Kumz, Russia, and Amag, Austria, place orders for their aluminium hot rolling and plate stretcher projects

Leading Chinese steelmakers rely on the latest Danieli technologies for high-speed wire rod mills

North American Forgemasters orders to Danieli Breda a 90-MN forging press, the largest in the USA

Page 8Danieli News n.165 October 2012, Danieli Group

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ALSO IN THIS ISSUEIRON AND STEELMAKING 20 STEEL MELTSHOP AND VERTICAL CASTER STARTED UP AT POSCO SPECIAL STEEL, KOREA. FLAT PRODUCTS 26 1,750-MM DANIELI STECKEL MILL FOR SPECIAL ALLOYS AND STAINLESS STEELS AT CHINALCO SHENYANG, P.R. OF CHINA. 28 FINAL ACCEPTANCE OF TWO COLD MILL COMPLEXES AT MMK METALURJI, TURKEY. LONG PRODUCTS 46 COMMISSIONING OF TWO SIX-STRAND CASTERS AT VIZAG STEEL, INDIA 50 SUCCESS CONTINUES FOR DANIELI SBQ ROLLING MILL TECHNOLOGY IN P.R. OF CHINA. 56 HIGH-SPEED REBAR MILL STARTUP AT DONGKUK STEEL, KOREA 62 FIRST SHELL PRODUCED AT VALLOUREC & MANNESMANN, YOUNGSTOWN (OH), USA.

First cold aluminium Diamond Mill successfully started up at NSA Thailand part of Nippon Light Metal groupOn August 10th, Takashi Ishiyama, President and CEO of Nippon Light Metal (NLM), pressed the Start botton and preliminary acceptance was accomplished in just one week.

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+ Highlights AUTOMATION INSERT

he mill was started up with a typical pass reduction of 50% and operated with very good flatness results as a consequence of the reasonable rolling speed. With this project, NSA was looking for a longterm partnership with Danieli to continue developing their plant and process capabilities in Thailand. The mill is a state-of-the-art, modular 4-high cold mill designed specifically to meet NSAs requirements for aluminum rolling and processes material from 2 mm down to a minimum thickness of 50 m, primarily rolling finstock and capstock products. The design, manufacturing, installation, and commissioning of this new mill is an exceptionally good example of global

cooperation between various Danieli companies. Danieli Frhling was the project and product leader, providing the mechanical design and supplying process critical components; Danieli of Thailand manufactured certain parts and was responsible for the full mill assembly and in-house testing; Danieli Automation provided an integrated and advanced automation and electrical package; and Innoval Technology contributed its comprehensive know-how during all phases of design and commissioning. This combined expertise, together with a close customer relationship led to the success that resulted in achieving the Preliminary Acceptance Certificate just one week after the inauguration of the mill.

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Ferriere Nord, Italy

Shangdong Laigang Yongfeng Steel, China

Nucor Steel Arizona, USA

ORI Martin, Italy

1-Mtpy wire rod mill for 5 to 20-mm-dia wire rod for deep-drawing purposes, welding wire and weldable grades for reinforced concrete applications rolled at 115 mps with 3-t coil capacity.

1.5-Mtpy twin rolling line for special steel wire rod fitted with latest generation DWB and TMB-Twin Module Block for the production of 5 to 25-mm-dia wire rod finished at up to 115 m/s in coils weighing 2.3 t.

126.6 mps world record speed reached in a 10-stand DWB high-speed wire rod block for 5.5-mm-dia carbon steel products.

110-mps high-speed wire rod line for superior-quality products from 5.5 to 22-mm-dia wire rod in coils up to 2.4 t for automotive and similar demanding applications.

FOUR LATEST REFERENCES AMONG A TOTAL OF 162

DANIELI MORGRDSHAMMAR WIRE ROD MILLS TO PRODUCE QUALITY COILS AT THE HIGHEST SPEED (UP TO 120 MPS)

SINCE 1975 DANIELI MORGRDSHAMMAR HAS SUPPLIED MORE THAN 240 HIGH-SPEED FINISHING BLOCKS, TOTALLING OVER 1,500 ROLLING PASSES, FOR MAX STABLE OPERATING SPEED OF 115 MPS FOR COMMERCIAL, CHQ AND SUPERALLOY GRADES FOR THE MOST DEMANDING APPLICATIONS.

Long product rolling mills

DaNewsN.165Approved by the Court of Udine under authorization n.16 dated 21.04.83

/ ALUMINIUM Introducing Innoval Technologys world-class Al expertise >6 New orders for cutting lines from P.R. of China > 12 FAC for high-speed trimming and slitting lines at Shanghai Datun, P.R. of China > 13

New records with high-productivity Danieli billet casters > 44 Excellent bloom caster operation at Masteel, P.R. of China > 45 CC02 caster in operation at Tenaris Dalmine, Italy > 47

Complete training package for long and flat product mills at Hadeed, Saudi Arabia > 76 Successful supply of spare equipment for a competitors bar mill at Revyakino Metal Rolling Mill, Russia > 78 Technical service for over gearbox refurbishment at Rizhao Steel, P.R. of China > 79 Hot Strip Mill F0 stand revamping, and new WR and BUR changing system at AM Florange, France > 80 DanOil easy and safe hydraulic locking system at Ruukki Hameenlinna, Finland > 82 SRB - Danieli square-design rest bar for long-product rolling cartridge stands > 84 CTR-RS exit twister guide for twisting of flats and squares > 86 Electrical arc furnace roof and columns lifting and swiveling system maintenance > 87

800,000-tpy special steels mill for NISCO, P.R. of China > 49 600,000 tpy mill for bar, wire rod, and light sections for Suryadev QST Rebars, India > 52 Wire rod mill modernization at P.T. The Master Steel Mfg, Indonesia > 53 500,000-tpy super-flexible bar and light section mill for M-Metal, Thailand > 54 300,000 tpy wire rod mill at Wempco Group, Nigeria > 54 Two high-speed wire rod lines in operation at Shanxi Jianbang, P.R. of China > 57 1.0-Mtpy bar and rod mill starts operation at Rajhi Steel, KSA > 58 Stacker replacement project at CMC Alabama, USA > 59

Danieli Publicity Dept. Tel. (39) 0432.1958244 info@danieli.com Graphic Design Polystudio DTP Danieli Publicity Dept Printing Grafiche Filacorda Udine

/ IRON & STEELMAKING Energiron-DR process: different reducing gas sources - same proven technology > 14 Fully automatic steelmaking at Masteel, P.R. of China > 17 Oder for four sublance-based BOF process control systems from JSW Steel, India > 17 First sublance measurement at Baosteel Meishan, P.R. of China > 17 Danieli Centro Recycling at full steam > 18

/ FLAT PRODUCTS Revamping of the Danieli TSC at Essar Steel Algoma, Canada > 24

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Highlights AUTOMATION/ TUBE PROCESSING Danieli Centro Tubes FTT algorithm for FQM seamless tube mills > 60 FAC for the spiral pipe welding line at Borusan Mannesmann, Turkey > 64 Danieli W+K Open Day > 65 Mill #2 revamping and new special sensors at Nucor Darlington (SC), USA / HEATING SYSTEMS Olivotto Ferr joins the Danieli Group > 66 Work in progress at Mittal Corp., India > 67 Commissioning of a 280-tph slab reheating furnace at ISD Dunaferr, Hungary > 68 A&E for reheating furnaces at Gerdau Group // 5 // 4 IntelliGrid - Intelligent Energy Saving System // 2 A&E supply for billet/ingot and slab grinders at Posco, Korea // 4 A&E supply for a 90-tph WBF at JNECO, India // 4

NMDC chooses Danieli TSCR technology, India > 25 First commercial coil from the HSKM No. 3 at Dragon Steel, Taiwan > 30 Successful startup of galvanizingpainting line No. 3 at Marcegaglia Ravenna, Italy > 32 First annealed coil at Arvedi Cold Mill Complex, Italy > 34 Hot-dip galvanizing line startup at TROSCO, P.R. of China > 36 Record-time commissioning of a rocking-type trimming shear at Wuhan I&S, P. R. of China > 37

Warehouse Management System at JSC Seversky, Russia // 5 HiLINE IFB system at Corporacion Aceros Arequipa, Per // 5 A&E for superflexible light section mill at M-METAL, Thailand // 6 Revamping of cut to length shear At Nucor Nebraska, USA // 6 Multilength cut management system at Celsa Huta Ostrowiec, Poland // 6 Basic automation and process control system At Shanxi Zhongyang, P.R. of China // 7 EAF upgrade to HiREG Plus at Suez Steel Company, Egypt // 7

/ LONG PRODUCTS The largest M-EMS ever designed and built by Danieli Rotelec > 38 Large bloom vertical and curved casters to Shougang Guiyang S.S. P.R. of China > 40 SBQ and MBQ billet casting plant at Gerdau St. Paul, USA > 42 Superflexible billet/bloom caster upgrading at Zeleziarne Podbrezova, Slovakia > 43 / HOT & COLD PROCESSING Danieli Centro Maskin new orders and plants startup > 72

/ CUSTOMER SERVICE DPT Danieli Pneumatic Template: a cost-saving tool for alignment of billet/bloom mould foot rolls > 74

