DaNews143

of the Volga Region, Mr. M. Khodyrev, theGovernor of the Nizhny Novgorod Region, Mr. M. Fadeev, the President of the RussianNational Railway Corporation, of Mr. A.Antonov, VP of Investments of UnitedMetallurgical Company, Mr. G. Lavaroni, VP of Italy’s Danieli, the supplier of the steelcomplex equipment and technology, Mr. E. Inanc, Chairman of Gama, Turkey, the supplier of the construction package

Danieli News n.143September 2005,Danieli GroupDANEWS

Cold steel mill complexestarted up at VSC,Vietnam.8

Major casting and rollingfacilities modernization at Corus Scunthorpe (UK) Page 28

Second Danieli slabcaster in six months atBaosteel, P.R. of ChinaPage 11

yksa, Russia, June 11th, 2005.The cornerstone laying ceremony wasopened by Mr. A. Sedykh, President

of the OMK Group, who addressed a warmwelcome to the authorities and thedistinguished guests, testifying to theimportance of this event for the City of Vyksaand the Nizhny Novgorod Region of Russia.Mr. S. Kirienko, the Delegate of the Presidentof the Russian Federation and Supergovernor

V

→ Page 2

ALSO IN THIS ISSUE

IRONMAKING4 SUCCESSFUL CASE-HISTORY

PROJECT AT ACESITA, BRAZIL.

STEELMAKING8 ACERBRAG: ARGENTINA’S

MOST MODERN MINIMILL. 9 37 HEATS/DAY FOR

THE DANARC EAF AT ACEROS AREQUIPA, PERU.

FLAT PRODUCTS12 EXCELLENT THICK SLAB

CASTER STARTUP AT XIN YU, P.R. OF CHINA.

13 THIN SLAB CASTER EXTENDSCASTABLE STEELS RANGEAT BENXI, P.R. OF CHINA.

LONG PRODUCTS30 SECOND HIGH-CAPACITY

SBQ MILL AT JIANGYINXINGCHENG, P.R. OF CHINA.

34 MODERN BAR AND SECTIONROLLING MILLS STARTED UPAT MAGNITOGORSK, RUSSIA.

AUTOMATION38 PLATE MILL UPGRADDING

AT BHILAI (SAIL), INDIA.

EXTRUSION LINES40 INNOVATIVE 32-MN

EXTRUSION PRESS AT PROFERALL, ITALY.

>Cornerstone< layingceremonyatOMK

The new 1.2-Mtpy fTSR steel complex

135 ELECTRIC ARC FURNACES 210 SECONDARY METALLURGY STATIONS 389 CONTINUOUS CASTINGSTRANDS 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 BLOOMS717 BASIC AUTOMATION AND PROCESS CONTROL SYSTEMS

FACTSCONFIRM

DANIELI LEADERSHIP IN LONG PRODUCT

STEEL PLANTS

1

Danieli News n.143

Worldwide Offices and Service Centers

WorldwideDanieli Companies

Danieli Headquarters

[email protected] (49) 208.3780000

















Via Nazionale, 4133042 Buttrio (UD) ItalyTel (39) 0432.5981Fax (39) [email protected]

Danieli Publicity Dept.: Tel. (39) 0432.598244E-mail: [email protected] Project: PolystudioDTP: Danieli Publicity Dept.Printing: Grafiche Filacorda. Approved by the Court of Udine under authorization n.16 dated 21.04.83

he last three months have been characterized by somesignificant events such as the OMK cornerstone layingceremony for the first fTSR thin slab casting rolling minimill

complex in Russia; the second slab caster order received from Baosteelin six months; and the VSC cold mill complex in Vietnam, whichreached full operation in one month from commissioning. We have also seen new examples of excellence in casting technologywith the startup of slab casters at Xin Yu and Benxi (second line)together with a productivity record with 6-strand >FastCast< billetcaster at Mechel, and the second order from Corus which chose Danielito 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 LatinAmerica. We also record the hot startup of the rolling mill of SSCminimill 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 complexof 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 MessinaDanieli, Executive ManagerPR and [email protected]

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.

T

2

>Cornerstone< laying ceremony for the OMK1.2-Mtpycomplete fTSR flexible Thin Slab Rolling plant

COVER STORYDANEWS

FROM FIRST PAGE

of the steel complex, Mrs. A. Ricci, Vice President of Medio Credito Centrale, the Italian financing bank for equipment andtechnology, Mr. N. Fychev, Director of Investments of Sverbank, the Russianfinancing bank for the local constructionpackage, took part in this meaningful event.The ceremony was an essential element of the greater project, confirming its industrialfeasibility, being financially supported byshareholders, the Italian and international

banking system and the Russian bankingsystem. This event also marked the beginning of project execution. Industrial operation is expected by the end of 2007, with a capacityof 1.2 Mtpy of hot rolled coils to feed the pipemills of the OMK Group.The new steel complex will be composed of an electric steel meltshop with EAF, ladlefurnace, vacuum degassing station, a mediumslab caster with hot strip mill for a continuouscasting and rolling process.

1 Mr A. Sedykh, President and CEO of OMKaddresses his speech at the first stone layingceremony.

2 3D representation of the fTSR process to beimplemented at OMK.

1

2

3 Schematic layout of thewhole new complex. The blu dashed lines show the possible futureexpansion.

4 A Danieli Wean United 6-stand finishing millequipped with f2CR stands.

5 Close-up of a f2CR stand,capable of crossing rollswhile rolling for asuperior strip flatnessand crown controlcapability.

3

The technologies applied in the new steelcomplex are unique both in Russia and all over the world, as they meet high-qualitysteel demanded for the production of arcticsteels, resistant to acid aggression (natural gasand crude oil) at very low temperatures (-65°C).The new plant will employ 2000 workers(direct and indirect manpower) thus being animportant prospect for young engineers and thepopulation of Vyksa City, which is nowcelebrating 250 years of steelmaking history. ■

4 5

>fT

SR<

4

Mr Paulo Magelhaes, Director of Acesita, signed the acceptanceletter for the full and complete

finalisation of the repair of BF No. 2 performedby Danieli Corus on July 12.It took place during a luncheon also attendedby Mr Marcondes (plant manager), Mr. Cardoso (BF manager), Mr. Helvio (projectmanager), Mr. Yamana (project engineer) fromAcesita, and Mr. P. Hemels (project manager)and Mr. F. Kaptein (sales manager) fromDanieli Corus.Danieli Corus was paid compliments for the excellent results of the project.Moreover, Acesita stated that, within theArcelor Group, this project was selected to be discussed and assessed at highermanagement level as an excellent example of project management and working methodsin order to achieve a similar great success in future projects.The first project step was taken in December2002 with an order for operational assistance.In November 2003, Danieli Corus received the order for the design and supply of newrefractory and cooling system to be installed inthe tuyere zone, the bosh and the so-called belly.Included in the design is a state-of- the-artheat flux monitoring system measuring the heat load on the furnace wall in the differentsections; it enables the operator to adjust andimprove the charging of the furnace to obtainan optimum process.A fast track supply schedule could bemaintained due to worldwide sourcing for supplies by Danieli Corus who also had on site supervisors to guarantee the properconstruction. Training and startup supervisionwere also part of the contract.

The furnace was blown down on April 10 and started up on May 8, four days ahead of schedule. The repair was executed withoutany accident. The ramping up to the aimedproduction of 1270 tonnes per day was reachedas planned. Noteworthy is that the furnaceuses fuel coke in the charge and charcoal asinjectant in the tuyeres- a system developed by Acesita. ■

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.

IRONMAKINGDANEWS I

M

Director Paulo Magelhaes of Acesita signing the finalacceptance letter for therepair of Acesita BF No. 2performed by Danieli Corus.

aiyuan Iron & Steel (Group)Co. will install 40 DanieliCorus Blocktectors and 3

tuyere cameras on its new BF #1.The delivery time for the equipmentwill be approximately 3 months.Blocktectors & Cameras have beenoperating at Corus IJmuiden sincethe late 80’s and are well-proven for detecting the onset of a blockedtuyere and turning off coal supply to that specific tuyere. In this way,they help to prevent explosions orother potential hazards of pulverisedcoal collecting in the tuyere. Blocktectors are also very usefulinstruments during blowing in achilled furnace, to identify blockedtuyeres would be very useful indeciding prior to injecting fuel into the furnace. If pulverised coalcontinues to be injected when thetuyere is blocked, it may lead to:

spillage of pulverised coalaround the mouth of the tuyere;

tuyere burn-out;damage to the hot blast main,

where combustion of coal in the bustle pipe would lead toextreme heat resulting in hot spotsand pipe rupture;

explosion in the hot blast main, when sufficient quantities of burning coal come into contactwith oxygen-rich blast.The use of Blocktector offers manyadvantages:

proven technology, specificallydesigned and developed for the BF environment;

easy installation and use;no additional maintenance;no special (expensive)

instrument piping close to the tuyereis required.

