New, state-of-the-art minimill

complex for long products

at Posco SS-Vina, Vietnam

New hot-strip mill started

up at Baosteel Meishan,
P.R. of China

Horizontal galvanizing line

revamping at ArcelorMittal
Eisenhttenstadt, Germany

Page 8

Page 32

Page 72

Danieli News n.164 May 2012, Danieli Group

DaNews

164

ALSO IN THIS ISSUE

MINIMILLS
10 DANIELI TO SUPPLY A COMPLETE
NANO MILL TO ASC, ANGOLA.
IRON AND STEELMAKING
14 DANIELI CENTRO RECYCLING
CONTINUES TO WIN THE CONFIDENCE
OF NEW CUSTOMERS.
24 SUCCESSFUL STARTUP OF THE
1.32-MTPY SPECIAL STEEL MELTSHOP
AT DNEPROSTEEL, UKRAINE.
FLAT PRODUCTS
38 FLAT PRODUCTS MINIMILL NEARING
COMPLETION AT MMK-METALURJI,
TURKEY.
42 TWENTY-HIGH MILL IN PRODUCTION
AT CHINALCO SHANGHAI COPPER,
P.R. OF CHINA.
LONG PRODUCTS
54 SBQ BAR MILL MODERNIZATION AT
GERDAU SPECIAL STEEL NA, USA.
58 NEW 400,000-TPY REBAR MILL
FOR ABHIJEET GROUP, INDIA.

+ Highlights AUTOMATION INSERT

Enduring success in aluminium mills:

Danieli Aluminium Strip Division was awarded with three contracts
for hot and cold rolling mills by Kamensk Uralsky Metallurgical Works
(KUMZ), Russia; and by AMAG Austria Metall AG, Austria.

wo different countries, two different

world-class aluminium producers,
and both have made the same decision
to trust in a common technical, technological,
and services supplier.
Kamensk Uralsky Metallurgical Works and
Austria Metall have placed orders for their hot
rolling expansion projects with Danieli
Aluminium Strip Division, the Danieli
aluminium business unit. On April 11, 2012,
KUMZ officially signed the contract for the
construction of a new plate and hot-strip mill
at Kamensk, Russia, which follows the recent
order to Danieli for the worlds widest
aluminium cold rolling mill. This order also calls
Danieli to supply both mechanical equipment

and automation systems, as well as to oversee

the on-sitecommissioning activities.
On May 2, 2012, AMAG officially signed a
combined order for Danieli to construct a new
twin-coiler finishing mill, and a 80-MN plate
stretcher in Ranshofen. This order includes the
supply of both mechanical equipment and
automation systems, as well as the installation
activities on site. The orders are part of AMAGs
announced investment volume of approximately
EUR 220 million, which makes this project one
of the largest expansions undertaken in the
European aluminium industry. Level 1 and
Level 2 automation system will be provided by
Danieli Automation, while Innoval Technology
will provide the rolling process technology.
Page 4

JYXC, China

JYXC, China

SAIL RSP, India

WPM, Middle East

3500-mm wide plate/Steckel

mill to transform liquid steel
into wide coils or plates via
the most cost-effective
transformation route.

4300-mm wide, fully

equipped two-stand plate
mill to produce more than
1.6 Mtpy and capable
of rolling API X120 plates.

A step into the future

of plate production thanks
to the most sophisticated
rolling facility of the SAIL
group with a capacity of
approx 1.0 Mtpy in a onestand configuration and
in excess of 1.6 Mtpy in
a two-stand configuration.

The first wide plate mill

in the region to supply
high-strength plates up to
4,700 mm wide to pipe
mills, ship yards and the
petrochemical industry.

FOUR LATEST REFERENCES

AMONG A TOTAL OF 72

DANIELI WEAN UNITED

RELIABLE TECHNOLOGY
TO SHAPE STEEL INTO
THE WIDEST PLATES AND COILS

Flat product casting,

rolling and processing

THE HEAVIEST MILLS IN THIS INDUSTRY COMBINE EQUIPMENT

STABILITY, POWER, SPEED, AND THE RESPONSE TIME OF
SOPHISTICATED ACTUATORS TO SHAPE THE HEAVIEST SLABS
(MORE THAN 70 T) INTO THE WIDEST PLATES (UP TO 5.2 M).
HAGC, HAWC, BENDING, SHIFTING, SHAPED ROLLS, LEVELERS
AND SHEARS, TO GUARANTEE OPTIMAL GEOMETRY. ACCELERATED
COOLING, DIRECT QUENCHING, AND HEAT TREATMENT LINES
ADD MECHANICAL STRENGTH AND HARDNESS.

DaNews
N.164
Approved by the Court
of Udine
under authorization n.16
dated 21.04.83

Danieli Publicity Dept.

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

/ IRON & STEELMAKING

Danieli H3 wire rod mill at Nucor

Steel Darlington (NE) USA > 52

DRP No. 2 reaches 1 Mt of DRI

production at Emirates Steel,
UAE
> 12

Pusher reheating furnace to

Tecpro Systems Ltd., India
> 75

Upgrade of NNII rolling mill

at Nucor Steel Norfolk, USA > 53

Danieli Corus gets order for BOF

Process Control System from
Baotou I. & S., P.R. China > 13
Meltshop auxiliary plants and
systems at Abul Khair Group,
Bangladesh
> 16
Fume Treatment Plants upgraded
at Acerbrag S.A., Argentina > 18
80-t ladle refining station
at Riva Acciaio Verona, Italy > 19

Danieli SHS stands for rolling mill

upgrading at Gerdau Siderperu,
Peru
> 55
Further wire rod mill modernization
at Ferriere Nord, Italy
> 56
New production records
at BSRM, Bangladesh

Fast-track commissioning of
super-flexible bar mill at Deacero
Ramos Arizpe, Mexico
> 60
Work in progress on the 1.1-Mtpy
rail and section mill at Mechel
Chelyabinsk, Russia
> 62

New EAF electrode conductive

arms at SN Longos Seixal,
Portugual
> 21

Final Acceptance for rebar and

light section mill released at
Chico, Sri Lanka
> 63

Meltshop modernization at Sohar

Steel, Oman
> 22

Danieli TMB technology in

operation at Zhejiang Qingtian
Ruipu, P.R. of China
> 64

/ FLAT PRODUCTS
Danieli seminar on Thin Slab
Casting technology in India > 26
4th-generation Danieli TSC design
at Dongbu Steel, Korea
> 28
Danieli shakes up the upgrade
of Indias first and biggest hotstrip mill
> 30
First Q&T plate leveled
at SSAB NAD, USA

