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 8
Danieli News n.165 October 2012, Danieli Group

Page 48

Page 70

DaNews

165

ALSO IN THIS ISSUE

IRON 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 group
On 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.

+ 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.

Page 4

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

DaNews
N.165
Approved 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

// INSERT:

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

DANEWS 165

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.

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

Executive Vice President_Long Product Rolling Mills

3

ALUMINIUM STRIP MILLS

COVER STORY

First cold aluminium Diamond Mill successfully started up at NSA Thailand part of Nippon Light Metal group
In 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

Al
Main 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.

ALUMINIUM STRIP MILLS

DANEWS

Introducing Innoval Technologys world-class aluminium expertise

Al

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.

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 problems
6

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.

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.

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

ALUMINIUM STRIP MILLS

DANEWS

Kumz, Russia, awards Danieli the order for its new 250,000 tph aluminium plate and hot strip mill
Following 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.

Al

W
At 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.

DANEWS 165

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.

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 m
2

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 t
3

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

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

Al

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 hydraulic
10

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

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.

DANEWS 165

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ALUMINIUM STRIP MILLS

DANEWS

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

Al
Winding 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.

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.

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.

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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DANEWS 165

FAC follows successful achievement for high-speed trimming and slitting lines at Shanghai Datun, P.R. of China
Commissioned 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

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

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

COAL

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 reason
14

1 Sinter plant

COKE

Coke oven plant

COG

Lump Pellets DR reactor BLAST FURNACE BFG Power plant

PCI

BOFG

HM

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 0.4

2

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

1.2 0.8 0.4

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

DANEWS 165

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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IRON & STEELMAKING

DANEWS

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)
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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 continues

Since 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

DANEWS 164 / PROCESS CONTROL, POWER, AND INSTRUMENTATION

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.
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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 grinders

AT POSCO, KOREA

A&E supply for a 90-tph WBF

AT JNECO, INDIA

Mill #2 revamping and new special sensors

AT 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 furnaces

AT GERDAU GROUP

Warehouse Management System

AT JSC SEVERSKY, RUSSIA

HiLINE IFB system

AT 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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DANIELI AUTOMATION

Additional direct orders

A&E for superflexible light section mill

AT M-METAL, THAILAND

Revamping of cut-to-length shear

AT NUCOR NEBRASKA, USA

Multilength Cut-Management system

AT 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 system

AT SHANXI ZHONGYANG, P.R. OF CHINA

EAF upgrade to HiREG Plus

AT 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.
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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

DANEWS 165

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

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

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.

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

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 steelmakers
1

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

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 KGHM
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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

DANEWS 165

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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IRON & STEELMAKING

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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.

DANEWS 165

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

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

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

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%.
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DANEWS 165

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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FLAT PRODUCTS

DANEWS

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.

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 that
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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

DANEWS 165

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.

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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FLAT PRODUCTS

DANEWS

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

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 the
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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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10

13

12

11

1 2 3 4 5 6

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

7 8 9 10 11 12 13

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

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 the
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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

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

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

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.

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
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Successful startup of galvanizing-painting line No. 3 at Marcegaglia Ravenna, Italy

This 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.

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 line

When 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

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 quality
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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 necessary during the first

phase of production, with minimized fuel consumption. Ultra-rapid cooling system for complex annealing cycles is designed to prevent strip buckling, surface scratches and oxidation, with cooling from the cycle temperature (720 C) down to the maximum allowed by the process without a final water quench. Particular care is taken to achieve all the parameters for the controlled atmosphere that the CAL process requires, taking into

account the unavoidable lack of a hydraulic exit seal. After being cooled the strip is skinpassed for final roughness control, tension leveled, and passivated. After the vertical looper at the lines exit, the strip is visually inspected before being rewound. Danieli also supplied the entire electrical and automation package for this line. For the first time in processing lines, Danieli Automation is introducing the innovative OA (Operator Assistant) user interface that guides operators in taking timely action to run the line. The OA is an evolution from the standard HMI to the new NUI (Natural User Interface) that features the latest technology in multitouch applications. The line is now in the hot commissioning stage, with attention focused on thingauge material with the aim of producing the entire thickness range and ramping up production according to the learning curve. The next step is to switch the line from annealing to galvanizing and to allow a similar fast startup and commissioning to produce thin, wide strip reliably, and to enter new market segments competitively

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On April 23, 2012, Arvedi started annealing production. Performance tests are in progress and the project is expected to be a success, in compliance with the learning curve and the time schedule.

1 Danieli Automations innovative OA (Operator Assistant) user interface guides operators in taking timely action to run the line. The OA is an evolution from the standard HMI to the new NUI (Natural User Interface). 2 The joint Arvedi and Danieli Team that carried out the startup.

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Continuous galvanizing line startup at TROSCO, P.R. of China

he June 2009 order from TROSCO (Tianjin Metallurgical No.1 Iron & Steel Group & Co.) concerned the design, manufacturing, installation, and commissioning of a 300,000- tpy continuous galvanizing line, to be installed in Dagan (Tianjin): it was to be the final addition to the first part of the TROSCO site development. (A recoiling line supplied by DME is one of the lines that have already been completed). The project was carried out by Danieli Wean United and Danieli Metallurgical Equipment (DME) of Beijing, and also involved Danieli Centro Combustion (DCC) for the annealing furnace, Danieli Automation (DA) for the automation and process control systems, and Danieli Kohler for the zinc wiping system. The line processes strip that ranges from 0.2 to 1.6 mm thick and 700 to 1,300 mm wide at a max. speed of 180 mpm, and is provided with a double payoff reel entry and cleaning section. The entry horizontal looper structure also is designed for the installation of the horizontal furnace at the upper level. Two movable pots are available for producing GI and GL coated coils. Danieli Kohler air knives, skin pass, and tension leveler control the coating and finishing surface conditioning. The chemical coater, vertical looper, and double tension reel complete the exit section. On February 16, 2012, the first GI galvanized coil was successfully produced to the satisfaction of both teams
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Success continues for Danieli Wean United galvanazing lines in China

From left: A. Donetti, Technical Executive Manager, DCC; B. Vasilijevic, Site Manager; A. Ceretti, VP DWU; M. Bavaresco, CEO, Danieli China; C. Laviosa, Executive Operations Manager, DCC; Wang Xin, Project Manager, DME, with the first GI galvanized coil produced.

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Record-time commissioning of a rocking-type trimming shear at Wuhan I&S, P. R. of China

Installation and commissioning of the rockingtype double-side trimming shear was completed in less than two months. After less than three months of operation, on July 27, 2012, the FAC was signed.

1 Detail of a cut plate edge. 2 Width adjustment is carried out by a fixed and movable head. 3 Construction work at Wuhan Iron and Steel Co. Plate Mill.

nstallation work for the new shear was completed on May 2, 2012, and on May 24 the DSTS the first plate was cut (24x2,000x19,000 mm) with excellent results. Performance tests were carried out immediately after and completed on June 18, 2012. The shear is conceived to process approximately 1,000,000 tpy, and based on the rolling cut principle with eccentric shaft and curved top knives, with a maximum static force of 6,000 kN. Plates to be processed range from 1,500 to 3,250 mm wide and 5 to 50 mm thick. Plate length is up to 42,000 mm. In this case, the side trimming process is carried out by stepped threading of the machine, with maximum cut length of 1.3 m. The shear is equipped with a fixed and a movable head that shifts to match the expected width of the incoming plate. The mother plate is, at first, aligned in front of the shear through a multiple magnet system and laser beam. Entry and exit pinch rolls hold the

material throughout the trimming process. One scrap chopper per side cuts the trimmed strips into shorter lengths suitable for collecting into steel buckets. The machine was designed according to the latest technology in the field of steel plant machinery and equipment, and it is characterized by the choice of high-quality solutions, by which it is possible to achieve extremely efficient operating results with low manpower and specific energy consumption, thereby making the plant highly competitive. The machine was completely preassembled at the Danieli Changshu (DCS) workshop and shipped to the site in a mostly assembled condition, so as to minimize the line shutdown during installation. The great efforts of the local offices of Danieli Metallurgical Equipment - Beijing (DME) have been the most useful and important contribution to the successful completion of every step of the project
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LONG PRODUCTS
1 Geometry of the simulations. 2 Electromagnetic forces calculated inside the liquid steel. 3 CFD simulation of the liquid steel movement in the mold. 4 Top shrinkage cavity of bloom cast without (left) and with (right) EMS. 5 750-mm round bloom caster at ABS, Italy. 6 600-mm round bloom caster at Acciaierie Venete, Italy. 7 420x530-mm bloom vertical caster at Posco Specialty Steel, Korea. 8 The Jumbo stirrer assembled, tested, and ready for shipment.

DANEWS

The largest M-EMS ever designed and built by Danieli Rotelec

n recent years, the sections of continuously cast blooms have increased considerably, and electromagnetic stirring (EMS) had to follow that evolution because the stirrer surrounds the bloom. In the case of stirring in the mold (M-EMS), the stirrer becomes even larger because it must go around the additional mechanical structure of the mold. Several continuous casting machines have been built in the last several years for large rounds, up to a diameter of 600 mm (e.g. Acciaierie Venete, Italy; Maanshan and Chengde, P.R. of China). At ABS-Acciaierie Bertoli Safau, Italy, rounds are cast up to a diameter of 750 mm. To equip these machines with EMS in the mold (M-EMS) and in the final solidification zone (FEMS), Danieli Rotelec has developed large and powerful new stirrers. In the case of ABS for example, the M-EMS has an internal/external diameter of 1,050 x 1,490 mm and weighs 3,000 kg; the FEMS is 880 x 1,200 mm and weighs even more, 3,200 kg, because of its height of 1,000 mm. These large stirrers are used not only for rounds: They have been installed and commissioned recently on a bloom caster with a 420 x 530mm rectangular section at Posco Speciality Steel, Korea. Posco now goes to even larger sections of up to 770 x 770
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mm square (diagonal 1,089 mm). Since this section size is beyond current experience in casting practice as well as in EMS, Posco decided to build a pilot caster in Pohang and asked Danieli Rotelec to participate in this development. For geometrical reasons, the stirrer ID had to be at least 1,500 mm in diameter and its height less than 610 mm. With such a large diameter and an unfavorable flatness ratio diameter/height of 2.5, it would have been too hazardous to use the conventional design and extrapolate from smaller sections. Therefore, we decided to make a completely new design study including: (i) electromagnetic simulation of the stirrer that makes it possible to obtain the exact behavior in space and in time of the two relevant physical observables, magnetic induction B (Gauss or Tesla) and induced electromagnetic force F (N/m3) inside the liquid steel; and (ii) CFD simulation that computes the

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three-dimensional velocity vectors of the liquid steel under the driving force of the stirrer and hence supplies the movement of the liquid steel in the mold. Then, this method is used to find the optimal power supply frequency and the amp-turns that are necessary to obtain the required steel velocity. The result of this work is a stirrer with the largest OD, 2,000 mm, and the highest coil current, 2,000 A, that we have ever built. It has been successfully commissioned on the pilot caster and is operated as a movable stirrer that stirs in the mold during casting, then is moved below the mold and continues stirring the bloom top until final solidification. The improvements of the internal solidification structure are outstanding in terms of equiaxed zone (100%), center porosity and macro-segregation, and the top shrinkage cavity of the bloom has been reduced from 800 mm cast without EMS to 300 mm cast with EMS

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>FastCast <

Further progress in the long-term cooperation between Danieli and Shougang Group that counts seven Danieli conticasters supplied during the last 15 years.

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Large bloom vertical and curved casters to Shougang Guiyang S.S. P.R. of China

n June 15, 2012, Danieli and Shougang Guiyang Special Steel Co. Ltd. signed a contract for the supply of two new casters: a two-strand vertical and a four-strand large-radius curve machines, to be installed in Guiyang Special Steel plant located in Guizhou Province. The two-strand vertical caster will produce up to 210,000 tpy of 410x530 mm and 470x620 mm rectangular sections, and will feature state-of-the-art technologies to manage the highly demanding process requirements and quality targets of cast products. This will include alloy structural steel, axle shaft steel, and a substantial amount (more than 50% of production) of tool steel and bearing steel.