These instruments will enhance the operation of the PCI system at Taiyuan, especially with high injection rates expected of the system. ■

5

DANEWS 143

Danieli Corus Blocktectors and tuyere cameras at Taiyuan I&S, P.R. of ChinaThis is the same furnace for which Danieli Corus supplied a PCI system in 2004.

JB

Pulverised Coal

Purge N2

Blocktector

Individual tuyere injection stopsautomatically in case of blockage

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 BlastFurnace No. 2. BF No. 2 has an inner volume of 2650 m3 andis 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 beconstructed during 2005/2006 and ready foroperation later in 2006. The contract also includes supervisory servicesduring the equipment installation, and training of BF personnel at Danieli Corus offices in The Netherlands. ■

New PulverisedCoal Injectionsystem atShougang I&S,P.R. of China

This is Danieli Corus' 5thorder for a PCI system in China to date.

D

T

6

n both cases Danieli Corus received an order for engineering, refractorysupply material inspection and

installation supervision services.Both projects foresee stoves designed for aconstant hot blast temperature of 1250 ºC to optimize the production and minimize fuel consumption of the new blast furnace.

Shougang Qian’anThe first order, signed on April 19, 2005, with the China Shougang Trade & EngineeringCorp., 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 pipewith tuyere stocks.Thanks to the reliable performance of theDanieli Corus stoves, hot blast system andceramic burners supplied through the previousorders, the Shougang Design Institute wished to continue that excellent relationship with its order for one of its new high productiveblast furnaces.The total order volume over the last five yearsmakes Shougang I & S Corp, together with China Shougang Trade & EngineeringCorp, one of the most valuable customers for Danieli Corus in the P.R. of China.

New orders from the Chinese market for hot blast stoves

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 existingblast furnaces No. 3 & 4, which will bereconstructed in the coming years to increasetheir 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 towardmodernizing the existing facilities at Taiyuan,Shanxi Province.This order is the logical continuation of thecooperation between the two companies whichis based on the excellent performance of theDanieli Corus technology already applied to one of the BFs at Taiyuan some years ago.Moreover, this is the first contract in thehistory of Danieli Corus to call for five DanieliCorus hot blast stoves. ■

IRONMAKINGDANEWS I

I

Danieli Corus expertise will provide Shougang Qian’an and TaigangTaiyuan with state-of-the-art equipment and services.

View of the hot blaststoves erected during a previous Danieli Corusproject at Shougang.

7

DANEWS 143STEELMAKINGDANEWS S

iderurgica Tultitlan S.A. de C.V. (Sidertul) will completely re-construct its steelmaking facilities to increase billet productionfrom present 350,000 tpy to 600,000 tpy. Also included in the

project is the upgrading of the rolling mill, originally supplied by Danieliin early 90's. Major modification will basically include:

Replacement of the electricarc furnace with a new 60-tDanarc EAF.

Complete revamping and modernization of the three-strand conticaster with newtundish, tundish car, moulds,oscillating tables, secondarycooling system and withdrawalstraightening 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.

New order for steelmaking and continuous casting plant at Sidertul, Mexico

S

The project also involves the modernization of the 75-tph bar and section mill.

The new meltshop's capacity will be suitable to meet billet demandof the existing bar and sectionmill, and to supply billets to themarket, too.The rolling mill will bemodernized by extending thecooling bed and installing a CCLsystem (multi-strand straightenerand pendulum-type cold shear) at the delivery side to keep pacewith mill's production capacityand enhance finished productquality. New bending machines for barbundles will also be installed.

The mill's operations will beoptimized thanks to a newcomplete automation system (up to Level 2) supplied by DanieliAutomation.The mill is designed to producesmall bars and profiles at a rate of up to 75 tph. ■

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.

8

n May 26th 2005, the new meltshopsuccessfully started operation bydelivering its first billets and enabling

Acerbrag to enter the modern era of minimilllayout design.The state-of-the-art steelmaking plant basicallyincludes a 50-t Danarc EAF fitted with twoModules for O2 and C injection and a 2/3-strandbillet caster directly connected to the rolling millfor hot-charging operation. The supply alsoincluded plant auxiliaries such as Fe-alloysystem, fume dedusting plant, an 80/130-t ladlehandling crane and Danieli Automationelectricals and automation for the whole plant.This was the last step of the modernization

Acerbrag: the new meltshop of the most modern and competitive minimill in Argentina starts operation

The 350,000 tpyminimill is now themost modern andcompetitive minimillin the country.

1

1

6

7

8

9

10

4

2

3

STEELMAKINGDANEWS S

O

of the existing steelworks, a project that alsoincluded a bar and rod mill multi-stagereconstruction program concluded in March 2004 with the startup of the rebuilt hot rollingmill area. The 60-tph Danieli rolling mill isdesigned to produce 8 to 25-mm-diaplain/deformed bars, up to 50-mm angles,corresponding flats and 5.5 to 14-mm-dia wire rodin up to 1.5-t coils. Acerbrag's new minimill, witha 350,000-tpy nominal capacity, is now one of themost modern and complete steelmaking androlling plants in operation in the country and will grant both higher productivity and efficiencyin the manufacturing of long products. ■

Layout legend1 Scrap yard 2 50-t AC EAF and LF3 3-strand billet CCM4 FTP5 60-tph WH reheating

furnace6 19-pass rolling mill7 QTB bar quenching

and self-temperingsystem

8 Cooling bed andautomatic bar coldfinishing services

9 8-pass high-speedwire rod finishingblock

10 Wire rod controlledcooling line (QTRsystem) andautomatic coldfinishing services

9

he 40-t EAF at Aceros Arequipa in Piscoperforms at top levels, after the majorimprovements carried out by Danieli Centro

Met. The furnace, which restarted in December 2004,was upgraded with the installation of a new electroderegulation system, a completely new automationsystem and a "burnjector" unit for better chemicalenergy 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 betterperformances 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 theinstallation of a new high-speed wire rod line. ■

Top-performing minimills: up to 37 heats/day and regularly over 30 at Aceros Arequipa, Peru

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.

Benchmark results from the upgraded EAF.

DANEWS 143

Best results obtained at the EAF (*)

Min tap-to-tap time 36 min (or 40 heats/day)

Productivity +10%

Electrode consumption -22%

Electr. energy from 490 to 420 kWh/tonconsumtpion of good billets

(*) With a charging mix based on 35-40% DRI content

ssar Steel placed theorder for the majorupgrading of a fourth

150-ton DC EAF for its Hazirasteelworks, to increaseproductivity and optimise furnaceoperation. Danieli was alreadycontracted to upgrade three otherelectric arc furnaces of the samesize at the same plant, two of which are successfullyoperating since December 2004and May 2005.Satisfactory results were achievedafter the EAFs’ modification, withtap-to-tap time down to 52

minutes and electric powerconsumption 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 DRIand 55% cold DRI.The extent of the EAF No. 4modification will be the same as that of the other three furnacesand will include:

Enlarging the furnace shell tobring heat size to 155 t and hotheel from 40 to 70 t.

Installation of the latestgeneration multi-purpose

oxigen/carbon injectors, with Cucooling blocks.

Installation of pneumatic lime injection system.

Automatic temperature and sampling devices to optimiseon-line process control.

Logistics optimisation. Level 2 automation system

for the supplied equipment. ■

T

E

Hot DRI charging intothe 150-t Electric ArcFurnace.