> 34

New integrated forging plant

at MTE Group, Russia
> 76
Successful startup
of pipe upsetting plant
at Tenaris Tamsa, Mexico

> 77

> 59

EAF upgrade at Charter Steel,

USA
> 20

200-t twin-tank VD with

mechanical pump at Jindal
Shadeed, Oman
> 23

/ FORGING & EXTRUSION

Successful startup of the HSSHigh Speed Shear at Diler Demir

elik, Turkey
> 65
Final Acceptance of the wire rod
line at Shandong Laigang
Yongfeng, P.R. of China
> 65

/ CUSTOMER SERVICE
Condition Monitoring system for
long product mill stands
> 78
Danieli Service Centers expansion
projects in Russia and India > 80
>Resin tech< for the revamping
of a 4-high reversing plate mill
at Marcegaglia, Italy
> 82
Safer, faster, more accurate
CRM's equipment alignment with
BUR dechocking machine > 84
SRW-E: the new benchmark
for high-speed guides
> 85
Long-Term Service Agreement for
flat product plants maintenance
signed at OMK, Russia, and
Unicoil, KSA
> 86

Commissioning of section
products completed successfully
at CMC Zawiercie, Poland > 66
Bar finishing services started up
at Acciaierie Valbruna, Italy > 67
Fast ramp-up of EWR billet
welding line at Cape Gate,
Republic of South Africa
> 67

// INSERT:

Highlights AUTOMATION
Q3Intelligence - Business
Intelligence for the metals
industry

// 2

New hot skin-pass mill with

in-line side trimmer at Gerdau
Aominas, Brazil
> 36

/ HOT & COLD PROCESSING

High-speed trimming lines

at Shandong Weiqiao Al. &
Power, P.R. of China
> 43

HiPROFILE PR84120F at Gerdau

Mogi das Cruzes, Brazil
// 5

New in-line hot slab inspection

and conditioning plant
at Posco, Korea
> 69

New HiPROFILE PR86300 C/M

at OneSteel Whyalla, Australia // 5

/ LONG PRODUCTS

Two high-speed drawing lines

ordered by Ningbo Powerway Alloy
Material Co., P.R. of China
> 69

Danieli Morgrdshammar
Seminar in China

MES solutions at Vizag, India // 4

Q-Zinc Robot systems for HDGLs

at Marcegaglia Ravenna, Italy // 5
New automation for ladle furnace
at Riva Acciaio Verona, Italy // 6

> 44
/ TUBE PROCESSING

Danieli Automation at AITISM

2012 in Ranchi, India
// 6

Two EPCPM-Extreme Performance

Cold Pilger Mills at ElemashSpetstrubprokat Ltd., Russia > 70

New HiREG at OneSteel Laverton,

Australia
// 7

Excellent Combi-caster startup

at IDC, Turkey
> 50

/ HEATING SYSTEMS

3Q unified control pulpit for two

conticasters at Riva Acciaio
Verona, Italy
// 7

Final Acceptance of revamped

caster at SAM Neuves Maisons
(Riva Group), France
> 51

Revamping of a tube heattreatment line at Vallourec &

Mannesmann TK, Brazil
> 74

New speedmeter SM300 for

Exacut technology at Gerdau
Cosigua Santa Cruz, Brazil
// 7

Danieli wire rod technologies at

the forefront
> 46
First heavy sections produced in
the Middle East
> 48

DANEWS 164

The Route to Success:

Startup services and ramp-up assistance
guide customers to the finish line

anieli has a broad range of capabilities and we continue to improve our

expertise, from iron-ore processing to steelmaking, casting, hot and cold
rolling, bar and strip processing.
Over the past 15 years Danieli has started and ramped-up over 1,000 projects
worldwide, achieving success with singular processes in existing facilities, and with
complete plants, minimills and integrated complexes on turnkey basis.
Programming of all site activities, timely organization, effective deployment of
personnel as per required skills, managing/supervising installation, conducting cold
and hot startups so as to achieve the agreed performance, and assisting customers'
ramp-ups, is our mission. To fulfill it, we observe these principles:
> On-time project completion;
> Respect for the assigned budget;
> Customer's overall satisfaction.
To succeed in this, we make available 1,200 professionals of over 50 different
nationalities. With operations in eight countries, our department is the fullest
expression of Danielis international culture and skills.
This multiethnic community counts about 80 site and commissioning directors and
managers, over 100 technicians and process engineers, around 450 specialists in
mechanical, hydraulic, piping and other specific disciplines, and over 150 electrical
engineers, as well as about 380 specialists in levels 1 to 3 automation disciplines.
To cope with the huge number of contemporaneous starts and ramp-ups, these
personnel are organized as working teams for each process technology, and most of
these teams retain their key personnel for consistency and proficiency. We consider
language barriers and cultural differences to be a stimulus: by integrating different
experiences and approaches we improve our teams ability to interact with customers,
to overcome quickly any operating and maintenance difficulties, and to establish
strong relationships. These factors will speed the ramp-up for any new plant or
operation.
We work continuously to improve the average time (from 30 to 35%) and the average
man/months (20 to 25%) of our on-site activities, including:
> Improving a company's production chain for any "quick intervention" that might be
needed;
> Developing software for coordinated planning of site activities, to optimize
selection and availability of materials and personnel;
> Specialized training to improve the skills and professionalism of our personnel;
> Improving teams efficiency by emphasizing specific attitudes, such as passion,
vision, and dedication to their own site tasks.
Our success at improving these essential services will prove our capacity to be a
"Reliable and Innovative Partner" for metal industry equipment or plant installations.

D A R I O FA B R O

Executive Vice President_Head of Erection and Commissioning Department

ALUMINIUM STRIP MILLS

DANEWS

Three prestigious orders

acquired in less than six
months from Kumz,
Russia, and Amag, Austria.

DANEWS 164

Enduring success in aluminium mills:

Danieli Aluminium Strip Division has earned three contracts for hot
and cold rolling mills: from Kamensk Uralsky Metallurgical Works (KUMZ),
Russia; and from AMAG Austria Metall AG, Austria.