The main highlights of the caster are: a high-capacity tundish, electromechanical stopper rod, submerged casting with SEN, plate mold with anti-breakout prediction system, radioactive mold level control, mold and final EMSs, hydraulic mold oscillation, airmist secondary cooling, top feeding rigid dummy bar, and dynamic soft reduction stands. The four-strand curved caster will produce up to 630,000 tpy of 410x530 mm blooms. It features a 16.5-m nominal radius with multi-point unbending design, electromechanical stopper rod, submerged casting facilities, plate mold with radioactive mold level control, mold EMS, hydraulic mold oscillation, airmist secondary cooling, future

provision for final EMS, bottom feeding chain dummy bar, and dynamic soft reduction stands. The product mix includes carbon structural steel, alloy structural steel, hollow steel, boiler pipe blank, cold heading steel, prestressed wire steel, marine anchor chain steel, nonhardening and tempering steel, tire cord steel, spring steel, and bearing steel. Automation will play a fundamental role on both casters, with Level 1 and Level 2 systems for the full equipment operation and process control. For both projects, Danielis supply includes all technological equipment (from ladle turret to run-out area equipment) suitably shared

between imported (from Danieli Centro Met of Italy) and local supply (to be manufactured in Danieli facilities in Changshu). Both the vertical caster and curved caster projects will follow the same execution schedule, and will be due for startup by middle of January 2014

Handshake between Hu Zhi Guo, Chairman, Shougang Guiyang Special Steel, and A. Colussi, EVP Danieli China, in the presence of Managers and Executives of Beijing Shougang Intl. Engineering Technology, Shougang Guiyang Special Steel, Guiyang Steel Mills I & E Corp., China Shougang Intl. Trade & Engineering Corp., Tangshan Shougang Baoye Iron & Steel, and Danieli.

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New SBQ and MBQ billets casting plant at Gerdau St. Paul, USA
This project will solidify Gerdaus leadership in the North American SBQ market, improving quality and throughput, and thus confirming the Gerdau Groups commitment to pursuing excellence in that market.
is presented to the operator via a modern, user-friendly graphical interface. Advanced mathematical models support the process control, including: tundish steel mixing prediction; QUART (in-line quality estimation); dynamic spray cooling -based on the Element Lifetime Model; billet cutting optimization; equipment tracking; and mold friction monitoring with an anti-sticking function. Operator training and Factory Acceptance Test will be performed with iStand, a project developed by Danieli Automation that reproduces the functionality of a casting plant using virtual reality to simulate all the equipment and relevant operations. With the iStand it is possible to perform a virtual commissioning, checking all software applications. It is also a very useful tool for Interactive Training of the operators, with a significant reduction in the crews learning curve. The performance analysis of stored process data is provided by a series of powerful tools, such as: the Fast Data Analyzer (high-speed recorder of all the process parameters); the off-line QUART (billet quality analyzer); and MOREIntelligence (a multi-dimensional data analysis system based on On-line Analytical Processing technology). Plant startup is planned for the Q3 of 2014

he order for the FastCast conticaster for SBQ and MBQ grades to be installed in St. Paul, MN, is the third conticaster project in a row that Gerdau Group has awarded to Danieli, following the projects to be executed in Gerdau Special Steel in Monroe, Michigan USA, and at Sidenor, Spain. The new 10-m radius, four-strand machine will cast formats from 5 x 5 inches up to 8 x 8 inches. It will feature the most advanced Danieli technologies in order to obtain the highest product quality standards, which are destined for the SBQ and MBQ automotive markets. The mold will include Danieli Rotelec Electromagnetic Stirrers, external type (M-EMS). The modular design of the bar guiding system, the cooling chamber, and the withdrawal and straightening units will ensure optimal product quality while minimizing spares inventories. A state-of-art control system to supervise process and operations will be provided by Danieli Automation. The 3Q system, included in the automation package, will provide automatic process setups tracking of heats, billets and the quality of the cast material - and
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1 Handshake between (from left) J. R. Borsato, Procurement Gen. Mgr. Global CapEx; L. Mottes, VP Key Account Management, Danieli; M. Sattolo, Executive Manager, Sales CCM, Danieli, and B. Dickerson (Manager Procurement Capital - North America). 2 St. Paul Mayor Chris Coleman, third from left, and Minnesota Gov. Mark Dayton, fifth from left, breaking ground on the site of the new steel mill.

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>FastCast <

Superflexible billet / bloom conticaster upgrading at Zeleziarne Podbrezova, Slovakia

New life for the existing caster with FastCast package upgrade from Danieli Centro Met

n May 2012, Danieli Centro Met was assigned an order by Zeleziarne Podbrezova a.s., Slovakia, to modernize the core of the existing conticaster, from molds through to the oxy-cutting system, including complete new automation and quality tracking system. The machine will cast 13 classes of products, including squares, rounds, billets and blooms, mainly for seamless pipe applications, and special steel grades. New equipment to be installed as part of the upgrade project will include a mold electromagnetic stirring system (M-EMS), hydraulic oscillators, cooling chamber -including air-mist secondary coolingand a withdrawal and straightening system. The new automation package will include a completely new Level 1 automation system (including the PLCs and related application software for the new functions and set-up) and a new Level 2 system, including the LPCLiquid Pool Control system for process and quality control. The whole project execution will be specifically engineered in order to minimize the plant shutdown. Plant startup is scheduled for mid September 2013

Vladimir Sotak, (left) Chairman and CEO of Zeliezarne Podbrezova, and Marco Lerz, President of Danieli Czech Engineering, signing the contract. Attending the ceremony were, from left: Miroslav Domovec, Vladimir Zvarik, Ludovit Ihring, Milan Srnka, Lubor Schwarzbacher, for Zeliezarne Podbrezova, and Marco Sattolo, Luca Verga, Ladislav Rericha, Andrea Fontana, for Danieli.

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Plants equipped with conventional molds (Kroman elik, Turkey), and Power Molds (Riva SAM Neuves Maisons, France, and Sovel, Greece) are producing topquality billets at extremely high casting speeds.
Kroman elik The contract awarded to

1 Kroman elik: 160-mm billet cast at 3.46 mpm. 2 SAM Neuves Maisons: 155-mm billet (steel grade TSBNF - C% 0.08, Mn% 0.53, Si% 0.11, S% 0.027) cast at 4 mpm. 3 Sovel: 140-mm billet cast at 5.6 mpm.

Danieli in July 2010 centered on a new meltshop able to produce an average of 34 heats/day. The conticaster is a 6strand machine, 10-m radius, equipped with an improved conventional mold designed for medium- to high-speed casting. The mix of cast sizes includes square sections from 150 to 200 mm, rectangular sections up to 260x360

mm, and 360x260x90 mm beam blanks. The main section cast is 160x160 mm in rebar grades (0.08<%C<0.24). Since the first year of operation, 160-mm square sections have been cast consistently, with excellent quality (average rhomboidity below 2%, and good internal quality for all grades) at 3.5 mpm maximum casting speed.

SAM Neuves Maisons The 12-m radius, six-strand conticaster of Riva Groups SAM Neuves Maisons plant is casting 155x155 mm billets in peritectic grades, and open-stream casting lowcarbon grades (0.04<%C<0.20) for rebar applications. Aiming to keep the same production volumes with fewer strands, strand No. 5 was equipped with the Danieli solution for highspeed casting, i.e. Power Mold and Fast Cube. Moreover, a mold EMS was

installed, in order to reach high equiaxial zone, and still at high speed. Just by adding this new equipment, the caster steadily reached a 35% increase in maximum production volume, casting at up to 4 mpm, with the same internal quality and improved product dimensions. As a consequence, Riva contracted Danieli to upgrade three additional strands, with the target to cast with just four of the available six strands, starting from August 2012.
2

Sovel is casting 0.20%C grades for

rebar applications in 140x140 mm section in open stream and submerged casting with a 9-m radius, six-strand conticaster. Since 2009, one of the six strands has been equipped with Danieli solution for high-speed casting, i.e. Power Mold and Fast Cube. This made it possible to

steadily increase the casting speed to 5.6 mpm (with peaks of 6 mpm for 40 minutes), maintaining a good billet quality and low BO rate. Thanks to the high casting speed, billets can be rolled in endless mode after the addition of in-line induction reheating, providing significant savings in terms of yield and energy.

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>FastCast <

New records with high-productivity Danieli billet casters

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Excellent bloom caster operation at Masteel, P.R. of China

asteel maintains the largest train wheel production line in the world, and is the production base for research and development of the train wheels to be used for CRHChina Railway high-speed trains. Masteels products are exported to more than 20 countries. Since November 2011, the 380-, 450-, and 600mm round sections that feed the wheel production line have been cast by a Danieli fivestrand caster. The high-quality, medium-carbon blooms produced by submerged casting also are required for other several demanding applications. In order to reach the requirements for high internal and external quality, a 15-m radius was adopted as well as a new type of

secondary cooling sprays (hollow cone) and three EMS systems (mold, strand, and final). After a very short time, an outstanding surface quality was achieved and, after finetuning of the stirrers, the high

equiaxal zone (55%) that had been guaranteed was reached, too. Carbon segregation is low as well, allowing the caster to produce the current range of products with high quality results

1 Since November 2011, the three-strand conticaster for 380-450600 mm round sections in operation at Masteel since November 2011. 2 Examples of the high equiaxial zone consistently reached.

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Two six-strand casters commissioned in a row at Vizag Steel, India

At Visakhapatnam Steel Plant, Andhra Pradesh, from April 20 to May 12, 2012, Danieli put into operation two billet casters, confirming once again its efficiency, skill, and dedication to performance goals

he two machines are part of a project that includes a third conticaster for round blooms, supplied on a semi-turnkey basis, to transform up to 2.8 Mtpy of liquid steel into topquality round and square conticast products for engineering applications. Square sections produced on the two 10-m radius billet casters range from 150 to 200 mm. The third, 10-m radius caster will produce 150-mm square sections and 220-, 280-, and 350-mm round blooms. Maximum casting speed will range from 0.65 to 3.8 mpm, depending on the steel grade and section processed. Individual strand production rates will reach up to 42-tph, depending on steel grade and ladle sequence index. Ladle shroud, tundish slidegate system, submerged

>FastCast <

nozzle practice, and mold powder automatic feeding systems will allow for complete protection of the liquid steel stream, thus preventing oxygen pick up and non-metallic inclusions. The products excellent subsurface and internal quality is ensured by Danieli Rotelec

mold EMS, while the hydraulic mold oscillation system provides the required surface quality. The contract for the complete engineering, manufacturing and supply, construction, and commissioning was carried out by Danieli Centro Met in consortium with Danieli

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CC02 conticaster in operation at Tenaris Dalmine, Italy

Another successful startup for the Danieli Centro Met FastCast Team

Engineering India Ltd. (DEIL) and Gillanders Arbuthnot Co. Ltd. Danieli Automation developed a complete process control program, with Level 2 automation and including the Finite Elements dynamic solidification model, to optimize the application of mechanical soft reduction

1 Layout of the 2.8-Mtpy continuous casting complex. 2 Souvenir photo of the Danieli Team that carried out the commissioning of CCM No. 1 and No. 2. 3 CCM No. 1 and No. 2 in operation. Individual strand productivity will reach up to 42-tph depending on steel grade and ladle sequence index.

fter the quick installation and commissioning carried out in May 2012, the fourstrand caster for round sections started successfully with a very short period of cold and hot tests. The main equipment details of the revamp related to: > Adding a new, larger casting section (dia 330 mm) to the existing round sections of 148, 180, 225, 260 mm. The Danieli molds supplied for the new section had to be designed to fit with the existing oscillation table and stirring facilities. > Replacing withdrawal units in order to have lowest elongation values to prevent possible internal defects even in the most severe casting conditions. New withdrawal units and new secondary cooling sectors will allow Tenaris Dalmine to increase the casting speed while maintaining the current product quality level for some of the sections and steel grades produced. > Completely replacing the secondary cooling circuit and cooling chamber, so that it is able now to optimize cooling areas on

direct contact of the rounds. > Installing a new, rigid dummy bar parking function, now fully automated to ensure shorter restranding times. Prefabrication of most of the equipment in Danielis workshop (parts of the cooling chamber, withdrawal and straightening units together with the related supporting structure and onboard circuits, and the entire dummy bar parking device) made it possible to optimize installation work on-site, minimizing the plant shutdown

Project milestones

Contract coming into force August 1, 2011 End of construction works May 25, 2012 Cold test start May 26, 2012 Cold test completion May 30, 2012 First heat May 31, 2012 47

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Leading Chinese steelmakers continue to trust Danieli technologies for high-speed wire rod mills

10

1 2 3 4

Reheating furnace 7-stand roughing mill 16-stand intermediate and prefinishing mill 2-pass DWB Miniblock

5 6 7 8

10-pass DWB prefinishing and finishing mill 4-pass TMB-Twin Module Block Loop laying head Controlled cooling conveyor with

side shiftable EDC system Coil reforming pit, Easy-down and coil handling system 10 Horizontal coil compactors 9

Jiangyin Xingcheng Special Steels Works Co. Ltd.