10

anieli Centro Met will supply HighveldSteel with a 75-t ladle furnace -complete with materials handling

system and water treatment plant- on a turnkeybasis. The new unit will allow an optimizedproduction process and an improved cleanliness of the liquid steel coming from the LD convertershop. Another LF of the same size was suppliedby Danieli in 1993 and operates successfully at the same plant since then. The new inert-rooftype LF, served by a 13-MVA transformer, will befitted with automatic sampling equipment, wirefeeding system, emergency stirring lance and will be suitable for granting a heating rate equalor higher than 4.5 °C/min. The new unit features all the latest advances insteel refining technology and also is completelyinterchangeable with the previous one foroperation and spare parts optimization. The hotstartup is expected in October 2006. ■

New turnkey order for a second 75-t ladle furnace at Highveld, South Africa

t the end of July 2005, a new 120-t ladle furnacewas successfully started

up at Hunan Valin I&S Group Co.Ltd. (Xiangtan), Hunan Province, as part of the existing steelworksupgrade project, which alsoincludes a second LF and a VD unitof the same capacity, scheduledfor startup later this year.When in full operation the twoladle furnaces and the degasser,designed to process 2.5 Mtpy and 1.2 Mtpy of liquid steelrespectively, will be an integratedpart of Xiangtan No. 1 newsteelmaking plant and feed theexisting bloom and slab casters. Steel grades to be processed arehigh-quality tube and pipe steels,high-pressure boiler steel, carbonstructural, shipbuilding, pipelineand pressure vessel steel plates. •

120-t LF starts operation at Hunan Valin(Xiangtan),P.R. of China

STEELMAKINGDANEWS S

D

Since the early 80’s, Danieli has been one of theleaders in secondary refiningfor ordinary, specialty andstainless steels, with morethan 135 units supplied allaround the world.The know-how gained overmany years has been used to develop and optimizeequipment and process so as to also meet the moststringent customers’ requests.

Steelmaking

A

11

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:

Vertical curved design with a vertical length exceeding 2.6 m, a 9.5 main radius andcontinuous bending andunbending roll diagram.

Top feeding dummy bar.Complete breakout

prevention system with thermalmapping of the mould.

State-of-the-art INMO mould, including in-line widthadjustment during casting.

Hydraulically operated oscillator.

OPTIMUM type segments,designed for the application of Dynamic Soft Reductionprocess.

Air mist secondary cooling,controlled by a dynamic model.

Complete automation system including predicting mathematical models for LiquidPool Control (LPC) andSolidification process used forDynamic Soft Reduction (DSRC)and Dynamic Secondary Cooling(DSC) system.

Of particular note, this is the 20thDanieli slab strand (8 in China)adopting INMO mould technology,the last generation patentedmould, designed with superiorzero-clearance guidance systemfor outstanding slab surfacequality.This second order awarded to Danieli in just a few months by Baosteel (the largest Chinesesteel producer) confirms theleading technical position ofDanieli Davy Distington as supplierof superior slab castingequipment, as well as customersatisfaction reached during theexecution of the contract of thecaster for plant No. 4, presentlyunder advanced design stage. ■

Second Danieli high-tech slab casterat Baosteel, P.R. of ChinaAfter 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.

DANEWS 143FLAT PRODUCTSDANEWS F

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.

T

12

Thick slab caster successfully started up at Xin Yu, P.R. of ChinaExcellent performances thanks to the advanced and reliablemechanical and electrical/automation equipment supplied.

he single-strand medium slab casterwas successfully started in Xin Yu Iron& Steel Co. Ltd. in Jianxi province on

May 12th, 2005. It is a medium slab caster that has beenequipped with the most advanced castingtechnology, such as soft reduction, hydraulicoscillation and mould width taper adjustment.A wide range of steel grades can be produced at high rates, as the advanced process controlsystem supplies a stable and reliable conditionfor the caster to maintain the high productivityand prime quality rate.A total of 300 t from three ladles were cast at startup, and a daily production of more than2200 t from 20 ladles was reached after only 12 days from the first cast. An even moreimportant performance achievement wasreached on July 3, 2005. After only 54 days fromthe startup, the caster had processed a longsequence of 42 ladles. During the sequence,

Danieli technologicalpackage composed ofcassette mould and hydraulic

oscillator was successfullyintegrated and started up at Jiu QuanIron & Steel Co. Ltd. plant on April25th, 2005. Equipped withhydraulically actuated, mould widthtaper adjustment, the Danieli DavyDistington mould can cast 160 or220 mm thickness of a wide range of steel grades. The Mould BreakoutPrevention System controlled byDanieli Automation Mould DetectorServer Software detects any sharptemperature variations on the mould surface and prevents any risk of strand breakout slowing down the casting speed. •

Danieli high-tech slab casting technologycommissionedat Jiu Quan, P.R. of China

three different tundishes have been used bysuccessfully realizing two fly tundish change. The short period between the first slab and thisgoal proves that the equipment is "user-friendly"and how easily the customer can become familiarwith the equipment. ■

TFirst slab coming out of the conticaster on May 12, 2005. The automation and processcontrol system features several Danieli technologicalpackages such as MLC, HOC, WAM, LPC, DSRC and QUART.

A

FLAT PRODUCTSDANEWS F

13

DANEWS 143DANEWS 143

he smooth and fullyautomatic commissioningconfirms the high reliability

of Danieli TSC equipment. Benxi I & S Co. is now focusing itsproduction on a wide range of steelgrades, aiming to become areference Thin Slab Caster in China,covering the whole range ofproduction both in width (850 up to 1750 mm) and slab thickness (70 and 85 mm). Both strands have now entered theperformance test period and up to now several grades have beentested for all the steel groups, from IF steel grades to high carbon,achieving very high qualitystandards.For the very first time in Thin SlabCasting, silicon steel has also beensuccessfully cast in different grades, as have been HLSA and peritecticgrades.In detail, the following steel gradeshave already been cast: IF steel(St16), ELC (St 14, St 12F), lowcarbon (SPHC, St12, SS330, SPH-T1,SPH-T2, BG510-L1), medium carbon(SS400, Q345 A, Q235 B), peritecticsteel (SS400P), HLSA MC (J55),HLSA LC (X46, X52, SPAH), highcarbon (C45), Si steel (50BW600,BGD, 50BW400). Processing ofadditional steel grades is scheduledin the near future.This second strand flanks the first, in operation since November 2004and will allow Benxi Group to reachthe production target -as soon as thesecond shuttle furnace iscommissioned.This wide range of steel grades castright from the very beginning ofproduction confirms Danieli as thetop supplier and technology partnerin Thin Slab Caster. ■

Successful startup of the 2nd flexible Thin Slab Castingstrand at Benxi Iron & Steel, P.R. of ChinaSince the first heat was cast on June 19, 2005, an impressive list of different steel grades has already been successfully commissioned.

1 Overall view of thecasting floor with the twostrands in operation.

2 Mr. Qi Zhen, CasterResponsible (Benxi I&S)congratulates Mr. F. Faivre,Danieli Site Manager.

3 Pendulum shear at theexit of the coolingchamber.

4 Front view of theconticaster. In theforeground the tunnelfurnace and the dummybar parking.

1

2

3 4

T

14

ork on the Tangshan Guofeng 2-Mtpy hot strip mill complex, located in Tangshan City, is

proceeding rapidly. The target for the plant startupis 20 months from order date.As of the end of June, all main civil works in the rolling mill area are completed and erectionactivity of Danieli Wean United equipment hasstarted. Danieli equipment is already on site ready for installation and most of the locally

>Work in progress< at the 2-Mtpy hot strip mill complexof Tangshan Guofeng, P.R. of China


Incoming slab

Thickness 135 (mm)

Width 600 - 1,300 (mm)

Length 15,600 (mm)

Weight 21 (t)

Hot Strip Mill

Thickness 1.2 - 12.7 (mm)

Width 600 - 1,300 (mm)

Coil OD 762 (mm)

Coil ID (max) 1,850 (mm)

Weight 21 (t)

Specific coil weight 16 (kg/mm)

Plant layout and main material data

W 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 qualitycarbon steel and 10% of low alloy steel. Plant configuration features a reversingroughing stand with attached edger, coilbox,rotary crop shear, water descaler, six 4-hifinishing stand, waterwall cooling system and downcoiler.The Tangshan Guofeng HSM takesadvantage of the most up-to-date and provenrolling technology coming from Danieli WeanUnited and includes the newest technologyfor strip shape control:

edger HAWC (Hydraulic AutomaticWidth Control);

HAGC (Hydraulic Automatic GapControl);

positive bending;WR shifting;roll thermal crown (RTC) control;shaped roll technology to improve

flatness control.Project development and progress are basedon a full co-operation between Danieli,Erzhong and the Yanshan University. Eachparty brings its own expertise to the project in order to achieve the market’s strictest qualityrequirements. ■

Roughing area Finishing area Coil conveyor line

Downcoiler area

n order to satisfy the highest qualityrequirements, an accurate knowledge of rollingparameters and strip profile is very important.