KUMZ, Russia: Danieli will

supply the worlds widest
aluminium cold mill
On December 1, 2011,
Danieli was awarded the
contract for the Kamensk
Uralsky Metallurgical
Works (KUMZ), Russia,
aluminium cold rolling mill.

anieli strengthens its position in the

aluminium flat products market with the
latest order from KUMZ for the worlds
widest cold rolling mill, a line that will be built
around an advanced six-high, single-stand cold
rolling Diamond Mill. Following the Diamond
Mills supplied to Nikkei Siam Aluminium
(NSA), Thailand, and Aleris, Belgium, this new
installation will represent the latest cutting-edge
rolling technology and will firmly establishes
Danielis position as the leading supplier of
advanced rolling mill solutions to the aluminium
market.
The mill to be supplied for KUMZ is of
particular note in that it will produce coiled
sheet up to 2,800 mm wide for aerospace
applications, in thicknesses ranging from 8 mm

Kamensk Uralsky Metallurgical Works (KUMZ) situated in the Ural

Mountains, is one of the largest semi-finished products companies in Russia.
It was founded in 1944 as a manufacturer of semi-finished products in Aland Mg-based, and Al-Li alloys. Today, KUMZ supplies high-quality
aluminium plates, and a wide variety of extruded products (rods, bars,
profiles of different shapes, wide railway extruded panels, as well as
aluminium tubes and drill pipes). KUMZ also specializes in forged materials,
supplying die forgings, hand forgings, rolled rings, forged plates, and bars
to aerospace, military, and automotive industries. The quality standards
achieved by KUMZ are demonstrated by its qualification as an aerospace
supplier to Boeing and Bombardier.

Vladimir I. Skorniakov, Chairman of the Board and President

of UK Alyuminievye produkty (right), and Gianpietro Benedetti,
Chairman and CEO of Danieli, sign the contract for the new mill.

FLAT PRODUCTS

DANEWS

to 0.2 mm, thus producing the worlds widest

flat-rolled aluminium. The 6-high design of the
Diamond Mill is up to this technological
challenge and will enable KUMZ to roll an
extensive assortment of products encompassing
a broad range of strip widths and thicknesses, as
well as a wide variety of alloy steels, including
military aerospace products, in order to meet
KUMZs current and future requirements.
The key technological features required for this
project include a six-high stand design with
intermediate-roll dynamic side-shifting, using
parallel rolls; advanced mill-stand stabilization
design for the roll stack across a wide range of
material parameters and rolling phases; Danielis
HI-RES coolant spray design with constant
stand-off distance, and using electrical valves to
regulate the 26-mm pitched spray nozzles across
the entire strip width, coupled with Hot Edge
Sprays (HES) that cover the strip edge, with all
systems installed for ease of operation while
providing the highest level of strip flatness
performance; DAN-ECO2 fume cleaning and
coolant recovery system to ensure that the
highest emission standards are achieved with
reduced operating costs achieved by recovery
of the rolling oil; Dan-Purity coolant plate filter
to ensure improved process performance and
product quality, with the additional benefit of
extended coolant life; Danieli Automations
HiPAC TCS, dynamic model-based Level 2
system, with Level 1 electrics; coil handling by
a pallet conveyor system linked to a coil
preparation station, coil inspection station, and
high bay storage system; and Innoval
Technology process and product support.
Furthermore, all equipment is being supplied
from Europe, and all technological parts are
manufactured in Danielis European workshops.
In addition to supplying advanced technology,
Danieli has set-up a team made up of people
from Danieli Frhlings UK and German offices,
Danieli Wean United, Danieli Automation, and
our process partner INNOVAL Technology, who
will be working together closely on this
challenging project

AMAG, Austria: Danieli to supply

a Twin-Coiler hot-strip mill
In May 2012, AMAG Rolling GmbH,
a wholly owned subsidiary of AMAG Austria Metall AG, contracted Danieli
to supply a new Twin-Coiler Hot-Strip Mill,
to be installed at its plant in Ranshofen.

n May 2012, AMAG Rolling GmbH, a wholly

owned subsidiary of AMAG Austria Metall
AG, contracted Danieli to supply a new Twin
Coiler Hot-Strip Mill to be installed at its plant
in Ranshofen. The twin coiler rolling mill is
designed to produce hot rolled coils, heavy and
light plate, clad panels in thicknesses of 3 to
160 mm and widths of up to 2,300 mm.
Considering the specific product mix of AMAG,
the twin-coiler rolling mill will have a rolling
capacity of up to 225,000 tpy of finished
products. The product range covers aluminium
alloys of all series from 1xxx to 8xxx, including
automotive and aircraft applications. The lines
main equipment will include entry/exit coilers
with a belt wrapper, rolling stand and side
trimming shear for coil production, and 160-mm
heavy shear for plate cut to length. The mill will
operate with Danieli Automation Level 1 and
Level 2 automation systems. Installation
services at the Ranshofen site also will be
supplied by Danieli. The rolling stand will be
designed to roll with a force of 50 MN,
equipped with top-mounted electro-mechanical
screw down, bottom-mounted HAGC, work-roll

1 Contract signing
ceremony. From left,
signing the contract, are:
G. Weger, Managing Dir.
AMAG Rolling; G.
Ximeris, EVP DWU; A.
Eberle, Managing Dir.
AMAG Rolling; and E.
Grossmann, EVP Danieli.
Attending the ceremony,
standing, from left, are:
G. Mayer, CFO AMAG,
H. Kaufmann, COO
AMAG, G.P. Benedetti,
Chairman and CEO
Danieli, G. Falch, CEO
AMAG, F. Stella, Director
Projects, DWU;
P. Schantl, Project
Director, Head of
Technical Services
AMAG Rolling; and
G. Vecera, Head of
Purchasing AMAG.
2 Handshake between
Gerhard Falch, CEO
AMAG (right), and
Gianpietro Benedetti,
Chairman and CEO
Danieli.

DANEWS 164

AMAG-Austria Metall AG, is a supplier

of primary aluminium and semi-finished
aluminium products in selected markets.
As a consequence of aligning its capabilities
with the requirements of its markets, its strong
commitment to customer service, and the
quality-focused attitudes and actions of its
employees, Amag is a reliable business partner.
Together with the integrated production
facilities in Ranshofen (cast house and rolling
mill), Amag has a high level of experience and
metallurgical competence in aluminium.
Amags raw material foundation is based on its
investment in the Canadian smelter Alouette
and via access to the aluminium scrap market.

bending system, twin-drive motor configuration.