The order signed in May 2012 with Jiangyin Xingcheng Special Steels concerns a 500,000tpy rolling mill for high-carbon and special steel grades (e.g., cord steel, spring steel, pre-stressed steel, steel cables, tool steels) for wire rod products. The state-of-the-art plant will be installed at Jiangyin, in Jiangsu Province, and will be implemented with all of Danielis latest technologies and high-tech equipment available for rolling, and on-line heat-treatment for wire rod, including the LTR-Low Temperature Rolling process. The upstream rolling mill is made up of 23 SHS housingless H and V stands. This new wire rod line design includes: a twopass pre-finishing section; a 10-stand, heavyduty Delta-type high-speed pre-finishing mill; DSC-Danieli Structure Control system, including a water cooling line; CCW-Controlled Cooling Conveyor featuring advanced and patented EDC (incorporated in the controlled cooling conveyor) for cooling of wire rod loops in hot water for those steel grades that require
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Jiangyin Xingcheng Special Steels Works Co. Ltd., and Sichuan Dazhou I&S Ltd. assign orders to Danieli Morgrdshammar for two wire rod lines for engineering and special steel grades, both fitted with the latest WRS-Wire Rod Sizing block technology. This will bring to 20 the number of high-speed wire rod lines supplied in China since 1996.

it; a HSS-High Speed Shear for trimming coil loops at high speed; four-stand WRS-Wire Rod Sizing block; and the latest-generation high-tech OFB-Oil Film Bearing (Patented) loop laying head. The Sund Birsta cold finishing package includes an RRT-Rotary Reforming Tube with an Easydown system for perfect coil formation, with associated V handling system. Two horizontal

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compacting stations complete the line. Given the different requirements for the extensive range of steel grades to be produced (e.g., engineering and special steel grades for advanced applications, such as cord steel, spring steel, pre-stressed steel, steel cables, tool steels), starting material will include 150-, 200-, 240-mm square and 200x280 mm rectangular sections. Wire rod in diameters from 4.5 to 25 mm will be rolled at a maximum speed of 112 mps and collected in coils weighing up to 2,550 kg. The whole project will be executed by Danieli China. Plant startup is scheduled for the middle of 2013.

800,000-tpy mill for special steels for NISCO, P.R. of China

Danieli enhances its global leadership in rolling mills for SBQ products, which to date totals 121 installations, 33 of these in China.

Sichuan Dahzou Iron and Steel Ltd.

Danieli will supply the key equipment and technology for this new 600,000-tpy wire rod line, to be built at Dazhou City, in Sichuan Province. The line will be equipped with the latestgeneration, four-stand WRS-Wire Rod Sizing blocks to produce 5 to 22 mm dia wire rod in 2,350-kg coils at the guaranteed rolling speeds of up to 112 mps, with strict end-product size tolerances. The mix of grades will include structural, medium-carbon, low-alloy, spring, bearing, CHQ, high-carbon, and pre-stressed concrete wire steels.

Contract signing at NISCO, with Jiang Xiaochun, Vice General Manager of NISCO (right) and Fabrizio Mulinaris, EVP Danieli Morgrdshammar.

Also included in the supply will be a high-tech OFB-Oil Film Bearing loop laying head (patented) with associated auxiliaries, and a WCC-Wire Rod Controlled Cooling line suitable for processing UFG-Ultra Fine Grain rebar. The plant is scheduled to start in the middle of 2013

1-2 Souvenir pictures at the contract signing at Jiangyin Xingcheng and at the kick-off meeting at Danieli HQ. 3 Lei Zhongxi, Plant Director, and A. Celano, Area Sales Manager, Danieli, signing the contract at Sichuan Dahzou.

ISCO-Nanjing Iron & Steel chose Danieli to supply its new high-tech bar mill, one of the most modern plants of this type in the world. The very wide selection of steel grades will include alloy structural, carbon structural, bearing, spring, cold-heading, free-cutting, and anchor steel grades. The production will start with 150- and 220-mm billets with a max. length of 12 m, to produce 16to 80-mm SBQ round bars in bundles weighing up to 4 tons. The 160-tph mill will be made up of 20 SHS housingless stands in H and V configuration; on-line water cooling boxes for LTR-Low Temperature Rolling; and a Kocks 4-pass RSB 370++ Reducing and Sizing Block, acting as the finishing unit for straight bars. The LTR system will impart highquality mechanical and technological characteristics to the finished product obtained directly from the mill, avoiding or minimizing other downstream heat treatments. State-of-the-art finishing outlets with online heat treatment facilities will allow production of superior-quality finished products. More specifically, the straight bar finishing line will include a 126x10m-long cooling bed, combined cut-to-length areas with cold shear and cold saws, slow cooling boxes area, short bar collecting system, bundling, tying and collecting facilities. The project will be carried out by Danieli China. The plant startup is scheduled for the Q3 of 2013

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Success continues for Danieli SBQ rolling mill technology in P.R. of China

Sun Shaohua, Vice Chief Engineer of Wuhu Xinxing, and Antonello Colussi, Danielis Chief Representative signing the contract for the two SBQ mills.

Wuhu Xinxing Ductile Iron Pipes, located in

Wuhu, Anhui Province, will install two SBQ mills, one for large bars and one for medium bars. The 800,000-tpy Big Bar mill will produce square bars in dimensions of 165 and 180 mm, and round bars in diameters from 120 to 350 mm, for automotive, engineering, mining, and mechanical manufacturing applications. The basic components of the plant will be: > Reversing break-down rolling mill stand (an existing unit, to be relocated), equipped with entry and exit roller tables and manipulators (supplied by Danieli in 2006). > Continuous finishing mill made up of sixstands SHS in vertical and horizontal arrangement. > Expansion of the existing finishing facilities with state-of-the-art equipment to enhance

3 2

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Four new orders for SBQ and special steel grades bring our scorecard to 122 plants supplied worldwide, for capacities up to 1 Mtpy. These four rolling mills have a common characteristic: an optimized roll-pass design arranged as a few families, to enhance the mill's efficiency and operating flexibility.

product marketability. These include in-line hot disc saws for "net-end" cutting-to-length of bars; marking and deburring beds; and final cooling and collecting beds. The supply also includes the automation and process control systems for the key equipment, supplied by Danieli Automation. Plant startup is scheduled during Q2 2013. The 1,000,000-tpy medium bar mill will produce round bars from 40 to 120 mm for automotive and mechanical manufacturing purposes. The plant will be basically made up of: > Continuous rolling mill composed of 16 horizontal and vertical alternately arranged cartridge-type rolling stands. > State-of-the-art finishing facilities, which includes in-line hot disc saws for "net-end" cutting-to-length of bars; final cooling and collecting beds. Plant startup is scheduled in the Q1 of 2013.

Big Bar Mill 1 Reheating furnace 2 Breakdown reversing mill 3 6-stand finishing mill 4 Slow cooling facilities 5 Cut-to-length system 6 Final collecting services

Medium Bar Mill 1 Reheating furnace 2 6-stand roughing mill 3 10-stand finishing mill 4 Bar layer transfer 5 Cut-to-length system 6 Final collecting services

Fushun Special Steel, located in Fushun, Liaoning Province, will expand its production facilities with a new Danieli 600,000-tpy Big Bar mill for SBQ. The rolling mill will produce rounds from 40 to 300 mm, squares from 40 to 300 mm, and flats from 40 to 120 mm thick by 40 to 310 mm wide, for automotive, engineering, mining, and mechanical manufacturing applications. Basically, the plant will be made up of: > Existing reversing break-down rolling mill stand with entry and exit working roller tables and manipulators. > Continuous finishing mill made up of 12 SHS stands in vertical and horizontal arrangement. > State-of-the-art finishing facilities, which include marking and deburring beds, and final cooling and collecting beds. Quick changing systems will be provided for the finishing mill stands. Plant startup is scheduled in the Q1 of 2013.

Deqing Tianma Heavy Machinery, one of Chinas

largest manufacturers of bearings, is located in Hangzhou, Zhejiang Province. Danieli will supply critical equipment for Deqings new 300,000-tpy Big Bar mill. The rolling mill will produce round sections from 50 to 300 mm diameter for bearing production. Round bars from 50 to 140 mm diameter will be rolled in a new continuous mill that will feature 12 SHS-Star Housingless Stands arranged in horizontal and vertical configuration. Sections from 150 to 300 mm will be rolled in the existing break-down mill. Plant startup is scheduled in the Q4 of 2012
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New 600,000 tpy mill for bar, wire rod, and light sections for Suryadev QST Rebars, India

Featuring some of the latest Danieli Morgrdshammar innovations for long products rolling technology, the mill will be one of the most advanced plants in the region.

Key points of the SHSPLUS Star Housingless Stands units

> Number of components reduced by about 15%; > Stiffness increased by about 12%; > Pipeless rolling unit, increasing safety in the rolling area and eliminating the risk of damage in case of cobbles; > Reduced installation time by about 10-12%; > Reduced maintenance time thanks to the new design of the cartridge, rest bar, and guards.

he new mill will be installed in the Gummidipoondi Taluk steel complex, Tiruvallur District, near Thrivallur, and nearby the new Danieli factory, presently under construction. The superflexible mill will be arranged over 20 SHSPLUS Star Housingless Stands in H, V and H/V convertible configuration, with quickchanging facilities, a 10-pass WRB high-speed Wire Rod Block, CCW-wire rod controlled cooling line, and state-of-the-art finishing facilities for straight bars and coils. The main technology highlights of the plant will be: > SHSPlus, the most advanced version of the SHS design (almost 8,000 SHS stands have been installed worldwide). Its unique features - well ahead of any competitors design- made it applicable for

even the worst rolling conditions. > HTC-High speed Twin Channel bar delivery system. Ultra-high speed bar discharging onto the cooling bed, one bar per notch, for both oneand two-strand rolling, is the way to obtain high productivity with small size bars. >CCL-type combined in-line straightening and cold cutting-to-length system. This will be an ideal solution for a modern flexible bar and section mill. Two CCL systems are available, based on continuous and start-stop operation mode, respectively. Basically, they are composed of a multistrand straightening machine for inline straightening of layers of profiles, and a cold shear located immediately after the straightener for cold cutting to commercial length of the layer of profiles or bars. >Winstack - will include different types of

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Wire rod mill modernization at P.T. The Master Steel Mfg, Indonesia
Souvenir photo at the contract signing. Mukesh Agrawal, Managing Director, Suryadev Alloys and Power (center) with, from left: A. Diasparro, VP Sales, Danieli; M. Guarino, Managing Director, Indochina Merchants Enterprise; Mrs. Anna Mareschi Danieli, Area Manager, Financing and Contracting; G Bikramjit, CFO Danieli India Ltd.

A bar rolling and finishing line will be added to Surabajas Danieli wire rod mill, to add rebars from 7.6 to 50 mm to its product mix.

stackers that meet all market requirements with reliable, high-performance equipment. Having designed and built more than 130 automatic stacking stations for bars, sections, and beams 24 of these during the past five years, 9 of which are in India- Danieli Morgrdshammar is the worlds reference supplier for cold finishing equipment for long products. >Sund Birstas V-type compacting system will address the highest demands for quality and cost efficiency. The purpose of the coil handling system is to receive coils on empty hooks/pallets in the conveyor system coming from the loader, and transport them to different downstream process stations. The handling system is completely automatic, though some parts of the system can be operated manually. The product range (starting with 165-mm conticast billets) will include round bars from 8 to 63 mm, equal angles from 40x5 to 90x7 (100x12) mm, ISMC channels from 50x25 to 100x50 mm, and 5.5 to 20-mm wire rod in coils. Coil weights will range up to 2.5 t. Finishing speeds will be up to 105 mps for wire rod and up to 25 mps for straight bars. Carbon and alloyed steels are processed for various applications in construction and mechanical industries. Danieli Automation will supply electricals and the L1 / L2 automation system. Plant startup is scheduled for the beginning of 2014

stablished in 1972 as one of Indonesias steelmaking and rolling pioneers, the Master Steel plant was set up initially as a green-field project on twelve hectares of land in Pulogadung, East Jakarta. Over the years it has confirmed its leadership in the Indonesian archipelago, and with its on-going modernization and expansion projects it aims to produce more than 2 Mtpy of steel by the end of 2012. The new bar line will incorporate the latest Danieli merchant bar mill technology to produce quality bar bundles at 90 tph, adding substantial flexibility to wire rod coil production. Rebars from 7.6 to 50 mm in commercial steel grades (with multi-strand slitting for the smaller diameters), and light sections will be rolled at a maximum finishing speed of 16 mps. In addition to the major modification of the existing stands and gear boxes, the project will involve installation of: > Four SHS housingless stands downstream of the existing mill, with a quick changing system; > QTB system for in-line quenching of rebars, equipped with pinch roll and shear; > Run-in roller table with aprons at the cooling-bed entry side, and 78-m long automatic cooling bed with associated feeding/delivery devices; > Static cold shear with a bundling and counting station,

tying machines for sub- and main bundles, bundle bending station and tying machine, weighing and collecting services supplied directly by SundBirsta (part of the Danieli Group). The Danieli wire rod line also will be upgraded to produce QTRQuenching and Tempering products from 6 to 12 mm rebars, with the addition of water boxes, pinch rolls, and a RRT system to satisfy the new working conditions. Electrical equipment and an automation system will be supplied by Danieli Automation. Startup of the new facilities is scheduled for the Q2 of 2013

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500,000-tpy super-flexible bar and light section mill for M-Metal, Thailand
Danieli reaffirms the undisputed supremacy of its rolling mill technology for long products, with 448 plants supplied worldwide since 1961.
Souvenir photo at the contract signing. From left: C. Pagano, Director, Sales, DFE, and G. Mareschi Danieli, DFE CEO, for Danieli; Pakin Meksereekul, Managing Director; Sen. Suvit Meksereekul, President; Mrs. Jintana Meksereekul, Director; Mrs. Suwadee Meksereekul, Director; Chaiyuth Meksereekul, Director, for M-Metal.

