELDING ROLLING UNITS 8 SPOOLER LINES 450 DRAWING LINES 12 FORGING SHOPS 246 EXTRUSION PRESSES 783 GRINDING MACHINES FOR BILLETS AND BLOOMS 717 BASIC AUTOMATION AND PROCESS CONTROL SYSTEMS
FACTS CONFIRM DANIELI LEADERSHIP IN LONG PRODUCT STEEL PLANTS
Danieli News n. 143 Danieli Publicity Dept.: Tel. (39) 0432.598244 E-mail:
[email protected] Graphic Project: Polystudio DTP: Danieli Publicity Dept. Printing: Grafiche Filacorda. Approved by the Court of Udine under authorization n.16 dated 21.04.83
Dear reader, We are pleased to present you this issue of the Danieli quarterly journal which, as you may have already noticed, features some layout re-styling aimed at providing you with better information and more enjoyable reading.
Danieli Headquarters Via Nazionale, 41 33042 Buttrio (UD) Italy Tel (39) 0432.5981 Fax (39) 0432.598289 www.danieli.com
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he last three months have been characterized by some significant events such as the OMK cornerstone laying ceremony for the first fTSR thin slab casting rolling minimill complex in Russia; the second slab caster order received from Baosteel in six months; and the VSC cold mill complex in Vietnam, which reached full operation in one month from commissioning. We have also seen new examples of excellence in casting technology with the startup of slab casters at Xin Yu and Benxi (second line) together with a productivity record with 6-strand >FastCast< billet caster at Mechel, and the second order from Corus which chose Danieli to enhance product quality at Scunthorpe, among others. The top performances at Aceros Arequipa (up to 37 heats/day), Acerbrag and Arcelor's Belgo Piracicaba plant, which has become a benchmark, confirm the Danieli leadership in minimills in Latin America. We also record the hot startup of the rolling mill of SSC minimill whose meltshop is scheduled to spark by the end of the year. A new meltshop and casting plant order was received from Sidertul. Two strip processing lines are fully producing at the cold mill complex of the leading Chinese producer, TISCO. KME, Germany, one of the largest copper producers worldwide, has ordered the third rolling mill from Danieli Froehling. Two out of the new three long product rolling mills ordered by MMK have been started up, also. You will find this and more information browsing through the pages of this issue of DaNews. Thank you for your attention. Paolo Messina Danieli, Executive Manager PR and Information
[email protected]
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COVER STORY
>Cornerstone< laying ceremony for the OMK 1.2-Mtpy complete fTSR flexible Thin Slab Rolling plant 1
FROM FIRST PAGE
of the steel complex, Mrs. A. Ricci, Vice President of Medio Credito Centrale, the Italian financing bank for equipment and technology, Mr. N. Fychev, Director of Investments of Sverbank, the Russian financing bank for the local construction package, took part in this meaningful event. The ceremony was an essential element of the greater project, confirming its industrial feasibility, being financially supported by shareholders, the Italian and international
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1 Mr A. Sedykh, President and CEO of OMK addresses his speech at the first stone laying ceremony. 2 3D representation of the fTSR process to be implemented at OMK.
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3 Schematic layout of the whole new complex. The blu dashed lines show the possible future expansion. 4 A Danieli Wean United 6-stand finishing mill equipped with f2CR stands.
5 Close-up of a f2CR stand, capable of crossing rolls while rolling for a superior strip flatness and crown control capability.
banking system and the Russian banking system. This event also marked the beginning of project execution. Industrial operation is expected by the end of 2007, with a capacity of 1.2 Mtpy of hot rolled coils to feed the pipe mills of the OMK Group. The new steel complex will be composed of an electric steel meltshop with EAF, ladle furnace, vacuum degassing station, a medium slab caster with hot strip mill for a continuous casting and rolling process.
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>fTSR<
The technologies applied in the new steel complex are unique both in Russia and all over the world, as they meet high-quality steel demanded for the production of arctic steels, resistant to acid aggression (natural gas and crude oil) at very low temperatures (-65°C). The new plant will employ 2000 workers (direct and indirect manpower) thus being an important prospect for young engineers and the population of Vyksa City, which is now celebrating 250 years of steelmaking history. ■
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Customer satisfaction for Danieli Corus blast furnace repairs at Acesita (Arcelor Group), Brazil The successful project is already referred to as a case-history inside Arcelor Group.
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Mr Paulo Magelhaes, Director of Acesita, signed the acceptance letter for the full and complete finalisation of the repair of BF No. 2 performed by Danieli Corus on July 12. It took place during a luncheon also attended by Mr Marcondes (plant manager), Mr. Cardoso (BF manager), Mr. Helvio (project manager), Mr. Yamana (project engineer) from Acesita, and Mr. P. Hemels (project manager) and Mr. F. Kaptein (sales manager) from Danieli Corus. Danieli Corus was paid compliments for the excellent results of the project. Moreover, Acesita stated that, within the Arcelor Group, this project was selected to be discussed and assessed at higher management level as an excellent example of project management and working methods in order to achieve a similar great success in future projects. The first project step was taken in December 2002 with an order for operational assistance. In November 2003, Danieli Corus received the order for the design and supply of new refractory and cooling system to be installed in the tuyere zone, the bosh and the so-called belly. Included in the design is a state-of- the-art heat flux monitoring system measuring the heat load on the furnace wall in the different sections; it enables the operator to adjust and improve the charging of the furnace to obtain an optimum process. A fast track supply schedule could be maintained due to worldwide sourcing for supplies by Danieli Corus who also had on site supervisors to guarantee the proper construction. Training and startup supervision were also part of the contract.
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Director Paulo Magelhaes of Acesita signing the final acceptance letter for the repair of Acesita BF No. 2 performed by Danieli Corus.
The furnace was blown down on April 10 and started up on May 8, four days ahead of schedule. The repair was executed without any accident. The ramping up to the aimed production of 1270 tonnes per day was reached as planned. Noteworthy is that the furnace uses fuel coke in the charge and charcoal as injectant in the tuyeres- a system developed by Acesita. ■
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Danieli Corus Blocktectors and tuyere cameras at Taiyuan I&S, P.R. of China This is the same furnace for which Danieli Corus supplied a PCI system in 2004.
New Pulverised Coal Injection system at Shougang I&S, P.R. of China
Pulverised Coal
Purge N2
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Individual tuyere injection stops automatically in case of blockage Blocktector
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aiyuan Iron & Steel (Group) Co. will install 40 Danieli Corus Blocktectors and 3 tuyere cameras on its new BF #1. The delivery time for the equipment will be approximately 3 months. Blocktectors & Cameras have been operating at Corus IJmuiden since the late 80’s and are well-proven for detecting the onset of a blocked tuyere and turning off coal supply to that specific tuyere. In this way, they help to prevent explosions or other potential hazards of pulverised coal collecting in the tuyere. Blocktectors are also very useful instruments during blowing in a chilled furnace, to identify blocked tuyeres would be very useful in deciding prior to injecting fuel into the furnace. If pulverised coal continues to be injected when the tuyere is blocked, it may lead to: spillage of pulverised coal around the mouth of the tuyere; tuyere burn-out; damage to the hot blast main, where combustion of coal in the bustle pipe would lead to extreme heat resulting in hot spots and pipe rupture;
This is Danieli Corus' 5th order for a PCI system in China to date.
D explosion in the hot blast main, when sufficient quantities of burning coal come into contact with oxygen-rich blast. The use of Blocktector offers many advantages: proven technology, specifically designed and developed for the BF environment; easy installation and use; no additional maintenance; no special (expensive) instrument piping close to the tuyere is required. These instruments will enhance the operation of the PCI system at Taiyuan, especially with high injection rates expected of the system. ■
anieli Corus was awarded a contract for design, supply and services by the Shougang Iron & Steel (Group) Co. at Qian'an for a new injection system for the PCI facility serving their new Blast Furnace No. 2. BF No. 2 has an inner volume of 2650 m3 and is expected to produce in excess of 6500 thm/d. The PCI system will inject a minimum of 200 kg/thm and ensure that the BF consumes the injected coal in an efficient manner. This BF has 30 tuyeres. The system will be constructed during 2005/2006 and ready for operation later in 2006. The contract also includes supervisory services during the equipment installation, and training of BF personnel at Danieli Corus offices in The Netherlands. ■
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New orders from the Chinese market for hot blast stoves Danieli Corus expertise will provide Shougang Qian’an and Taigang Taiyuan with state-of-the-art equipment and services.
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n both cases Danieli Corus received an order for engineering, refractory supply material inspection and installation supervision services. Both projects foresee stoves designed for a constant hot blast temperature of 1250 ºC to optimize the production and minimize fuel consumption of the new blast furnace.
Shougang Qian’an The first order, signed on April 19, 2005, with the China Shougang Trade & Engineering Corp., calls for three new hot blast stoves for the new 2650-m3 inner volume BF No. 2, as well as a complete new hot blast system, containing a hot blast main and bustle pipe with tuyere stocks. Thanks to the reliable performance of the Danieli Corus stoves, hot blast system and ceramic burners supplied through the previous orders, the Shougang Design Institute wished to continue that excellent relationship with its order for one of its new high productive blast furnaces. The total order volume over the last five years makes Shougang I & S Corp, together with China Shougang Trade & Engineering Corp, one of the most valuable customers for Danieli Corus in the P.R. of China.
View of the hot blast stoves erected during a previous Danieli Corus project at Shougang.
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Contract signing ceremony for the Taigang Taiyuan project. From left to right: Mr. Wang, Vice Mgr. for Ironmaking plant, Mr. Liang, Ironmaking Mgr. responsible for all Taigang BFs, Mr. R. Stokman, Senior Sales Mgr. of Danieli Corus, Mr. Zhang, Contract Mgr., Mr. Xu, Project Mgr. of Taigang Design Institute, Mr. Wei, Danieli Corus Beijing representative.