The side-trimming shear is mounted between
the mill stand and the exit coiler in order to cut
the strip edges in-line. The heavy shear, capable
of operating on plates up to 160 mm thick, shall
be used for head and tail cropping during rolling,
and for cutting the plate to length at finishing
thickness. Plates are removed from the line by
means of automatic piler with peculiar features
to avoid any potential plate surface scratches.
The plant is then completed with all related
auxiliary facilities, such as a fume-exhaust
system, all media system, and emulsion cooling
system. Innoval Technology (part of Danieli
Aluminium Strip Division) will be the process
partner for the project. The project is expected
to start up in late 2014, and completely
commissioned by Q1 of 2015

Danieli scorecard
in aluminium flat product mills
2010_2012
KumZ, Russia

1 + 1 Hot rolling mill

Amag, Austria

Hot rolling mill

Nikkei Siam, Thailand

Universal Diamond foil mill

Aleris Europe, Belgium

Six-high Diamond strip mill

KumZ, Russia

2850-mm six-high cold rolling mill

Dalian Huicheng, P.R. of China

60-MN plate stretcher

Amag, Austria

80-MN plate stretcher

KumZ, Russia;
Aleris Europe, Belgium

3 DanEco fume cleaning

and oil recovery systems

KumZ, Russia; Aleris Europe, Belgium;

Nikkei Siam, Thailand;
Termomecanica / Brazil

5 DanPurity multi-plate filter systems

Luoyang Wanji, Nanshan Light Alloy,

Weiqiao P.R. China; Alcoa Maaden, KSA;
Novelis, Korea; Hindalco, India;
Novelis do Brazil, Brazil

12 slitting / edge trimming lines

(cuts up to 120, speed up to 1,800 mpm)

DANIELI MINIMILLS

DANEWS

Green light for the new, state-of-the-art

minimill complex for long products
at Posco SS-Vina, Vietnam

79

th

IE
DAN

This order, placed

in November 2011,
represents the
79th minimill
plant built by
Danieli Group
since 1964, and
again strengthens
Danielis
indisputable
leadership in this
field.

MIN MIL
I

osco has been expanding continuously

since its founding in Korea in 1968 with
a 1 Mtpy, and now it ranks third among
steel producers worldwide, with 35.4 Mtpy
produced in 2010. With its motto, We move
the world in silence, the steelmakers expansion
in neighboring countries continues, as does the
development of its relationship with Danieli
Group since the 80s. The strong relationship
and the several projects in different sectors
carried out successfully (recently, a new
meltshop with jumbo bloom vertical caster for
Posco Specialty Steel) laid the groundwork for
a new greenfield minimill in Vietnam.
The 1.0-Mtpy complex to be supplied directly

to Posco SS-Vina, a part of Koreas Posco Group,

will include:
> A steel meltshop, made up of a scrap-fed 120t FastArc EAF, ladle furnace, 6-strand
FastCast conticaster for billets up to 160-mm,
200x300 mm blooms, and beam blanks) with
auxiliaries and fume-treatment facilities.
> Rolling mill No. 1, a 90-tph rebar mill to
produce deformed rounds from 10 to 61 mm
dia., in order to satisfy growing domestic
demand for steel bar for construction purposes.
> Rolling mill No. 2, a 160-tph heavy-section
mill to produce H-beams up to 700 mm, equal
leg angles up to 200 mm, unequal leg angles up
to 150x90x12 mm, inverted angles up to 300x90
mm, and channels up to 400 mm. This mill is
designed to produce track shoes, sheet piles,
and rails as well, for the domestic market and
neighboring countries.
The technologies applied at the complex will
be the latest from Danieli; from large to small,
from nano to micro, more than 50 years of
experience has brought the Danieli Group to its
No. 1 rank in minimill turnkey installations.
Around 80% of the minimills operating

DANEWS 164

1
2
3
4
5

120-t FastArc EAF

Ladle furnace
Scrap yard
Fume treatment plant
Six-strand FastCast
conticaster
6 Reheating furnace
(Heavy-section mill)
7 Breakdown mill
8 UFR finishing mill
9 Cooling bed and
straightening services
10 Cold finishing services
11 Reheating furnace
(Rebar mill)
12 18-pass rebar mill
13 Cooling bed
14 Cold finishing services

8
14
10

Souvenir photo at the

contract signing ceremony.
Hyun-Uk Seong, CEO,
Posco SS (fifth from right),
and G. Mareschi Danieli,
CEO, DFE, and Member of
the Board of Directors
(sixth from right) signed
the contract in the
presence of Ju-Yeol Ryu,
Jai-Hyen Cho, Seung-Seok
Lee, for Posco, and H.Y.
Sohnm, A. Nardone,
A. Mordeglia, F. Mulinaris,
for Danieli.

13

7
12

11

2
1

worldwide today have been supplied by Danieli,

or operate with Danieli equipment.
FastCast, UFR-Ultra Flexible Reversing, and
SCC-Stand Core Concept, are main process
technologies planned as the cornerstone of the
new Vietnamese mill, connected to the Danieli
Automation that will supply all the electricals
and fully integrated automation systems for the
whole plant. The complete supply of process
technology on a turnkey basis will include two
water-treatment plants and systems, cranes,
and transportation means. The plant startup
is scheduled for the Q3 of 2014
9

DANIELI MINIMILLS

DANEWS

Danieli to supply Nanomill

to Angola Steel Corp., Angola

ASC and Danieli teams

after the contract signing
at Danieli Centro Met Swiss
in Rheinfelden.
From left: G. Nigris, EVP
Danieli; G. Choucair, CEO
ASC; A. Diasparro, VP
Sales, DMH; JP. Artigala,
ASC; S. Vieria, ASC;
T. Narholz, EVP Sales,
DCM; F. Ambroise, ASC.

10

ASC-Angola Steel Corp.,

a privately owned company
based in Luanda, has
awarded to Danieli the
contract for a new complex
made up of a 150,000-tpy
meltshop and a 200,000tpy rebar rolling mill.