-Metal Co. Ltd. contracted Danieli of Thailand to supply a state-of-the-art, 500,000-tpy super-flexible rolling mill. The plant will be integrated in the M-Metals production site located in Lopburi Province, 150 km north of Bangkok, which currently produces bars

and wire rod for the construction industry. The 18-stand continuous mill will be equipped with the latest-generation SHS Plus housingless stands, in H, V, H/V, and combined H/U universal arrangement (the latter being particularly dedicated to producing of

high-quality parallel flange beams). The bar finishing facilities will feature an 84-m long cooling bed fitted with a water-spray extra-cooling system, start & stop-type in-line straightening and cut-to-length services, disk saws, and a 24-m long singlehead magnetic stacker, plus

bundling and collecting facilities.The product range will include quenched rebars, smooth rounds, squares, equal angles, channels, beams, and flats.The mill will be fed by a 100-tph walking-hearth reheating furnace supplied by Danieli Centro Combustion. Danieli Automation will supply the electrical equipment and the automation and process control systems. Plant startup is scheduled for Q3 2013

300,000 tpy wire rod mill at Wempco Group, Nigeria

O
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n April 19, 2012, Western Metal Products Co. Ltd. (Wempco), in co-operation with Salzgitter Mannesmann International (part of the Salzgitter Group of Germany), awarded a contract to Danieli Morgrdshammar for its first wire rod mill. The new plant

will produce smooth and deformed wire rod for construction applications, and will be fed by a 60-tph pushertype reheating furnace, suitable for heating 12-m long, 130- and 120-mm billets. The 14-stand continuous rolling mill will be made up entirely of SHS housing-less stands in H and V configuration and a 10-pass DWB-type high-speed wire rod block. The high-speed wire rod line will include an OFBOil Film Bearing loop-laying head (patented), a WCC-Wire rod Controlled Cooling line, a CCC-Controlled Cooling Conveyor with a coil reforming station and associated vertical coil transporting system, compacting, tying, and final collection equipment.

The main focus of the operation will be rolling 5-mm smooth wire rod, at the max. speed of 80 mps. Danieli Automation will supply all the electrical equipment and an advanced automation package, including L1 process control system. The startup is scheduled by the Q4 of 2013

From right: A. W. Theobald, Salzgitter Mannesmann, Director Dept. Africa; A. Diasparro, Danieli Morgrdshammar, VP Sales; Lewis S. N. Tung, Wempco, Group Managing Director; Mrs. Tung; R. Oklitz, Executive Manager Sales, Danieli Morgrdshammar.

Danielis innovative technologies for modern bar mills for commercial steels:

> MSR-Multi-strand slit-rolling, to obtain high productivity with small-size bars, through the slitting of the rolled stock into 2, 3, 4 or 5 individual strands. > QTB process for the production of high-tensile straight bars for concrete reinforcement. > HTC-Twin Channel system, to obtain high productivity with small size bars at the highest speeds. > The bar counting system features compact design and zero-error counting, resulting in higher-quality finished bundles. > PFB-Perfect Forming and Bundling system forms regular and precise bundles, with fast lances that gently lay the bar into the pocket. > Patented DRB system, a cooling bedfree system for final cutting-to-length of bars at the delivery side of the finishing mill and feeding the bundle forming/tying station. > Sund Birsta is the leading supplier of handling systems, including wire binding and strapping machines for packaging of products from rod mill, bar mill, and strip mills.

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High-speed rebar mill starts production at Dongkuk Steel, Korea

Warm handshakes and smiling faces celebrated the successful startup of the 1.0-Mtpy rolling mill at Incheong Works, confirming the good relationship between the two companies.
3

n June 7, 2012, exactly two years after the contract signing, specialists from Dongkuk Steel and Danieli Morgrdshammar started up the new 1-Mtpy high-speed rolling mill for 10 to 57 mm rebars. The main highlights of the new plant are its high production capacity and the very high finishing speed for small-size bars, delivered onto the cooling bed at up to 42 mps through the Danieli HTC-Double Twin-Channel system. The equipment installation, which took six months, was carried out by Dongkuks specialists in an excellent manner and according to the project time schedule. The plant cold start-up took place on May 1, and 35 days later the first hot test was carried out along the
56

center line, to the customers complete satisfaction. Now the plant is in its commissioning phase, with the sections to be rolled and the release of the PAC/FAC certificates expected by the middle of September this year. Around 3,000 t were produced successfully on the rolling mill over about two weeks. The plant layout includes a 17-stand continuous mill plus two four-stand, high-speed twist-free finishing blocks fed by two-strand slit-rolled stock coming from the upstream intermediate mill. In this way the smaller bar sizes will be produced on two strands at very high speed, thus fully exploiting the mill's capacity for the whole product range (over 150 tph starting from

1-2 Official inauguration of the 1-Mtpy rebar mill installed at Incheong. 3 The 17-stand continuous mill. 4 The cooling bed, equipped with Highspeed Twin Channel system. 5-6 Automatic cold finishing services, with Sund Birsta tying machines. 7 3,000 t of rebars have been produced in the first two weeks of operation.

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Two high-speed wire rod lines in operation at Shanxi Jianbang, P.R. of China
4

T
5

he commissioning activities took place on line No. 1, and will continue on line No. 2 during the coming weeks. Each line is comprised basically of a twopass DWB pre-finishing miniblock, high-speed finishing rolling line with 10pass DWB block, CCWControlled Cooling Conveyor for Wire Rod, OFB-Oil Film Bearing (patented) loop-laying head with associated auxiliaries, RRT-Rotary Reforming Tube, and an Easydown system for perfect coil formation. Operating finishing speed is of up to 110 mps to produce 2,300 kg coils of 5 to 20 mm wire rod. Deformed wire rod from 6 to 16 mm will be produced on just one of the lines, equipped for QTR production. The mix of steels produced ranges from quality carbon, to cold heading, alloy

FAC of line B on July 3, 2012. From left: Chen Wei, Project Manager, DME; Zhang Xi Cheng, Plant Manager, Shanxi Jianbang; Luca Pasqualotti, Project Manager, Danieli.

structural, spring, and welding wire grades. The Final Acceptance Certificate for the line B was released on July 3, while the FAC for line A is expected during the Q3 of 2012

In early June 2012, the new Danieli Morgrdshammar high-speed wire rod lines started operation at Shanxi Jianbang Group as part of a new 1.5-Mtpy wire rod mill project.

10 mm and larger diameter bars). All these activities have been possible thanks to the strong co-operation between the two companies and the hand-in-glove work of the two teams involved, showing they are ready to face future challenges together
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1.0-Mtpy bar and rod mill starts operation at Rajhi Steel, KSA

The new rolling mill complements the Danieli steel meltshop in operation since 2007, and makes Rajhi Steel one of the most important suppliers of commercial steel grades in the Gulf area.

he high-speed combined bar and rod mill, supplied on a complete lump-sum turnkey basis, started operation in early May 2012 and is proceeding toward for a fast ramp-up. The rolling mill is part of a steel complex located in the Alkhumra district, south of Jeddah. It will produce 10- to 40-mm rebars and 5.5- to 16mm smooth and deformed wire rod. Main highlights of the new rolling mill will be its high production capacity and the very high finishing speed for small-size bars and wire rods, of 35 mps and 105 mps, respectively. The final acceptance of this ultramodern plant is expected by September 2012
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Stacker replacement project at CMC Alabama, USA

Handshake between E. Roiatti, Danieli Site Manager, and R. Wood, CMC Rolling Mill Manager, in the presence of M. Lirussi, Danieli Project Manager; J. Schrimscher, CMC Project Engineer; R. Hubka, CMC General Supervisor Rolling Mill; J. Fesperman, CMC General Supervisor rolling Mill Service.

Teamwork leads to a successful project execution and completion.

n June 8, 2012, the Final Acceptance Certificate was released for the new SMH 580 WinStack automatic stacker, with complete customer satisfaction. To date a total of 22,500 sht have been produced in different shapes (channels, flats, equal and unequal leg angles) and different lengths up to 65 ft. The coupled stacking mode passed its startup tests successfully and then commissioned. Next CMC put all the products through testing, during which the contracted productivity targets were fully met. In May, production exceeded forecasts by 30%. CMC Alabama was fully satisfied with the Danieli Teams (Project Management and Site Team) performances and activities that led to a successful project execution and completion (squeezing the outage duration to the minimum). The successful conclusion of this project once again confirms the strong relationship between the two companies, and promises a fruitful and long-lasting cooperation in the future

On behalf of the employees at CMC Steel Alabama, we wish to express our gratitude and appreciation for the planning, coordination, and execution of the recent stacker project at our Birmingham mill. The Danieli team worked professionally and proficiently with the CMC team, as well as the entire project team. From your sales / customer service staff, to the project coordination, to the implementation / commissioning team; the project was completed ahead of schedule, and with minimal complications. Lastly, and most important, it was completed without injuries. Once again, Danieli provided to CMC what they committed to deliver. Furthermore, this project gave us an opportunity to work first-hand with the Danieli Automation team. Our electrical group was quite pleased with the workmanship and thoroughness that the DA team brought to the table. Please pass along our sincere appreciation to the individuals that worked on the design, fabrication and assembly throughout the different Danieli locations, along with those who were here during the very successful installation and commissioning. We are experiencing great things so far with the stacker, and we look forward to continued improvements. Thanks again for your focus on service and execution. Stephen Weaver, Director of Ops. Mark Brune, Engineering Manager Rick Wood, Mill Manager Jeff Schrimscher, Project Manager Jeff Brosseau, Project Manager
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Project Milestones

April 22

Demolishing of the north portion of the existing stacker and beginning installation of a new stacker portion Rolling mill shutdown, demolishing of existing stacker south portion and beginning installation of new stacker portion Beginning of cold tests for north stacker Beginning of hot tests for north stacker 24-h production Release of the Provisional Acceptance Certificate (PAC) Beginning of cold tests for south stacker Beginning of hot tests for south stacker Release of the Final Acceptance Certificate (FAC)

April 29

May 10 May 16 May 17 May 21 May 23 May 25 June 8

TUBE PROCESSING

DANEWS

Danieli Centro Tubes FTT algorithm for FQM seamless tube mills
The FTT-Front Tail Tapering algorithm developed by DCT improves plant yield by acting on FQM parameters to reduce the SRM effect of WT overthickening along the pipe axis, even with huge stretching coefficients.
Crop end control on SRM A well-known procedure, known as Crop End Control, is usually applied to reduce crop losses. It consists of overstretching the ends of the tube during the transient states of filling and emptying the SRM. This technique has a limitation that is related to the friction forces between rolls and tubes. Excess torque cannot be transferred to the under-standmaterial because the friction coefficient is too low if compared with the field power. In some cases the maximum allowable torque should be limited even though the final result is less effective. Therefore, Crop End Control is possible to act collectively with FTT to achieve higher results. FTT is applied to the FQM process as a mandrel-elongating mill. Compared to Crop End Control, the FTT is free from the friction coefficient between the mother tube skin and roll surface. This is extremely advantageous for the range of FTTs available to act on the process. FTT - Front Tail Tapering FQM The algorithm produces a specified thin end shape on the mother tube, thus reducing wall thickness at tube ends significantly. FTT is also suitable for compensating mandrel surface variations due to thermal and geometrical effects during rolling. This operation is performed by controlling both FQM roll speeds and capsule strokes under load. The system must be able to change continuously and simultaneously during all the rolling schedules. If

V=xR

Expected WT distribution

QM- Fine Quality Mill - is Danielis primary equipment for seamless pipe production. It is an innovative elongating machine responsible mainly for shaping wall thickness to achieve final target values and lengthening the inlet shell. Sophisticated process control functions, developed by DCT and Danieli Automation, are integrated into the mill. Raw materials are a major part of the production cost in transforming billets into green pipes, and therefore the yield must be maximized. The consequences of pipe stretching are significant. Especially in smaller plants where the multiple-stand Stretch Reducing Mill (SRM) is used (up to 30 stands, 70-80 % OD reduction), pipe end overthickness is due to the transient effect of mill loading and unloading. The stretch factor multiplies this effect to reach maximum OD reduction. In other words, the more stretching is applied, the greater will be the transient effect of pipe end overthickness from mill loading to mill unloading. The pipe extremities need to be cut, and this obviously leads to overall yield loss. The FTT algorithm controls over thickness by acting on Danieli FQM mill
60

parameters at SRM, and improves hot rolling line yield. The concept is simple: if overthickness is expected for a certain length from the pipe ends, then the algorithm will act in advance to prevent this undesirable effect.