Taigang Taiyuan I&S Corp. The second order (July 2, 2005) relates to five new hot blast stoves for the existing blast furnaces No. 3 & 4, which will be reconstructed in the coming years to increase their inner volume up to 1800 m3. Thanks to this order, Taigang I & S Corp, together with the Taigang Group Intl. Trade Co. Ltd. made an important step toward modernizing the existing facilities at Taiyuan, Shanxi Province. This order is the logical continuation of the cooperation between the two companies which is based on the excellent performance of the Danieli Corus technology already applied to one of the BFs at Taiyuan some years ago. Moreover, this is the first contract in the history of Danieli Corus to call for five Danieli Corus hot blast stoves. ■
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STEELMAKING
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New order for steelmaking and continuous casting plant at Sidertul, Mexico The project also involves the modernization of the 75-tph bar and section mill.
From left to right: Mr. Samuel Nanes, Financial Director (Sidertul), Mr. Don Israel Feldman, Chairman (Sidertul), Mr. GP Benedetti, President and CEO (Danieli), Mr. Ernesto Edelstein, Plant Director (Sidertul) and Mr. A. Zanoni, Executive Manager, Sales (Danieli). Other pictures show production units similar to those to be installed at Siderurgica Tultitlan.
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iderurgica Tultitlan S.A. de C.V. (Sidertul) will completely reconstruct its steelmaking facilities to increase billet production from present 350,000 tpy to 600,000 tpy. Also included in the project is the upgrading of the rolling mill, originally supplied by Danieli in early 90's. Major modification will basically include: Replacement of the electric arc furnace with a new 60-t Danarc EAF. Complete revamping and modernization of the three-strand conticaster with new tundish, tundish car, moulds, oscillating tables, secondary cooling system and withdrawal straightening units, plus
provision for the fourth strand. New primary and secondary fume dedusting system. Plant auxiliaries, including a new water treatment plant. All electricals, automation and process control system. The installation of a ladle furnace is foreseen at a later stage.
The new meltshop's capacity will be suitable to meet billet demand of the existing bar and section mill, and to supply billets to the market, too. The rolling mill will be modernized by extending the cooling bed and installing a CCL system (multi-strand straightener and pendulum-type cold shear) at the delivery side to keep pace with mill's production capacity and enhance finished product quality. New bending machines for bar bundles will also be installed.
The mill's operations will be optimized thanks to a new complete automation system (up to Level 2) supplied by Danieli Automation. The mill is designed to produce small bars and profiles at a rate of up to 75 tph. ■
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Acerbrag: the new meltshop of the most modern and competitive minimill in Argentina starts operation
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n May 26th 2005, the new meltshop successfully started operation by delivering its first billets and enabling Acerbrag to enter the modern era of minimill layout design. The state-of-the-art steelmaking plant basically includes a 50-t Danarc EAF fitted with two Modules for O2 and C injection and a 2/3-strand billet caster directly connected to the rolling mill for hot-charging operation. The supply also included plant auxiliaries such as Fe-alloy system, fume dedusting plant, an 80/130-t ladle handling crane and Danieli Automation electricals and automation for the whole plant. This was the last step of the modernization
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The 350,000 tpy minimill is now the most modern and competitive minimill in the country.
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Layout legend 1 Scrap yard 2 50-t AC EAF and LF 3 3-strand billet CCM 4 FTP 5 60-tph WH reheating furnace 6 19-pass rolling mill 7 QTB bar quenching and self-tempering system 8 Cooling bed and automatic bar cold finishing services 9 8-pass high-speed wire rod finishing block 10 Wire rod controlled cooling line (QTR system) and automatic cold finishing services
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of the existing steelworks, a project that also included a bar and rod mill multi-stage reconstruction program concluded in March 2004 with the startup of the rebuilt hot rolling mill area. The 60-tph Danieli rolling mill is designed to produce 8 to 25-mm-dia plain/deformed bars, up to 50-mm angles, corresponding flats and 5.5 to 14-mm-dia wire rod in up to 1.5-t coils. Acerbrag's new minimill, with a 350,000-tpy nominal capacity, is now one of the most modern and complete steelmaking and rolling plants in operation in the country and will grant both higher productivity and efficiency in the manufacturing of long products. ■
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Top-performing minimills: up to 37 heats/day and regularly over 30 at Aceros Arequipa, Peru Benchmark results from the upgraded EAF.
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Best results obtained at the EAF (*)
Min tap-to-tap time
36 min (or 40 heats/day)
Productivity
+10%
Electrode consumption
-22%
Electr. energy consumtpion
from 490 to 420 kWh/ton of good billets
he 40-t EAF at Aceros Arequipa in Pisco performs at top levels, after the major improvements carried out by Danieli Centro Met. The furnace, which restarted in December 2004, was upgraded with the installation of a new electrode regulation system, a completely new automation system and a "burnjector" unit for better chemical energy utilisation. This was part of an overall meltshop upgrading that also included a new fume treatment plant and the modernisation of a billet conticaster. The burnjector gives operators the advantage of keeping the EAF door closed during almost 95% of the entire process, helping to increase the slag volume inside the furnace, resulting in better performances and efficiency. The Pisco minimill also includes a 320,000-tpy bar and rod mill upgraded in 2002 and completed by Danieli Morgårdshammar in 2004 with the installation of a new high-speed wire rod line. ■
(*) With a charging mix based on 35-40% DRI content
Major upgrading of the fourth 150-t EAF at Essar Steel, India A confirmation after the excellent results achieved by the other upgraded Essar’s EAFs.
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ssar Steel placed the order for the major upgrading of a fourth 150-ton DC EAF for its Hazira steelworks, to increase productivity and optimise furnace operation. Danieli was already contracted to upgrade three other electric arc furnaces of the same size at the same plant, two of which are successfully operating since December 2004 and May 2005. Satisfactory results were achieved after the EAFs’ modification, with tap-to-tap time down to 52
minutes and electric power consumption equal to 450 kWh/t (against original values of 80 min and 564 kWh/t, respectively) with furnace operation based on combination of 45% hot DRI and 55% cold DRI. The extent of the EAF No. 4 modification will be the same as that of the other three furnaces and will include: Enlarging the furnace shell to bring heat size to 155 t and hot heel from 40 to 70 t. Installation of the latest generation multi-purpose
oxigen/carbon injectors, with Cu cooling blocks. Installation of pneumatic lime injection system. Automatic temperature and sampling devices to optimise on-line process control. Logistics optimisation. Level 2 automation system for the supplied equipment. ■
Hot DRI charging into the 150-t Electric Arc Furnace.
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New turnkey order for a second 75-t ladle furnace at Highveld, South Africa
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anieli Centro Met will supply Highveld Steel with a 75-t ladle furnace -complete with materials handling system and water treatment plant- on a turnkey basis. The new unit will allow an optimized production process and an improved cleanliness of the liquid steel coming from the LD converter shop. Another LF of the same size was supplied by Danieli in 1993 and operates successfully at the same plant since then. The new inert-roof type LF, served by a 13-MVA transformer, will be fitted with automatic sampling equipment, wire feeding system, emergency stirring lance and will be suitable for granting a heating rate equal or higher than 4.5 °C/min. The new unit features all the latest advances in steel refining technology and also is completely interchangeable with the previous one for operation and spare parts optimization. The hot startup is expected in October 2006. ■
120-t LF starts operation at Hunan Valin (Xiangtan), P.R. of China
Since the early 80’s, Danieli has been one of the leaders in secondary refining for ordinary, specialty and stainless steels, with more than 135 units supplied all around the world. The know-how gained over many years has been used to develop and optimize equipment and process so as to also meet the most stringent customers’ requests.
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Steelmaking
t the end of July 2005, a new 120-t ladle furnace was successfully started up at Hunan Valin I&S Group Co. Ltd. (Xiangtan), Hunan Province, as part of the existing steelworks upgrade project, which also includes a second LF and a VD unit of the same capacity, scheduled for startup later this year. When in full operation the two ladle furnaces and the degasser, designed to process 2.5 Mtpy and 1.2 Mtpy of liquid steel respectively, will be an integrated part of Xiangtan No. 1 new steelmaking plant and feed the existing bloom and slab casters. Steel grades to be processed are high-quality tube and pipe steels, high-pressure boiler steel, carbon structural, shipbuilding, pipeline and pressure vessel steel plates. •
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Signing cermony, 1st row from left to right: Mr. Chen Weidong, GM of Baosteel International Trading Co., Mr. Jiang LiCheng, President of Baosteel Pudong Steel Co., Mr. J. Lester, Director Danieli Davy Distington, Mr. O. Pinarello, Area Sales Manager, Danieli.
Second Danieli high-tech slab caster at Baosteel, P.R. of China After 6 months from the first order to Danieli Davy Distington, Baosteel awarded the order for a second thick slab caster, to be installed in No. 3 plant in Shanghai. he contract calls for the supply of a single-strand machine with a yearly production exceeding 1.5 Mtpy of qualified slabs in special steels, structural steels, vessel, boiler and ship application steels. Slab sizes are 200 and 250 mm in thickness, 1500 to 2300 mm in width. The main features of the machine include:
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Vertical curved design with a vertical length exceeding 2.6 m, a 9.5 main radius and continuous bending and unbending roll diagram. Top feeding dummy bar. Complete breakout prevention system with thermal mapping of the mould. State-of-the-art INMO mould, including in-line width adjustment during casting. Hydraulically operated oscillator.
OPTIMUM type segments, designed for the application of Dynamic Soft Reduction process. Air mist secondary cooling, controlled by a dynamic model. Complete automation system including predicting mathematical models for Liquid Pool Control (LPC) and Solidification process used for Dynamic Soft Reduction (DSRC) and Dynamic Secondary Cooling (DSC) system.