78

th

IE
DAN

SC is one of the leading steel traders of

long products in Southern Africa and this
project represents the first phase of
future implementation for other steel plants in
the country, to achieve a comprehensive
capacity of up to 1 Mtpy of finished long
products.
The new, induction furnace-based meltshop is
part of the diversification program for ASC, in
reaction to the expanding demand for rebars in
Angola and the neighboring countries. As usual,
by the nature of such projects, the concept is
driven by optimized investment and conversion
costs. The Nano Mill concept of Danieli
provides both to the customers. It has been
Danielis overall capability to cover the full
process line under a single design authority,
from the raw material preparation by a scrap
shredder through to the dispatch of high-quality
finished product, which has been a decisive
factor for the investors. In the first stage of the
project the scope of the order includes a scrap
shredder, 25-t induction furnace, 25-t ladle
furnace and oxygen blowing stand, fume
treatment plant, two-strand FastCast
conticaster for billets, the reheating furnace, the
rebar rolling mill, all meltshop auxiliaries, and
all process cranes, as well as the water
treatment plant for the entire facility. A second
project stage already has been planned that will
increase the plant capacity to 500,000 tpy.
This order reconfrims Danieli as the market
leader for this innovative technology, and
Danielis sustainable approach as a standard for
the future of Africa. As well, the project will
establish the strong leadership of ASC in the
domestic and international markets.
Startup of the new plant is scheduled for the
Q4 of 2013

MIN MIL
I

DANEWS 164

DANIELI
NANOMILL

is a new concept for compact steel

plants suited for regional and
extra-low CAPEX investments.
The key factors of the Danieli NANO Mill
concept can be listed as follows:
9

> NANO Mill Businessland

these plants are economically sized to cover

regional finished-product demands;

11
8
10
L

> Compact basic production units:

the NANO Mill requires less than 50% of the
space required for conventional long-product
mills;
> Utilizing fully integrated processes

due to Danielis overall process competence,

having all process steps in its own portfolio
(including shredder and cranes) allows full
balancing of the process line;

6
4

> Balanced Melting-Casting-Rolling process

2

1
2
3
4
5
6
7
8
9

Scrap shredder
Scrap yard
Induction melting furnace
Ladle furnace
Fume treatment plant
Billet conticaster
Reheating furnace
16-pass rebar mill
Cooling bed and cold
finishing services
10 Water treatment plant
11 Future expansion

in case the plant set-up includes the installation

of a long-product rolling mill, the plant
arrangement allows hot-charging of billets and
full overall process control, from the scrap yard
to the final product. This allows a newcomer to
get products certified more easily and makes it
easier to prove the process consistency;
> 19-month construction path

the high degree of standardization, the

simplicity of design, and the high degree
of pre-assembly of equipment manufactured
in Danielis own workshops not only ensures fast
delivery of the equipment, but it also supports
the fast and on-time construction of the local
portion of the project.

11

IRON & STEELMAKING

DANEWS

DRP No. 2 reaches

1 Mt of DRI production
at Emirates Steel, UAE

12

1,200
Production (t x 1,000)

n January 25, 2012 the second

Energiron DRI plant at Emirates Steel
in Abu Dhabi reached the milestone of
1 million tons of production.
This important result was reached just 10
months after plant startup, and the last 500,000
t were achieved in the last four months of that
period. In August 2011 the plant already had
reached 100% availability, with a record
production of 144,000 t.
The production track demonstrates the quick
learning curve of the Energiron technology
made possible by the professionalism and
dedication of ES and Danieli teams

1,000
800
600
400
200
0

Months from startup

Cumulative production from Month 1 (April
2011) to Month 10 (January 2012).

10

DANEWS 164

1,000,000 tons
in ten months
from startup

Danieli Corus gets order

for BOF
Process Control System
from Baotou Iron & Steel,
P.R. China

anieli Corus has signed

a contract with Baotou I&S
Group to design and supply
three sublance-based BOF
process control systems, including
bottom-stirring equipment. Plans
call for the new, triple 240-t
converter BOF plant to apply
automatic steelmaking with the
Danieli Corus SDM-StaticDynamic process control model in
order to achieve the plant's full
potential.

With over 100 sublances

installed, Danieli Corus is a
market leader and is thoroughly

experienced at both installing

sublance systems in new plants
and retrofitting systems for
existing plants. Its SDM model
covers the whole area, from hot
metal and scrap preparation up
to and including ladle alloying.
At an existing BOS plant, the
following improved operational
parameters were found:
> Plant output increased by 25%
> Tap-to-tap time reduced by 17%
> Converter lining life was
increased by 41%
> Hit rates for carbon percentage
and bath temperature (combined)
over 90%

Handshake between Wu
Gangsheng, VP Baotou Iron
and Steel, Project Director;
and Walter Vortrefflich,
Senior Sales Manager for
Danieli Corus at the end of
the kick-off meeting.

13

IRON & STEELMAKING

DANEWS

Danieli Centro Recycling:

the product line continues to win
the confidence of new customers

n October 2012, the worlds most productive

shredder plant started up at the Severstal steel
plant in Cherepovets, Russia. The event was
marked by an opening ceremony attended by
Alexander D. Grubman, CEO, and Andrey N.
Lutsenko, COO of Severstal Russian Steel Division.
Tim Christian, Executive Vice President of Danieli
Lynxs escorted the guests and demonstrated the
productive capacity of the plant. The 10,000-HP
plant has the capability to process in excess of
1 million tons per year and will fulfill the complete
needs of the Cherepovets site for high-density,
clean steel scrap. Designed specifically to operate
during the harsh winter months in northern Russia,
the plant brings the added benefit of removing ice
from the scrap feed, which greatly reduces the
risk of explosion during steelmaking. In the
meantime the Final Acceptance Test has been
already finalised.
The success of this project in northern Russia has
been a major technical advantage for Danieli
Lynxs, bringing with it excellent experience when
discussing the installation of a new, 7,000-HP
shredder plant for Donetsk Iron & Steel Works
(DMZ) in Ukraine. Installation of the Danieli Lynxs
DCR 2727 plant will commence during the
14

Souvenir photo at the startup of the worlds

most productive shredder at the Severstal
steel plant in Cherepovets, Russia. From
left: A.D. Grubman, CEO, Severstal Russian
Steel Div.; T. Christian, Danieli Lynxs; A.N.
Lutsenko, COO, Severstal Russian Steel
Div.; I. Belov, Project Manager; S. Panin,
Maintenance Mgr.; V. Shashkin, Consultant.