FTT parameter

Others Energy

Labour Raw material

Tube stretching process on SRM The deformation process in the SRM includes both OD tube reduction and wall thickness (WT) variation. WT reduction is achieved through the application of a proper tensile stretch between stands. During the SRM filling transient and relevant emptying, no tension can be applied between stands; therefore, wall ends are thicker than the tube body. As mentioned previously, if the wall ends are out of tolerance, then these ends must be cut.

1 Breakdown of costs for production of Green Pipes from billet. 2 Input data for FTT algorithm and preview of the expected Wt shape after FQM. 3 Tangential speed on roll surface (V) is angular speed multiplied by roll radius (R). 4 Stretching effect. The speed of the downstream roll is higher than the natural pipe speed, so a tensile force is applied to the material between stands. This strain causes material thinning and final pipe product elongation. 5 Standard deformation scheme without FTT: Wt0 is lowered to Wt1 value due to stretching effect. Pipe ends are affected by over-thickness. Sections L1 and L2 must be cut out. 6 Deformation scheme on Wt with FTT: The algorithm integrated in FQM logic, provides tapering along T1 and T2 lengths. The result after SRM is that crops are shortened by 30% to 50%. In actual fact C1< L1 and C2 < L2.

DANEWS 165

Danieli Centro Tube won the ITA speakers award The winning paper was presented at the Tube Dsseldorf Conference in 2012 by Fabio Lacapruccia, Sales Manager of DCT.

1 x R

2 x R > 1 x R

Stretching Effect

Elongation Effect

WT Thinning Effect

WITHOUT FTT Wt0

SRB INLET

SRB OUTLET L1 Wt1 5 L2

Stephen Loynes, The chairman of the TMC and the Awards Committee (left) and Fabio Lacapruccia.

WITH FTT T1 Wt0

SRB INLET T2 Wt0

he prestigious Professor Hugh Sansome Trophy, named after a founding member of the ITA and long-time chairman of the Technical Management Committee (TMC), is given to the speaker who presents the most outstanding paper during the two-year period between the previous and current editions of the exhibition. The Papers Award Committee is an international jury comprised of experts with longstanding industrial and eminent academic experience. The chairman of the TMC and the Awards Committee, Stephen Loynes, presented the trophies at the ITA's members' lunch on 28 March during Tube Dsseldorf. His remarks are reproduced below:

SRB OUTLET C1 Wt1

6

C2 W

we declare the number of FQM Stands as N, then the control system acts over the last N-1 stands. The first stand is used as a time reference. FTT algorithm requires the outgoing profile and the length of the desired tapered section to be input. The automation interface allows the operator to enter set length and thickness requirements for different pipe sections. Roll speeds and capsule stroke positions are the output of FTT functions, and therefore are calculated for each rolling instant. Level 1 will pre-set the

motors and the capsules to the calculated dynamic parameters recorded from the model.

"It is very important that we explain the latest technology at our conferences. Please come forward with your papers: We promise to give a good balance of papers, including industry overviews and commercial understanding of the tube industry. "I am very pleased to tell you that this year we are presenting awards to the young generation of technologists. This year the Professor Hugh Sansome Trophy goes to Fabio Lacapruccia. His winning paper 'Four Roll Technology - new boundaries for hot rolling OD finishing' shows how they used simulation to improve the mill performance and thus improve productivity and cost

Performances of FTT on crops produced by SRM At several Danieli reference plants around the world, FTT has shown its effectiveness at achieving improved material yields: crop loss for standard lengths to be cut is reduced by approximately 30 to 50 %. The relevant yield advantage of saved material depends on the WT of the product being rolled
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TUBE PROCESSING

DANEWS

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DANEWS 165

First shell produced at Vallourec & Mannesmann, Youngstown (OH), USA

On June 29, 2012, the very first shell was produced from the 7-in seamless pipe plant supplied by Danieli Centro Tube. Major efforts in guaranteeing smoother commissioning this time gave remarkable scores: the time lag between PLC activation and the first shell rolled on the was only 23 days.

anieli Centro Tube designed a full hot rolling line to produce 350,000 tpy or up to 120 pieces/hour of seamless pipes for V&M Star (a Vallourec Group company). Mechanical installation and civil commissioning activities were difficult but rewarded Danieli once again with the title of leading international player.

The line is composed of: Rotary Hearth Furnace, provided by Danieli Centro Combustion (DCC); CTP Cone Type Piercer, provided by Danieli Centro Tube (DCT); FQM Elongating Mill, provided by DCT; Extracting Mill, provided by Kocks; Reheating Walking Beam Furnace, provided by DCC; 24-stand Stretch Reducing Mill, provided by Kocks. Billets are transformed into shells in the CTPtpy piercing mill and then further elongated by the FQM and subsequently sized with Kocks multiple-stand SRB-Stretch Reducing Block. The greatest benefit of startup for this plant is the record-time commissioning. However, this is only the first step towards completion of the FQM Hot Rolling Line for 7 Seamless Pipe Production. The first mother pipe produced by FQM and the first green pipe by Kocks SRB are expected soon. Major efforts in guaranteeing smoother commissioning gave remarkable scores this time. During the three-day trial period, the target was to roll 21 billets with dimensions and ODs for the different lengths listed below: > First day of trials - 9 shells rolled; > Second day of trials - 6 shells rolled; > Third day of trials - 6 shells rolled; Danieli could not have asked for more with the outcome of this commissioning. Throughout the project efforts by both V&M and the various

1 V&M Youngstown. Overview of the Danieli Centro Tube CTP-ConeType Piercing mill. 2 Danieli Centro Tube FQM-Fine Quality Mill under final installation stage.

departments from Danieli involved were outstanding, and respected and underlined the strong partnership that benefited both companies. Knowledge and cooperation from V&M were a baseline for significant cooperation and the achievement of such positive results. The V&M project will become a worldwide reference plant for state-of-the-art seamless pipe making, and a great scorecard for Danieli Centro Tube
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TUBE PROCESSING

DANEWS

FAC for the spiral pipe welding line at Borusan Mannesmann, Turkey

The spiral pipe mill installed at Gemlik passed performance tests successfully, both for individual equipment and the complete line. As a matter of fact, BMB now has one of the most modern spiral pipe mills installed in Europe.

he plant can produce welded pipes in diameters from 20 to 64, with wall thicknesses up to 25.4 mm, in steel grades up to API X80. It is the first plant developed by Danieli W+K with the ability to produce such a large range of diameters with different wall thickness consistently, with strict tolerances as well as to process materials with yield strength up to 800 N/mm2. Production is carried out according to API 5L and ISO 3183 standards. The supply consisted mainly of two process steps: forming and tack-welding, and final welding in multiple stands. In the first step, the strip is decoiled, straightened, cross-seam welded (coil to coil), pulled through the forming section, tack welded and, finally, cut to length by a flying pipe cutting system. In the second step, the pipe is finishwelded in the submerged-arc welding stands. The scope of supply for Danieli W+K included the complete engineering for OCTG line pipe production, including the finishing line. The plant is the first of its kind manufactured in Danielis facilities and will be a benchmark for spiral pipe welding technology. Danieli W+Ks fully automated, Two-Step production process exceeded a speed of 10 mpm (in tack welding), providing optimal

production capacity. The plants productivity leads to an output of more than 200,000 tpy. Definitely worthy of emphasis is the close cooperation between the customer and Danieli W+K engineers that contributed to the successful startup

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DANEWS 165

Danieli W+K Open Day

On July 12, 2012 Danieli W+K had the pleasure of hosting an Open Day for clients to introduce the newly developed, high-frequency pipe welding line, recently manufactured for a valued German customer, that marks DWKs entry into the market for precision pipes.

The significant number of visitors demonstrated a keen interest in the latest developments from DWK. The plant was designed to produce precision pipes with diameters ranging from 10 to 60 mm and wall thicknesses from 1 to 6 mm, with a limit ratio wall thickness on diameters of 1:6 (diameter 36 x 6 mm). These conditions led to a very rigid design that ensures stable construction and a tight framework that guarantees long-lasting production parameters. The supply included complete strip preparation with coil storage; a forming, welding and calibration line; and a complete finishing line with automatic inside scarf removal system, chamfering and bundling section. The plant is designed to operate in complete automatic mode at 80 mpm. The plant has been equipped with a quick-change system to optimize size-changing times and all the working axis adjustments are driven and controlled by line automation. In this way, fast and reproducible process set-ups are possible, and all working parameters are guaranteed. Mr. Hartwig Hiestermann, Managing Director of DWK, welcomed guests to the workshop. In his opening remarks, he expressed his wish for future cooperation with the customers and also mentioned that he considers this plant, the very first ERW pipe plant to be constructed under the Danieli flag, an excellent indicator of the success of Danieli W+K in such a competitive market. The music of Jrg Hegemann, a well-known pianist, accompanied guests during their visit. This event concluded with a networking lunch that allowed DWK personnel and customers to build new, and confirm old, partnerships

65

HEATING SYSTEMS

DANEWS

Olivotto Ferr joins the Danieli Group

he takeover agreement was signed on June 15, 2012. Olivotto Ferr is a widely recognized, leading specialist in industrial heating and heat treatment facilities with protective atmospheres, for both the ferrous and nonferrous metals. The combined capabilities of Danieli Centro Combustion and Olivotto Ferr will extend the range of equipment and services offered to make what may be considered unparalleled expertise in this particular market sector, including: > Reheating furnaces for long and flat products, and pipes (walking beam, walking hearth, pusher, roller hearth tunnel, Steckel, rotary hearth, walking beam for pipe reheating, and mandrel bogie furnaces); > Heat treatment and quenching facilities (walking beam, roller hearth, bell type, bogie hearth, and pit furnaces); > Annealing furnaces for strip process lines (horizontal/ vertical for CGL/CAL, and drying/curing for CCL). The acquisition of OlivottoFerr transforms Danieli Centro Combustion and its Indian operating division into a new force to be reckoned with, and now able to provide global turnkey solutions to the widest possible range of customers with continuous, semi-continuous and batch production
66

Olivotto Ferr, a leading specialist in industrial heat treatment facilities for ferrous and non-ferrous metals, has been acquired by Danieli Centro Combustion. The result, in terms of range of equipment and services offered, is an organization with unparalleled expertise in this particular market sector.

1 After signing the takeover agreement, a handshake between Giulio Napoli, President & CEO Olivotto Ferr, and Stefano Deplano, President & CEO Danieli Centro Combustion. 2 Heat treatment furnace for aluminium strip coils. 3 Heat treatment furnace installed in a seamless pipe mill.