Of particular note, this is the 20th Danieli slab strand (8 in China) adopting INMO mould technology, the last generation patented mould, designed with superior zero-clearance guidance system for outstanding slab surface quality. This second order awarded to Danieli in just a few months by Baosteel (the largest Chinese steel producer) confirms the leading technical position of Danieli Davy Distington as supplier of superior slab casting equipment, as well as customer satisfaction reached during the execution of the contract of the caster for plant No. 4, presently under advanced design stage. ■
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Thick slab caster successfully started up at Xin Yu, P.R. of China Excellent performances thanks to the advanced and reliable mechanical and electrical/automation equipment supplied.
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he single-strand medium slab caster was successfully started in Xin Yu Iron & Steel Co. Ltd. in Jianxi province on May 12th, 2005. It is a medium slab caster that has been equipped with the most advanced casting technology, such as soft reduction, hydraulic oscillation and mould width taper adjustment. A wide range of steel grades can be produced at high rates, as the advanced process control system supplies a stable and reliable condition for the caster to maintain the high productivity and prime quality rate. A total of 300 t from three ladles were cast at startup, and a daily production of more than 2200 t from 20 ladles was reached after only 12 days from the first cast. An even more important performance achievement was reached on July 3, 2005. After only 54 days from the startup, the caster had processed a long sequence of 42 ladles. During the sequence,
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three different tundishes have been used by successfully realizing two fly tundish change. The short period between the first slab and this goal proves that the equipment is "user-friendly" and how easily the customer can become familiar with the equipment. ■
A Danieli high-tech slab casting technology commissioned at Jiu Quan, P.R. of China
First slab coming out of the conticaster on May 12, 2005. The automation and process control system features several Danieli technological packages such as MLC, HOC, WAM, LPC, DSRC and QUART.
Danieli technological package composed of cassette mould and hydraulic oscillator was successfully integrated and started up at Jiu Quan Iron & Steel Co. Ltd. plant on April 25th, 2005. Equipped with hydraulically actuated, mould width taper adjustment, the Danieli Davy Distington mould can cast 160 or 220 mm thickness of a wide range of steel grades. The Mould Breakout Prevention System controlled by Danieli Automation Mould Detector Server Software detects any sharp temperature variations on the mould surface and prevents any risk of strand breakout slowing down the casting speed. •
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Successful startup of the 2nd flexible Thin Slab Casting strand at Benxi Iron & Steel, P.R. of China Since the first heat was cast on June 19, 2005, an impressive list of different steel grades has already been successfully commissioned.
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he smooth and fully automatic commissioning confirms the high reliability of Danieli TSC equipment. Benxi I & S Co. is now focusing its production on a wide range of steel grades, aiming to become a reference Thin Slab Caster in China, covering the whole range of production both in width (850 up to 1750 mm) and slab thickness (70 and 85 mm). Both strands have now entered the performance test period and up to now several grades have been tested for all the steel groups, from IF steel grades to high carbon, achieving very high quality standards. For the very first time in Thin Slab Casting, silicon steel has also been successfully cast in different grades, as have been HLSA and peritectic grades. In detail, the following steel grades have already been cast: IF steel (St16), ELC (St 14, St 12F), low carbon (SPHC, St12, SS330, SPH-T1, SPH-T2, BG510-L1), medium carbon (SS400, Q345 A, Q235 B), peritectic steel (SS400P), HLSA MC (J55), HLSA LC (X46, X52, SPAH), high carbon (C45), Si steel (50BW600, BGD, 50BW400). Processing of additional steel grades is scheduled in the near future. This second strand flanks the first, in operation since November 2004 and will allow Benxi Group to reach the production target -as soon as the second shuttle furnace is commissioned. This wide range of steel grades cast right from the very beginning of production confirms Danieli as the top supplier and technology partner in Thin Slab Caster. ■
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3 Pendulum shear at the 1 Overall view of the exit of the cooling casting floor with the two chamber. strands in operation. 4 Front view of the 2 Mr. Qi Zhen, Caster conticaster. In the Responsible (Benxi I&S) foreground the tunnel congratulates Mr. F. Faivre, Danieli Site Manager. furnace and the dummy bar parking.
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>Work in progress< at the 2-Mtpy hot strip mill complex of Tangshan Guofeng, P.R. of China
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ork on the Tangshan Guofeng 2-Mtpy hot strip mill complex, located in Tangshan City, is proceeding rapidly. The target for the plant startup is 20 months from order date. As of the end of June, all main civil works in the rolling mill area are completed and erection activity of Danieli Wean United equipment has started. Danieli equipment is already on site ready for installation and most of the locally
Incoming slab
Thickness
Hot Strip Mill
135 (mm)
Thickness
Width
600 - 1,300 (mm)
Width
600 - 1,300 (mm)
Length
15,600 (mm)
Coil OD
762 (mm)
Weight
21 (t)
Coil ID (max)
1,850 (mm)
Weight
21 (t)
Specific coil weight
16 (kg/mm)
Roughing area
Finishing area
1.2 - 12.7 (mm)
Coil conveyor line
Downcoiler area Plant layout and main material data
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manufactured equipment has been delivered. Erection of the finishing mill has begun and F5 and F6 stands are already aligned on foundation. The new facility will have a product mix of 35% of carbon steel, 55% of high quality carbon steel and 10% of low alloy steel. Plant configuration features a reversing roughing stand with attached edger, coilbox, rotary crop shear, water descaler, six 4-hi finishing stand, waterwall cooling system and downcoiler. The Tangshan Guofeng HSM takes advantage of the most up-to-date and proven rolling technology coming from Danieli Wean United and includes the newest technology for strip shape control: edger HAWC (Hydraulic Automatic Width Control); HAGC (Hydraulic Automatic Gap Control); positive bending; WR shifting; roll thermal crown (RTC) control; shaped roll technology to improve flatness control. Project development and progress are based on a full co-operation between Danieli, Erzhong and the Yanshan University. Each party brings its own expertise to the project in order to achieve the market’s strictest quality requirements. ■
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FE model for prediction of strip profile in a 6-high cold rolling stand The results of simulations are now used to tune the analytical model of roll stack deflection which is included in the control system of the stand.
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n order to satisfy the highest quality requirements, an accurate knowledge of rolling parameters and strip profile is very important. The key to achieving precision shape control is to know the mechanical behaviour of the roll stack and its effect on the strip. The way to obtain a good strip profile is through shape actuators: these devices deform rolls to give the strip the desired shape. To investigate the behaviour of roll stack, two fully deformable FE models have been prepared: the first, symmetrical, to study work roll bending and intermediate roll bending, the latter, asymmetrical, for intermediate roll crossing. Rolls were modeled as perfectly elastic bodies, strip as an elastoplastic body with exponential hardening. Although BUR has a great stiffness (compared to other rolls), treating it like a rigid body may give inaccurate results in terms of strains of the strip. Several rolling conditions were taken into account: each shape actuator acting alone and together.
Mesh of models is uneven: in contact zones (stripWR, WR-IR and IR-BUR), there are small elements, while in other parts mesh is coarse. There is also a mesh refinement along the width of the strip to evaluate the edge drop phenomenon. The entire contact procedure was managed by software; the contact algorithm automatically detects nodes coming in contact and generates the appropriate constraints to ensure that no penetration occurs and the compatibility of displacements across all touching surfaces is maintained. Every simulation brings more results: the main ones are total rolling load, deflection of rolls axes, shape of roll gap and profiles of the strip. The effect of shape actuators is described in terms of shape coefficients which are a useful indicator of how much the stand can change the strip profile. A new procedure to obtain shape coefficients has been developed. A comparison between FE simulations and real rolling conditions was made on the total rolling load. Results agree with experimental measurements; in the best cases, the difference between measured and calculated values is less than 4% (usually this figure is considered very good when below 10%). ■ 4
1 Stresses in the mill housing under max rolling load. 2 FE model of the 6-hi roll stack. 3 Strain on the rolled stock.
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4-5 The 6-hi 3C cold reversing in operation at Shougang Iron & Steel, P.R. of China.
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The new temper mill at Baotou, P.R. of China, starts operation Another successful commissioning completed in short time.
Official opening ceremony at the presence of Mr D. Li (Director of Flat Product Division, VP of Baotou I&S), Mr. Z. Lu (Deputy Director of Flat Product Division, Baotou I&S), Mr. Z. Bin, (Level 2 Engineer, Baotou I&S) and Danieli Project Managers.
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n June 29, 2005, an official ceremony was held to mark the first coil successfully processed by the new temper mill in Baotou I&S (Group) Co. Ltd. in Baotou City, Inner Mongolia. Mill commissioning was quite smooth and quick, and the results exceeded all the most optimistic expectations of both customer and supplier. Maximum rolling speed of 1,000 mpm and high separating force of 1,000 t were tested just days after the first coil. Surface quality and metallurgical effects of the processed strip are good and steady, thanks to accurate strip tension control. A reliable mechanical and hydraulic equipment design is improved by very efficient Level 1 and Level 2 hardware and software,
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both developed by Danieli Automation. The final CQ, DQ, DDQ and HSLA steel quality are guaranteed by the mill’s wet rolling system and an electrostatic oiler downstream. They assure the cleanliness and surface conditions of the higher quality, saleable product for construction and household appliances, and later on for the automotive industry. A high, daily strip production rate (in its whole dimensional range -thickness from 0.25 to 3.0 mm; width from 960 to 1600 mm- and all steel grades) is a good guarantee of the full potential of the temper mill (designed for 0.8 Mtpy), which was reached by the end of August 2005, when the Final Acceptance Certificate was signed by both parties, as scheduled. ■
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New hot skinpass mill for Lianzhong Stainless Steel Corp, P.R. of China
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n June 9, 2005, Danieli and Lianzhong Stainless Steel Corp. signed a contract for the complete supply of a new hot skinpass mill, to be installed in Economy & Technology Development Zone of Guangzhou. The new mill will process both stainless and carbon steel strip with the following dimensions:
technological equipment, both imported and local; the latter will be delivered by Danieli Metallurgical Equipment (Beijing) Co. Ltd., while Danieli Automation will supply the electrical and automation portion, including Level 1 and Level 2. The startup of the plant is expected within 18 months from the contract placement. ■
SSAB selects again Danieli technology New cold plate leveller order for Oxelösund plant
Contract signing. From left: Mr. P. Hyvönen (Sr Contract Mgr., SSAB), Mr. M. Righini (VP Sales, Danieli Wean United), Mr. J. Steninger (Project Mgr., Head of Supporting, Production, SSAB) Mr. H. Eidelöf (Project Mgr., New Investments, SSAB). Danieli cut-to-length lines for ultra high strength steel in operation at SSAB Tunnplåt in Borlänge, Sweden.