Contract signing for the new shredder to be

installed at Medenasa, Spain. Ramon Zufia,
Owner of Medenasa (right) signs the
contract with F. Alzetta, Danieli COO and
Member of the Board. Also attending the
ceremony were Jos Vela, Head Engineer
of Medenasa, N. Santangelo, D. Braga, and
F. De Martino for Danieli.

DANEWS 164

The 10,000-HP shredder

plant started up at the
Severstal steel plant in
Cherepovets, Russia, is
the worlds most productive
unit of its kind, and is
capable of processing in
excess of 1 million tons
per year of scrap.

Danieli acquires Akros Henschel

ollowing the purchase of Lynxs

Shredders in late 2010, Danieli
has added to its scrap recycling
product portfolio with the strategic
share buy-out of Akros Henschel
SAS, a world leader in hydraulic scrap
shears, balers, pre-shredders and
vertical grinders. Since 1970 Akros
Henschel businesses have delivered
more than 450 large scrap-processing
machines worldwide.
The deal will see Danieli take control
of primary manufacturing facilities in
Chambry, France and Kassel,
Germany, both of which will continue
to work alongside existing Danieli
facilities in Italy, Thailand, China
and India. The on-going business will
adopt the name Danieli Henschel.
Emanuele Brusini, EVP The Akros
Henschel product line and business
units will be merged into the Danieli
Centro Recycling division. In the past
year Danieli has delivered significant
turnkey projects for scrap processing

facilities within our traditional steel

making markets. By adding large
hydraulic scrap shears and balers, we
see tremendous opportunity for further
vertical integration of scrap
preparation, handling and continuous
charging processes within electric arc
furnace (EAF) melt shops.
Daniel Damart, former Managing
Director of Akros Henschel, who will
adopt a leading role in Danielis
senior management team with
responsibility for developing scrap
processing markets outside of steel
making, added The Henschel brand is
long established and renowned within
the scrap metal recycling communities
of the world for quality in both design
and operation. The combination of our
pre-shredders, large static and mobile
scrap shears and balers with Danielis
existing shredder range, enables the
new group to meet the needs of both
the smallest and largest scrap
processing companies of the world

summer of 2012 with commissioning due to

commence before the years end.
With major new legislation in the EU demanding
even greater metallic recovery levels by all recyclers,
the expertise demonstrated in this field by Danieli
Lynxs at existing plants in Spain and Portugal
ensured that Metales de Navarra, S.A. (Medenasa)
based in Pamplona, Spain, had no doubt as to who
they would trust with their largest investment. The
Danieli Lynxs 1,400-HP DCR 1822 shredder plant
with offline NonFerrous Recovery and Enrichment
will be delivered during summer 2012, after which
fast-track installation commissioning will start less
than three months later
15

IRON & STEELMAKING

DANEWS

Meltshop auxiliary plants and systems

at Abul Khair Group, Bangladesh

With the order signed in January

2012 concerning Fume
Treatment Plants (FTP), an
Integrated Material Handling
System (MHS), and meltshop
auxiliaries, Danieli will be the
sole technology supplier for
the first electric steel meltshop
in Bangladesh.

bul Khair Group is one of the fastest

growing business conglomerates in
Bangladesh, engaged in steel, cement,
tobacco, and a diversity of other emerging
consumer markets.
The order for the meltshop to produce up to
1.2-Mtpy of billets was awarded to Danieli in
July 2010. Already in August 2011, Abul Khair
Group selected Danieli Environment as sole
technological supplier to design, manufacture,
and supply the new FTPs, integrated material
handling system, and the scrap and liquid steel
handling systems. The order signed in January
2012 covers all the remaining technological
equipment included in the meltshop for scrap
and liquid steel handling.
FTPs have been designed to control primary and
16

DANEWS 164

secondary fumes and dust emissions for two

85-t Electric Arc Furnaces and ladle furnaces,
and fume-extraction lines. The material
handling system is designed to provide HBI,
coarse materials, and ferroalloys to both the
meltshop units from the storage yard to EAF,
and for tapping and LF additions. The new
FTPs will comply with the more stringent
European emission values in terms of dust
content at the stack, to be less then 10 mg/Nm3.
Main features of each FTP are:
> Extraction capacity of EAF primary off gas:
140,000 Nm3/h at 1,200 C;
> Secondary suction capacity during bucket
charging: 1.5 Mm3/h;
> Auxiliary suctions capacity: 230,000 m3/h;
> Treatment capacity at each Pulse-Jet filter:
1.73 Mm3/h.
FTP technology is based on the Pulse-Jet type
filter to guarantee high filtration efficiency, low
pressure drop, and limited consumption of
compressed air. Bag cleaning is controlled
electronically and can be programmed with the
bag compartments on-line or off-line.
The bags can be replaced without entering into

the filter, thus occupational health and safety

are not compromised. VFD-Variable Frequency
Drives, also called inverters, are used to vary the
fan speed over a wide range in order to adjust
the flow rate of the treated fumes based on the
operating requirements. Compared with flow
adjusting dampers, the variation of the fan
speed provides a savings on the electric
consumption of the fan motors. Hairpin coolers
and water-cooled ducts are used to control and
reduce the fumes temperature before entering
into Pulse-Jet filters. The new Material
Handling System includes:
> HBI storage area with stacker outside the
meltshop and connections to meltshop bay;
> HBI, lime, and ferroalloys daily storage system
inside meltshop;
> Feeding system from daily silos to EAF No. 1,
EAF No. 2, Ladle at tapping No. 1, Ladle at
tapping No. 2, LF No. 1 and LF No. 2;
> Charging system of carbon into the scrap
buckets.
The MHS is designed to provide HBI
continuous charging in EAF through the V hole
up to 85% of the charge mix, to allow a flexible
EAF melting operation

1 Souvenir photo at Danieli Far East.

Honorable Abul Kashem, Chairman
AKSL (6th from left), with
G. Mareschi, CEO DFE and Member
of the Board Danieli, and F. Alzetta,
COO Danieli and Member of the
Board, together with M. Moretti,
DFE PM; S. Singh, AKSL Senior
GM Flat; D. Ambrosino, CFO DFE,
Abu Saeed Chowdhury, AKSL
Deputy MD; P. Burin, Executive
Manager Sales Steelmaking;
R.K. Garg, AKSL DGM (Melting);
D.Kapoor, AKSL DGM (Project).
2 ASKL and Danieli Executives at the
contract signing ceremony. From
left: Xun Li (Xian); A. Aldama,
A. Vitiello, C.Moro, F. Valvason,
L. Tomadin for Danieli; D. Kapoor,
AKSL DGM (Project); A. Gandhi
AKSL (Melting); M. Moretti,
F. Giancristofaro, A.Scamarda for
Danieli; H.Uppoor, AKSL Senior
CM; RK Garg, AKSL DGM (Melting).
3 Auxiliary plants in the AKG
meltshop: DRI handling system
(brown); scrap handling and
auxiliary meltshop systems (green);
fume treatment plant (blue).