The key to achieving precision shape control is to know the mechanical behaviour of the roll stackand its effect on the strip. The way to obtain a good strip profile is throughshape actuators: these devices deform rolls to givethe strip the desired shape. To investigate the behaviour of roll stack, two fullydeformable FE models have been prepared: the first,symmetrical, to study work roll bending andintermediate roll bending, the latter, asymmetrical,for intermediate roll crossing. Rolls were modeled as perfectly elastic bodies, strip as an elastoplasticbody with exponential hardening. Although BUR has a great stiffness (compared to other rolls), treating it like a rigid body may giveinaccurate results in terms of strains of the strip.Several rolling conditions were taken into account:each shape actuator acting alone and together.

1 Stresses in the millhousing under maxrolling load.

2 FE model of the 6-hi roll stack.

3 Strain on the rolledstock.

4-5 The 6-hi 3C coldreversing in operationat Shougang Iron &Steel, P.R. of China.

FE model for prediction of strip profilein a 6-high cold rolling standThe 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.

Mesh of models is uneven: in contact zones (strip-WR, 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 bysoftware; the contact algorithm automatically detects nodes coming in contact and generates theappropriate constraints to ensure that no penetrationoccurs and the compatibility of displacements acrossall touching surfaces is maintained. Every simulationbrings more results: the main ones are total rollingload, deflection of rolls axes, shape of roll gap andprofiles 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 canchange the strip profile. A new procedure to obtainshape 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 measuredand calculated values is less than 4% (usually thisfigure is considered very good when below 10%). ■

DANEWS 143

I

1 2

3

4 5

16

n June 29, 2005, an official ceremonywas held to mark the first coilsuccessfully processed by the new

temper mill in Baotou I&S (Group) Co. Ltd. in Baotou City, Inner Mongolia. Mill commissioning was quite smooth andquick, and the results exceeded all the mostoptimistic expectations of both customer andsupplier.Maximum rolling speed of 1,000 mpm andhigh 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 efficientLevel 1 and Level 2 hardware and software,

both developed by Danieli Automation. The final CQ, DQ, DDQ and HSLA steelquality are guaranteed by the mill’s wet rollingsystem and an electrostatic oiler downstream.They assure the cleanliness and surfaceconditions of the higher quality, saleableproduct for construction and householdappliances, and later on for the automotiveindustry. A high, daily strip production rate (in its wholedimensional 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 fullpotential of the temper mill (designed for 0.8 Mtpy), which was reached by the end of August 2005, when the Final AcceptanceCertificate was signed by both parties, asscheduled. ■

The new temper mill at Baotou, P.R. of China, starts operationAnother successful commissioning completed in short time.


O

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.

17

n June 9, 2005, Danieliand Lianzhong StainlessSteel Corp. signed a

contract for the complete supplyof a new hot skinpass mill, to be installed in Economy & Technology Development Zoneof Guangzhou.The new mill will process bothstainless and carbon steel stripwith the following dimensions:

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 loadcapacity, the mill is equipped with HAGC, positive and negativebending system, constant passlineand backup roll brushes. An in-line inspection station willallow visual check of both stripsurfaces. Main motors, for a totalof 4 MW, will allow a maximumspeed of 600 mpm.Danieli will supply the complete

technological equipment, bothimported and local; the latter will be delivered by DanieliMetallurgical Equipment (Beijing)Co. Ltd., while Danieli Automationwill supply the electrical andautomation portion, including Level 1 and Level 2. The startup of the plant isexpected within 18 months fromthe contract placement. ■

New hot skinpass mill for Lianzhong Stainless Steel Corp,P.R.of China

DANEWS 143

SSAB selects again Danieli technologyNew cold plate leveller order for Oxelösund plant

urther to the startup of the innovative cut-to-length 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 strengthsteel, to be installed at the Oxelösund plant. The new machine will be part of a completely newexpansion project to increase the production of the well-known SSAB Oxelösund steel plates. The levelerwill have a 9-roll design. Rolls will be independentlydriven. The roll barrel length will be 3.4 m. The design of the machine will incorporate outstanding featuressuch as HAGC, roll bending, top roll independent heightadjustment, automatic cassette change. The maximumleveling force will be 18,000 kN. The frame sturdinesswill be enhanced by four pretensioned tie-rods. A completely innovative design will be applied to thedrives in order to optimize their performance whilekeeping 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. ■

OContract 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.

Mr. Li Pi Hsien (ChairmanLianzhong Stainless SteelCorp.) and Mr. A. Mordeglia(Vice President Sales, Danieli). F

n 2002 Danieli Wean United received anorder for a new Cold Mill Complex to beinstalled 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 monthafter 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 performedat a very high level.The plant soon will reach its maximum yearlyproduction of 405,000 tpy; material that will beused in the local construction industry, automotive

Successful and fast startup of the cold mill complexat Vietnam Steel CorporationOnly one month after the completion of the construction activities, the entire facility has started its production phase.


2 Cold mill complex layout:Pickling lineProvision for cleaning lineBatch annealingfurnacesCold reversing mill

Cold reversing and temper millCoil transferCoil transfer andtilterRecoil and tensionlevel lineBAF control andelectrical rooms

I

Customer satisfaction

1

Mr. Huynh Quang Bau,General Manager of Phu Mycold rolling complex (PFS),VSC Group, congratulatingwith Mr. Antonello Mordeglia, Vice President Sales, Danieli.

19

DANEWS 143

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 mechanicalequipment 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 2automation systems including all mathematicalmodels for quality control. A common server will provide coils tracking duringthe production cycle.The maintenance system will be based on FastData Analyzer (FDA) server/client configurationthat will allow the system monitoring from everyelectrical cabin or pulpit. The surprising results achieved by Danieli indicatea highly professional level of job execution andproject management, and the key has been thecoordination between Danieli Wean United,Danieli Automation and Danieli Service. ■

1 Entrance of the Officebuilding.

2 The Turboflo push-pullpickling 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 millstand.

4

32

5

6

THE MOST MODERN MINIMILLFOR ULTRA-LIGHT GAUGE HOT STRIPWithout 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 CONFIRMDANIELI WORLD-CLASS

ACHIEVEMENTSIN 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 HeadquartersVia Nazionale, 4133042 Buttrio (UD) ItalyTel. (39) 0432.5981Fax (39) 0432.598289www.danieli.com

22

he strip processing lines successfully put into operation at Tangshan I&S Co.,with full customer satisfaction, once

again confirmed the leading position of DanieliWean United technologies for strip pickling andgalvanizing lines. The pickling line is designed toprocess HR steel strip at a rate of about 1.5 Mtpyof pickled coils. The strip ranges from 0.8 to 4.0mm in thickness and 850 to 1,680 mm in widthwith a maximum coil weight of 30 t. The processsection of the line, based on the patented DanieliTurboflo system, consists of three tanks withbackup rinse cell, a five-stand rinsing section andthree horizontal accumulators for continuousoperation, 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

Strip processing lines full on-streamat Tisco, P.R. of ChinaFinal Acceptance Certificate for both the pickling line (CPL1) and the galvanizing line (CGL1) was signed on June 21, 2005.


designed to supply galvanized steel to all majormarkets, including products for construction anddomestic appliances. The line processes HRpickled and CR steel strip with a thickness rangefrom 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 rangingfrom 60 to 600 g/m2. The first coils were producedat the end of November 2004 (pickling line) and of December 2004 (galvanizing line). Since then, the two lines have produced galvanized andpickled strip of excellent quality with an optimallearning curve.Another pickling line and galvanizing line are being supplied by Danieli to Tisco. Installation works are expected to start at thebeginning 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 andgalvanized products and, at the same time, willstrengthen the success of Danieli technology andequipment for strip processing lines. ■

T

1 DFF and radianttubes verticalannealing furnace inthe galvanizing lines.

2 Overall view of theTurboflo continuouspickling line.

3 4-hi skinpass mill at the exit of thegalvanizing line.