Strip thickness: 1.2 to 6.5 mm Strip width 800 to 1,600 mm Max coil weight 30 t for a maximum elongation of 4%
With a 1500 t rolling load capacity, the mill is equipped with HAGC, positive and negative bending system, constant passline and backup roll brushes. An in-line inspection station will allow visual check of both strip surfaces. Main motors, for a total of 4 MW, will allow a maximum speed of 600 mpm. Danieli will supply the complete
Mr. Li Pi Hsien (Chairman Lianzhong Stainless Steel Corp.) and Mr. A. Mordeglia (Vice President Sales, Danieli).
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urther to the startup of the innovative cut-tolength lines for high strength strip in Borlånge, SSAB has awarded a challenging new order to Danieli. In fact, as of June 29, a contract is in force for the supply of a new cold plate leveler for high strength steel, to be installed at the Oxelösund plant. The new machine will be part of a completely new expansion project to increase the production of the well-known SSAB Oxelösund steel plates. The leveler will have a 9-roll design. Rolls will be independently driven. The roll barrel length will be 3.4 m. The design of the machine will incorporate outstanding features such as HAGC, roll bending, top roll independent height adjustment, automatic cassette change. The maximum leveling force will be 18,000 kN. The frame sturdiness will be enhanced by four pretensioned tie-rods. A completely innovative design will be applied to the drives in order to optimize their performance while keeping the maintenance as simple as possible. Beside the complete machine supply, Danieli will be in charge of the auxiliary equipment, as well as the interconnecting piping. Production for the new line is expected to start in March 2007. ■ 17
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Successful and fast startup of the cold mill complex at Vietnam Steel Corporation Only one month after the completion of the construction activities, the entire facility has started its production phase.
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n 2002 Danieli Wean United received an order for a new Cold Mill Complex to be installed at VSC in the Phu My industrial area, Ho Chi Minh City. After a very fast period of manufacturing and installation of the new lines, the commissioning period started. Only one month after the completion of the construction activities, the entire facility started its production phase. The following lines are now running: a Push-Pull Pickling Line, a Single Stand Cold Reversing Mill, a Single Stand Cold Reversing & Temper Mill, a Batch Annealing Plant, a Recoiling and Tension Levelling Line. Since the beginning, the equipment has performed at a very high level. The plant soon will reach its maximum yearly production of 405,000 tpy; material that will be used in the local construction industry, automotive
Customer satisfaction
Mr. Huynh Quang Bau, General Manager of Phu My cold rolling complex (PFS), VSC Group, congratulating with Mr. Antonello Mordeglia, Vice President Sales, Danieli.
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Cold mill complex layout: Pickling line Provision for cleaning line Batch annealing furnaces Cold reversing mill
Cold reversing and temper mill Coil transfer Coil transfer and tilter Recoil and tension level line BAF control and electrical rooms
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industry and home appliances. Until now, Vietnam has been importing this kind of product. The special design of the pickling tanks grants a constant and defect-free flow of pickled coils for the downstream lines. Thanks to a perfect optimisation of mechanical equipment and automation process, the CRMs are now rolling thickness down to 0.25 mm, reaching a maximum speed of approx. 1,200 mpm. The complex is controlled by Level 1 and Level 2 automation systems including all mathematical models for quality control. A common server will provide coils tracking during the production cycle. The maintenance system will be based on Fast Data Analyzer (FDA) server/client configuration that will allow the system monitoring from every electrical cabin or pulpit. The surprising results achieved by Danieli indicate a highly professional level of job execution and project management, and the key has been the coordination between Danieli Wean United, Danieli Automation and Danieli Service. ■
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1 Entrance of the Office building. 2 The Turboflo push-pull pickling line. 3 Cold rolling mills bay. 4 Control pulpit of the push-pull pickling line. 5 Batch annealing bay. 6 Close-up on the cold reversing and temper mill stand.
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THE MOST MODERN MINIMILL FOR ULTRA-LIGHT GAUGE HOT STRIP
Without any doubt a highly competitive minimill complex thanks to: Danarc EAF, long funnel mould and soft reduction Thin Slab Caster, flexible crown-free rolling HSM, Self-learning automation.
FACTS CONFIRM DANIELI WORLD-CLASS ACHIEVEMENTS IN INTEGRATED AND FLAT PRODUCT PLANTS
IN FLAT PRODUCTS
FROM DANIELI SCORECARD (FLAT PRODUCTS) 96 BLAST FURNACE PROJECTS 135 ELECTRIC ARC FURNACES 210 SECONDARY METALLURGY STATIONS 71 THICK SLAB CASTING STRANDS 24 MEDIUM/THIN SLAB CASTING STRANDS 150 HOT STRIP AND PLATE MILLS, 4 OF WHICH THIN SLAB ROLLING PLANTS 14 STECKEL MILLS 86 COLD ROLLING MILLS 282 NARROW COLD ROLLING MILLS FOR NONFERROUS METALS AND STAINLESS STEELS 144 STRIP PICKLING LINES 89 HOT DIP GALVANIZING AND ALUMINIZING LINES 108 ELECTROLYTIC TINNING LINES 23 COLOR COATING LINES 332 SLITTING AND SHEARING LINES 267 GRINDING MACHINES FOR SLABS 717 BASIC AUTOMATION AND PROCESS CONTROL SYSTEMS
Danieli Headquarters Via Nazionale, 41 33042 Buttrio (UD) Italy Tel. (39) 0432.5981 Fax (39) 0432.598289 www.danieli.com
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Strip processing lines full on-stream at Tisco, P.R. of China Final Acceptance Certificate for both the pickling line (CPL1) and the galvanizing line (CGL1) was signed on June 21, 2005.
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he strip processing lines successfully put into operation at Tangshan I&S Co., with full customer satisfaction, once again confirmed the leading position of Danieli Wean United technologies for strip pickling and galvanizing lines. The pickling line is designed to process HR steel strip at a rate of about 1.5 Mtpy of pickled coils. The strip ranges from 0.8 to 4.0 mm in thickness and 850 to 1,680 mm in width with a maximum coil weight of 30 t. The process section of the line, based on the patented Danieli Turboflo system, consists of three tanks with backup rinse cell, a five-stand rinsing section and three horizontal accumulators for continuous operation, allowing a maximum process speed of 306 mpm. The galvanizing line has a capacity of 450,000 tpy for galvanized (GI) and galfan (GF) products with CQ, DQ and HSLA grades, and is 2
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designed to supply galvanized steel to all major markets, including products for construction and domestic appliances. The line processes HR pickled and CR steel strip with a thickness range from 0.3 to 2.0 mm and a width range from 850 to 1,680 mm at speeds up to 180 mpm. Final products include normal, minimized and no-spangle coating, with coating weights ranging from 60 to 600 g/m2. The first coils were produced at the end of November 2004 (pickling line) and of December 2004 (galvanizing line). Since then, the two lines have produced galvanized and pickled strip of excellent quality with an optimal learning curve. Another pickling line and galvanizing line are being supplied by Danieli to Tisco. Installation works are expected to start at the beginning of August. These new lines will enable Tisco to achieve a remarkable position in the Chinese market as a reliable supplier of high quality pickled and galvanized products and, at the same time, will strengthen the success of Danieli technology and equipment for strip processing lines. ■
1 DFF and radiant tubes vertical annealing furnace in the galvanizing lines. 2 Overall view of the Turboflo continuous pickling line. 3 4-hi skinpass mill at the exit of the galvanizing line.
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Danieli Kohler technology for Hyundai plant
Timely supply and installation of four Danieli Fröhling cutting lines Tong Ling (two lines) and Yun Cheng in P.R. of China, Zaporozhstal in Ukraine.
Revamping of the combined pickle-galvanizing line at the Dangjin Works in Chungnam, Korea.