DANEWS 165

Work in progress at Mittal Corp., India

The walking-hearth reheating furnace supplied by Centro Combustion Furnaces (CCF) has started its cold trial sequence. Since its inception in 2008, CCF has been contributing significantly to the growth of the Indian steel industry, undertaking a series of prestigious orders.

n mid 2011 Centro Combustion Furnaces of Pune was assigned the order to design and supply a reheating furnace, to be installed at Mittals bar and wire rod mill at Indore, Madhya Pradesh (supplied by Danieli Morgrdshammar), for stainless and special steels. This furnace will process a large series of low-, medium-, and high-carbon steels, alloy steels and stainless steels, with a production volumes that will reach 150,000 tpy. With the goal of a smooth installation and commissioning on site,

complete furnace installation was performed during the first months of 2012. Now, after only 12 months since the contract come into force, Centro Combustion Furnaces can confirm that this one-of-its-kind unit is in its cold trials phase. Now, Centro Combustion Furnaces teams will move the project toward the commissioning phase and first hot billet production (scheduled between Q3-Q4 of 2012) working continuously to accomplish their commitments
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HEATING SYSTEMS

DANEWS

Commissioning of a 280-tph slab reheating furnace at ISD Dunaferr, Hungary

The Final Acceptance Certificate was signed on July 23, 2012. The walking-beam furnace had demonstrated excellent performance in terms of furnace production flexibility, specific fuel gas consumption, discharging slab temperature uniformity, and scale formation.
working at 100% of its capacity only for a variable cycle time, calculated according to the actual thermal power required of the zone. Below the self-ignition temperature, the combustion system is set to work in modulated mode, to comply with safety regulations. The main advantages of PHL technology are: > Each burner works only at nominal condition at any thermal requirement. This results in constant and uniform flame length, optimization of heating uniformity on the stock, better control of NOx emissions in all the production range. > The burners on/off pattern is shifted at each firing time, sharing the heating average in all zones. > It is possible to unbalance the heating power on the two sides or to control with two virtual sub-zones. Walking-beam movement, lifting of charging / discharging machines and furnace doors are operated by means of heavy-duty hydraulic cylinders. A centralized, self-pressurized, water treatment plant, with inert gas and a 3-Level safety strategy cools the beams and other furnace equipment. The longitudinal furnace profile, which includes a fixed/moving skids layout, is basically characterized by: > An unfired recuperative tunnel, important for optimizing specific fuel consumption; > Centralized recuperator installed in the waste flue duct, for combustion air preheating, to save further energy; > Uptake exhaust gas routing to minimize excavation and civil works; > Preheating and intermediate heating chamber zones, arranged with lateral longflame burners, developed to achieve high-temperature uniformity of heated stock; > Presoaking and final soaking zones, equipped with top radiant burners and bottom lateral / frontal burners to complete stock heating, and maximize soaking time, for optimal thermal uniformity; > Skids (fixed and movable) inside the furnace, with proper hot rider design, performing with minimal skid-mark effects on over-heated slabs: the number of fixed skids has been increased from charging to discharging side, allowing skid relocation in the last furnace portion, thus removing the shadow effect; > Furnace portion of relocated skids optimized by using DCC off-line mathematical model; > Lateral / frontal and radiant burner flame patterns studied in our test facility optimize performance for furnace chamber uniformity. The winning combination of furnace configuration, correct skid re-location, and suitable flame pattern each represent state-of the-art slab reheating technology and guarantee homogeneous slab heating throughout the heating process, and uniform slab temperature at the moment of discharge, as demonstrated during the Final Acceptance Test of the plant

SD Dunaferr awarded a contract to DCC for the supply of the furnace, including auxiliary systems such as a water treatment plant, hydraulic station, external charging and discharging roller tables, shuttle car, and a slab management system by Danieli Automation to integrate production of the new WBF and the two existing pusher furnaces from slab yard to mill. Then, the contract was amended and upgraded to a turnkey project, including excavation and civil works. The first hot slab was discharged according to the terms of the turnkey contract.

firing logic (PHL); > Low-NOx radiant burners; > Integrated L1 / L2 automation and process control system; > Slab management system to plan stock charging all along the new walking-beam furnace and the existing pusher furnaces.
Furnace longitudinal profile and main characteristics

Keynote technological features

> Dual-fuel, NG and COG firing; > Low-NOx lateral burners, with proportional high- low
68

The furnace is a walking-beam type, top and bottom fired, automatically charged and discharged by means of frontal machines and opening doors. Main technical feature of the combustion system is the PHL (Proportional High Low) control logic. PHL technology consists of an on/off control of the combustion zones. The thermal energy is generated by a sequential on/off lighting of each burner individually,

Table 2 ISD Dunaferr slab parameters

Slab thickness Slab length Slab width Steel grade Charging temperature Discharging temperature

200 - 250 mm 5,200 - 10,500 mm 940 - 1,550 mm Low carbon, structural, alloyed, medium alloyed, Si-steel (1.15% Si max) 20 - 700 C 1,150 - 1,280 C

Table 1 - ISD Dunaferr WBF dimensions

Furnace inside length Furnace inside width Furnace inside height (above pass line) Furnace inside depth (below pass line) Charging-discharging roller table axis distance

42,950 mm (wall-to-wall) 40,600 mm (useful length) 11,400 mm 1,200 mm unfired tunnel 2,200 mm pre-heating and heating 1,500 mm soaking 2,300 mm 48,500 mm

Eugeny Tankhilevich, CEO of ISD Dunaferr.

FORGING & EXTRUSION

DANEWS

90-MN RNST-type forging press for North American Forgemasters, USA

It will be the largest forging press in the USA, and just like the 45-MN press supplied by Danieli Breda to the Ellwood Group in 2007, will be entirely manufactured in Danielis Italy workshops.

n August 17, 2012 the contract to supply the largest forging press in the USA was awarded to Danieli Breda (DBE). North American Forgemasters (NAF), a joint venture of Ellwood City Forge (ECF, a division of Ellwood Group Inc.) and Scot Forge, ordered a 10,000-UST (90-MN) fourcolumn open die forging press, RNST-type (Rapid New Standard). To achieve efficiency over a wide product mix, the main challenge of the new RNST family is to match high forces and high deformation speeds. More than 100 strokes/min are achievable with substantial deformation, allowing high flexibility in the product mix. The new press is to be installed near their current New Castle (PA) facilities, adjacent to the Ellwood Quality Steels plant, and shall enhance the forging range of
70

the joint venture. This new press, in conjunction with additional investments in manipulation and forge heating capacity, initially will allow NAF to produce forgings from ingots weighing up to 100 t and eventually up to 150 t. Forgings larger than ECF or Scot Forge can produce now will be marketed independently by NAF.

Forging Technology Leadership in the USA

NAF, North American Forgemasters In 1998, a joint venture was formed between the Ellwood Group Inc. and Scot Forge called North American Forgemasters. The facilities include a custombuilt 4,500 ton hydraulic forging press with an automated 10station die change magazine, capable of producing forgings as large as 80,000 pounds.

DANEWS 165

ECF, Ellwood City Forge ECF, founded in 1910, manufactures concentric and eccentric contoured forgings and single cross-section products including hollow and disc forgings, up to 94 inches in diameter, 55 ft in length and 110,000 pounds in weight. Applications include oil and gas well service and wellhead parts, power transmission, power generation, mining equipment, steel and other metals-forming equipment, plastic and other injection-molding equipment, and parts for process industry equipment. Scot Forge Scot Forge is a 100% employeeowned manufacturer of custom open die and rolled ring forgings from 5 pounds to 80,000 pounds, in carbon, alloy and stainless steel, aluminum, nickel and other ferrous and non-ferrous materials. The company started as a small hammer shop in Chicago (IL) in 1893, and today it has grown into one the most modern and respected forging companies in the world with three facilities and two joint ventures, with over 1,000,000 square feet of manufacturing space. Scot Forge has over 100 years of forging experience in the mining, oil and gas, military, aerospace, and power generation industries

At Danie l

e dont sho iw

round pa

no ble e quip m

2 1 Contract signing on August 17, 2012. From left: M. Panaja, EMP Plant Manager; R. Smith, DanCorp Managing Director; P. Fraternale, DBE EVP; M. Baldassi, DBE Proposal Director. 2 K. Handerhan, COO, EGI; and R. Smith.

en

f or

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HOT & COLD PROCESSING

DANEWS

Posco Specialty Steel, Korea, orders a new slab

Danieli Centro Maskin

New orders Plants startup

Dragon Steel (China Steel Group), Taiwan orders

and ingot grinder for special alloy steels. Quality control is particularly critical for the stainless steel, tool steel, and titanium grades that Posco SS will process in Chang Wong with the new grinder ordered recently from Danieli Centro Maskin. Working at material temperatures of up to 500 C, a special grinding carriage was designed for Posco to process the wide range of material dimensions produced at the plant, from square ingots sized at 700 mm, as well as slabs up to 9.5 m long and 400 mm thick.

Baosteel Shanghai No. 1, P.R. of China

Danieli Centro Maskin continues to acquire new orders for grinding (conditioning) and cold finishing plants due to rising market demand from the automotive, aerospace, and similar advanced industries for zerodefect finished products.

new billet grinding plant. To increase its output of high-quality carbon steel grades, Dragon Steel Corporation, the largest steel producer in Taiwan, has ordered a complete billet grinding plant from Danieli Centro Maskin. Processing 12-m-long billets, the main grinding machine will condition both the main faces of the billets as well as their edges and corners. Dragon Steel chose the Centro Maskin billet grinding car system rather than the rollerway/pinch roll movement system offered by the main competitor, while the main grinding machine from Danieli also will incorporate the Higrind system to optimize grinding wheel life and machine performance.

A second grinding machine was installed successfully to condition stainless steel slabs. This plant (comprised of two 315-kW motor power grinding machines and four grinding tables) is the state-of-the-art solution for hot and cold conditioning of stainless steel slabs in spot grinding mode. Thanks to the layout solution, the reliable equipment supplied, and the Danieli process know-how, together with the Baosteel engineers skill and competence, the plant is operating consistently with a productivity yield of over 95%: the highest yield reached in a grinding plant, ever.

Posco Gwanyang, Korea, orders two further slab

MMK-Magnitogorsk Iron & Steel Works, Russia

grinders. Posco has reconfirmed its preference for Danieli Centro Maskin grinders over machines from other manufacturers by ordering two more advanced hot grinding plants for ultralow carbon steel grades. Hot slabs will be processed directly from the caster exit at up to 700 C on two machines, with a customdesigned material handling system to ensure a minimal plant footprint and yet guaranteeing maximum productivity. The close cooperation between Posco and Danieli continues with a total of 18 grinding machines installed now, 12 of which are for flat products.

The Danieli Centro Maskin Super-Grinder, the most powerful grinding machine available in the market, is equipped with a 630-kW main motor power and 200-kW edge motor power. The installation at MMK will include state-ofthe-art solutions developed by Danieli Centro Maskin and Danieli Automation, such as the Higrind system for automatic pressure control, and the e3 system for surface quality enhancement and grinding wheel life optimization. Carbon steel slabs up to 2.7-m wide and 300-mm thick will be processed at the highest levels of productivity now available for grinding.

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DANEWS 165

10 8 4 2 7 9

6 4

10

11

3 4

10

10

1 2 3 4 5 6

Runway transfer table Frame with alignment device Tilting device Grinding carriage Machine bed (rails) Grinding machine

7 8 9 10 11

Swarf collecting box Wheel changing device Wheel preparation room Inspection platform Hydraulic unit

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CUSTOMER SERVICE

DANEWS

DPT Danieli Pneumatic Template: a cost-saving tool for alignment of billet/bloom mould foot rolls
A perfect conticaster machine operation is the result of a perfect equipment setup. Operator-dependent plant performance is a variable that could seriously inhibit production achievements, but through operation standardization and dedicated equipment maintenance and setup tools this variable could be minimized.
Traditional mould foot rolls alignment system

4-times traditional system

Vs
1-time DPT system

Presently, to center the rollers at the foot of an ingot mould, the operator performs a series of manual operations to adjust the rollers position using a monolithic template, designed to be adapted and secured by means of shims or spacers to the inner walls of the crystallizer, housed inside the ingot mold body, such that it follows the tapers existing in the walls of the crystallizer. In particular, the operator first aligns the intrados rollers by means of the spacers and the template, and then repeats the same operation for the extrados rollers and the side rollers. If necessary, the centering is completed by adjusting the position of the rollers at other sides of the crystallizer, as in the case of a quadrangular section. The aforementioned manual operations of centering by using this monolithic template disadvantageously require long times, and the centering effectiveness is however highly related to the operators experience and skills. The large numbers of variables inherent in those operations carries the risk of misaligned foot rolls, which may lead to: - sub-surface diagonal cracks - un-squareness product shape (rhomboidity) - deviation from dimensional tolerances - unsymmetrical cooling with increased thermal stresses - mechanical distortion - in-line adjustment requirement. It is therefore felt necessary to implement a template for centering the rollers at the foot of an ingot mould to allow it to overcome the aforementioned drawbacks.
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Reliable and operator errorfree mould foot rolls tuning tool (setup), available for any kind of billet and bloom conticaster.