3

2

1

23

DANEWS 143

our slitting lines havebeen set for delivery since beginning of 2005 for

Danieli Fröhling. This includes thealuminium slitter for Yun Cheng,the two slitting lines for Tong Ling(all to P.R. of China) and theslitting line for steel products toZaporozhstal (Ukraine). The YunCheng line is already underconstruction. Good cooperationwith the customer, which hadalready been established in thejoint design effort, was a properbasis for the following cold andhot test phase, and acceptance.Mr Peng, Deputy General Managerof Yun Cheng stated in a letterafter the meetings were finished: "…I would like to take thisopportunity, on behalf of ourmanagement and the projectteam, to extend our sincerethanks to you and your excellentproject team…". Danieli Fröhling's experienced

commissioning staff supervisesthe activities and supportscustomer in on-site training andproduction startup. Tong Ling'sline installation will start soon, as the equipment for Zaporozhstal is right now on the way toUkraine. Sixteen trucks wereneeded to ship the completeequipment from Germany to thesite of the third largest Ukrainiansteel producer. Despite the stricttime schedules and complexity of the lines, Danieli Fröhling was able to keep the deadline for supply in order to meet thetight further schedules of the project itself. ■

Timely supply and installation of four DanieliFröhling cutting linesTong Ling (two lines) and Yun Cheng in P.R. of China,Zaporozhstal in Ukraine.

F

1 Danieli Fröhling and YunCheng design liaisonteams.

2 Installation of the 800-mpm slitting line for aluminium strip(thickness from 0.05 to 0.4 mm; width up to1400 mm) at Yun Cheng’sKunshan facilities.

1

2

Danieli Kohler will upgrade the wipingequipment at Hyundai HYSCO’s combinedpickle-galvanizing line at the Dangjin Works

in Chungnam. The original equipment was purchased by Hanbo Steel and installed in 1995, but nevercommissioned.After a thorough analysis, the mechanical equipmentwas found to be in excellent condition. Minorupgrades had to be made to the elevator/positioners,while the only parts replaced were seals andinstrumentation and the edge baffle rig with a moremodern 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 Automationwill supply a complete new automation package ofPLC with remote I/O, operator desk with HMI, localcontrol panel and MCC. Working within HYSCO'sdemanding schedule, Danieli Kohler's innovativedesign and production team was able to modernize the equipment with minimal changes to reach the required performance. •

Danieli Kohler technologyfor Hyundai plant

Revamping of the combined pickle-galvanizing line at the DangjinWorks in Chungnam, Korea.

D

24

Rolling mill modernization at KM Europa Metal AG, GermanyThis 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.


M Europa Metal AG (KME) has beena satisfied customer of DanieliFröhling for more than 30 years, both

for rolling mills and cutting lines. KME is theworldwide largest copper and copper alloymanufacturer, and produces more than700,000 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 torqueof all related machines as a result of optimisation of the drives, combined withcompletely new dimensioning of main drives. For further improvement of material qualities,additional actuators for flatness control will beimplemented. This includes the positive andnegative bending of work rolls combined with a sophisticated selective cooling system. The necessary shapemeter roll of the latestdesign features zone distances of 26 mm

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 fiveminutes.A special design is foreseen for the mill stand itself: the new diagonal arrangement of bending blocks will allow an exact andsymmetric distribution of bending torquetoward work rolls and bearing arrangements. This ambitious order emphasizes both thetrust in available know-how and the goodexperience gathered by the Customer duringprevious order executions. Danieli Fröhlingwill demonstrate that it has earned this trustand do the utmost to set another benchmarkin design, supply and execution. Startup is planned for early 2006. ■

K

1 A Danieli Fröhling 4-highcold reversing mill at KMEin Stolberg.

2 Detail of the reversiblecoiler.

3 Close-up of WR and BURpackage and actuators forflatness control.

25

DANEWS 143LONG PRODUCTSDANEWS L

>Fa

stC

ast<

n June 2005 Tangshan I&SGroup Co. Ltd awardedDanieli the order for the

supply of a new 6-strand billetcaster for quality steel grades. The 9-m radius CCM will have a1.2-Mtpy nominal capacity forproduction of 150x150-mm billetsin different quality steel grades,including low, medium and highcarbon and low-alloy fine-grainsteels. Ladle shroud, tundishstopper rod device associatedwith submerged nozzle and mouldpowder practice will allow acomplete protection of liquid steelstream, thus reducing the oxygenpick-up and consequently the

non-metallic inclusion content.Thanks to a 1.000-mm-long mouldcopper tube, high speed castingwill be available and steel outputfrom the individual strands willrange 28 to 30-tph/strand,according to the specific steelgrade being cast. The machinealso will be equipped with DanieliRotelec mould EMS, to achievehigh sub-surface and internalquality, and hydraulic mouldoscillation to enhance billet surfacequality. Complete process controlwith Level 2 automation will be supplied. The new castingmachine will deliver its first billetin September 2006. ■

Tangshan I&S chooses Danieli technology for its new high capacity quality steel billet caster

iscol (Southern I&S Co Ltd)has contracted Danieli to supply a bloom caster

for the production of 600,000 tpyof large-size special steel bloomsat Tamil Nadu. The 3-strand, 12-m-radiusconticaster will be designed to cast 200 to 400-mm-dia roundand 200x200 to 340x400-mmsquare or rectangular sections in a wide range of top-qualitysteels such as high carbon, free-cutting, cold-heading, ballbearing, and low alloy grades.The new caster's capacity will bein line with the existingmeltshop's 90-tph rated output

capacity and it will be equippedwith all the latest technologyavailable for quality steel bloomcasting, such as submergednozzle, electromechanical stopperrods, radioactive mould leveldetection, EM stirrers, hydraulicoscillators and air mist secondarycooling. The caster's outlet will be equipped with oxy-cuttingtorches and a cooling area withslow-cooling facilities for the most sensitive steel grades. Level 1 and 2 automation andprocess control systems will besupplied by Danieli Automation.Startup is planned in the thirdquarter 2006. ■

FastCast bloom casting technology in India:

New special steel conticaster for SISCOL (India)

I

S

26

Casting quality: evolution in CCM technologyThe latest generation of Danieli hydraulic oscillators

roduct quality in continuous castingmainly originates in the mould. For this, great efforts have been made

to optimize mould level control, tapers,lubrication and oscillation. To date, Danielihydraulic oscillator technology has beenadopted in 29 continuous casting machines, for a total of 135 billet strands, worldwide (seeReferences Table). Different mechanical design and two mainfamilies of hydraulic driving units are available,as reported in the following table:

LONG PRODUCTSDANEWS L

Mechanical Guides Drive location

Short lever Bearings On the lever(No cantilever weight)

Short lever Leaf springs On the oscillator (Cantilever weight) table

Typical tolerance achieved (acceleration <4 mps)

Deviation on the XY plane

Lateral < 0.10mm

Radial < 0.20 mm

The most significant parameters are stiffness of the design, levers and leaf springs compactshape, pivot point proximity to the machineradius and minimization of the inertia. A family of moulds featuring stationary EMSsupported by a dedicated frame was developedby Danieli in order to reduce the oscillatingmass. This way, it is now possible to consistently achieve the tightest mechanicaltolerances, as reported in the following table:

P

27

a latest generation Danieli compact designhydraulic oscillator was run for 4 months, enablinga full and detailed tracking of the results, incomparison with the rest of the strands, stillequipped with the previously designed oscillatingtables. ■

Specialty steel casters equipped with hydraulic oscillators.

Customer Year Strands Outfit for Steel and grades

radius (m)

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

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,

320x400/610x100 CS

23 Seah-Besteel, Korea 2005 2 16.5 390x510 CS, AES

22 Deacero SA de CV, Mexico 2005 6 10 sq 170 CS, AES

21 Republic, USA 2005 5 10 sq 6 3/4”, 9 3/4”x7 1/2” AES

20 Qasco, Qatar 2005 4 8 sq 130, sq 150, sq 200 CS, AES

19 Charter Steel, USA 2004 4 9 sq 7”, sq 1/2” AES, SS

18 Sail - DSP, India 2004 4 9 sq 200, 160x210, 160x230,

150x300, 150x350 CS, AES

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

9 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 Stainless Steels: SS

DANEWS 143

Quality improvements on SBQ billets with hydraulic oscillators

Item All strands Danieli compact(previous design) (latest generation)

Powder Occasionally Fully absententrapment present

Surface 2.2 % 0.6%scrap/downgrade

>Fa

stC

ast< Actual measurements made in an SBQ shop

(before and after the replacement ofoscillators) are shown in Figure 1. All theseindications brought us to the use of hydraulicoscillators capable of exceeding 400 OPM,without affecting mechanical performances. Maintenance-free design (with no movingparts, no joints and no need of lubrication) isanother important feature of Danieli oscillators. Their performances can be continuouslymonitored via accelerometer or through thetrending snapshot function, typical of our highsampling rate control units (Figure 2). The large number of the latest generationcompact hydraulic oscillators in operation hasproven the achievement of tight mechanicaltolerances and high performances, introducingoutstanding quality improvements in castproducts. A significant practical example isreported in Quality Improvement Table:

Rad

ial d

evia

tion

@ 6

mm

str

oke

(mm

)

0.00.10.20.30.40.50.60.70.80.91.0

0 50 100 150 200 250 300 350

frequency (OPM)

Old New

Simmetrical shape of the frictional pattern

Unconsistent behaviour1 Comparison of actual

results from an SBQshop, before and afteroscillators eplacement.