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Danieli Kohler will upgrade the wiping equipment at Hyundai HYSCO’s combined pickle-galvanizing line at the Dangjin Works in Chungnam. The original equipment was purchased by Hanbo Steel and installed in 1995, but never commissioned. After a thorough analysis, the mechanical equipment was found to be in excellent condition. Minor upgrades had to be made to the elevator/positioners, while the only parts replaced were seals and instrumentation and the edge baffle rig with a more modern design. Demand for high quality coating on HR product will be met by Dual Kohlerjet Airknives, elevator/ positioners, edge baffles, roll equipment and completely new automation. Danieli Automation will supply a complete new automation package of PLC with remote I/O, operator desk with HMI, local control panel and MCC. Working within HYSCO's demanding schedule, Danieli Kohler's innovative design and production team was able to modernize the equipment with minimal changes to reach the required performance. •
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our slitting lines have been set for delivery since beginning of 2005 for Danieli Fröhling. This includes the aluminium slitter for Yun Cheng, the two slitting lines for Tong Ling (all to P.R. of China) and the slitting line for steel products to Zaporozhstal (Ukraine). The Yun Cheng line is already under construction. Good cooperation with the customer, which had already been established in the joint design effort, was a proper basis for the following cold and hot test phase, and acceptance. Mr Peng, Deputy General Manager of Yun Cheng stated in a letter after the meetings were finished: "…I would like to take this opportunity, on behalf of our management and the project team, to extend our sincere thanks to you and your excellent project team…". Danieli Fröhling's experienced
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commissioning staff supervises the activities and supports customer in on-site training and production startup. Tong Ling's line installation will start soon, as the equipment for Zaporozhstal is right now on the way to Ukraine. Sixteen trucks were needed to ship the complete equipment from Germany to the site of the third largest Ukrainian steel producer. Despite the strict time schedules and complexity of the lines, Danieli Fröhling was able to keep the deadline for supply in order to meet the tight further schedules of the project itself. ■ 1 Danieli Fröhling and Yun Cheng design liaison teams. 2 Installation of the 800-mpm slitting line for aluminium strip (thickness from 0.05 to 0.4 mm; width up to 1400 mm) at Yun Cheng’s Kunshan facilities.
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Rolling mill modernization at KM Europa Metal AG, Germany This is the third consecutive order for a rolling mill awarded by KME and represents the most extensive revamping project ever carried out by Danieli Fröhling.
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M Europa Metal AG (KME) has been a satisfied customer of Danieli Fröhling for more than 30 years, both for rolling mills and cutting lines. KME is the worldwide largest copper and copper alloy manufacturer, and produces more than 700,000 tpy of high value material. In spring 2005, Danieli Fröhling was awarded a contract for the modernisation of a cold mill. The primary goal of the project is to increase rolling speed up to 600 mpm, and of the torque of all related machines as a result of optimisation of the drives, combined with completely new dimensioning of main drives. For further improvement of material qualities, additional actuators for flatness control will be implemented. This includes the positive and negative bending of work rolls combined with a sophisticated selective cooling system. The necessary shapemeter roll of the latest design features zone distances of 26 mm
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even in the edge area of the rolled material. In order to obtain wide tension range, the two reversing reels will be equipped with a combination of two different drives. The stop times shall be drastically reduced by means of a new work roll changing car, leading to changing times less than five minutes. A special design is foreseen for the mill stand itself: the new diagonal arrangement of bending blocks will allow an exact and symmetric distribution of bending torque toward work rolls and bearing arrangements. This ambitious order emphasizes both the trust in available know-how and the good experience gathered by the Customer during previous order executions. Danieli Fröhling will demonstrate that it has earned this trust and do the utmost to set another benchmark in design, supply and execution. Startup is planned for early 2006. ■
1 A Danieli Fröhling 4-high cold reversing mill at KME in Stolberg. 2 Detail of the reversible coiler. 3 Close-up of WR and BUR package and actuators for flatness control.
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FastCast bloom casting technology in India:
New special steel conticaster for SISCOL (India)
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iscol (Southern I&S Co Ltd) has contracted Danieli to supply a bloom caster for the production of 600,000 tpy of large-size special steel blooms at Tamil Nadu. The 3-strand, 12-m-radius conticaster will be designed to cast 200 to 400-mm-dia round and 200x200 to 340x400-mm square or rectangular sections in a wide range of top-quality steels such as high carbon, free-cutting, cold-heading, ball bearing, and low alloy grades. The new caster's capacity will be in line with the existing meltshop's 90-tph rated output
capacity and it will be equipped with all the latest technology available for quality steel bloom casting, such as submerged nozzle, electromechanical stopper rods, radioactive mould level detection, EM stirrers, hydraulic oscillators and air mist secondary cooling. The caster's outlet will be equipped with oxy-cutting torches and a cooling area with slow-cooling facilities for the most sensitive steel grades. Level 1 and 2 automation and process control systems will be supplied by Danieli Automation. Startup is planned in the third quarter 2006. ■
>FastCast<
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Tangshan I&S chooses Danieli technology for its new high capacity quality steel billet caster n June 2005 Tangshan I&S Group Co. Ltd awarded Danieli the order for the supply of a new 6-strand billet caster for quality steel grades. The 9-m radius CCM will have a 1.2-Mtpy nominal capacity for production of 150x150-mm billets in different quality steel grades, including low, medium and high carbon and low-alloy fine-grain steels. Ladle shroud, tundish stopper rod device associated with submerged nozzle and mould powder practice will allow a complete protection of liquid steel stream, thus reducing the oxygen pick-up and consequently the
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non-metallic inclusion content. Thanks to a 1.000-mm-long mould copper tube, high speed casting will be available and steel output from the individual strands will range 28 to 30-tph/strand, according to the specific steel grade being cast. The machine also will be equipped with Danieli Rotelec mould EMS, to achieve high sub-surface and internal quality, and hydraulic mould oscillation to enhance billet surface quality. Complete process control with Level 2 automation will be supplied. The new casting machine will deliver its first billet in September 2006. ■
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Casting quality: evolution in CCM technology The latest generation of Danieli hydraulic oscillators
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roduct quality in continuous casting mainly originates in the mould. For this, great efforts have been made to optimize mould level control, tapers, lubrication and oscillation. To date, Danieli hydraulic oscillator technology has been adopted in 29 continuous casting machines, for a total of 135 billet strands, worldwide (see References Table). Different mechanical design and two main families of hydraulic driving units are available, as reported in the following table: Mechanical
Guides
Drive location
Short lever Bearings (No cantilever weight)
On the lever
Short lever (Cantilever weight)
On the oscillator table
Leaf springs
The most significant parameters are stiffness of the design, levers and leaf springs compact shape, pivot point proximity to the machine radius and minimization of the inertia. A family of moulds featuring stationary EMS supported by a dedicated frame was developed by Danieli in order to reduce the oscillating mass. This way, it is now possible to consistently achieve the tightest mechanical tolerances, as reported in the following table: Typical tolerance achieved (acceleration FastCast<
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Old
New
50
100
150
200
250
300
350
frequency (OPM)
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Specialty steel casters equipped with hydraulic oscillators.
Customer
Year
Strands and radius (m)
Outfit for
Steel grades
29 Corus Scuntorpe, UK
2005
6 12
230x283
CS, AES
28 Benxi I&S, P.R. of China
2005
4 14
350x470
CS, AES
27 Nanjing I&S, P.R. of China
2005
6 14
rd 380, rd 450, rd 500
CS, AES
26 Tangshan I&S, P.R. of China
2005
6 9
sq 150
CS, AES
Actual measurements made in an SBQ shop (before and after the replacement of oscillators) are shown in Figure 1. All these indications brought us to the use of hydraulic oscillators capable of exceeding 400 OPM, without affecting mechanical performances. Maintenance-free design (with no moving parts, no joints and no need of lubrication) is another important feature of Danieli oscillators. Their performances can be continuously monitored via accelerometer or through the trending snapshot function, typical of our high sampling rate control units (Figure 2). The large number of the latest generation compact hydraulic oscillators in operation has proven the achievement of tight mechanical tolerances and high performances, introducing outstanding quality improvements in cast products. A significant practical example is reported in Quality Improvement Table:
25 Siscol, India
2005
3 12
sq 250, 350x400, rd 200, rd 310 CS, AES
24 AG Siderurgica Balboa, Spain
2005
6 10
sq 140/160/250, bb 220x280x90,
23 Seah-Besteel, Korea
2005
2 16.5
390x510
CS, AES
Quality improvements on SBQ billets with hydraulic oscillators
22 Deacero SA de CV, Mexico
2005
6 10
sq 170
CS, AES
Item
21 Republic, USA
2005
5 10
sq 6 3/4”, 9 3/4”x7 1/2”
AES
All strands Danieli compact (previous design) (latest generation)
20 Qasco, Qatar
2005
4 8
sq 130, sq 150, sq 200
CS, AES
2004
4 9
sq 7”, sq 1/2”
AES, SS
Powder entrapment
Occasionally present
Fully absent
19 Charter Steel, USA 18 Sail - DSP, India
2004
4 9
0.6%
CS, AES
Surface scrap/downgrade
2.2 %
150x300, 150x350
320x400/610x100
CS
sq 200, 160x210, 160x230,
17 Mechel I&S works CCM4, Russia
2004
6 9
sq 100
CS
16 Hunan Valin I&S, P.R. of China
2004
4 12
rd 220, rd 280, rd 330
AES
15 NAS, USA
2004
4 10
sq 165, sq 200
SS
14 Corus Aldwarke, UK
2003
5 10
sq 180, sq 210
CS, AES
13 Aceralia Zumarraga , Spain
2003
6 7
sq 160
CS, AES
12 Baosteel Shanghai #5, P.R. of China 2002
3 9
sq 160
AES, SS
11 Mechel I&S works CCM3, Russia
2002
6 9
sq 100
CS
10 Taiyuan I&S Co, P.R. of China
2001
4 8
sq 220, 175x215
CS, AES, SS
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Acciaierie Valbruna, Italy
2001
4 10
sq 145, sq 160, sq 180, sq 220
SS
8
Acciaierie Venete, Italy
2001
4 7
sq 160
CS, AES
7
ISPAT Stahlwerk Ruhrort, Germany
2001
6 9
sq 130
CS, AES
6
ABS Acciaierie Bertoli Safau, Italy
2000
2 9
160x200, 200x240
AES, SS
5
Sidor, Venezuela
2000
6 8
sq 130
CS, AES
4
Shougang I&S, P.R. of China
2000
4 10
sq 180, 160x200, 160x245
CS, AES
3
Sidenor, Spain
1999
6 9
sq 155, sq 185
CS, AES
2
Tung Ho Steel, Taiwan
1999
4 10
sq 130, sq 150, sq 200
CS
1
Ori Martin, Italy
1998
5 5
sq 140
CS, AES
Carbon Steels: CS
Alloy Engineering Steels: AES
a latest generation Danieli compact design hydraulic oscillator was run for 4 months, enabling a full and detailed tracking of the results, in comparison with the rest of the strands, still equipped with the previously designed oscillating tables. ■ Simmetrical shape of the frictional pattern
Stainless Steels: SS
1 Comparison of actual results from an SBQ shop, before and after oscillators eplacement. 2 Performance monitoring.
Unconsistent behaviour
2
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Corus chooses Danieli again for major steelworks modernization at Scunthorpe (UK) Danieli will install a new bloom caster, reheating furnaces and a 7-stand breakdown mill.