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Innovation: the fuel for any companys longevity

ver the last 150 years Danieli Morgrdshammar has been a pioneer in consistent innovation with its technology and processes that improve Quality, Efficiency, Productivity, and Transformation Cost for rolling mills for long products, including wire rod, SBQ in straight or coiled bars, and rebars. In the wire rod field, with the performances of our H3 (High Speed -High Efficiency- High Quality) system, the quality of an as rolled wire rod has reached values ( 0.1 with 50% ovality) which, in the past, was possible to achieve only with extra downstream cold drawing or peeling. Tolerance is obtained together with metallurgical quality thanks to the design of the in-line DSC Danieli Structure Control process working in a closed loop to perform normalizing, thermomechanical (down to 750 C), and UFG-Ultra Fine Grain rolling, to control and refine the grain size of the steel product, saving at least 13 Euro/t in transformation cost. High operating speeds are no longer a limit since we achieved 120 mps on consistent basis, thanks to our wire rod blocks and our sizing blocks (24 references), TMB-Twin Module Block (four-pass), and CSB-Compact Sizing Block (three-pass) with single- or multiple-drive configuration. In a recent installation, on a two-strand wire rod mill equipped with multiple-drive CSB, we are close to reach a speed of 130 mps. Higher efficiency (over 92% of mill utilization factor), is achieved thanks to the quick changing system provided for all the equipment of the H3 system, including water boxes with fix or multiline shiftable or Rotocooler-type configuration. The Rotocooler (patented) is one of our most recent, proven innovations for wire rod, together with twin-pipe laying head and Turboloop pipeless laying head; high and consistent performances are obtained from our well proven HSS-High Speed Shear and Controlled Cooling Conveyor with EDC-Easy Drawing Continuous process for unique high-carbon steel production (tire cord). In SBQ production for straight and coiled bars, our leadership is reconfirmed and embedded thanks to the most recent references among 120 installations world wide. A further improvement of product quality and tolerances will be achieved through our newly designed HPS4 four rolls reducing and High Precision Sizing block, suitable for wide free-size rolling and repetitive and constant product quality. Productivity of 8 and 10 mm rebars is enhanced by our 50 mps top speed (with consistent running speed of 47 mps) in the cooling bed through our Twin Channel System with 120 installations worldwide. Since 2010 all our rolling mills for bars and wire rod are equipped with the sixth generation of housingless stands, the so called SHSPLUS, featuring pipeless configuration and a 20% reduction in spare and operational parts requirement. For supercompact layout configuration, like for example the MiDa-Micromill Danieli but not only, our ESS Cantilever stands are the ideal solution, making it possible to save up to 30% of the overall building length and 30% of civil works. All the above is possible thanks to the spirit of teamwork established between Danieli Morgrdshammar, Danieli Automation, and Sund Birsta, resulting in our cube Vision3 for your most modern mills.

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FA B R I Z I O M U L I N A R I S

Executive Vice President_Long Product Rolling Mills3

ALUMINIUM STRIP MILLS

COVER STORY

First cold aluminium Diamond Mill successfully started up at NSA Thailand part of Nippon Light Metal groupIn common with all Diamond Mills, the new mill at NSA includes special features and solutions that ensure good operation, ease of maintenance, robust construction, and, finally, high-quality finished strip properties. Even during the mill assembly at Danieli Thailands workshop, NSAs personnel had the opportunity to be trained on maintenance procedures, as well as operating details and quality aspects. DFs design engineers supported the assembly phase to ensure a trouble-free mill build, thus forming the basis for a quicker rampup on-site. The new mill at NSA is the most advanced aluminum cold mill in Southeast Asia and the first of any type of mill to be assembled in Thailand for a Thai customer, a fact that makes NSA very proud

Main technical data of the NSA mill: Mill type Roll dimensions Materials to be processed Strip thickness range Strip width Rolling speed Main motor power Maximum coil weight 4 4-high non-reversing aluminium cold mill 870/330 x 1,650 mm AA1xxx; AA3xxx; AA5xxx, AA8xxx series 2.0 mm (max. entry) to 50 m (min. exit) 800 mm to 1,500 mm 1200 mpm max. 2,500 kW 7,740 kg

AlMain features of NSA cold mill> Advanced coolant spray system with selective WR cooling and Hot Edge Spray (HES). > Automatic Strip Threading System. > WR and BUR stabilization system to ensure correct and stable roll stack alignment. > Hydraulic roll gap adjustment with double-acting cylinders and easyto-access position measurement transducers. > Positive / negative bending of work rolls. > HiPAC technological control system with automatic flatness and gauge control. > Dan-Purity Filter coolant filter to ensure rolling oil cleanliness.

page 14: Mr. Ishiyama, President of NLM, and senior management of NSA, NLM, and Danieli proudly stand in front of the Diamond Mill following its smooth start-up. Snapshots from the official inauguration of the plant, celebrated together with NSAs 40th anniversary. The successful startup of the first Diamond Mill will help NSA to pursue its vision to become the most responsive provider of aluminium solutions in South East Asia.

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ALUMINIUM STRIP MILLS

DANEWS

Introducing Innoval Technologys world-class aluminium expertise

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In March 2012 Innoval Technology Ltd, a leading provider of worldclass expertise to the worlds downstream aluminium industry, is now a part of the Danieli Group. Innoval Technology joins Danieli Frhling and Danieli Wean United to form the new Danieli Aluminium Strip Division.

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n todays competitive marketplace, aluminium manufacturers are under constant pressure to improve their products and processes, to deliver increased customer satisfaction and loyalty and, ultimately, greater financial returns. To achieve world-class levels of product quality and machine performance requires solving difficult problems. These may relate to the complexity of the product metallurgy, the evolution of the product surface during the process, the need for precise control of product dimensions and residual internal stresses, or the need to overcome machine constraints. Solving the most challenging problems6

requires a deep technical understanding provided only by experienced industry experts, such as Innoval. Being an integral part of the Danieli Aluminium Strip Division means that Innoval becomes an exclusive added benefit to all Danieli clients purchasing a rolling mill. Furthermore, Innovals widely recognized position as a leading technical consultant to the worlds aluminium industry is strengthened by the support of a large, global group allowing Innoval to take its clients and the Danieli Aluminium Strip Division to the cutting-edge of aluminium process technology. The integration of Innoval into

Danieli follows five years of successful collaboration between the two companies in designing and marketing the Danieli Diamond Mill. Prior to joining Danieli, Innoval enjoyed nine years of growth brought about by diversifying the business into end-user markets, and developing strategic support for investors and companies looking to upgrade, expand or build new plants. Innoval now has a diverse client base of over 300 aluminium industry clients ranging from financial investors to specialist end users of rolled and extruded products. As well as providing independent expertise, the team at Innoval has developed

products to help their clients become the best at what they do. Product and Process Training Packages, specifically designed to train engineers and operators in aluminium manufacturing operations, are one example. Included in these training packages is the highly successful Aluminium Rolling Technology Course the worlds only training course in the dedicated to rolling aluminium. Last year, Innoval delivered eight of these weeklong courses. In its problemsolving and consulting work Innoval often adopts a modeling approach to improve product quality and process performance for clients. The companys extensive

DANEWS 165

Innoval was formed in 2003 by experts from Alcan's Banbury Research Centre. The team, based in Banbury, England, provides expertise and training for a wide range of technical disciplines, including metallurgy and surface science, process engineering and manufacturing best practices. Most of the companys staff have more than 25 years experience developing world-class product quality and process practices, first for Alcan (prior to 2003) and then for many other global aluminum operations. Innovals expertise and know-how is available to all clients of the Danieli Aluminium Strip Division, making it a unique resource within the aluminum industry.

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1 Part of the team at Innoval Technology outside their facility in Banbury, UK. 2 The Aluminum Rolling Technology Course features small class sizes to maximise tutordelegate interactions. 3 The pilot size rolling mill at Warwick University; a fully integrated off-line prototyping facility developed and used by Innoval Technology. 4 Typical results from the Innoval Rolling Model a physics-based simulation of all aspects of the rolling process. 5 Typical screenshot from the Innoval Preheat Model predicting temperatures and energy consumption during the process.

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aluminium process and product knowledge is used to create detailed, physics-based process models that allow the team to investigate a much wider range of manufacturing parameters than is possible in normal production. These models are used in the design process for the Danieli aluminum rolling mills, and also are available to clients. Some of the process models include: Innoval Rolling Model, Innoval Ingot Preheating Model, Innoval Coil Heating & Cooling Models, and the Innoval Spray Impact Model. Furthermore, in the field of rolling, the Innoval team has developed over 90 spray-cooling systems for aluminium, steel, copper, and titanium rolling mills, in each case improving upon the existing system. At its center in Banbury, Innoval boasts impressive experimental facilities that are used to help clients solve difficult product

issues. The company has also developed an experimental route to support clients in new alloy and product development. In summary, there can be significant benefit to involving the right technical experts to solve the more difficult problems faced by many aluminum plants as they work to improve product quality and reduce operating costs. Innovals role in the Danieli Aluminium Strip Division ensures that, not only are Danieli rolling mills stateof-the-art, but any client purchasing one has direct access to the unique and diverse aluminum expertise that is Innoval Technology

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ALUMINIUM STRIP MILLS

DANEWS

Kumz, Russia, awards Danieli the order for its new 250,000 tph aluminium plate and hot strip millFollowing the order placed in December 2011 for the worlds widest aluminum cold mill, Kumz renews its confidence in Danieli for the new upstream plate and hot strip mill.