2 Performancemonitoring.

1

2

28

he contract is part of Corus' previously announced £130 million investment at Scunthorpe steelworks, andincludes the installation of a new bloom caster and the development of the Rod Mill to accept direct-castbloom 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, significantlyimproving 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 willbe suitable for casting 1 Mtpy of 283x230mmblooms at a rate of 230-250 tph. A wide range of steels will be cast, including low carbon, highstrength structural, tyre cord, free cutting, coldheading, spring, bearing and commercial grades.The machine will be equipped with all the latestconticasting technology such as a long tubular

mould (equipped with a radioactive mould levelcontrol), a mould powder measuring device(MPMD) and a mould EMS (external type),hydraulic oscillating tables, extensive belowmould support, an air-mist secondary coolingsystem and a dynamic soft reduction system withsix modules per strand.The conticaster will operate with protectedstream technology using a liftable ladle turret(300 t capacity), liftable tundish cars and anelectromechanical stopper rod. A flexible dummybar system will be used, with the dummy barparked on transport roller tables. An oxy-cuttingsystem, complete with sample cutting system,

Corus chooses Danieli again for majorsteelworks modernization at Scunthorpe (UK) Danieli will install a new bloom caster, reheating furnaces and a 7-stand breakdown mill.


T

Contract signing ceremony at Danieli headquarters with the presence of Mr. A. Page, ManagingDirector (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 castersuccessully started up at Corus Aldwarke in Rotheram, UK in February 2005.

>Fa

stC

ast<

will cut the blooms into 5 to 9.4-m long sizes. A mechanical deburring system, a marking systemthat hard-stamps blooms with a bar code, a laterallifting system, walking beam cooling beds and a collecting table for normal and slow coolingprocesses, will complete the machine. The conticaster was designed for high levels of casting speeds and productivity. In addition,the low internal strain during straightening andthe control of the liquid and mushy zones for softreduction will result in consistently high qualityproducts.

2) The 4-strand wire rod mill will be upgradedwith new reheating facilities, a single-strandcompact breakdown mill and a heated roller table for connection to the existing 4-strand mill.This will allow the increase of billet size to283x230mm or 180x180mm conticast blooms,weighing up to 4.5 t. The new 200-tph DanieliCentro Combustion walking beam reheatingfurnace with feeding, delivery and descalingfacilities is designed to grant high productivity,minimized fuel consumption, as well as lowdecarburization and scale losses. The single-strand, high-speed, twist-free breakdown mill willbe made up of seven heavy-duty SHS housinglessstands arranged in V and H positions. A DanieliCentro Combustion heated roller table will beprovided for temperature equalization and properdelivery of the feeding section to the 4-strandrolling mill. A crank shear, located at newbreakdown mill's exit, will enable the cropping of 283x230 mm, 4.5 t blooms in order to copewith mill's present coil weight dimensioning (up to 2.2 t coils).

3) Danieli Centro Combustion will also beresponsible for the relocation of an existingreheating furnace to Scunthorpe's mediumsection 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 mmblooms 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 buildingsmodification for the new conticaster will also be part of the supply. ■

DANEWS 143

ince the middle of lastyear, the 6-strandFastCast billet caster in

operation at Mechel -ChelyabinskMetallurgical Plant- hasperformed at record levels,reaching a productivity rate in excess of 90,000 t/month of cast billets. The installation of the new conticaster introduceda radical change in theChelyabinsk plant productionroute, enabling the existing rollingmills to be directly supplied with100-mm conticast billets,eliminating the need of theexisting blooming mill, and thus

enhancing plant productivity and efficiency, and reducingproduction costs.A second 6-strand FastCastconticaster, presently underconstruction, will be installed and started up in the secondquarter of 2006.Mechel is one of Russia's leadingmetals and mining companies and has a total capacity in excessof 6 Mtpy of carbon and specialtysteels. ■

>Fast Cast< billet casting technology

Record productivity at Mechel, Russia

S

29

30

ust a few months afteer the order of a 500,000 tpy SBQ mill, JiangyinXingcheng Special Steel Co. Ltd., No.1

producer of bearing steels in China, awardedDanieli a contract for a second, larger SBQ mill to be installed beside the first one.The project will be executed by DME - DanieliMetallurgical Equipment (Beijing) Co. Ltd.,the recently established company located inthe Beijing BDA area.DME is also in charge for part of the otherXingCheng mill under construction.The new 180-tph rolling mill, one of the largestplants for long products in China, will produce800,000 tpy of 120 to 250-mm-dia SBQ barsand 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 alloystructural steels, ball bearing, spring, coldheading and pipe blank grades.The rolling mill will be basically made up of a reversing Break-Down stand (mechanizedwith front and back work tables andmanipulators), plus a continuous finishing millmade 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 dedicatedroll-pass design arranged in “families,” willenhance the mill's efficiency and operationflexibility.State-of-the-art finishing facilities will includeonline hot saws for "net-end" cut-to-length of bars to further enhance productmarketability. Plant startup is scheduled for spring 2007. ■

Second high-capacity SBQ mill at Jiangyin Xingcheng, P.R. of ChinaTwo orders of this kind in just few months prove full confidence in Danieli Morgårdshammar technology.

1 23

4

5

6

78

910


J

Rolling Mill No.26 WB reheating furnaces7 Reversing Break-Down stand8 6-stand finishing mill (SHS

housingless stands)9 On-line hot saws10 Cooling and collecting

services

Rolling Mill No.11 WB reheating furnace2 18-stand mill

(SHS housinless stands)3 5-pass Kocks-Danieli RSB-

Reducing & Sizing Block4 Cooling bed5 Cold bar finishing services

Layout of the two Jiangyin Xing Cheng SBQ mills.

31

he new wire rod line at INCA (IndustriasNacionales, C por A) in

Santo Domingo will be made up of an eight-pass twist-freefinishing block, water-coolingline, loop layer, roller coolingconveyor and coil finishingfacilities.This will allow the production of 5.5 to 12.7-mm wire rod incoils at speeds of up to 80 mps.The Danieli bar mill has alwaysperformed at high levels and farabove its nominal capacity.An upgrade project was carriedout at the beginning of 2005aimed at doubling present outputcapacity to 50 tph, particularly for the smallest-size rebarsproduction. This included the

introduction of two-strand slit-rolling technology, extension of the cooling bed and associatedfeeding and delivery facilities, as well as various auxiliaryequipment.The plant, a typical example ofsmall-scale, highly productive andefficient long product rolling mill,produces 9.5 to 25.4-mm-diarebars for concrete reinforcementthat are supplied to the entireCaribbean area. ■

New wire rod line at INCA, Dominican RepublicThe new production line will complete the Danieli bar mill operating since 2001.

he new mill will have a nominal capacity of 300,000 tpy and will be made up of 14 SHShousingless stands and a 10-pass twist-free

finishing block plus DSC-controlled cooling line andcoil finishing facilities. The scope of supply alsoincludes electricals, automation and process controlsystems, as well as auxiliary plants and services suchas water treatment plant, compressed air system, rollturning shop, etc. The product range will be 5.5 to 16-mm-dia wire rod in low and medium carbon and lowalloy steels, in coils weighing up to 1.5 t. Plant startupis scheduled for the second quarter of 2006. ■

New wire rod mill at Talleres Y Acero,MexicoAfter a steelmaking plant and a rolling mill, again Talleres Y Acero relies on Danieli.

FACTS CONFIRM

DANIELI LEADERSHIP

174DWB

AND TMBHIGH-SPEED

BLOCKSSUPPLIEDSINCE THE

MIDDLE 70’s

T

T

10-pass high-speed Delta-typewire rod finishing block, layinghead and controlled coolingconveyor similar to those beingsupplied to Talleres y Acero.