Contract signing ceremony at Danieli headquarters with the presence of Mr. A. Page, Managing Director (Corus Construction), Mr. P. Hogg, Director (Wire Rod Business), Mr. D.B. Lawson, Director Scunthorpe Cast Products. Pictures at bottom and right show the bloom caster successully started up at Corus Aldwarke in Rotheram, UK in February 2005.
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he contract is part of Corus' previously announced £130 million investment at Scunthorpe steelworks, and includes the installation of a new bloom caster and the development of the Rod Mill to accept direct-cast bloom feedstock. Mr Andrew Page, Managing Director of Corus Construction and Industrial commented:
>Danieli has an excellent reputation for innovative caster design and offered us the best technical solution to meet our product requirements. The enhancements will deliver consistently high product quality and create a shorter, more efficient process route.< >The benefits of the total investment will extend the scope of the whole Scunthorpe operation, significantly improving the Medium Section Mill's rolling capability by enabling the introduction of rail manufacture to the site alongside structural sections and by delivering a world class supply chain for wire rod manufacture.<
Plant modification will include: 1) A new 6-strand Danieli bloom caster. 2) Major upgrading of the 4-strand wire rod mill. 3) Bloom reheating facilities for the medium section mill.
1) The new 6-strand, 12-m-radius conticaster will be suitable for casting 1 Mtpy of 283x230mm blooms at a rate of 230-250 tph. A wide range of steels will be cast, including low carbon, high strength structural, tyre cord, free cutting, cold heading, spring, bearing and commercial grades. The machine will be equipped with all the latest conticasting technology such as a long tubular 28
mould (equipped with a radioactive mould level control), a mould powder measuring device (MPMD) and a mould EMS (external type), hydraulic oscillating tables, extensive below mould support, an air-mist secondary cooling system and a dynamic soft reduction system with six modules per strand. The conticaster will operate with protected stream technology using a liftable ladle turret (300 t capacity), liftable tundish cars and an electromechanical stopper rod. A flexible dummy bar system will be used, with the dummy bar parked on transport roller tables. An oxy-cutting system, complete with sample cutting system,
>FastCast<
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will cut the blooms into 5 to 9.4-m long sizes. A mechanical deburring system, a marking system that hard-stamps blooms with a bar code, a lateral lifting system, walking beam cooling beds and a collecting table for normal and slow cooling processes, will complete the machine. The conticaster was designed for high levels of casting speeds and productivity. In addition, the low internal strain during straightening and the control of the liquid and mushy zones for soft reduction will result in consistently high quality products.
>Fast Cast< billet casting technology
Record productivity at Mechel, Russia
2) The 4-strand wire rod mill will be upgraded with new reheating facilities, a single-strand compact breakdown mill and a heated roller table for connection to the existing 4-strand mill. This will allow the increase of billet size to 283x230mm or 180x180mm conticast blooms, weighing up to 4.5 t. The new 200-tph Danieli Centro Combustion walking beam reheating furnace with feeding, delivery and descaling facilities is designed to grant high productivity, minimized fuel consumption, as well as low decarburization and scale losses. The singlestrand, high-speed, twist-free breakdown mill will be made up of seven heavy-duty SHS housingless stands arranged in V and H positions. A Danieli Centro Combustion heated roller table will be provided for temperature equalization and proper delivery of the feeding section to the 4-strand rolling mill. A crank shear, located at new breakdown mill's exit, will enable the cropping of 283x230 mm, 4.5 t blooms in order to cope with mill's present coil weight dimensioning (up to 2.2 t coils). 3) Danieli Centro Combustion will also be responsible for the relocation of an existing reheating furnace to Scunthorpe's medium section mill. This will also include the upgrade of some furnace components (e.g. burners, combustion and process control system). The furnace will process up to 355x305 mm blooms at output rates of up to 160 tph. Scunthorpe Steelworks' upgrade programme will be carried out on a turnkey basis which will include electric and automation systems from Danieli Automation as well as various plant auxiliary systems. Civil works and buildings modification for the new conticaster will also be part of the supply. ■
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ince the middle of last year, the 6-strand FastCast billet caster in operation at Mechel -Chelyabinsk Metallurgical Plant- has performed at record levels, reaching a productivity rate in excess of 90,000 t/month of cast billets. The installation of the new conticaster introduced a radical change in the Chelyabinsk plant production route, enabling the existing rolling mills to be directly supplied with 100-mm conticast billets, eliminating the need of the existing blooming mill, and thus
enhancing plant productivity and efficiency, and reducing production costs. A second 6-strand FastCast conticaster, presently under construction, will be installed and started up in the second quarter of 2006. Mechel is one of Russia's leading metals and mining companies and has a total capacity in excess of 6 Mtpy of carbon and specialty steels. ■
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Second high-capacity SBQ mill at Jiangyin Xingcheng, P.R. of China Two orders of this kind in just few months prove full confidence in Danieli Morgårdshammar technology.
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ust a few months afteer the order of a 500,000 tpy SBQ mill, Jiangyin Xingcheng Special Steel Co. Ltd., No.1 producer of bearing steels in China, awarded Danieli a contract for a second, larger SBQ mill to be installed beside the first one. The project will be executed by DME - Danieli Metallurgical Equipment (Beijing) Co. Ltd., the recently established company located in the Beijing BDA area. DME is also in charge for part of the other XingCheng mill under construction. The new 180-tph rolling mill, one of the largest plants for long products in China, will produce 800,000 tpy of 120 to 250-mm-dia SBQ bars and 100 to 180-mm squares for automotive and engineering applications. Starting material will be 370x490-mm blooms, weighing from 6.2 to 9.4-t in carbon and alloy structural steels, ball bearing, spring, cold heading and pipe blank grades. The rolling mill will be basically made up of a reversing Break-Down stand (mechanized with front and back work tables and manipulators), plus a continuous finishing mill made up of six-stands in H and V arrangement. Fast changing systems will be provided for both BD and finishing stands ("ready-to-roll" concept). This, together with the dedicated roll-pass design arranged in “families,” will enhance the mill's efficiency and operation flexibility. State-of-the-art finishing facilities will include online hot saws for "net-end" cut-to-length of bars to further enhance product marketability. Plant startup is scheduled for spring 2007. ■
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Layout of the two Jiangyin Xing Cheng SBQ mills.
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Rolling Mill No.1 1 WB reheating furnace 2 18-stand mill (SHS housinless stands) 3 5-pass Kocks-Danieli RSBReducing & Sizing Block 4 Cooling bed 5 Cold bar finishing services
Rolling Mill No.2 6 WB reheating furnaces 7 Reversing Break-Down stand 8 6-stand finishing mill (SHS housingless stands) 9 On-line hot saws 10 Cooling and collecting services
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DWB AND TMB HIGH-SPEED BLOCKS SUPPLIED SINCE THE MIDDLE 70’s
New wire rod mill at Talleres Y Acero, Mexico After a steelmaking plant and a rolling mill, again Talleres Y Acero relies on Danieli.
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he new mill will have a nominal capacity of 300,000 tpy and will be made up of 14 SHS housingless stands and a 10-pass twist-free finishing block plus DSC-controlled cooling line and coil finishing facilities. The scope of supply also includes electricals, automation and process control systems, as well as auxiliary plants and services such as water treatment plant, compressed air system, roll turning shop, etc. The product range will be 5.5 to 16-mm-dia wire rod in low and medium carbon and low alloy steels, in coils weighing up to 1.5 t. Plant startup is scheduled for the second quarter of 2006. ■
10-pass high-speed Delta-type wire rod finishing block, laying head and controlled cooling conveyor similar to those being supplied to Talleres y Acero.
New wire rod line at INCA, Dominican Republic The new production line will complete the Danieli bar mill operating since 2001.
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he new wire rod line at INCA (Industrias Nacionales, C por A) in Santo Domingo will be made up of an eight-pass twist-free finishing block, water-cooling line, loop layer, roller cooling conveyor and coil finishing facilities. This will allow the production of 5.5 to 12.7-mm wire rod in coils at speeds of up to 80 mps. The Danieli bar mill has always performed at high levels and far above its nominal capacity. An upgrade project was carried out at the beginning of 2005 aimed at doubling present output capacity to 50 tph, particularly for the smallest-size rebars production. This included the
introduction of two-strand slitrolling technology, extension of the cooling bed and associated feeding and delivery facilities, as well as various auxiliary equipment. The plant, a typical example of small-scale, highly productive and efficient long product rolling mill, produces 9.5 to 25.4-mm-dia rebars for concrete reinforcement that are supplied to the entire Caribbean area. ■
1 External view of the rolling mill building. 2 The finishing mill features H and V SHS housingless stands. 3 The 42-m-long cooling bed with “twin channel” high-speed bar delivery system.