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WAt the press conference held following the contract signing. From left: G. Benedetti, Danieli Chairman and CEO; H.E. A. Zanardi Landi, Ambassador of Italy in Moscow; A. Misharin, former Governor of Sverdlosk Region; V. Skornyakov, Chairman and President of Alyuminievye Produkty; A. Filippov, Managing Director of KUMZ.

ithin the frame of its new major investment plan to set up an integrated aluminium hot-strip mill and cold rolling plant, on April 11, 2012, Kamensk Uralsky Metallurgical Works (KUMZ) officially signed the contract with Danieli Aluminium Division for the design and supply of an innovative plate and hot strip mill. Further to the supply of mechanical equipment, automation system and commissioning activities at site also are part of the order. The innovative plant design will include the 1+1 hot strip mill, with roughing stand and finishing mill in a twin coiler configuration to produce 4,300-mm wide aluminium plate and 2,800-mm wide aluminium strip. The rolling mill has the capacity to process different finished product. The plant will be completed with all related auxiliary facilities, such as a fume exhaust system, all media systems, and emulsion cooling system. The rolling line is fully controlled and operated by the L1 and L2 systems supplied by Danieli Automation. The two four-high reversing rolling mills incorporate the latest technology and actuators dedicated to aluminum rolling, such as topmounted electromechanical screw-down, hydraulic operated load cylinder (HAGC), positive double-jack heavy bending, work-roll axial shifting, OSR-Optimized Shaped Roll, the

Danieli solution for variable crown control, and dedicated roll-coolant control with option of selecting different cooling patterns. Along the mill line are installed an 80- and 60-mm lightplate shears and a 160-mm heavy-plate shear. Each shear is then supported with individual plate pilers for different product handling.

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1 Overall view of the 4,300 mm 1+1 rolling mill for aluminium alloys for high-demanding applications. 2 Reversing roughing mill. 3 Plate piler area. 4 Reversing finishing mill, twin-coiler configuration.

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Hot rolled plate Plate thickness Plate width Plate length 10 - 300 mm 1,100 - 4,300 mm 4.0 - 33.0 m

Hot rolled sheet Sheet thickness Sheet width Sheet length 10 - 30 mm 1,100 - 3,500 mm 4.0 - 10.0 m2

Hot rolled coil Strip thickness Coil width Coil I.D. Coil O.D. Coil weight 3.0 - 10.0 mm 1,000 - 2,800 mm 610 mm Max. 2,600 mm Max. 25 t3

Cold rolled sheet Sheet thickness: 1.5 - 25 mm Sheet width: Sheet length: 1,100 - 3,500 mm 8.0 - 13.0 m

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The goal of rolling cold sheets down to 1.5 mm, a real challenge, has led to a plan to design and equip the complete finishing area with a specific material handling solution to upload and download sheets in the line. Moreover, the stand also features a dedicated kerosene-based coolant system in addition to the conventional emulsion system. The new mill and the automatic material handling system are designed to ensure minimal idle times and optimal strip surface quality. The trend toward green design is reflected in the efficient filtering and cleaning system, DAN-ECO2 fume cleaning, and coolant recovery system, as well as Dan-Purity coolant plate and rolling oil filters and recovery system. All high-tech components and equipment will be manufactured, preassembled, and tested at Danielis workshop in Buttrio, Italy 9

ALUMINIUM STRIP MILLS

DANEWS

The new 80-MN aluminium plate stretcher for Amag, Austria

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n May 2, 2012 Amag officially signed the order for the construction of a new, 80-MN plate stretcher in Ranshofen. The order concerns the supply of the mechanical equipment and the automation system, as well as the on-site installation activities. The contract is part of the approximately 220 million Euro Amag investment that makes this project one of the largest expansion projects undertaken in the European aluminium industry. The 80-MN plate stretcher, a sophisticated piece of equipment with the ability to treat high-end alloys for aircraft components, will be the third machine of this kind at Ranshofen, but with higher capacity than the existing units. The machine will be installed in a new plate heat treatment plant nearby the new hot rolling mill. A new design was developed for the machine head to overcome the difficulty of transporting it to the site, due to the equipment dimensions and weight. Specific requirements from Amag were incorporated in the design, such as low-friction jaws (a special system of jaws to ensure the uniform pick-up of plate on its width, offering a uniform tension, on the whole plate width), head anti-skew prevention (synchronization control system aims to achieve uniform elongation along the plate width and prevent head skew), plate cantering guides, pinch roll for thin plate threading, and a new transversal press solution (operated by hydraulic10

cylinder for plate bending). This 80-MN stretcher will process medium-thickness plates with high surface quality and high performance requirements for alloys ranging from series 1xxx to 7xxx, for demanding applications from aerospace to marine, defense, and commercial transportation. Maximum plate widths will be 2,450 mm, and thicknesses will range from 25 to 160 mm, with maximum length of 12.5 m, and maximum weight of 8.5 t. The nominal annual production rate of the new plate stretcher recker III will be 25,000 tpy of plate. The processing line is fully controlled and operated by the automation system supplied by Danieli Automation. The challenging project will be executed by the joint team of experts assembled from Danieli Wean United, Danieli Automation and Innoval Technology, who will work together to provide the necessary expertise for successful plant startup and operation

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Detail of the low-friction jaws that ensure the uniform pick-up of plate on its width, offering a uniform tension, on the whole plate width. 2 High surface quality and high performance plates produced by Amag for demanding applications spanning from aerospace to marine, defense, and commercial transportation. 3-4 Assembly of the main stretching cylinders for a 60-MN plate stretcher. 5 Overall view of the 80-MN aluminium plate stretcher.

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ALUMINIUM STRIP MILLS

DANEWS

New orders for cutting lines Success goes on in P.R. of China

AlWinding tension is the single most important parameter in the recoiling process. To obtain a perfectly wound coil, different factors have to be observed. This means that interaction between recoiler and braking system is essential for slitting lines that use a looping pit. In the design of the line, special care was taken to meet these requirements. The trimming line, with its proven basic concept and reliability at stable operating speeds of 1,500 mpm, or more, is equipped with special features to provide precise products at maximum production rates. This includes: > High-speed, in-line cropping of out-of tolerance head and tail ends; > Edge trimming shear with automatic adjustment of cutting gap and immersion; > Suction devices for side trimming scrap, especially for high-speed applications; > Dedicated design of the exit guide unit downstream of the trimming shear for the shortest possible distance between cutting and recoiling zones. Both lines will be equipped with the necessary hydraulics, automation, electrical, and other auxiliary units. Installation and commissioning will be supervised by our experienced staff to ensure a fast learning curve and optimal fine-tuning of the plants Slitting line characteristics Material grades: Strip thickness Strip width Coil O.D. Coil weight Line speed Slitting width Number of strips Al and Al alloys Series 1xxx, 3xxx, 5xxx, 8xxx 0.1 - 1.0 mm 900 - 2,150 mm 1,200 - 2,750 mm 31,000 kg 0 - 400 - 800 mpm 30 - 2,130 mm 40 max.

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Orders from Henan Zhongfu Industrial Co., Ltd. for advanced cutting lines reconfirm Danieli Frhlings technological leadership in the field of highproduction, precision cutting lines for aluminum strip.

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1 Contract signing ceremony. From left: Li Shuaijie, Mechanical Engineer; Han Xiaolei, Electrical Engineer; Du Aili, Director of Purchasing Dept.; Leander Zielenbach, DF Executive Sales Mgr. Finishing Lines; Zou Kai, Director of Cold Rolling Depart of new project. 2 Trimming Line: 3D model of the trimming section.

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he two advanced Danieli Frhling (DF) cutting lines for aluminum strip will be part of Henan Zhongfus large aluminum complex to be built in Gongyi City (Henan Province). Henan Zhongfu is part of the International VIMETCO Group present in several countries, including The Netherlands, China, Romania, Guinea and Sierra Leone as an integrated aluminum company with electrical power plants, an alumina refinery and smelter, as well as downstream aluminum production. The new orders comprise a slitting line as well as a high-speed trimming line. The slitting line design, based on DFs vast experience, incorporates all the latest improvements, and provides the customer with a high-end machine able to cut strips at the closest tolerances. The core of the cutting process is the CNC slitting shear, made of pre-tensioned elements to reduce backlash in shear adjustment, computercontrolled knife shaft positioning in closed-loop mode, as well as an automatic tool clamping system. The widely proven DF vacuum roll braking design will provide the most uniform and smoothest tension to all individual strips. Braking force is applied without touching the upper surface of the material and with very low friction on the bottom of the strip.

Trimming line characteristics Material grades Strip thickness Strip width Coil O.D. Coil weight Line speed Al and Al alloys Series 1xxx, 3xxx, 5xxx, 8xxx 0.1 - 0.8 mm 900 - 2,150 mm 1,200 - 2,750 mm 31,000 kg 0 - 750 - 1,500 mpm

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FAC follows successful achievement for high-speed trimming and slitting lines at Shanghai Datun, P.R. of ChinaCommissioned in June 2012, this hightech line made it possible for Shanghai Datun Energy Resources Co. Ltd. to enter new business segments.Line data Coil weight Coil diameter Max. 19,600 kg Max. 2,200 mm

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Strip thickness 0.10 - 1.0 mm Strip width Line speed No. of cuts 420 - 2,100 mm 0 - 600 - 1200 mpm 2 (with center scrap)

he line now operating at Shanshai Datun, Xuzhou City (owned by China National Coal Development Co., Ltd.) is designed according to Danieli Frhling state-ofthe-art technology, and matches the customers specifications to trim and slit incoming material from 0.10 to 1.0-mm thickness and up to 2,150 mm in width, into a maximum of two strips; the center scrap is wound onto one recoiler. In the design process, special attention was paid to the high-precision rotary blade shear, supported by CNC knife tool immersion-depth adjustment, and combined with the vacuum suction system for trimmed scrap removal to achieve the highest cutting quality (close width tolerances and burr-free cutting). In order to maintain optimized strip flow during operation of the main equipment at a speed of 1,200 mpm, the line is installed above floor level on an operator platform. Because of this arrangement and the short distance between the cutting and recoiling areas, as well as the compact design of the exit

guides, the line matches the best rewinding results. The Final Acceptance Certificate was signed after successful installation and commissioning - supervised by Danieli Frhlings specialists and after close cooperation with the lines operators throughout the design phase 2

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1 3D rendering of a DF trimming and slitting line. 2 CNC rotary blade shear with trimmed scrap suction (installed on the operator platform).