17

IRON & STEELMAKING

DANEWS

Fume Treatment Plants upgraded

at Acerbrag (Votorantim Group),
Argentina

Front and side view of the Fume

Treatment Plant upgrade project:
Phase 1 (green); Phase 2 (red).

Contract signing, from left,

for Votorantim Siderurgia:
Egidio J.B. de Oliveira, PMP
Gerencia de Suprimentos
e Contratos, I. Goldaracena,
Dep.to Juridico; and for
Danieli: L. Mottes, VP Key
Account Management;
and L. Tomadin, Director,
Danieli Environment.

n June 2011, Acerbrag selected Danieli

Environment as the sole technological
partner for the design, manufacturing, and
supply of equipment for the upgrading project
of the Fume Treatment Plant (FTP) of its steel
meltshop located in Bragado.
The meltshop was supplied by Danieli in 2002
to produce up to 350,000 tpy of billets.
The FTP was designed to control the primary
and secondary fumes and dust emissions of a
50-t Electric Arc Furnace, as well as of ladle
furnaces. The upgrade project is meant to
be implemented in two phases:
18

DANEWS 164

Phase1
> Enlargement of the existing bag filter (+12
compartments);
> Third ID fan and new impellers for existing
fans;
> New dust chain conveyor;
> Silo modification;
> New axial cyclone;
> Electrical and automation systems.

80-t ladle refining station

at Riva Acciaio Verona, Italy

Phase 2
> New enlarged canopy hood (building roof);
> New secondary ducts from canopy hood to
connection point;
> New fourth hole elbow;
> Complete new water-cooled ducts;
> New water-cooled panels (combustion and
settling chambers);
> New quenching tower;
> New primary dry ducts;
> Electrical and automation systems.
The design is finalized to achieve the following
goals:
> High efficiency, relative to both fume
capturing and fume filtration;
> Integration in the treatment process of the
existing equipment, which can be reused;
> Minimization of the meltshop shut-down time
required for the installation works;
> Compliance with the area limitations and
other constraints of the site;
> Easy maintenance and long life of the
components.
When the second phase is completed, the
following parameters will be guaranteed:
> Maximum dust content emission at stack less
than 15 mg/Nm3 (already in Phase 1)
> No visible emission (opacity) at monitor level
(building roof location-Phase 2)
> Future production capacity increasing, up to
450,000 tpy of liquid steel.(Phase 2)

n February 2012, Riva

Acciaio assigned to Danieli
the order for a Ladle Furnace
with 80-t nominal rated capacity.
The new LF, together with an
existing one, will treat liquid
steel coming from two existing
EAFs and will deliver 24-25
ladles/day of treated steel to
the existing casting and rolling
facilities. Grades to be produced
include low- and mediumcarbon steels for concrete
reinforcing bars, wire rod, and
welded mesh. The ladle refining
station, served by an existing,

21-MVA transformer, features

inert roof design, ladle bottomstirring system, and emergency
stirring lance, together with wire
feeder and automatic sampling
machine supplied by customer.
LF operation will grant a heating
rate higher than 4 C/min, less
than 2-ppm/minute carbon pickup, and less than 5-ppm/heat
nitrogen pick up.
Danieli Automation will supply
an advanced Level 1 and 2
automation systems.
The startup of the unit is
planned for January 2013

Each FTP features an extraction capacity of up

to 118,000 Nm3/h of EAF primary off-gas at
1,200 C, and a secondary suction capacity
(during bucket charging) of 1.15 Mm3/h.
FTP technology is based on Pulse-jet type filter
to guarantee high filtration efficiency, low
pressure drop, and limited consumption of
compressed air.
Bag cleaning is controlled electronically and can
be programmed with the bag compartments, online or off-line.
The bags can be replaced without entering into
the filter, thus occupational health and safety
are not compromised
19

IRON & STEELMAKING

DANEWS

EAF upgrade
at Charter Steel, USA

harter Steel (part of Charter

Manufacturing) has contracted Danieli
for the mechanical upgrade of the
91-sht EAF currently in operation at the
Cleveland (OH) facility, to increase its capacity
to 113 sht in order to maximize productivity and
reduce transformation costs. The supply covers
the design, manufacturing, preassembly, and
supervision for installation and commissioning
of the revamped AC EBT furnace with a higher
steel and slag-retention capacity than the
present design. To maximize the furnace size
and suppress revamp costs and installation time,
significant efforts and analysis were conducted
to avoid excessive modifications: building
columns and working floor, EAF foundations
and rocker system, transformer and secondary
system, lifting and rotation unit, electrode arms
20

and columns are reused entirely, or without

major modifications. In order to increase the
tapping weight up to 95 sht with a total liquid
steel capacity of 113 sht, the existing shell
(lower and upper part), water-cooled panels,
roof, EBT mechanism, tilting platform, and the
main bearing are fully replaced. Since the
bidding phase Danieli has cooperated closely
with the assembly and installation companies in
order to ensure the scheduled outage time, and
to address any unforeseen construction issues.
Together with the supply of the EAF upgrade,
Danieli earned the order for the complete
engineering re-design of the caster spray
chamber, and for the pre-engineering study of
new rolling mill coilers

From left: D. Thompson,

Sr. Purchasing Specialist,
Charter Steel; U. Wilhelm,
Executive Manager, Danieli
Centro Met Swiss; G. Coco,
Project Manager, Danieli
Centro Met; R. Brisbin,
Head of Corp. Purchasing,
Charter Steel; J. Sarrocco,
Project Manager, Charter
Steel; G. Cappellari, Sales
Manager, Danieli
Corporation; S. Terlicher,
Director Engineering,
Danieli Centro Met; S.
Collins, Maintenance
Engineer, Charter Steel.