1 External view of the rollingmill building.

2 The finishing mill featuresH and V SHS housinglessstands.

3 The 42-m-long coolingbed with “twin channel”high-speed bar deliverysystem.

1

2 3

DANEWS 143

32

1 External view of therolling mill building. In the forefront theelectric substaion and theoxygen plant are shown.

2 The first billet enters theroughing mill stands.

3 First rolled bars on thecooling bed.

Rolling mill starts operation at Southern Steel Corporation (VSC Group), VietnamIt is the first startup step for the 500,000 tpy minimill supplied on a turnkey basis.

2

4

5

6

7

1112

8

9 10

3

1

1 Scrap yard2 Fume dedusting

plant3 Ferroalloy and

additive storage4 Meltshop5 Casting bay6 Reheating furnace

and rolling mill

7 Roll shop8 Wire rod line9 Cooling bed10 CCL system and

stacking station11 Water treatment

plant12 Maintenance

workshop

he 400,000-tpy bar and rod mill started itscommissioning stage

at the beginning of August 2005.The 500,000-tpy steel meltshopsection, featuring 70-t EAF, LF, three-strand billet caster andauxiliaries, is foreseen to startoperation by the end of 2005.The new Southern SteelCorporation steelmaking androlling plant (part of VSC-VietnamSteel Corp.), features all the latestDanieli technologies in longproducts production and is thelargest and most advanced projectever undertaken in Vietnam in this field.The 80-tph state-of-the-art bar and rod mill is fed by a DanieliCentro Combustion walking hearthreheating furnace and it is madeup of 18 SHS housingless stands, a 10-pass Delta-type high-speed wire rod block, plus

T


1

2 3

33

500,000-tpy rolling mill for large-size SBQ bars started up at Shijiazhuang, P.R. of China

On June 30th hot rolling of the first bars wascelebrated with aceremony, held in thecompany of high-rankinglocal authorities, topcompany responsible andsuppliers representatives.

Southern SteelCorporation ProjectMilestones from the contract signingto startup

nother high-productive rolling mill for special steel long products hasstarted up successfully in P.R. of China,

extending the long list of the Danieli plants inoperation there. At the end of June 2005, thefirst bars were rolled and the commissioningstage started at the new 500,000 tpy large sizebar mill for automotive special steels atShijiazhuang Iron and Steel, Hebei province.The 15-stand bar mill is designed to produce 50 to 150-mm-dia SBQ bars with strictdimensional tolerances, optimal surface qualityand suitable technological properties, at rates of up to 100 tph. Entirely made up of SHShousingless stands in H and V arrangement withautomatic fast changing facilities, the mill alsofeatures a Danieli Automation HiPROFILE®

laser measuring unit. The state-of-the artfinishing facilities, featuring slow and naturalcooling, enable on-line thermal treatment of bars,according to needs. ■

A

DANEWS 143

production outlets for structural and quality steel straight bars, wire rod coils and sections.Product range is 10 to 50-mm-diaplain and deformed bars, 40 to 100-mm angles, correspondingchannels and 5.5 to 16-mm-diawire rod in coils weighing up to2000 kg.Danieli Automation supplied allelectricals, automation and processcontrol systems. ■

34


Two high-capacity bar and section mills started up at Magnitogorsk, RussiaThe most modern rolling mills for long products in Russia.

ne of the largest single-step reconstruction projects everundertaken 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 startedoperation in mid-June and July, respectively.

1

2 3 4 5 6

7

1413109

16 17 18

19

11

12

8

15

O

The MMK project to completelyreplace the hot-rolling facilities in a single step also includes a 130-tph, two-strand high-speedwire rod mill, to be started up inJanuary 2006. Full satisfaction on the quality of the job done and the collaboration with Danieliwas expressed by Mr. GhennadijSenicev, MMK General Director,who also recalled the company’sprevious positive experience with Danieli thanks to the hot dipgalvanizing line in operation since 2002.The three superflexible rollingmills will together comprise a capacity of over 2 Mtpy. This was one of the most ambitious

recent projects for MMK, Russia'slargest single-site integrated steelworks with a 10-Mtpy overallcapacity, and one of world'slargest steelmaking companies.The main features and highlights of the two plants:

The 16-stand, 130-tph bar and section mill is designed toproduce 22 to 75 mm plain anddeformed bars, up to 125-mmangles, 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, correspondingsmall sections and 14 to

Upgrading of Celsa rolling millsin Spain and Poland

Celsa (Compañía Española de Laminación,S.L.) has contracted Danieli Morgårdshammarto upgrade two of its rolling mills in Spain andPoland.

Celsa Barcelona bar and rod mill: two SHShousingless stands added to the four-standDanieli compact rougher in operation since2000 and various auxiliary equipment willenable rolling of larger-size billets, increasingthe 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 HutaOstrowiec is aimed at expanding the productrange for smaller sizes. On each strand, twovertical stands will be replaced with combinedH/V P-624-series housingless stands to allowrolling down to three-strand slit 8-mm-diarebar. The supply also includes quick roll-changing facilities (also for the existing stands),guides, and auxiliaries. New equipmentinstallation will start in November this year.

Jumbo-size straightenerat Dongkuk, Korea

In June 2005, Dongkuk Steel Mill Co. Ltd.awarded Danieli Morgårdshammar the orderfor a nine-roll double-support Jumbo-sizestraightener for its Pohang Works section mill.The unit, located at the delivery side of thecooling bed, will perform on-line straighteningof up to 600x300 or 400x400 mm H-beams,up to 150-mm angles and 250-mm channels.The new design will allow production of high-quality finished products with very closetolerances. The machine, sized for a maximumstraightening modulus of 2000 cm3, will beequipped with five powered bottom rollers,four adjustable top rollers, load cells forstraightening load monitoring, and it willfeature an adjustable pass line in relation tothe product being processed. An automaticrobotized quick roll changing system will beadded too. Danieli Automation will supplyelectricals and controls. The commissioning of the new straightener is scheduled for August2006. The order also includes a new advanced

35

DANEWS 143

Worldwide new orders for sectionand bar rolling mills

Wire rod mill

1 WH reheating furnace2 Single-strand high-speed

rougher3 Double-strand intermediate

mill4 Single-strand twist-free

prefinishing mills5 High-speed finishing blocks6 DSC controlled-cooling lines7 SUND coil finishing facilities

Bar and bar-in-coil mill

8 WH reheating furnace9 18-stand rolling mill10 QTB line11 Cooling bed and services12 Finishing facilities

for straight bars13 Coilers14 On-line coil controlled

cooling and handlingfacilities

Bar and section mill

15 WH reheating furnace16 16-stand rolling mill17 Cooling bed and services18 On-line multistrand

straightening and cut-to-length services

19 Automatic stacking,bundling and collectingservices

descaling system for H-beams to be installed at entry side of stands #7-8-10 of the rolling mill.This order extends Danieli record for Jumbo-sizestraighteners which already lists several similarunits supplied in the Far East, Europe and P.R. of China for in-line straightening of large-size profiles and rails.

Stacking plant extension at Nucor Jewett (TX), USA

The Danieli single-head 18-m-long magneticstacker in operation since 2000 at the NucorSteel, Jewett No.1 bar and light section mill willbe extended -as originally foreseen- by a 6-m-longsection. The additional section will be added atthe cooling bed side in order to allow operation in one 24-m-long or in two independent andsymmetrical 12-m-long sectors. Thus, the stackerwill be able to handle four 6-m-long or two 12-m-long or one 18-m-long bar layers for a range ofproducts that includes up to 75-mm angles andchannels, 25- to 100-mm flat bars and up to 35-mm plain and deformed rounds, in stacksweighing up to 5 t, at rates of up to 110 sht/h.Danieli Automation will supply the electricalsand automation and process control system. ■

36-mm-dia bar-in-coils in qualitystructural and alloy steel grades.

The 800,000 tpy wire rod millwill produce 5 to 22-mm-dia plainand 6 to 16-mm-dia deformedquality structural and engineeringsteel wire rod, in 2-t coils atspeeds of up to 110 mps.

Danieli Centro Combustionsupplied the walking hearthreheating furnaces for the threerolling mills, while all electricals,automation and process controlsystems up to Level 2 are suppliedby Danieli Automation. ■

36

Second Danieli Spooler lineat Nervacero (Spain)Full customer satisfaction for this revolutionary technology.

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 secondline to be installed at its double-strand rollingmill in Vizcaya. Installation of the second Spooler line will take advantage of the mill’s full potentialcapacity (150 tph) for coiled bars. Presently,the rolling mill operates with on one stranddelivering 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 revolutionaryspooling technology, bringing-in importantinnovations and substantial benefits

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 uncoilingcapability. This enables spooled coils directfeeding to the downstream cold processinglines without any intermediate operation (like uncoiling, stretching and regular recoiling)with consequent significant savings intransformation 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. ■


>Sp

oole

r<A

Layout arrangement of the two twist-freeSpooler lines (highlightedin red) in the existingdouble-strand rolling mill, beside the cooling bed for straight bars.