DANEWS 165

DPT Danieli Pneumatic Template for mould foot rolls setup

Danieli has studied and developed the current innovative pneumatic template that will ensure correct centering of the rollers at the foot of an ingot mould, allowinga quick and accurate centering of said rollers, regardless of the operators skill and experience, ensuring the centering repeatability. Another aspect of the invention is to implement a template that may self-adapt to the taper of the inner walls of the crystallizer. A further object of this invention is to provide a corresponding method for centering the rollers at the foot of an ingot mould which may be performed easily with accuracy, even by less-experienced operators. The method for centering the rollers at the foot of an ingot mould, provided with crystallizer, by using aforementioned template, comprises the steps shown here. Advantageously, besides makinf it possible to facilitate and significantly reduce the duration of the centering operation, the device and method of invention help to avoid possible problems during the continuous casting process by the virtue of the high centering accuracy achieved and, therefore, of the high accuracy in guiding the cast product. Providing for properly shaped striking planes on the template, such that they perfectly follow the inner tapers of the crystallizer, further improves the centering accuracy and repeatability of the obtained result. The template may be implemented so as to be inserted into a crystallizer, which may have different shapes, e.g. a quadrangular section, for casting blooms or billets, or a round section. Depending on quadrangular section values, there are three main sizes of templates according to the following billets range: Size 1: 120x120 to 155x155 mm Size 2: 160x160 to 200x200 mm Size 3: 200x200 to 250x250 mm For round sections and different or larger sizes the DPT tool is customized in accordance with client requests

Clients that will use this pneumatic template will have the following advantages during the foot rolls alignment:

> Cash-cost reduction: 75% reduced time setup due to "single" DPT Danieli template positioning versus four positioning required by the traditional system > Clear operational instructions, > Repetitively of procedure > Independent procedure from operator skill > Accuracy of the measures (reduction of caster breakouts) > Safe operation procedure

DPT

Step 1 Inserting the template into the crystallizer;

DPT

Step 2 Expanding of the expansible means;

DPT

Step 1 Self-positioning of DPT template elements into the crystallizer;

DPT

Step 4 Centering the rolls at the foot.

Scheme of traditional mould foot-rolls alignment system.

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CUSTOMER SERVICE

DANEWS

Complete training package for long and flat product mills at Hadeed, Saudi Arabia

Theoretical and practical training covered the whole steel process, from DRI to rolling of long products, and hot and cold strip rolling and finishing lines.
The diagram shows a summary of the results achieved during the training sessions.
100 90 80 70 60 50 40 30 20 10 0

In January 2011, Saudi Iron & Steel Company (Hadeed), the largest steel producer in Saudi Arabia (fully controlled by SABIC-Saudi Basic Industries Co.) placed an order with Danieli Service for a complete training package for rolling mill engineers for flat and long products. A detailed training program was designed, with a total duration of 12 calendar weeks, including theoretical and practical courses/sessions to cover each job position and task, for a total of 125 instructor man/days and 540 trainee/days.

Activity location and instructors

Stage A B C Theory

Course location > Danieli Training Centre > Danieli Training Centre

> Danieli Training Centre > ABS, Italy (long products group) > Acroni, Slovenia (flat products group) C1 Similar plant

Final Average; 95

Hadeed/Sabic Expected Target; 85

Long Products

Starting Average; 62.4 Final Average Expected Target

> > > > >

Pittini, Italy Ori Martin, Italy Feralpi, Italy ABS, Italy Halivourgiky, Greece

C2 Similar plant Flat Cold Products > Vigan workshops, Italy > Iron Service plant, Italy > Marcegaglia, Italy C2 Similar plant Flat Hot Products > Tangshan Guofeng, P.R. of China

Starting Average 1

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DANEWS 165

STAGE A

STAGE B

STAGE C - Plants specialized training C.1 - Long RM Course

Meltshop

Academy

RM Long

Theory C.2 - Flat RM Course Theory 4 5 6 Theoretical 7 8 9 10

Similar

RM Flat

DRI

Similar 11 12

1 GROUP 1 - RMFlat

Similar Plants

GROUP 2 - Hot Flat

Theoretical

Theoretical Theoretical

Similar Plants

GROUP 3 - Cold Flat

Similar Plants

The whole training program was developed for three different groups (RM Long Products, RM Flat Hot Products, RM Flat Cold Products) and divided into three different stages. More than 20 specialists from Danieli Training Centre, Danieli technological and technical departments were involved, as instructors, to cover all the topics related to the entire steelmaking process from DRI to the finishing lines, in order to guarantee the best transfer of practical experience to the Hadeed personnel.
Similar plant activity

Customer satisfaction
Excerpt of a complimentary letter received from Hadeed Group Leader.

Each of the three groups spent the last four weeks in similar plant activities where the trainees were fully absorbed in a production reality similar to their own, and gathered experience under the supervision of Danieli instructors, and with the contribution of plant personnel who shared their knowledge in the various aspects and situations.
Evaluations system

In order to show, step by step, the increase of the Training Learning Curve, a full set of weekly evaluation reports were submitted to Hadeed Management in Saudi Arabia, including technical tests focused on the training programs and evaluation sheets on competencies, attitude, and behavior of each trainee. The evaluation system was based on: - Daily attendance; - Weekly quizzes and competencies examination; - End of Stage Exam; - On similar plant assignments developments. The grand total average (quizzes/exams and competencies) started from 62.4 and reached 95 at the end of the training program, well exceeding the target of 85 fixed by Hadeed/Sabic management for this project

"On behalf of my colleagues, I wish to express our appreciation for the first-class training program you managed. The organization, venue, course content, site visits and quality of the instructors were very good. Please extend on our appreciation to the instructors and administrators who were involved in the program. My colleagues and I returned to Hadeed with good ideas for performance improvement and with the knowledge of how to implement those ideas. Thank you and best regards." Mazen

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Quality products by a qualified team. Successful supply of DanJoint equipment at Revyakino Metal Rolling Mill, Russia
This results from the installation of new Danieli spindle holders and new coupling holders that provide a rigid design and zero clearance between the cardan shafts and the rolls. The results have been maximized thanks to the customized engineering and re-design Danieli carried out for existing work rolls. Concept Danieli spindle holders are supported via ball bearings in a self-centering coupling holder. Double rows of bearings and a reinforced spindle support frame guarantee the rigidity of Danieli spindle holders. The holders automatically cover the entire center distance range of the stands by mechanical counter balancing system. Absence of vibration also was achieved thanks to double centering solutions. DanJoint: Danieli spindle for efficient performance Danielis product line for drive shafts, named DanJoint, provides customers with a quality product capable of withstanding the tough working conditions typical of a metal-making complex. Recently, a new, heavy-duty optimized design has been developed to improve even further the shafts performance in terms of transmitted torque, reliability, and ease of maintenance

Facts Danieli Service was called by Revyakino Metal Rolling Mill to study and solve a critical problem they faced on the existing rolling mill, supplied by a competitor. After a preliminary study a solution was found that fully satisfied the customer and led to an order for six new spindle holders and couplings. The equipment was installed successfully and commissioned at Revyakinos plant, and the bar mill is working continuously now without stops due to the frequent breakdowns of the bearings mounted in the previously installed equipment. Results Revyakino is fully satisfied with the performances achieved by the Danieli solution that eliminates vibrations in their rolling stands.

Excerpt from an appreciation letter received from Revyakino: "This year our companies started working together more closely in order to modernize the equipment installed at our enterprise. " The spindle carriers... rendered a tangible effect in improvement of the mill operation. I very much appreciate the knowledge and professional experience of your company, and the competence of your experts, and I am thankful for the policy adopted by you in the field of cooperation, irrespective of the initial equipment maker. "... we got acquainted with a number of your designs in greater detail, and we propose to continue further cooperation to improve the mill 320 equipment operation. Once again I want to express my gratitude for the positive cooperation and I hope to enhance our technical relations." Igor Shishouk President & CEO of RMRP

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Technical service for over gearbox refurbishment at Rizhao Steel, P.R. of China

Rizhao Steel Holding Group, one of China's major private steel production companies, operates a full set of modern ironmaking, steelmaking, rolling, and finishing production processes and related facilities. In March 2012, Danieli Service provided advisory services for the overhaul of the Twin Module Block No. 1 and No. 2 over gearboxes, as a routine preventive maintenance program after five years of continuous rolling. Danieli Service experts executed a complete machine refurbishment in a fast and professional way. After 10 days, over gearboxes were back in operation within the scheduled time. For all its refurbishments, Danieli China is completely self-sufficient thanks to its stateof-the-art workshops that can support customers on a 24/7 basis. Furthermore, Rizhao has confirmed its trust in Danielis support, anticipating the award for its next planned equipment overhaul concerning the second rolling line

Customer compliments Danieli Team The comments about advisory service for Twin Module Block 1 and 2 over gearbox on site overhauling:
> Highly reliable > High technology, finished the job with good performance > Good cooperation.

Mr. Qi Jiangang, Vice President of Rizhao

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Hot Strip Mill F0 stand revamping, and new WR&BUR changing system at ArcelorMittal Florange, France
AM Florange is part of ArcelorMittal Flat Carbon Europe and is located in northeastern France. Its an integrated steelmaking facility, with hot and cold rolling mills for flat products. In August 2011, Danieli Service was assigned an important order to revamp the F0 stand on the 80 semicontinuous Hot Strip Mill. The HSM, manufactured by United in 1953, underwent its first and major revamping in 1984, when the traditional, fully continuous arrangement (comprising five roughing stands) was converted in to a semicontinuous one. The five roughing stands were removed and replaced by a reversing rougher and stand F0, subject of the actual revision, which is installed just before the crop shear. Stand F0 incorporates all the technological package of the 1950s, as it didnt undergo any major improvement since the startup of the mill. On the contrary, all finishing stands were upgraded to modern standards in 2001.The revamping of stand F0 involved subsituting the old stands rolls changing system -which involved the use of overhead crane for lift and slide the WR assembly, and a tractor operating in the changing pit to slide the BUR assemblywith the aim of reducing the WR and BUR change time, and improving personnel safety. The main technological issues necessary for installing the Danieli hydraulic WR and BUR changing system are hydraulic WR balancing and interstand rails lifting, WR and BUR clamps, retractable spacer on the top for quick BUR lifting, and a spindle holder at the drive side. The project also involved new hydraulic power units and valve stands to feed the new hydraulic actuators, new interconnecting and on-board piping, and new electric on-board conduits for energizing the limit switches. The whole project was designed in 3D to ensure the best result and to guarantee a perfect match at the interface between new equipment and existing equipment. The platforms covering the pit at the operator side of the mill are now of the removable type concept, for easy access to all systems in the pit and to allow efficient maintenance. All the equipment has been calculated both by means of analytical procedures and FEM method to ensure a durable heavy-duty design. Most parts boast a dedicated, tailor-made design to suit the customers needs and to minimize the
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Fast and successful revamp during the annual HSM shutdown, without plant production losses.

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1 Stand revamping stage during new equipment installation. 2 After successful new Danieli roll changing system startup, a friendly handshake, between Mr P. Callegari (AM) Florange, Projects and Activities Mgr) and Mr M. Falcomer (Danieli Service on site project supervisor). 3 The FEM shows total displacement contours for one of the cases studied considering different service factors. 4 Kick-off meeting for revamping engineering and final project signing between Mr P. Callegari (AM Florange, Projects and Activities Mgr) and Mr A. Donadon (Danieli Service, Executive Mgr, Engineering). 5 Old work-roll changing practice. 6 The new Danieli hydraulic WR and BUR changing system in operation. 7 3D FEM model of stool 1 with loading and boundary conditions.

modifications to the housing. Civil works comprised of new foundations, and therefore modifications of the existing foundations, have been carefully studied by Danieli to minimize the impact. Considering that the revamp also involved replacing the main drive slipper-type spindles with new gear-type ones, a new dedicated spindle hub holder was designed. It features a special arrangement that makes it possible to avoid any machining at the drive side of the housing. The whole job had to be carried out in a very short time, considering that the contract was signed in early August 2011 and the installation of all the equipment was scheduled from July 23 until August 8, 2012. To allow the F0 stand to receive the new equipment, several areas of the housing had to be machined and suitable solutions had to be found to install all the parts, saving the existing equipment and avoiding critical interferences. Entry and exit surfaces of the housing also had to be machined for installing the WR balancing blocks and the interstand lifting blocks. This made it possible to create a tolerated reference surface and to create the keyways for the vertical and horizontal keys. This job was carried out in December 2011 and, after machining, some temporary parts were manufactured and installed to make it possible to reinstall all existing parts, so as to be able to roll until July 2012, when the revamping took place during the HSM annual shutdown. Danieli Service provided an advisory service from the beginning of July 2012 until August 10, supporting all the operations carried out on site while assembling all new equipment in the existing housing. The equipment features state-of-the-art components made of premium materials, including the Danieli-designed and manufactured hydraulic cylinder for the WR change equipped with linear transducer. All materials and heat treatments are designed for a long-lasting service life. Most parts feature heat treatments to increase surface hardness, avoid corrosion and staining, especially parts in contact with the rolling stand cooling water. An efficient result was possible thanks to proper scheduling and management of each individual phase of the project, from the initial study up to the on-site advisory service during the installation of the equipment. The whole design phase was accomplished in less than four months! This was possible by a focused commitment of a specialized and dedicated design team. Production of all items was done in Danieli workshops. All the operations on-site were accomplished in four weeks, including equipment preassemblies before HSM shut down, installation during shutdown, anchor bolts fixation, equipment leveling, on-board piping, interconnecting piping, hot tests and startup. Overall, the shutdown took 18 days thanks to the efficient support of Danieli Services site managers