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IRON & STEELMAKING

DANEWS

Energiron: the superflexible DR process Different reducing gas sources, same proven technology

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ver 250 million people in developing nations, including China, are expected to move to urban areas by 2020, thus creating a huge demand for housing and other infrastructure. At the same time, developed countries with substantial infrastructure and reduced economic growth, like the US and a fair part of the European Union, are recovering their stability and looking at future development. For this reason, the outlook for the global market for the next decade is positive and steel demand is expected to grow steadily. Considering that the average time of service for steel products is around 40 years, and that 40 years ago steel production was about 30% of today, through 2050 a lot of scrap needed for the steelmaking supply chain will be missing. Consequently, in order to satisfy global market demand, steel has to be produced via the BF-BOF route or via DREAF route. The restrictions imposed by environmental regulations and the limited availability of coking coal have contributed significantly to the increase in the DRI/HBI production in the regions where natural gas is available at low cost, like MENA, Asia and now North America. Nevertheless, its also true that in recent years, steelmakers in regions like India and China, where the only coals that are available for use as a reducing agent are of lesser quality, are very much attracted by the possibility of producing DRI to feed the EAF, or to provide valuable metallics as a supplement to BF-BOF systems, enhancing the productivity and reducing the environmental impact of the integrated plant. In this context, Energiron - the innovative HYL Direct Reduction Technology developed jointly by Tenova and Danieli - is the most competitive and environmentally sound solution for making DRI regardless of the available energy source. With the same, proven basic configuration, which incorporates a CO2 removal system and thus allows the DR plant not only to reduce gaseous emissions but also to selectively capture the CO2 for commercial uses, high performances can be obtained without preference among the choice of fuel, either natural gas, Syngas or COG. For this reason14

1 Sinter plant

COKE

Coke oven plant

COG

Lump Pellets DR reactor BLAST FURNACE BFG Power plant

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BOFG

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to in-plant users

HM desulphurization

BOF Steel plant with treatment Recycle scrap

Slab Caster plant

Imported scrap

Coolant scrap

2 1.6 tCO2/tls 1.2 0.8 0.42

0 BF/BOF+PP 2 1.6 BF/BOF+DRP+EAF

1.2 0.8 0.4

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0 BF/BOF+PP DRP ZR with NG+EAF

1 Blast Furnace/Energiron process integration. 2 Tons of CO2 emitted into the atmosphere per ton of liquid steel produced in a traditional steelmaking route, and in the case with DRP. 3 Tons of CO2 emitted into the atmosphere per ton of liquid steel produced in a traditional route and in the case of DRP-EAF route. 4 (page 6) Process scheme of an Energiron plant producing 2.5 Mtpy of hot DRI fed with a mix of Syngas (from coal gasification) and COG gas. Only small modifications have been made to the reducing gas route to optimize the energy efficiency of the process.

tCO2/tls

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Environmental impact: CO2 and NOx emissions in the Energiron-DRP One of the major advantages of the Energiron-DR technology is the possibility of capturing a selective stream of CO2 generated from the reduction process: in this way only about 30% of total carbon input is released as flue gases from the PG heater stack, and about 65 kg C (or 240 kg of CO2) is selectively removed per each t of DRI. Energiron presents the market with a unique option for producing DRI while obtaining pure CO2 as a natural by-product of the process, which can be utilized further or stored. This is done without the need for additional thermal or electrical energy, which eventually will imply further direct and/or indirect non-selective CO2 emissions. The Energiron DRP also achieves low NOx emissions. This is accomplished by adopting ultralow NOx burners, with the possibility of avoiding any combustion air preheating, thus naturally inhibiting the NOx generation. With these precautions, the NOx emission, normally around 100 ppmv for this kind of applications, can be reduced to values below 25 ppmv (50 mg/Nm3 as NO2). A further reduction in the NOx emission can be obtained with the application of SCR technology, which can be installed easily in existing convective sections of the heater or reformer. The NO2 is reduced to N2 by catalytic reaction with a commercial solution of NH2. The evident benefit is the reduction of NOx emission to values below 10 ppmv (20 mg/Nm3 as NO2) The excellent performances of the plants already in operation, such as the two DR modules installed for Emirates Steel, UAE, confirm the increasing recognition of the economical and environmental advantages of this technology.

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while other companies recently have started to develop DR technologies suitable for these new market requirements, Energiron remains the unique DRI process configuration thats already widely proven. For example, Danieli and Tenova HYL developed and patented a special design and arrangement of the heater for heating COG efficiently, overcoming fouling problems caused by polymerization, and cracking of BTX and TARS. A complete destruction of these compounds,by means of a partial combustion of COG is adopted by other technology providers; nevertheless this requires a high amount of oxygen, with the further disadvantage that almost all the methane included in the COG is oxidized and then unavailable for carbon deposition in the DRI. With the Energiron innovative heater, which provides an on-line cleaning system for periodical elimination of carbon deposits that could cause fouling and clogging of the heater tubes, COG can be heated as it comes from battery limit, without any costly pre-treatment. In this way, the COG, traditionally employed for power generation, can be successfully used to feed the Energiron reduction circuit. In this way, it improves the overall performance of the integrated steel plant, not only in terms of energy efficiency but also in terms of environmental impact. Based on the principle of mass conservation, the carbon impact of the BF/BOF route equipped either with power plant or with a DRP, is the same at the output, but the distribution is different. In a BF-BOF route with a power plant, the input carbon is entirely emitted into the atmosphere as CO2. On the contrary, when the BF-BOF plant is integrated with a DRP, a part of the CO2 resulting from the carbon in the COG is selectively removed from the process, with the additional advantage that it can be used for other industrial applications. Additionally, due to the increased volume of liquid steel obtained when the route is integrated with a DRP, the CO2 emissions related to total liquid steel for each route produce a significantly lower value when COG is used for DRI production instead of electrical energy production. Given that prospective metallurgical plants indicate a very strong environmental concern, the possibility of reducing the total amount of CO2 emitted in the atmosphere per ton of liquid steel by about 21% is an effective alternative -even for markets where the BF is still the most common steelmaking route. Additionally, when NG is available as a reducing agent, the improvement to the environmental performances per ton of liquid steel given by an Energiron plant integrated with the EAF is even more evident, because primarily the by-product of the DR reactions is simply water, and furthermore the CO2 byproduct can be selectively removed: in this way, the CO2 emitted to the atmosphere is reduced by more than 55%, and only about 30% of the total carbon input is released as free emission (flue gas) 16

Condenser

Top gas heat recuperator

Process Gas Compressor Cooling CO2 removal system Fired Heater

Iron ore

DR reactor

Syngas / COG Humidier

Fuel O2 DRP Tail gas

Fuel 4 DRI

Energiron Partnership continuesSince it was established in February 2006, the Energiron alliance has brought to the market the most revolutionary technology, as a result of the partners merging and co-developing the original HYL and Danarex processes. Also, the partnership has secured seven new plant projects over the eight assigned since 2006. Among the achievements of the Energiron collaboration have been the two largest Zero-Reformer DR plants ever realized, with a production capacity of 2.0 Mtpy at Suez Steel (Egypt) and 2.5 Mtpy at Nucor (USA). Moreover, since 2009 Emirates Steel in Abu Dhabi has been operating the two most efficient Hot DRI Energiron units, each of which will reach a capacity of 2.0 Mtpy following the ongoing modifications. Meanwhile, in Egypt another module that duplicates the Emirates Steel plants design is under construction. The alliance invested a lot to make Energiron the state-of-the-art, environmentally friendly DRI technology. Beyond having the highest energy efficiency, resulting in lower fuel consumption, Energiron can segregate up to 70% of CO2 emission. Coupled with coke ovens and coal gasifiers it helps to reduce the total greenhouse gas emissions that result from the use of this type of gas. During the coming years the Energiron Partnership will renew its enthusiasm in pursuit of even more challenging targets, in terms of energy and raw material flexibility and efficiency, environmental protection, and service to customers. With this background and these longterm perspectives, Danieli and Tenova HYL, both market leaders in the Direct Reduction technology, will continue to offer their combined experience to support the competiveness of the steel producers and to enhance raw material quality and availability.

After six years of successful collaboration in the field of DR technologies, Danieli and Tenova HYL reconfirmed their exclusive alliance for an additional 10 years.

Highlights DANIELI AUTOMATION

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INTELLIGRID INTELLIGENT ENERGY-SAVING SYSTEM Energy Analysis for Steel plants, Planning and Control and Anti-Cobble system for Rolling Mills

Intelligent Energy-Saving System Steel plants Energy Analysis, Planning and Control and Anti-Cobble system for Rolling Mills

IntelliGrid

Its well understood that over recent years human activities have increased the global energy consumption signicantly, inuencing changes in global climate, while costs have grown and reduced yields, and alarming public opinion. We consider that a modern approach to automation systems cannot ignore these considerations. Danieli Automation, a leader in steel plants automation, is working to improve energy conservation and control in order to face todays challenges. The result of our efforts is the IntelliGrid product, a suite of high-level SW and Automation tools capable of covering energy generation, consumption planning and energy saving optimization, by managing possible strategies to reduce emissions.