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.

The line to be installed in Xinxiang is the world’sfirst application of the high-speed breakdowndrawing technology and will produce 70,000 tpy of copper tubes coiled in a basket for ACR andplumbing applications. The line will consist of fourchain-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 breakdowndrawing line will be produced by a KRM (KocksRotating Mill), the new four-roll mill engineeredby Kocks, Germany. The KRM, combined withDanieli chain-track break-down drawing, representthe beginning of a new era in the production of high-quality ACR copper tube.

Conditioning line for stainless steelslabs at LISCO, P.R. of China

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 edge-grinding unit. The line is complete with slabhandling equipment and auxiliaries, includingsecondary dust collecting filter and swarfhandling. The plant will be started up in the third quarter of 2006. ■

37

High-speed breakdown drawing linefor copper tubes at Golden DragonPrecise Copper Tube, P.R. of China

Latest orders forDanieli Centro Maskin

DANEWS COLD & HOT PROCESSINGDANEWS

he 120-tph pusher-typereheat furnace designedand built by Danieli Centro

Combustion (see DaNews 141page 23) was officially opened on Friday 11 March 2005.The new furnace replaces two 35-year-old walking-hearthfurnaces, substantially improvingproduct quality and productivitywith less than half of previous fuelconsumption.Danieli Centro Combustion'ssuccessful performance incompleting the turnkey project

in less than nine months waswitnessed in the HighveldNewsletter:

>... 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-trackprogramme for a project of thisnature, but a world first...< ■

1 Sir Mark Moody-Stuart,Chairman of AngloAmerican, owner ofHGVD, at the unveilingceremony.

2 Mr A. J. de Nyssehen,CEO of HGVD, with Mr F. Ajosa, VP and CEO of Danieli CentroCombustion.

Official opening of new reheat furnaceat Highveld, South Africa

T

HEATING SYSTEMSDANEWS H

38

AUTOMATIONDANEWS A

he project is aimed at achieving improvedproduct tolerances and yield. The plate mill consists of two four-high

stands to be retrofitted with new hydrauliccylinders. The turnkey project calls for supplying a new Level 1 system and new Level 2mathematical models for mill setup and Plan ViewRolling (PVR), as well as a new Hydraulic GapControl (HAGC) with related hydraulic unit andhydraulic cylinder installation on the stands. The automation system will be based on theDanieli Automation HiPAC platform, speciallydesigned 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 DanieliAutomation control;

revamping of the motor generator set and drives digitalization;

modification of mechnical equipment, thickness gauge after the finishing stand and a laser-based plate lengthmeasurement 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 coordinateall the activities related to the turnkey job in consortium with GA Danieli India (a sistercompany of the Danieli group). The project completion date is June 2006. ■

New HAGC and PVO (Plan View Optimization) systems will be implemented in the 2-stand plate mill.

Plate mill upgrading at Bhilai Steel Plant(BSP, SAIL), India

Conventional rolling

Plan view optimization

T

39

DANEWS 143

Universal Metal CoatingCompany Ltd.’s (Unicoil)new facility for

processing HR and galvalumesteel coils in Al-Jubail is expectedto start production in Q1, 2006.The 250,000 tpy output willconsist of a mix of galvanized,blanks and painted coils. The contract reconfirms thereliability of Danieli Automation IT technology and its position as a front-runner for the uniquesolutions for steelmaking plants to cover market demand for a total integration of commercialand production data into anintegrated system.Furthermore, the MET2000 systemwill replace functions performedby the existing ERP system withsteel plant-specific functions forsales 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 synchronisationof the entire production process.Additional important subfunctionsare:

order entry, receipt of coils for

production,quality-related operations, production tracking, storage operations, shipping, reports,ERP system integration.

A wireless network supports craneterminals and wireless bar-code

reader terminals, while label printers ensure error-free identifi-cation and tracking of production.The data warehouse solutionensures vital support of storingand analysis of historicaldocuments, order, production, and quality certification for finalproduct release. The application was developedwith BusinessObjects for effective,easily configurable reports and queries to further supportUnicoil in the use of the availabledata for their strategic decisions.

Figure 1 shows the data analysissupport for processing Customerorder stages (mean value ofCumulative Frequency-CFdistribution for processing time).The MET2000 will be running on a modern, cost-effective, highly-available and automatic recoveryserver platform using Microsoft

Windows Server 2003 and OracleRDBMS. To secure a maintenancesuite for Unicoil, effective toolssuch as RAS-teleservice RemoteASsistance are provided to givedirect access to and exploit thesupport of Danieli Automationexperts. This important order,besides confirming Danieli

Automation’s leadership in supplychain management for the metalsindustry and the process control of steel plants, will also provideUnicoil with a powerful tool toexploit the full potential of the newmodern cold mill complex whereoperating costs and sales will becontrolled in real time. ■

Galvanized & Colorcoated storage

Hot dip galvanizing line

Cold rolling mill

Packing station

Slitting / Cut-to-lenght line

Finishedcoils

storage

Cold rolled storage

INCOMINGBLACKCOILS

INCOMINGGALVANIZEDCOILS

TO CUSTOMER

Inspection-SlittingPacking

Push-pull pickling lineBlack coils storage Pickled coils storage

Color coating line

Wireless Hand-held Terminal

Crane Terminal

Label Printer

PC Terminal

Printer

MET2000 supply chain management systemat Unicoil, Saudi ArabiaIt will be used as production control system for the new 250,000 tpy cold mill complex.

2 Material flow of Unicoil cold mill complex.

Weight (tons)

Days

Weight %

Product: ASTM A653Stage: PCK

-Slittingand cut-to-lenght-Inspection-Packaging

-Pickling-Rolling-Galvanizing-Cooling

95%

50%

5%

Data analisys support for Processing Customer order stages mean value of Cumulative Frequency (CF) distribution for processing time.

Long term evaluationon products leadtime and new production potentials

1 Data analisys support for Processing Customerorder stages (mean value of Cumulative Frequency -CF distribution forprocessing time).

U

40

AUTOMATIONDANEWS A

he press will be installed in the newProferall facilities located at Cortenova(Lecco) and will be positioned in the same

building where a Danieli Breda 20-MN short-stroke press has been in operation since 2000. This new press is the first front-loading unitdesigned by Danieli Breda and will be equippedwith a newly designed billet loader. This innovativeconcept has been developed at the DanieliResearch & Development Centre and is now under patent pending. This solution solves all theproblems related to the short-stroke front loadingcycle and now makes possible the extrusion of very short billets in one or two pieces, even inaluminium soft alloys. This new design completesthe range of extrusion presses offered by DanieliBreda, which include conventional long-stroke and short-stroke back- and front-loading solutions.All these solutions will guarantee excellentperformances, reliability and top product quality. ■

Danieli Breda innovative technologyin the 32-MN extrusion press for Proferall, ItalyThe press features a new concept billet loader to solve all the problemsrelated to short-stroke front loading cycle.

Movableplaten

Container

Telescopicloader

Extrusionplaten

Die holder

Dummyblock

Fixedstem

FORGING & EXTRUSIONDANEWS

DAN

IELI

BR

EDA

NEW

DES

IGN

CO

NCE

PT

Step 1:- Extrusion wnd- Container backward (Strip)- Stem backward- Billet ready for loading

Scheme of the new short-stroke front loading system.

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

Main press data

Press type SS - front loading

Extrusion force 32 MN

Billet diameter 10"

Billet length 1.300 mm

Working pressure 285 bar

Dead cycle time 13.0 sec

T

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

FACTSCONFIRM DANIELI

WORLD-CLASS ACHIEVEMENTS IN INTEGRATED AND FLAT

PRODUCT PLANTS

SGW

PRD RTC PRG WEG MSL CTD

SGB SR/DR SRW/DRW FRS

Tel (39) 0432.5981Fax (39) 0432.598289www.danieli.com

Danieli HeadquartersVia Nazionale, 4133042 Buttrio (UD) Italy

Morgårdshammar ABSE-777 82 Smedjebacken,SwedenTel (46) 240.668500Fax (46) 240.668501

E-mail [email protected]

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.

DaNews143

Documents

Transcript of DaNews143