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LONG PRODUCTS
Rolling mill starts operation at Southern Steel Corporation (VSC Group), Vietnam It is the first startup step for the 500,000 tpy minimill supplied on a turnkey basis.
he 400,000-tpy bar and rod mill started its commissioning stage at the beginning of August 2005. The 500,000-tpy steel meltshop section, featuring 70-t EAF, LF, three-strand billet caster and auxiliaries, is foreseen to start operation by the end of 2005. The new Southern Steel Corporation steelmaking and rolling plant (part of VSC-Vietnam Steel Corp.), features all the latest Danieli technologies in long products production and is the largest and most advanced project ever undertaken in Vietnam in this field. The 80-tph state-of-the-art bar and rod mill is fed by a Danieli Centro Combustion walking hearth reheating furnace and it is made up of 18 SHS housingless stands, a 10-pass Delta-type high-speed wire rod block, plus
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1 Scrap yard 2 Fume dedusting plant 3 Ferroalloy and additive storage 4 Meltshop 5 Casting bay 6 Reheating furnace and rolling mill
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Roll shop Wire rod line Cooling bed CCL system and stacking station 11 Water treatment plant 12 Maintenance workshop
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1 External view of the rolling mill building. In the forefront the electric substaion and the oxygen plant are shown. 2 The first billet enters the roughing mill stands. 3 First rolled bars on the cooling bed.
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production outlets for structural and quality steel straight bars, wire rod coils and sections. Product range is 10 to 50-mm-dia plain and deformed bars, 40 to 100-mm angles, corresponding channels and 5.5 to 16-mm-dia wire rod in coils weighing up to 2000 kg. Danieli Automation supplied all electricals, automation and process control systems. ■
Southern Steel Corporation Project Milestones from the contract signing to startup
500,000-tpy rolling mill for large-size SBQ bars started up at Shijiazhuang, P.R. of China
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nother high-productive rolling mill for special steel long products has started up successfully in P.R. of China, extending the long list of the Danieli plants in operation there. At the end of June 2005, the first bars were rolled and the commissioning stage started at the new 500,000 tpy large size bar mill for automotive special steels at Shijiazhuang Iron and Steel, Hebei province. The 15-stand bar mill is designed to produce 50 to 150-mm-dia SBQ bars with strict dimensional tolerances, optimal surface quality and suitable technological properties, at rates of up to 100 tph. Entirely made up of SHS housingless stands in H and V arrangement with automatic fast changing facilities, the mill also features a Danieli Automation HiPROFILE® laser measuring unit. The state-of-the art finishing facilities, featuring slow and natural cooling, enable on-line thermal treatment of bars, according to needs. ■
On June 30th hot rolling of the first bars was celebrated with a ceremony, held in the company of high-ranking local authorities, top company responsible and suppliers representatives.
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LONG PRODUCTS
Two high-capacity bar and section mills started up at Magnitogorsk, Russia The most modern rolling mills for long products in Russia.
ne of the largest single-step reconstruction projects ever undertaken in recent years in the field of long products mills in Europe is coming to a conclusion after the successful startup of two of the three new high-capacity rolling mills at MMK. The new 800,000 tpy section mill and the 600,000 tpy bar mill started operation in mid-June and July, respectively.
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The MMK project to completely replace the hot-rolling facilities in a single step also includes a 130-tph, two-strand high-speed wire rod mill, to be started up in January 2006. Full satisfaction on the quality of the job done and the collaboration with Danieli was expressed by Mr. Ghennadij Senicev, MMK General Director, who also recalled the company’s previous positive experience with Danieli thanks to the hot dip galvanizing line in operation since 2002. The three superflexible rolling mills will together comprise a capacity of over 2 Mtpy. This was one of the most ambitious
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recent projects for MMK, Russia's largest single-site integrated steel works with a 10-Mtpy overall capacity, and one of world's largest steelmaking companies. The main features and highlights of the two plants: The 16-stand, 130-tph bar and section mill is designed to produce 22 to 75 mm plain and deformed bars, up to 125-mm angles, up to 180-mm channels, flats, I-beams and special profiles. The 18-stand, 100-tph bar and bar-in-coil mill is designed for producing 10 to 50 mm plain and deformed bars, corresponding small sections and 14 to
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Worldwide new orders for section and bar rolling mills Upgrading of Celsa rolling mills in Spain and Poland
36-mm-dia bar-in-coils in quality structural and alloy steel grades. The 800,000 tpy wire rod mill will produce 5 to 22-mm-dia plain and 6 to 16-mm-dia deformed quality structural and engineering steel wire rod, in 2-t coils at speeds of up to 110 mps. Danieli Centro Combustion supplied the walking hearth reheating furnaces for the three rolling mills, while all electricals, automation and process control systems up to Level 2 are supplied by Danieli Automation. ■
Wire rod mill 1 WH reheating furnace 2 Single-strand high-speed rougher 3 Double-strand intermediate mill 4 Single-strand twist-free prefinishing mills 5 High-speed finishing blocks 6 DSC controlled-cooling lines 7 SUND coil finishing facilities
Bar and bar-in-coil mill 8 WH reheating furnace 9 18-stand rolling mill 10 QTB line 11 Cooling bed and services 12 Finishing facilities for straight bars 13 Coilers 14 On-line coil controlled cooling and handling facilities Bar and section mill 15 WH reheating furnace 16 16-stand rolling mill 17 Cooling bed and services 18 On-line multistrand straightening and cut-to-length services 19 Automatic stacking, bundling and collecting services
Celsa (Compañía Española de Laminación, S.L.) has contracted Danieli Morgårdshammar to upgrade two of its rolling mills in Spain and Poland. Celsa Barcelona bar and rod mill: two SHS housingless stands added to the four-stand Danieli compact rougher in operation since 2000 and various auxiliary equipment will enable rolling of larger-size billets, increasing the rolled stock weight up to 3 t. Startup of the new stands is scheduled for Q1, 2006. The upgrading of the double-strand bar and section conti-mill at Celsa Huta Ostrowiec is aimed at expanding the product range for smaller sizes. On each strand, two vertical stands will be replaced with combined H/V P-624-series housingless stands to allow rolling down to three-strand slit 8-mm-dia rebar. The supply also includes quick rollchanging facilities (also for the existing stands), guides, and auxiliaries. New equipment descaling system for H-beams to be installed installation will start in November this year. at entry side of stands #7-8-10 of the rolling mill. Jumbo-size straightener This order extends Danieli record for Jumbo-size at Dongkuk, Korea straighteners which already lists several similar units supplied in the Far East, Europe and In June 2005, Dongkuk Steel Mill Co. Ltd. P.R. of China for in-line straightening of largeawarded Danieli Morgårdshammar the order size profiles and rails. for a nine-roll double-support Jumbo-size straightener for its Pohang Works section mill. Stacking plant extension at Nucor Jewett (TX), USA The unit, located at the delivery side of the cooling bed, will perform on-line straightening The Danieli single-head 18-m-long magnetic of up to 600x300 or 400x400 mm H-beams, stacker in operation since 2000 at the Nucor up to 150-mm angles and 250-mm channels. The new design will allow production of high- Steel, Jewett No.1 bar and light section mill will be extended -as originally foreseen- by a 6-m-long quality finished products with very close tolerances. The machine, sized for a maximum section. The additional section will be added at the cooling bed side in order to allow operation straightening modulus of 2000 cm3, will be in one 24-m-long or in two independent and equipped with five powered bottom rollers, symmetrical 12-m-long sectors. Thus, the stacker four adjustable top rollers, load cells for will be able to handle four 6-m-long or two 12-mstraightening load monitoring, and it will long or one 18-m-long bar layers for a range of feature an adjustable pass line in relation to products that includes up to 75-mm angles and the product being processed. An automatic channels, 25- to 100-mm flat bars and up to robotized quick roll changing system will be 35-mm plain and deformed rounds, in stacks added too. Danieli Automation will supply weighing up to 5 t, at rates of up to 110 sht/h. electricals and controls. The commissioning of the new straightener is scheduled for August Danieli Automation will supply the electricals 2006. The order also includes a new advanced and automation and process control system. ■ 35
LONG PRODUCTS
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Second Danieli Spooler line at Nervacero (Spain) Full customer satisfaction for this revolutionary technology.
Overall view of the Spooler line in operation since December 2004, detail of the twist-free winding of bars and spooled coils ready for shipment.
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few months after the starup of the first Danieli Spooler line, now in commercial production to full Customer satisfaction, Nervacero SA (Celsa Group) placed the order for the second line to be installed at its double-strand rolling mill in Vizcaya. Installation of the second Spooler line will take advantage of the mill’s full potential capacity (150 tph) for coiled bars. Presently, the rolling mill operates with on one strand delivering to the Spooler line and the other to the cooling bed for straight bars. Startup of the new line has introduced for the first time in Spain the revolutionary spooling technology, bringing-in important innovations and substantial benefits
>Spooler<
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in bar-in-coil production. The highlight of the Spooler process is twist-free winding of bars into ultra-compact, ultra-heavy coils, resulting in a unique cobble-free uncoiling capability. This enables spooled coils direct feeding to the downstream cold processing lines without any intermediate operation (like uncoiling, stretching and regular recoiling) with consequent significant savings in transformation costs. The Nervacero Spooler lines are designed for twist-free-winding of 8 to 32-mm rebars or up to 22-mm plain bars, in up to 3.5-t ultra-compact coils, at finishing speeds of up to 35 mps. The second Spooler line will be started up in the third quarter of 2006. ■ Layout arrangement of the two twist-free Spooler lines (highlighted in red) in the existing double-strand rolling mill, beside the cooling bed for straight bars.