IntelliGrid controls energy ows in steel plants and represents a comprehensive suite that accomplishes the following:

Control scheme of Intelligrid control on electric network. Logic scheme for anti-cobble function.

> Analysis Energy ows and tariffs are dynamically linked to effective loads and easy determination of energy costs can be allocated to each plant area. Using such tools, potential or hidden cost saving areas can be identied quickly and evaluated. The interface with ERP or MES systems will improve the transformation costs analysis and benets.Visualization of trends for power consumption.

> Planning With this function the system schedules production when the realization costs in terms of consumed energy are minimized. Production plan is compared to the real energy requirements for the specic product. Energy contract limits, seasons, night/day periods and climatic forecast are used to optimize the energy consumption planning. Steel

> Acquisition Data from power feeders or from incoming lines is stored in the historical database and clearly shown to the energy manager. Power feeders and incoming lines are t or retrot with intelligent circuit breakers or power measurement eldbus units. Reports of energy consumption and greenhouse gas emissions are available on request.I2

Overview of plant consumption for each technological area.

Production scheduling in function of minimum electrical cost.

Highlights DANIELI AUTOMATION

transformation phases are considered to plan the production and the maintenance periods in order to reduce the delays and maximize the energy optimization and benets. All the energy related variables are considered for the main goal. > Control Plant areas are monitored to evaluate energy and productivity in relationship to the specic product. Forecast analysis can be performed to anticipate stand-by plant situations and energy possible scenario. Automatic adjustment on plant main loads and relevant media according to the tariff constrains can be realized automatically, whereas normally the manual operator intervention is required. LED-based lamps can be controlled and planned to illuminate at the proper time and with the specied power, reducing

Monitoring and control of plant main loads.

Anti-Cobble slowdown function is realized to avoid such cobbles due to power blackouts. It means that the blackout, the control system immediately acts to slow down the plant production speed and start the cut-to-length cycle. This function also covers the typical delay required by generators to startup and ramp up after a grid power break down, or inline generator fault reacting to the critical situation and avoiding the cobble situation. The IntelliGrid system takes advantage, for the operators graphical interface, from the new ergonomic Danieli Automation Q3 technology, which is studied to perform in the most efcient way for > Excellence in Quality and Product Quality certication; > High productivity; > Faster Reaction to Situations.

costs, maintenance and substitutions. Unfortunately, for many customers its a matter of fact that energy suppliers cannot guarantee constant power supply to the plant. As a consequence, frequent energy blackouts are possible, often implying an unlucky cobble. The cost of this for everyone is easy to measure.

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DANIELI AUTOMATION

Additional direct orders

A&E supply for billet/ingot and slab grindersAT POSCO, KOREA

A&E supply for a 90-tph WBFAT JNECO, INDIA

Mill #2 revamping and new special sensorsAT NUCOR DARLINGTON (SC), USA

Danieli Automation has been awarded the fourth order in less than 6 months for a grinding machine by Posco Group (Two billet grinders in Pohang; three slab grinders, including Level 2 and automated inspection system detection in Pohang; an ingot grinding machine in Pohang; two slab grinders in GuangYang). The basics of this architecture rely on a SW mathematical model -HiGRIND- and an actuators assembly to assure the highest grinding standard on the market. This environment, together with the INTELLIGrind defect detection system, has the ability to optimize grinding time/production, minimizing the material removal and buffering information per product piece. In terms of cost-savings and quality control the impact is obvious. Danieli Automation assures the highest quality standards in a totally integrated automation system.

The new order acquired by Danieli Automation integrates the original supply of the entire billet mill. The supply includes full automation and electrics with superimposed Level 2. Danieli Automations proposal was prized for the technological synergy with the mill supply (architecture and maintenance), and the reliability of proposed SW technology, able to assure the optimal thermal and metallurgical process for each product, for size, quality and distribution. The ability to modulate the heating process on a product basis makes it possible to achieve consisten productivity and quality, and signicant energy savings and reduced gas emissions. Similar applications have achieved savings of specic fuel consumption in the range of 10-15%, with a project pay-off time of less than one year.

After the successful revamping of the automation system for the rolling mill No. 1, Nucor has reconrmed its condence in Danieli Automation with another purchase order for the complete revamping of rolling mill No. 2. In addition to the replacement of the Rockwell basic automation software, Danieli Automation will provide process control and Business Intelligence (Q3Intelligence) applications for both mills. Then, the supply will be completed by electrics, automation, and special sensors, such as HiPROFILE LITE (the new compact prole gauge for small proles and rebar), HiSECTION (section gauge for dimension control) and HiTEST (surface defects control), for the new Danieli wire rod and bar-in-coil lines.

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Highlights DANIELI AUTOMATION

A&E for reheating furnacesAT GERDAU GROUP

Warehouse Management SystemAT JSC SEVERSKY, RUSSIA

HiLINE IFB systemAT CORPORACION ACEROS AREQUIPA, PER

In April 2012, JSC Seversky Tube Plant awarded Danieli Automation with a new order for a complete Warehouse Management System (WMS). It is the key part of the supply chain, and aims primarily to control the movement and storage of materials within the pipe intermediate storage and process the associated transactions. The WMS is one of the modules of the Q3MET Danieli Automation Production Management system. Among the several advantages provided by a proper WMS are: material inventory kept under control, reduced stock, improved material identication.

Danieli Automation has earned a third order in less than six months for a reheating furnace A&E supply by Gerdau Group (Gerdau Monroe, MI, USA; Gerdau Pindamonhangaba, Brazil; Gerdau Sidegua, Guatemala). The Danieli Automations consistent and efcient architecture for RHF automation makes the assistance to production and the required maintenance easy tasks for the operator.

Danieli Automation will supply an additional HiLINE IFB, the optical aligning and calibrating system for roller guides and also for rolling rings, when used in remote mode directly on the FFB. After the rst HiLINE IFB early ordered at the beginning of 2012 has been supplied and commissioned, the condence of the customer in the benets deriving from the use of it has motivated Aceros Arequipa to purchase another unit for the second rolling mill at Pisco. Main benets deriving from HiLINE IFB system utilization are: > Accurate alignment of the rolling equipment, independent from the operator skill; > Reduced wear in rolls and bearings; > Faster rolling mill adjustments; > Improved quality of nal product; > Reduction of down times.

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Additional direct orders

A&E for superflexible light section millAT M-METAL, THAILAND

Revamping of cut-to-length shearAT NUCOR NEBRASKA, USA

Multilength Cut-Management systemAT CELSA HUTA OSTROWIEC, POLAND

The contract signed in May 2012 covers the technological supply of the automation and electrical systems for a new superexible, 500,000-tpy rolling mill for light sections. The state-of-the-art automation system will be supplied for the rolling mill control. In order to improve mill efciency and product quality, Danieli Automation also will provide M-Metal with a new HiPROFILE mod. PR84200/F, laser optical gauge system for non-contact, online measurement of all rolled stock proles (rounds and squares from 12 to 50 mm, hexagons from 25 to 40 mm, ats, Hbeams, channels, and angles up to 150 mm).

A Danieli Automation S7 standard application SW will replace Siemens PCS7 software. Complete revamping of the nishing area, based on Rockwell Logix 5000 PLC, also will be provided.

The possibility of managing up to three different sales lengths on the nished bars will improve the yield and the productivity of Celsa Huta Ostrowiec bar mill, installed in 2008 by Danieli. Thanks to the effective collaboration with the customer, the multilength cut system will be implemented at different levels of automation, from Celsa manufacturing and execution system (optimization) to Danieli Automation process control system and basic automation (automatic set-up and sequences management).

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Highlights DANIELI AUTOMATION

Basic automation and process control systemAT SHANXI ZHONGYANG, P.R. OF CHINA

EAF upgrade to HiREG PlusAT SUEZ STEEL COMPANY, EGYPT

Danieli Automation was deeply involved in the very demanding target for Shanxi Zhongyang Iron & Steel, to roll the rst billet on October 1, 2012. The order was placed on May 18, just 4.5 months before the scheduled hot test, and integrates basic automation, complete process control system (implementing billet yard, reheating furnace optimization, and quality control systems, among others) and special sensors like HiPROFILE LITE, HiSECTION and Speed Meter SM3100. The new HiPROFILE LITE, the unique innovative laser gauge, is able to measure rebars and plain rounds, and simple proles up to 70 mm, with 0.015 mm accuracy in measurement at 3. HiSECTION is used for rolls and roller guides wear monitoring. The infrared speed meter SM3100 is used for cut-to-length optimization.

The new supply consists of the HiREG Plus electrode regulators, the best package available to improve EAF performances. Danieli Automation is managing supply of

the entire automation and electric packages for the complete meltshop, Direct Reduction Plant and conticaster, including overall project coordination responsibilities. The main targets of the project are: > Improving the efciency of the electric arc, by minimizing power-on time, maximizing average power, reducing energy consumption, reducing electrode consumption, reducing icker; > Avoiding negative effects on the furnace equipment; and > Operating under safe conditions. These goals will be reached by operating with arc protected and at the highest possible power inputs, without creating arc instability.I7

DANIELI AUTOMATION PRODUCT LINES Process Automation and Control Systems Integrated Production Management Systems In-Line Quality Control Systems Contact-free Optical Gauges Turnkey Electrical Plants Customized Instruments for Steelmaking

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Fully automatic steelmaking implemented at Masteel, P.R. of China

Order for four sublance-based BOF process control systems from JSW Steel, India

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Souvenir photo of the Masteel/Danieli Corus joint team that cooperated to carryd out the startup of One Button Steelmaking at the Chinese BOF shop.