7 symmetry

normal force + inertial force

simply support

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Easy and safe DanOil hydraulic locking system at Ruukki Hameenlinna, Finland
The older design locknuts and threaded rings rely on the overhead crane to tighten the locknut during mounting. A steel peg is inserted in the locknut and a wire rope is attached to it and the crane hook. Then, the crane is raised to tighten the locknut until the sleeve of the bearing assembly is fully engaged on the taper neck of the backup roll. With growing awareness of plant safety issues, roll shop operators are seeking an alternative way to reduce any potential risk of injury. In addition to addressing the safety issue, the hydraulic locknut ensures that the required force can be applied every time, making certain that the sleeve is positioned correctly on the roll neck. Following our discussions with Ruukki on the many benefits of converting the existing locking to the DanOil hydraulic locking, the customer decided to purchase two units for trial purposes on one roll. DanOil engineers were on site to advise during the installation of the units in January this year. Practical training in the roll shop began immediately, because it is more effective to show the assembly procedure hands on, followed by classroom sessions for theoretical training. Two chock assemblies were prepared before the session commenced. DanOil engineers oversaw the installation of the locking units into the chock assemblies, the turning of the chocks for mounting on the BUR, and the fitting of the splined rings to the BUR recesses (Drive Side82
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Non-thrust side locking assembly Mount pressure 60 bar (860psi) dismount pressure 120 bar (1700psi) Piston Locknut End cap Cylinder

Thrust side locking assembly Mount pressure 115 bar (1680psi) dismount pressure 200 bar (2900psi)

Quick release 'mount' connection

54DF

.0000

CylinderEnd cap Locknut Piston

Quick release Connection 'Mount'

Non-thrust side Splined ring Assembly

Thrust side Splined ring Assembly

DS, and Operator Side-OPS). Then, the entire roll shop team was assembled and the first chock (DS) was mounted onto the BUR. The locking procedure was demonstrated twice, and then the roll shop team took control of the assembly, to ensure that they were comfortable with the operating procedure. Then, the same procedure was repeated for the OPS chock, and we demonstrated the procedure for dismounting followed again by the customers team taking control

themselves. Prior to this visit the customer had expressed concerns about how easy it would be to rotate the large locknut by hand. They were delighted to see how easily the whole operation was conducted, and were clearly happy with the ease and effectiveness of the locking procedure. The BUR assembly containing the two hydraulic locking units was installed in their fourstand cold mill in March 2012, and it is operating now without any problems

DAN
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1 Ruukki Metals Hameenlinna flat product cold processing complex. 2 The 4-stand cold rolling mill at Ruukki Metals Hameenlinna works, in operation after being upgraded with new DanOil technology hydraulic locking system for easy and safe BUR assembly. 3 Drive side locking unit installed, highlighting the locking key segment. 4 Operator side locking unit with hydraulic hoses connected for mounting the bearing onto the roll. 5 Bearing section through drawing showing the complete assembly.

ILTECHNOLOGY

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SRB - Danieli square-design rest bar for long-product rolling cartridge stands

This new technological improvement was conceived and developed to provide better stability and precision for rolling guides.

Danielis new square rest bar solution has been field-tested and approved. It offers suitable clamping of static and rolling guides in all mill stand applications (roughing, intermediate, finishing), and in all positions (horizontal, vertical, and convertible). Rest bars make it possible to keep roller and static guides in the proper position throughout the rolling process. On all stands, but in particular on the former and slitter passes, the rest bars have to: > ensure stability and rigidity of the guide cursor holder; > prevent rocking-torsion of the guides during rolling; > enable an easy, repetitive and precise guide alignment. These features are maintained during the rest bar life and therefore are easy to maintain, and design tolerances can be recovered after usage. Danieli recommends the use of square rest bars at least for critical passes. Danielis new bars are equipped with replaceable sliding pads and use a specially designed screw thread to simplify guide alignment, and the scraper-shaped nut keeps it clean.
Advantages

> Rest bars are manufactured to resist corrosion and wear, thereby ensuring utmost service life and total unit reliability under harsh environment conditions. > An optional stainless steel version is available. > Higher stability of guide cursor holder.
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> No rocking-torsion of the guides during rolling. > Easy fitting on existing cartridge stands. > Sliding pads and threaded nuts are made of a self-lubricating material; the rest bar sliding pads also can be supplied with the manual grease lubrication (option). > New thread type of the translation screw guarantees problem-free and quicker adjustment thanks to increased thread pitch and greater teeth size. > Special threaded nut scraper-design ensures screw thread self-cleaning. > Closed rest bar design prevents water and scale from entering into screw and threaded nut area. > Easier inspection and/or maintenance of the threaded screw and relative nut. > The new rest bar was specially developed for finishing stands, with particular attention to the slitting process. Rigidity and precision of the rest bars guarantee correct guiding precision for 3- and 4-strand slitting. > The stability of the cursor is guaranteed by sliding pads positioned on the rest bar angles. > The rest bar position close to the work rolls ensures roller guide stability and better guidegroove alignment. > The independent 2+2 taper blocks ensure reliable locking of the cursor on the rest bar. > The translation screw is in line with the cursor barycenter, ensuring smooth and precise guide movement on rest bar. > The sliding pads can be replaced with new ones at any time, to restore required clearances between rest bar and cursor

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MH always frontrunner in guiding CTR-RS, the new exit twister guide

CTR-RS twisting guides is the perfect solution for twisting of flats and squares, or to stabilize rolled stock.
The new CTR-RS series rotating-head twister guides originated from the wellknown CTR series. The main application for this guide is to address twisting of flats and squares, or to stabilize the rolled stock in critical applications, like the flat pass prior to the former on slitting processes. The guide could also be used as a standard twisting guide when the mill design involves a long distance between the stands. The distinctive features of the new CTR-RS guide are: > Single-point adjustment for guide rollers, enabling symmetrical, continuous, and precision gap setting, to optimize roller utilization. > Single-point adjustment of the rotating head for precise setting of the twisting angle. > Standard Morgrdshammar mounting with ability to get closer to the rolls to balance the redressing. The guide was developed in close cooperation with Danieli customers in order to optimize maintenance activities and simplify guide setting, allowing long intervals between maintenance activities, long operating time, and quick roller changes thanks to the split-type design. All regulating mechanisms are placed inside the guide box to protect them
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from scale. Moreover, this guide is completely interchangeable with older CTR series (in particular, the same guide mounting and consumables can be utilized). The new CTR-RS series is available in three standard sizes to cover all major applications. Special versions can be designed and manufactured for specific applications

For further information, contact your Morgrdshammar specialist or send an e-mail to guides@danieli.com
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The guide rendering shows the split-type design that allows fast and easy roll changes. 2-3 The head of the new RS-series CTR guide performs a rotating movement for the twisting of the rolled product.

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Correct maintenance practice for electrical arc furnace roof, columns lifting and swiveling system

A B C
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Maintaining capital equipment with Danieli specialized technical support for important checkup to prevent downtime and production losses, and to preserve safety.

During the past year Danieli has undertaken a series of advisory services for steelmakers arounf the world concerning slew bearings for the EAF roofs, lifting columns, swiveling systems, and electrode arms. These are important mechanical components of an EAF and a possible cause of long, unplanned, plant shut-downs, with related loss of production. Danieli interventions are focused on identifying possible causes of premature failures, and to advise customers on improved reliability of the equipment. The most common causes of slew bearing failures highlight the importance of maintenance practices, specifically: > Lubricating grease quality and supply; > Planarity of the bearing support; > Protection from external dust and scrap; > Electrical insulation.

On-site activities start with a preventive survey and, if necessary, continues through root-cause failure analysis to identify and resolve possible problems. On-site shutdown support, dismantling, machining to restore planarity surface (if needed), and reassembly can be provided by a Danieli Service specialized team. Implementing corrective maintenance, operational practices, and focused training courses are further services available. All the knowledge of the long-standing Danieli experience in design and manufacturing of steelmaking plants are incorporated by our technical office so as to grant continuous improvements of the roller bearings for specific meltshop use, and the lubrication systems, as well as for all the components of a meltshops equipment.

1 Details of the support rolls of the EAF rotating thrust bearing. 2 Section view of the EAF rotating thrust bearing showing main components: A) top row, B) radial row, C) bottom row.

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DANIELI PARTNERS IN FRONT RUNNING

Danieli Headquarters
Via Nazionale, 41 33042 Buttrio (UD) Italy Tel (39) 0432.1958111 Fax (39) 0432.1958289 www.danieli.com info@danieli.com

Worldwide Danieli Companies info@germany.danieli.com Tel (49) 208.3780000 info@netherlands.danieli.com Tel (31) 251.500500 info@austria.danieli.com Tel (43) 4232.51440.6101 info@sweden.danieli.com Tel (46) 240.668500 info@uk.danieli.com Tel (44) 114.2800300 info@france.danieli.com Tel (33) 1.49722269 info@spain.danieli.com Tel (34) 94.4872800 info@usa.danieli.com Tel (1) 724.7785400 infodme@china.danieli.com Tel (86) 10.58082828 infodcs@china.danieli.com Tel (86) 512.52267088 infodfe@thailand.danieli.com Tel (66) 38.955888 info@india.danieli.com Tel (91) 33.39847777

Worldwide Offices and Service Centers info@canada.danieli.com Tel (1) 905.3049337 info@brazil.danieli.com Tel (55) 11.35085900 info@mexico.danieli.com Tel (52) 81.83781055 info@egypt.danieli.com Tel (20) 2.26379229 info@uae.danieli.com Tel (971) 2.6812268 info@ksa.danieli.com Tel (966) 3.8993145 info@russia.danieli.com Tel (7) 495.9819073 info@russia.danieli.com Tel (7) 351.2674632 info@russia.danieli.com Tel (7) 3519.244043 info@ukraine.danieli.com Tel (38) 056.7904301 info@india.danieli.com Tel (91) 22.39917100 info@taiwan.danieli.com Tel (886) 7.3358655 info@thailand.danieli.com Tel (66) 2.6933520 info@korea.danieli.com Tel (82) 2.5626622 info@japan.danieli.com Tel (81) 45.6517077 info@switzerland.danieli.com Tel (41) 61.8368310

SN Longos, Portugal

Celsa Huta Ostrowiec, Poland

Vizag Steel, India

MMK, Russia

Worlds fastest high-speed bar mill: 50 mps onto the cooling bed for an 8-mm-dia and 96-m long bar, braked and discharged in less than 2 seconds.

Extra-wide product range superflexible mill with 200+ different products/sizes: rounds, squares, hexagons, flats, equal and unequal angles, channels, beams, and tees, from 20-mm angles up to 150x12 mm flats.

200 tph superflexible structural mill with double finishing outlet for the production of beams, parallel flange columns, channels, flats, angles, tees, rounds and squares.

Three rolling mills for 2 Mtpy production of long products. One of the largest single-stage reconstruction projects in Europe.

FOUR LATEST REFERENCES AMONG A TOTAL OF 145

DANIELI MORGRDSHAMMAR SUPERFLEXIBLE MERCHANT MILLS 8 PRODUCTS IN 25 SIZES EACH PRODUCED BY A SINGLE MILL

FROM 80 TO 250 TPH SUPERFLEXIBLE MERCHANT BAR MILLS FOR THE PRODUCTION OF AN EXTREMELY WIDE RANGE OF PRODUCT SIZES SUCH AS: ROUND BARS, DEFORMED BARS, SQUARES, HEXAGONS, ANGLES AND UNEQUAL ANGLES, CHANNELS, FLATS, I-BEAMS, WIRE ROD AND SPOOLED BARS IN COILS.

Long product rolling mills

GREEN STEEL: DANIELI ENVIRONMENTAL SOLUTIONS FOR A SUSTAINABLE STEEL INDUSTRY >NOISE CONTROL<
Danieli Environment supplies efficient and proven solutions to reduce both indoors and outdoors noise, with no interference on the operation of the steelmaking plant. Noise control systems to the steel industries, include: > Doghouse or Elephanthouse > Noise modeling > Noise of auxiliary plants Indoors noise must be carefully controlled in the steel industry, not only to protect the hearing of the operators, but also to prevent unsafe situations during the execution of tasks requiring attention and concentration.
More than 10 Electric Arc Furnace Doghouses, more than 100 fan-house noise insulation systems, and hundreds of noise complete studies have been performed and realized.

A complete line of environmental systems for the steel industry Danieli Environment offers a full range of proprietary technologies for air-pollution control, water treatment, energy savings, solid waste recovery, and noise reduction. Danielis goal is to reduce a plants environmental impact to zero. Danieli believes that reducing the environmental impact of steel production is not necessarily in conflict with the goal of cost-competitiveness; in fact, many environmental technologies are cost-friendly.