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HEATING SYSTEMS
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Official opening of new reheat furnace at Highveld, South Africa
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he 120-tph pusher-type reheat furnace designed and built by Danieli Centro Combustion (see DaNews 141 page 23) was officially opened on Friday 11 March 2005. The new furnace replaces two 35-year-old walking-hearth furnaces, substantially improving product quality and productivity with less than half of previous fuel consumption. Danieli Centro Combustion's successful performance in completing the turnkey project
DADNAEWS NEWS
COLD & HOT PROCESSING
Latest orders for Danieli Centro Maskin High-speed breakdown drawing line for copper tubes at Golden Dragon Precise Copper Tube, P.R. of China
in less than nine months was witnessed in the Highveld Newsletter: >... One of the old furnaces, including its foundations, was demolished to make way for the new one. The project was completed by the end of September 2004, nine months after the signing of the contract. This was not only an extremely fast-track programme for a project of this nature, but a world first...< ■
The line to be installed in Xinxiang is the world’s first application of the high-speed breakdown drawing technology and will produce 70,000 tpy of copper tubes coiled in a basket for ACR and plumbing applications. The line will consist of four chain-track drawing machines connected two by two in cascade with a final production speed of 400 mpm, a worldwide record! The mother tube that will feed the breakdown drawing line will be produced by a KRM (Kocks Rotating Mill), the new four-roll mill engineered by Kocks, Germany. The KRM, combined with Danieli chain-track break-down drawing, represent the beginning of a new era in the production of high-quality ACR copper tube.
Conditioning line for stainless steel slabs at LISCO, P.R. of China
1 Sir Mark Moody-Stuart, Chairman of Anglo American, owner of HGVD, at the unveiling ceremony.
2 Mr A. J. de Nyssehen, CEO of HGVD, with Mr F. Ajosa, VP and CEO of Danieli Centro Combustion.
Lianzhong Stainless Steel Co (LISCO) will install a conditioning line for hot (max 500 °C) stainless steel slabs. The facility will be made up of two grinding machines for conditioning of the slabs’ wide faces, assuring smooth operation and spindle long life (minimum guaranteed 7000 working hours). Slabs’ narrow faces will be processed by an edgegrinding unit. The line is complete with slab handling equipment and auxiliaries, including secondary dust collecting filter and swarf handling. The plant will be started up in the third quarter of 2006. ■ 37
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AUTOMATION
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Plate mill upgrading at Bhilai Steel Plant (BSP, SAIL), India New HAGC and PVO (Plan View Optimization) systems will be implemented in the 2-stand plate mill.
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he project is aimed at achieving improved product tolerances and yield. The plate mill consists of two four-high stands to be retrofitted with new hydraulic cylinders. The turnkey project calls for supplying a new Level 1 system and new Level 2 mathematical models for mill setup and Plan View Rolling (PVR), as well as a new Hydraulic Gap Control (HAGC) with related hydraulic unit and hydraulic cylinder installation on the stands. The automation system will be based on the Danieli Automation HiPAC platform, specially designed for the critical controls of flat products. Specifically, Danieli Automation will provide: HAGC sequencing; PVopt for the two stands; new high-performance cylinders to cope with high dynamics required by PVopt Danieli Automation control; revamping of the motor generator set and drives digitalization;
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modification of mechnical equipment, thickness gauge after the finishing stand and a laser-based plate length measurement system.
Besides the supervisory, basic automation and control system, Danieli Automation will provide: Level 2 scheduling and setup functions; tracking of material; hydraulic automatic gauge control for both stands; Plan View optimisation in the roughing stand; edger and roughing stand setup; finishing stand setup; temperature setup model; shape setup.
Danieli Automation will supply and coordinate all the activities related to the turnkey job in consortium with GA Danieli India (a sister company of the Danieli group). The project completion date is June 2006. ■
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MET2000 supply chain management system at Unicoil, Saudi Arabia It will be used as production control system for the new 250,000 tpy cold mill complex.
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Universal Metal Coating Company Ltd.’s (Unicoil) new facility for processing HR and galvalume steel coils in Al-Jubail is expected to start production in Q1, 2006. The 250,000 tpy output will consist of a mix of galvanized, blanks and painted coils. The contract reconfirms the reliability of Danieli Automation IT technology and its position as a front-runner for the unique solutions for steelmaking plants to cover market demand for a total integration of commercial and production data into an integrated system. Furthermore, the MET2000 system will replace functions performed by the existing ERP system with steel plant-specific functions for sales and shipping. The MET2000 main modules are: sales and order management, coil acquisition management, production planning, production scheduling, production progress control, quality management, coil yard management, shipping management, data warehouse system support. The MET2000 will co-ordinate and guarantee the synchronisation of the entire production process. Additional important subfunctions are: order entry, receipt of coils for production, quality-related operations, production tracking, storage operations, shipping, reports, ERP system integration. A wireless network supports crane terminals and wireless bar-code
reader terminals, while label printers ensure error-free identification and tracking of production. The data warehouse solution ensures vital support of storing and analysis of historical documents, order, production, and quality certification for final product release. The application was developed with BusinessObjects for effective, easily configurable reports and queries to further support Unicoil in the use of the available data for their strategic decisions. Figure 1 shows the data analysis support for processing Customer order stages (mean value of Cumulative Frequency-CF distribution for processing time). The MET2000 will be running on a modern, cost-effective, highlyavailable and automatic recovery server platform using Microsoft
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Long term evaluation on products lead time and new production potentials
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Days Data analisys support Processing 1forData analisysCustomer support order stages mean value for Processing Customer of order Cumulative stages Frequency (mean value (CF) distribution Frequency of Cumulative distribution for forCF processing time. processing time).
Windows Server 2003 and Oracle RDBMS. To secure a maintenance suite for Unicoil, effective tools such as RAS-teleservice Remote ASsistance are provided to give direct access to and exploit the support of Danieli Automation experts. This important order, besides confirming Danieli
-Pickling -Rolling -Galvanizing -Cooling
-Slitting and cut-to-lenght -Inspection -Packaging
Automation’s leadership in supply chain management for the metals industry and the process control of steel plants, will also provide Unicoil with a powerful tool to exploit the full potential of the new modern cold mill complex where operating costs and sales will be controlled in real time. ■
INCOMING BLACK COILS Black coils storage
Push-pull pickling line
Pickled coils storage
Cold rolling mill
PC Terminal
Crane Terminal
Hot dip galvanizing line
Cold rolled storage
Wireless Hand-held Terminal
Finished coils storage
Printer Color coating line
Label Printer
Slitting / Cut-to-lenght line
TO CUSTOMER INCOMING GALVANIZED COILS
Galvanized & Color coated storage
2 Material flow of Unicoil cold mill complex.
Packing station
Inspection-Slitting Packing
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DDAANNEWS EWS
AUTOMATION FORGING & EXTRUSION
Danieli Breda innovative technology in the 32-MN extrusion press for Proferall, Italy
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he press will be installed in the new Proferall facilities located at Cortenova (Lecco) and will be positioned in the same building where a Danieli Breda 20-MN shortstroke press has been in operation since 2000. This new press is the first front-loading unit designed by Danieli Breda and will be equipped with a newly designed billet loader. This innovative concept has been developed at the Danieli Research & Development Centre and is now under patent pending. This solution solves all the problems related to the short-stroke front loading cycle and now makes possible the extrusion of very short billets in one or two pieces, even in aluminium soft alloys. This new design completes the range of extrusion presses offered by Danieli Breda, which include conventional long-stroke and short-stroke back- and front-loading solutions. All these solutions will guarantee excellent performances, reliability and top product quality. ■
Main press data
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Press type
SS - front loading
Extrusion force
32 MN
Billet diameter
10"
Billet length
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Working pressure
285 bar
Dead cycle time
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DANIELI BREDA NEW DESIGN CONCEPT
The press features a new concept billet loader to solve all the problems related to short-stroke front loading cycle.
Movable platen
Fixed stem
Dummy Telescopic loader block
Container Die holder
Scheme of the new shortstroke front loading system.
Extrusion platen
Step 1: - Extrusion wnd - Container backward (Strip) - Stem backward - Billet ready for loading
Step 2: - Sheared butt - Billet to C/L - Container and stem forward
Step 3: - Billet in C/L - Container and stem forward - Telescopic loader shortening - Loader backward
Step 4: - Container closed - Stem forward - Billet upsetting - Burp cycle
96 BLAST FURNACE PROJECTS 135 ELECTRIC ARC FURNACES 210 SECONDARY METALLURGY STATIONS 71 THICK SLAB CASTING STRANDS 24 MEDIUM/THIN SLAB CASTING STRANDS 154 HOT STRIP AND PLATE MILLS, 4 OF WHICH THIN SLAB ROLLING PLANTS 14 STECKEL MILLS 86 COLD ROLLING MILLS 279 NARROW COLD ROLLING MILLS FOR NONFERROUS METALS AND STAINLESS STEELS 145 STRIP PICKLING LINES 89 HOT DIP GALVANIZING AND ALUMINIZING LINES 108 ELECTROLYTIC TINNING LINES 23 COLOR COATING LINES 332 SLITTING AND SHEARING LINES 267 GRINDING MACHINES FOR FLAT PRODUCTS 717 BASIC AUTOMATION AND PROCESS CONTROL SYSTEMS
FACTS CONFIRM DANIELI WORLD-CLASS ACHIEVEMENTS IN INTEGRATED AND FLAT PRODUCT PLANTS
Guiding is an art. We invented the roller guides in 1945 and ever since then MH has stood for reliability, quality and innovation in guiding technology.
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Danieli Headquarters Via Nazionale, 41 33042 Buttrio (UD) Italy
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Tel (39) 0432.5981 Fax (39) 0432.598289 www.danieli.com
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Morgårdshammar AB SE-777 82 Smedjebacken,Sweden Tel (46) 240.668500 Fax (46) 240.668501
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E-mail
[email protected] www.morgardshammar.se