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n Wednesday, 27 June, fully automatic steelmaking, which the Chinese call One Button Steelmaking, was initiated successfully at Masteels BOF Steel Plant No. 4 in Maanshan. The operating

MA STEEL

practice is based on the ability to have all BOF Process Control Systems run in full computerized mode, allowing for BOF steelmaking from raw material ordering all the way through to tapping, with no further need for operator intervention. It is a significant contribution to achieving a BOF steel plant's full potential, while reducing operating costs and increasing the quality of the finished product

anieli Corus has an order for four sublance-based BOF process control systems for the four 170-t converters of the Steel Melting Shop No. 2 operated by JSW Steel in Toranagallu, India. The systems will operate within the Static-Dynamic Process Control Model for BOF Steelmaking, that allows fully automated converter operation from charge to tap, with all systems running in fully computerized mode. This order confirms Danieli Corus' position as the global steel industrys market leader in BOF process control. This project is the second supply of a sublance-based system to

JSW Steel, after an earlier order for three identical units. These seven sublance-based systems provide JSW Steel with a competitive advantage in its BOF steelmaking operations. Currently, none of Indias steel producers have process control systems that offer similar capabilities at their disposal. Sublance-based, in-blow measurements allow for a significant reduction in cycle times, which in turn greatly enhances the steel plants capacity without requiring substantial capital expenditure

First sublance measurement at Baosteel Meishan, P.R. of China

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n April 17, 2012, the first sublance measurements were performed at Baosteel Meishan's Converter No. 5. This successful project conclusion confirms the excellent relationship between Baosteel Meishan and Danieli Corus following earlier sublance projects in 2002 and 2007

This is the fourth sublance-based BOF Process Control System that Danieli Corus supplied to this client.

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Danieli Centro Recycling at full steam Danieli Henschel is the unquestioned partner for scrap metal recyclers and steelmakers1

Part of Danieli Group since February 2012, with the core competence in development and assembly of machines dedicated to the recycling of steel and other metals, Danieli Henschel continues to enhance its range of shears, presses, preshredders and shredders, in order to meet the customers increasingly demanding requirements.

Galloo Group, Belgium

Galloo Group, one of Europes most prominent ferrous and nonferrous metal recycling companies, decided to replace its former press at Menen, Belgium, with a Danieli Henschel type PTC 2060 CV baling press. This tripleaction baler (2 horizontal + 1 vertical), installed with a shearing lid, has an oversized power and production rating. Weighing about 290 t, it enables production of up to 50 tph of compressed steel in bales, 750x600 mm, nearly one ton each. The third, final compression ram effort is 1,270 t. The new press is being built now and commissioning will take place next spring.Danieli Henschel works to establish itself in the Polish market

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The scrap-processing sector in Poland is equipped mainly with old shears, and the number of presses is insufficient. However, these deficiencies are being partially addressed by a number of Polish customers that have opted for Akros Henschel systems over the past few years. One of these is part of the KGHM18

group, which leads the Polish scrap-processing sector in terms of revenue and profits. For more than two years, the company has been operating a PTC 1440 triple-compression press to recycle copper. Another one uses a PCV 2560 closed press to press stainless steel, while five new customers have respectively purchased a CIV 700-8L C and four CIV 600-8L T baling shears. A new contract has been confirmed with the Polish group Olmet. This company conducts a wide range of activities, including: steel scrap

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trade and processing, recycling of vehicles, sale of used car parts, demolition, dismantling, and even hazardous waste disposal. As part of this contract, a CIB 1000-10L SV press-shear with lateral pre-compression box (range CIB) will be started later this year at its Tarnowskie Gry site. With a 1,000-t cutting force, this machine equipped with a three-level box plus a variable entry angle reducer, could reach production of around 45 tph of sheared scrap. This press-shear is being assembled in the Danieli Henschel plant at Kassel, Germany. Moreover, Olmet confirmed to Danieli Henschel an order for a reconditioned, threeshaft pre-shredder that will be installed during the fall months.

1-2 Commissioning of the PTC 2060 CV baling press at Galloo, Belgium. 3 CIV 700-8L C baling press at Centrozlom, Poland. 4 700-t baling shear: air cleaning system, loading box, detail of the shearing head.

Dismantling of former Russian nuclear submarines: all Danieli Henschel know-how for a contract under tight control!Danieli Henschels scope of supplies covers all the necessary equipment, transport to Murmansk, assembling in a close military zone, and of course service. The customer is the Federal Ministry for Economics and Technology, in which is overseeing this 1-billion euros international project to dismantle submarines! The objective of this project is to stop proliferation and recovery of nuclear materials for terrorist purposes. And, as part of disarmament agreements, Russia has reformed many submarines. It will take at least ten years of dismantling until all the nuclear submarines are scrapped.700-t baling shear

"This baling shear is fully integrated into a full installation for nuclear waste management," said the engineer Klaus Biermann, who leads the project.A press-shear adapted to destroy a submarine

This is a very special version of a baling shear that has just recently been tested at our plant in Kassel, Germany. It is able to shear steel sheets up to 9 cm thick. Another of its features is a system of dust extraction overkill, purifying the air by a system of filters.

Within a year, it will be commissioned at Saida Bay in Murmansk, where about 150 decommissioned nuclear submarines have to be scrapped. "The core hosting the nuclear reactor will be cut and stored tightly for at least 100 years ... The rest of the submarine is still slightly or moderately radioactive. This is the reason that the shears aircleaning system is so important. Submarines are dismantled in a big hall ... nothing escapes to the outside". Plant commissioning for that shear was conducted with the customer over several days. In a second step, it will be disassembled and prepared for transport. Loaded on a ship in Hamburg, it will cross the North Sea to Murmansk to perform the assembly during the winter

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Since the beginning of operation, the new facilities have shown their ability to achieve the most flexible and cost-effective production for blooms and ingots in special, stainless and non-stainless steels.

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New special steel meltshop and two-strand vertical caster started up at Posco Specialty Steel, Korea

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n March 2012 Danieli successfully startedup the meltshop plant in Changwon, and in April 2012 proudly delivered the first bloom from the new two-strand vertical caster. The meltshop is designed to produce 450,000 tpy of liquid steel to feed either the vertical caster or the ingot casting facilities. The target production rate for the vertical caster is 227,300 tpy of high-quality blooms. The product mix includes plain carbon and alloy steel, stainless steel, tool steel, and other special purpose steel grades. The electric arc furnace, equipped with an SVC and a 72-MVA transformer, is a full platform EBT FastArc-2 EAF, tapping up to 70 t/heat, complete with sidewall Danarc Module system for oxygen and carbon injectors; doormounted multiple lance manipulator, Robox, for oxygen, carbon and FeSi powder injection;

Main characteristics of the meltshop

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Liquid steel production EAF capacity Design tap-to-tap (stainless / carbon) LF heating rate VD/VOD suction capacity (at 0.5 torr)

450,000 tpy 65 t/heat 67 / 49 min 5.0 C/min 400 kg/h

and roof-mounted lime injectors. The secondary metallurgy area is comprised of a single-position ladle furnace, equipped with a 15-MVA transformer, served by two ladle cars and a twintank single-cover VD/VOD station. The ladle furnace is equipped with a water-cooled inert type roof and a full package of auxiliaries, such as: multipurpose lance for carbon and nitrogen

1 The 70-t AC EAF is equipped with Danarc Module system for oxygen, FeSi powder, and lime injection. 2 EAF control pulpit. Danieli Automation supplied the complete electrical and automation system, including Level 2.

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Main characteristics of the vertical caster

Production No. of strands Casting section Cutting lengths Mold Oscillator type Cutting systems Caster productivity Metallurgical length Casting platform height Bottom of caster depth Electromagnetic stirrer Secondary cooling system Withdrawal unit Soft Reduction units

227,300 tpy 2 420 x 530 mm 4 - 6 m (main cutting system); 2 - 3 m (secondary cutting system) Plate type, 700-mm long Hydraulic Oxy-cutting with powder 81.6 tph max. Approx 25.5 m 19 m from zero level -24 m from zero level M-EMS and F-EMS Zone 1: water; Zone 2 and 3: air mist; 2-loop regulation (inner/outer radius - lateral sides) for each zone 8 modules per strand, two rolls each 8 modules per strand (+bloom thickness measuring stand)

injection; automatic sampling and temperature measurement system. The VD/VOD is equipped with steam-ejector pump with suction capacity of 400 kg/h, to ensure the shortest possible treatment time. The new, two-strand vertical caster is designed to cast a rectangular section, 420x530 mm. The machines main highlights are its latest generation, high-capacity tundish design, electromechanical stopper rod mechanism in the tundish, submerged casting with SEN, plate mold with anti-breakout prediction system, mold EMS and final EMS, hydraulic mold oscillation, and dynamic soft reduction withdrawal and straightening units

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Facts!From startup to June 2012 the vertical conti caster already completed 95 heats, reaching a yield rate of about 97%! Some excellent quality results already achieved during these first months of production: > Side dimensions tolerance: 1% > Rhomboidity: 6 % (more than 20 blooms measured with rhomboidity less than 1%) > Surface cracks: 100 % of blooms free > Bulging: not found; > Internal cracks: 100 % of blooms free. Steel grades produced to date have the following distribution: carbon steel: 12%, alloyed carbon steel: 35%; tool steel: 5%, stainless steel: 48%.22

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1 Front view of the twostrand vertical caster for stainless and nonstainless special steels. 2 Twin-tank, single-cover VD/VOD station. 3 Control pulpit of the 15-MVA ladle furnace.

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Revamping of the two-strand Danieli Thin Slab Caster at Essar Steel Algoma, Canada

Adopting several well-proven and innovative Danieli technology packages will boost productivity and widen the product mix to more highvalue-added steels.

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n June 6, 2012, Danieli Davy Distington signed a contract with Algoma, Sault Ste. Marie, (ONT), to upgrade the two-strand Danieli thin slab caster installed in 2001, together with the complete hot strip mill, to form the DSPCDirect Strip Production Complex. This was one of the first vertical-curved thin slab casters ever installed in the world, and was fitted with all the technologies that Danieli had developed at that time. Compared with other vertical thin slab caster technologies then in operation, the Algoma plants success was obvious right from the very first heat, thanks to the wider range of high-quality steel grades that24

castable steel groups to include high-added-value steel; > Improve final product quality for all steel groups. In order to reach this goal, Algoma asked Danieli to propose a machine revamp at a minimal investment cost, given the current economic situation. In several meetings with the sales and engineering teams of Essar Algoma and Danieli, the following improvements were decided for both strands of the thin slab caster: > A new roll diagram with tight, gradual pitches, to contain dynamic bulging phenomena at higher casting speeds; > In accordance with casting

the new Danieli technology was able to cast. Right from the beginning, this and other factors led to a long-lasting, friendly relationship between Algoma and Danieli. Recently Algoma was purchased by the Indian Group Essar Steel, and changed its name to Essar

Steel Algoma Inc. With a view to becoming one of the leading steel producers, Essar intends to: > Increase plant production capacity to 2.6 Mtpy; > Increase casting speed to 5 mpm; > Increase the range of

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speed requirements, this modification is applied to segment 0, segment 1 and segment 2; > All new segments include the new Danieli sleeve-type rolls for increased roll and rollbearing life; > New, high-efficiency spray nozzles and a new, secondary cooling system, subdivided in multiple sectors, to ensure even slab cooling; > Air-oil lubrication for segment bearings. These technological packages are already applied and have been in operation for several years for three new Danieli plants, namely Posco CEM Project, Korea; OMK, Russia; and Dongbu, Korea. The changes are plug-and-play systems and require less than one week of caster shutdown, which means very little loss of productivity. Moreover, the new equipment is designed to accommodate the old segments, too. Thanks to these innovative technologies, the Algoma plant will reach its production targets while adding to the mix new, high value-added steels, such as HSLA, high-carbon, API, and peritectic grades. The project will be another clear example of Danielis ability to apply a high level of technology that meets customers requirements through customized revamps

Latest news NMDC, India, chooses Danieli Thin Slab Casting and Rolling technology

he complex is an integrated steel plant starting from iron ore through BF route to produce 2.9 Mt/y of HRC via thin slab casting and rolling technology. The thin slab rolling package includes vertical curved slab caster, tunnel furnace, 2R+4F(5F) finishing mill and coil handling and storage area. It will be supplied by Danieli and its associated partners on turnkey bases including all auxiliary facilities, civil works, buildings, cranes, roll shop, etc. The steel plant is a green field project located at Nagarnar, Chhattisgarh State, NE India. It will produce hot rolled coils having following specification: > Strip thickness: 1.0-16 mm > Strip width: 900-1650 mm > Coil weight: up to 35t > Specific coil weight: up to 22 kg/mm The target steel grades are: > API-5L X70/X80 > HSLA > Boiler > Pressure Vessel > Dual phase > Electrical Silicon Steel > TRIP > Autobody > HC, MC, LC etc.

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The NMDC plant is meant to become the most modern thin slab rolling mill in South East Asia and a will set a new bench mark in terms of productivity, quality and competitiveness. The first coil is expected to be rolled by January 2015. It is worth mentioning here that Danieli Corus is the supplier of the Blast Furnace for this same plant which is the largest Blast Furnace in India having a volume exciding 4,500 m3.

Souvenir photo at the contract signing. From left: M. Maurizio, Director Engineering and P. Adani, Product Manager, for DDD; D. Clingen, General Manager Engineering & Project Manager; D. Cesarin, Manager Engineering; K. Frechette, Automation Engineering; R. Alloi, Manufacturing Technology Automation; M. Twentyman, Manufacturing Technology Associate DSPC, for Essar Steel Algoma.

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1,750-mm HighTech Danieli Steckel mill for special alloys and stainless steels at Chinalco Shenyang, P.R. of China

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hinalco Shenyang NonFerrous Metal Processing Co. Ltd., a subsidiary of China Aluminum Corp. Ltd. (China), a giant among the worlds alumina and primary aluminium producers, recently placed an order with Danieli to supply a new Steckel Mill for special alloys and stainless steel, as part of a greenfield complex to be located in Shenyang, 650 km northeast of Beijing.Flexibility as a milestone

The new 1,750-mm-wide single-stand Steckel mill for both coils and discrete plates will be of an extremely compact design: all the equipment -including the plate finishing line- will fit into a mere 200 m. The customized layout, moreover, includes several particular features, such as a shiftable intermediate bar reheating furnace, typical of hot rolling lines that have extremely high requirements for production flexibility and nonconventional grade mix. This includes a requirement for rolling ferrous and nonferrous alloys, for which the Steckel technology has proven to be the ideal solution to satisfy high-value product market niches. The mix includes titanium grades, such as TA1, TA2, TC4, nickel alloys, copperzirconium alloys, and stainless steel grades such as AISI 304 and AISI 316 for an initial capacity of 62,000 tpy, which in the future may be expanded easily. Danieli will be responsible for the26

Wang Yonghong, General Manager of Shenyang Chalco and Matteo Bavaresco, CEO of Danieli China.

Danieli Steckel mill technology reconfirms its standing as the ideal solution for nonconventional product mix and special applications.

technological performances of the mill, supplying the most critical mechanical part and the whole automation system, including L1 and L2, for the entire line.Cast ingot furnace and intermediate bar reheating furnace

The layout includes two walking-beam furnaces to reheat ingots to a suitable rolling temperature, a highpressure water descaler

(mainly for stainless steels), and a separate intermediate reheating furnace located before the Steckel area to reheat the special alloy bars during re-rolling. The intermediate furnace is mounted on a traversing car and can be moved off the rolling line and replaced with a simple roller table if the technological process does not require intermediate bar reheating.

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Reheating furnaces Water descaler Intermediate reheating furnace Steckel mill Vertical edger Crop shear

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Laminar cooling Downcoiler Hot leveler Dividing shear Disc-type cooling bed Marking machine Plate piler

Coil data Thickness Width Weight 3 - 6 mm 850 - 1,560 mm Max. 12.2 t

Plate data Thickness Width Length 3.5 - 60 mm 850 - 1,560 mm 6 - 12 mm

60,000-kN four-high mill stand

The exceptional mix of grades requires a unconventional (for a product with max. width 1,560 mm) four-high mill stand in the Steckel area, capable of reaching a separating force of 60,000 kN. It will be fully equipped with state-of-the-art functions, such as HAGC for accurate gap control, positive and negative bending compensation system, and work-roll shifting system with Danieli OSR-Optimized

Shaped Roll technology to maximize crown control capability.Edger and flying shear

Laminar cooling and downcoiler

L1 and L2 automation package

A bottom-driven vertical edger is equipped with HAWC for automatic width control and improved transfer bar head and tail shape, as well as a flying crop shear to guarantee the proper head and tail strip geometrical properties for safe threading on the coiling drum.

U-tube laminar cooling for high cooling rates and precise strip temperature control. The three wrapper rolls of the downcoiler provide excellent tension control to prevent telescopic coils.Plate finishing line

It includes a hot plate leveler, hydraulic dividing shear, cooling bed, and vacuum piler to guarantee proper plate production management.

Danieli Automation will be responsible for the supply of the entire automation system for the mill line, including L1 and L2 complete with all the necessary process models, and HiPAC PLC technology. Accurate testing of all mechanical and automation equipment prior to commissioning will ensure a quick and smooth mill startup for the best ramp-up curve. Plant startup is scheduled for the summer of 2014 27

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Final Acceptance Certificate released for fTSR complex at MMK Metalurji Iskenderun, Turkey

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anieli performed the project engineering and supplied all main process equipment, as well as supervised of installation and training of personnel, for both MMK Metalurji (a subsidiary company of Russian Magnitogorsk Iron & Steel Works) production sites, at Iskenderun and Istanbul. The plants were put into operation in stages during 2010 (cold facilities) and 2011, starting with the coating facilities and ending with the meltshop and the hot rolling facility. The first hot-rolled coil, which concluded the28

The joint and full commitment of MMK Metalurji and Danieli led to project completion within the contracted schedule, to the customers great satisfaction.

startup of all the facilities of the new steel complex, was produced in 2011, and after the successful completion of the performance tests, the Final Acceptance Certificate was signed in spring 2012. This is the first Thin Slab process complex to be built in Turkey, and it operates one of the most powerful electric arc furnaces ever built in the world. Besides, it is combined with the most advanced technology for hot rolled coils. The Final Acceptance Certificate for the complete meltshop, twin-strand thin slab caster, tunnel furnace,

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Final Acceptance Certificate for HDGL and CCL at MMK Metalurji Istanbul

3 1 2 3 4 Control pulpit of the hot strip mill. Entry section of the hot-dip galvanizing line. Control pulpit of the twin-strand thin slab caster. Color coating section at MMK Metalurji Istanbul.

and hot-strip mill was signed as a natural result of this successful cooperation throughout the project. The Iskenderun installation includes:> One of the most powerful AC furnaces in the world

> fTSR Hot Strip Mill

The targeted production volume of 300 tph is assured by a jumbo size (250 t) EAF, and high-power (300 MVA) transformer capacity. The final product quality requirements are met thanks to the associated twin ladle furnace and twin vacuum degasser, while a powerful and effective fume dedusting plant with two parallel filters ensures the highest environmental protection.> Thin & Fast Slab Continuous Caster

The second part of the Casting and Rolling Facility is comprised of two roller-hearth tunnel furnace strands -one for each casting line- and the rolling mill. The furnaces guarantee proper temperature and buffer time between the casters and the mill. The 137m long Hot Strip Mill includes a vertical edger, two descalers, two roughing stands, a drum crop shear, four 4-high finishing stands, Water Wall laminar cooling benches, and two downcoilers with entry pinch rolls. The line is completed by a coil handing system that includes coil circumferential and radial strapping machines, coil weighing scale, coil marking unit, and coil visual inspection station. This successful project represents one the most important results Danieli has achieved in the Turkish market during the last few years. Its smooth execution and the excellent results already achieved strengthens its presence and reputation for reliability as a technology supplier and turnkey project developer, and are the best evidence of the good cooperation established by the respective management teams

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The first part of the Casting and Rolling Facility is a Danieli twin-strand thin slab caster with the capacity to produce from 50- to 80-mm thick slabs (after dynamic soft reduction), 800 to 1,570 mm in width. The current product mix includes low- and medium-carbon grades, and HSLA. However, the caster is already designed for future production of extra-low carbon, interstitial-free, and high-carbon grades.

s it did for MMK Metalurji Iskenderuns flat products minimill complex, Danieli also supplied all technological equipment and engineering for the Istanbul project, as well as supervision for installation and training of personnel. As a consequence of the global steel market crisis, the Istanbul plant suffered a six-month pause in development before resuming. In January 2012 the Performance Test Completion and Final Acceptance Certificates were signed, and the plant was handed over to MMK Metalurji for normal operation. The facility includes: > a hot dip galvanizing line

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producing 0.45 Mtpy of finished coils to feed the highquality color-coating line. It is equipped with a double entry end and a horizontal annealing furnace by Danieli Centro Combustion, and the zinc-coating thickness is tightly controlled by the Danieli Kohler wiping system. > a color-coating line producing 0.2 Mtpy, for white goods, construction, and general commercial applications. As these machines are the exact copy of the ones supplied for the Iskenderun site, the engineering and commissioning phases proceeded smoothly, thereby allowing a quick and challenging startup production

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1 1 The Dragon Steel-Danieli Team that carried out the successful startup of HSKM No. 3. Shaking hands are H. C. Yang (right), Project Manager, Manager of Rolling Mill Engineering Dept.; and B. Kustic, Danieli Site Manager. 2 Hot skin-pass mill No. 1 and No. 2 in operation at Dragon Steel since 2009. 3 Skin-passed strip inspection area.

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First commercial coil from the HSKM No. 3 at Dragon Steel, Taiwan

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On June 27, 2012 the first coil was processed in Hot Skin Pass Mill No. 3. The innovative solutions adopted for optimal operation and product quality make this unit one of the best of its kind in the world.

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ragon Steel is part of the China Steel Corporation, which has an overall capacity of more than 13 Mtpy. The need to increase the output of skin-passed coils at the Taichung plant led to the installation of a third Danieli Hot Skin Pass Mill, given the positive experience made with Hot Skin Pass Mills No. 1 and No. 2, supplied in 2008. The new mill has a nominal capacity of 800,000 tpy and can process strips at 400 mpm, in gauges from 1.2 to 4.5 mm, and widths from 700 to 1,880 mm, in low-carbon, Al- and Al-Si killed, HSLA, and API X80 steel grades. Compared with Hot Skin Pass Mills No.1 and

No.2, the new unit is equipped with a MIG welder, grinder, shapemeter roll, tension leveler, and an automatic surface inspection system. The highlight of the mill is the innovative solution that combines the MIG welder with post-annealing facilities and the grinder. Optimal operation of the welder and grinder makes the weld seam skin-passable, i.e. the strength and geometry of the weld seam after the grinder is such that it is no longer necessary to open the WR and tension leveler rolls as the weld seam goes by. With this configuration, HSKM No.3 can work continuously, and the total length of non-skinpassed strip at the head and tail ends is theoretically null. The tension leveler, which is located downstream of the mill stand, helps to improve results in terms of final strip flatness. The shapemeter roll, which works in closed-loop mode, and the automatic surface inspection system, contribute significantly to raising the operating efficiency of the mill and to reducing operator intervention, to find the most suitable settings for the best performances, and therefore the best quality strip 31

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Successful startup of galvanizing-painting line No. 3 at Marcegaglia Ravenna, ItalyThis is the first European-designed and -built line to apply a conventional two-layer solvent paint by using the NIR-Near Infra Red technology. If compared to a conventional line, the complete paint section line requires only 30% of the space, and ensures improved performance in terms of speed and uninterrupted painting without speed reductions,irrespective of product changes, including strip thickness, width, or color. Also, the use of dummy coils can be eliminated, which also increases line up-time.

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n July 2012 the hot-dip galvanizing and painting line successfully started producing its first galva-painted coils. The coating tests on the strip began in November 2011 and were completed in April 2012 when the oven and zinc pot started up for galvanizing process testing. Before starting to combine the two processes, both sections underwent an intensive tuning stage in order to reach the full contractual production targets. The painting section is composed essentially of two primer-coating units, two finish-coating units, and two NIR ovens for heating of each coating phase. The four coaters are installed in four separate painting rooms, which include suction hoods to evacuate the painting vapors. Afterward, these vapors will be eliminated by the RTO burners system. Due to the complexity of the painting section, all the equipment installed had to be certified according to latest European, Safety and potentially explosive atmospheres (ATEX) standards as indicated by the European 94/9/EC directive. The painting section could be by-passed easily (if only galvanized coils are requested) by redirecting the strip to the exit section of the line through a sequence controlled by the automation system. This makes it possible to respond flexibly to quickly changing market demands. Together, the NIR technology and the process speed designed to reach 180 mpm confirm this as one of the fastest painting lines in the world. The heating technology involves microwaves that activate the water molecules directly, in contrast to a conventional oven that has to heat up before the energy reaches the target coating. The NIR-radiation energy quickly enters deep into the coating and keeps water and solvents, respectively, out of the mixture. Moreover, the configuration of the heating zones makes it possible to adjust the heater field according to the coil width. Due to this feature, the energy consumption of NIR system will be reduced and the efficiency can be adjusted to the coil width. Danielis experience implementing the best practices on the new galvanizing line No. 4 at Marcegaglia Ravenna, started up more than one year ago, had a positive effect on saving time for commissioning galva-painting line No. 3, minimizing problem-solving times for customer satisfaction

HDGL No. 3 entry section

HDGL No. 3 cleaning section

Integrated NIR-based paint lineWhen compared to a conventional stand-alone coil coating line, the integrated NIR-based paint line, provides a 30 to 50% reduction in conversion costs (up to 100 Euro/t), and a significant energy savings, with 30 to 50% less CO2 generation.

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Main data Production output Process speed Strip thickness Strip width Coil weight Coating weight 350,000 tpy (150,000 tpy painted) 180 mpm max 0.25 to1.4 mm 900 to 1,550 mm 35 t max 80 to 450 g/m2 total Skin-pass mill Tension leveler Passivation Primer film Finisher film Back-coat film 1,000 t max rolling force Elongation 2% max. Cr3+,Cr-free, anti-finger print 5 to 7 m 17 to 23 m 5 to 7 m

HDGL No. 3 vertical furnace

HDGL No. 3 cooling tower

HDGL No. 3 exit section

Color coating exit section

HDGL No. 3 color coating section

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First annealed coil produced at Arvedi Cold Mill Complex , Italy

AcciaieriaArvedi

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n December 14, 2011, Arvedi signed an addendum to the contract for its No. 3 galvanizing line, for the installation of additional furnace equipment to produce annealed coils. The target is to achieve a reliable output of thin, wide strip (up to 0.25x1,500 mm), which is normally quite difficult to process, but which also represents a strategic product that is critical to market demand. Danielis scope of supply included a double-entry, vertical-entry accumulator and vertical annealing furnace from Danieli Centro Combustion. When operating in HDGL mode, the furnace is designed to accommodate the various thermal treatment cycles that are needed to anneal steel strip for cold forming applications, and in particular for: > Low-carbon steel LC/ULC (EN 10327) > Structural steel HSLA (EN 10326) > High-strength steel HSS (EN 10292) > Advanced high-strength steel AHSS (EN 10336). The annealing cycle was operated in CAL mode to achieve proper strip recrystallization, with final mechanical characteristics as per DC01 requirements (EN 10130) for coils in gauges ranging from 0.25 mm up to 1 mm. The heating part of the annealing furnace consists of: > a free-flame section to remove rolling mill oil and iron fines and to improve strip surface cleanliness; > a radiant tube chamber. Both sections are designed for high reliability and quality34

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production of thin, wide strip, which requires soft heating to reduce any surface defects. The latest generation of 2P radiant tubes, with DCC selfrecuperative burners, for a total of 42 installed units, all in operation, are grouped into three separate control zones and managed in a combined on/off - proportional mode. Light ceramic-fiber lining and low-radiant tube thermal inertia allow quick starting/stopping, which is ne