DANEWS 164

New EAF electrode conductive arms

at SN Longos Seixal, Portugual

The new arms will be

geometrically and electrically
identical to the existing ones,
but they will include all the
improvements developed
by Danieli in recent years.

N Longos Seixal has contracted Danieli for

a new set of electrode conducting arms to
be installed on the existing Danieli EAF,
supplied in 2001. The new design solution features
an internal water-cooled circuit that allows a higher
water speed, in order to avoid steel plates
overheating. In the existing arms the water-cooled
cables are connected directly to the arm structure
by means of threaded holes, while in the new arms
the threaded holes have been replaced by through
holes, in order to simplify the installation.
The new arms are completely coated with copper,
and are fixed on the columns by means of through
rods (with a complete insulation) in order to have
a better current distribution without local
concentration of overheating.
In the existing band a ceramic-coated plate was
used for sliding and insulation. In the new
installation, a special sliding bronze plate and an
independent insulating material guarantee a more
reliable condition and longer installation life

New arms characteristics

Electrode diameter (mm)

609

Electrode circle diameter (mm)

1,250

Voltage (V)

1,300

Inlet cooling water temperature (C)

35

21

IRON & STEELMAKING

DANEWS

Meltshop modernization
at Sohar Steel, Oman

Danieli Centro Met achieves

its goal to be the No. 1 supplier
for providing customized revamping
solutions for steelmakers.

From left: K.T.A. Rasoul, M. Redha Al Lawati, Shareholders;

and B.V. Mallya, Gen. Mgr. Financial, for Sohar Steel;
T. Narholz, EVP Danieli Centro Met; Sundeep Rao, Managing
Director; S.M. Rao, Shareholder, for Sohar Steel.

ohar Steel has awarded

Danieli Centro Met the
contract for a new, 75-t
FastArc Electric Arc
Furnace facility and a new,
140-t teeming crane, to be
installed at its meltshop in
Port of Sohar, Oman. Sohar is
the leading producer of long
products (billets and rebars)
in the country.
The new EAF is part of the
upgrading and modernization
of the meltshop, with the
target to produce 700,000 tpy
of liquid steel and to provide
Sohar Steel with the most
modern mechanical furnace
design. As for all revamping
projects offered by Danieli, a
22

deep analysis of the existing

facility, the involved logistics,
and operational practice had to
be performed, and the new
installation is the result of
intensive and fruitful
teamwork of the client
together with Danieli experts
from Danieli Centro Met
Swiss as the center of
competence for revamping
projects.
Due to the unique capability
of the Danieli Group to supply
the full range of equipment for
meltshops, it was a logical
consequence for the client to
contract not only the EAF
revamping to Danieli, but also
the new 140-t teeming crane

necessary to accommodate the

larger tapping volume of the
new furnace.
As for the EAF, also for the
crane: the combination of
viable technical approach
together with superior design
solutions, was the basis for the
order decision.
Decisive factors for placing the
order were Danielis technical
competence, the single source
responsibility, and the
continuous approach to find
the best quality manufacturing
for the client in Danielis own
workshops.
Plant startup is scheduled for
the mid of 2013

1,600/400-kN EAF
charging / teeming crane.
Right: 160-t twin-tank
vacuum degasser in
operation at OMKs
(Russia) 1.2-Mtpy,
QSP-based minimill
for hot-rolled coils.

DANEWS 164

200-t twin-tank
Vacuum Degasser
at Jindal Shadeed,
Oman
Danieli Centro Met consolidates
its market position in the supply
of VD with mechanical dry
pumps, a modern and reliable
solution that achieves the
optimal vacuum level necessary
for all clean and quality steels,
without any steam consumption
and related condenser water.

he new twin-tank type vacuum degasser

with a single cover will be installed in the
2.0 Mtpy Danieli meltshop under
construction, between the ladle furnace and the
conticaster, in an optimal location for logistics
and flexibility. The full set of auxiliary
equipment, such as automatic sampling and
temperature measurement units, wire feeders,
under-vacuum alloy hopper, and argon gas
stirring, is provided for all working positions.
A new material handling system, dedicated for
the facility, is provided, too. Vacuum is achieved
with a mechanical dry pump, the modern and
reliable solution that achieves the optimal
vacuum level necessary for all clean and quality
steels without any steam consumption or the
related condenser water. Suction capacity in the
range of 200 kg/h of dry air at 20 C is achieved
by eight mechanical pump skids, all connected
to a vacuum station by a textile filter with the
aim of removing all dust and guaranteeing a
maintenance-free installation.
An advanced Level 2 process control system
with metallurgical calculation, tracking, and
prediction functions, event data logging/replay
functions, and process simulation will enable
complete control of the refining process.
Products to be treated in the new facility
include structural and construction grade steels,
and API grades such as SAE 1019, SAE 1035,
SAE 1518, SAE 1541, SAE 4130, ST 52, API
5CT, and API 5 DP. Startup of the new plant is
scheduled for the end of 2012
23

IRON & STEELMAKING

DANEWS

Successful startup of the

1.32-Mtpy specialty steel meltshop
at Dneprosteel, Ukraine

he first cast was

performed on January
17, 2012, with 100 tons
of steel cast in 385-mm dia
blooms. Following the positive
results from macro-analysis
and chemical composition
tests, it was decided to roll the
first lot of pipes (to be used in
the oil-and-gas industry) on
January 30 at the Interpipe
NTZ facility. The test was
attended by directors and key
personnel of the installation,
technical service specialists,
the Deputy Chief Engineer of
Technology, Sergey Besednov,
and representatives of Danieli.
In total, 94 pipes of 12 m each
were produced according to
GOST 632-80 (OD 244.5
mm; WT 8.9 mm). Specialists
from Dneprosteels technical
department thoroughly
monitored all the technological
24

The facility, supplied by Danieli

on a turnkey basis, is made up of
a 160-t FastArc AC EAF, a twinstation ladle furnace, a double-tank
VD unit, and two FastCast
conticasters, to cover a wide range
of round billets and blooms for
producing pipes and rail wheels.

Congratulations for the successful plant startup are

exchanged by Marco Colloredo, CEO, Danieli Heavy
Machinery Engineering (Ukraine), Nikolay Soloshenko,
Chief Advisor and Project Coordinator, Interpipe
(center); and Aurelio Mortoni, Director Projects, Danieli.

parameters in every process

step, in order to verify all
aspects of pipe production,
starting from the conticast
blooms. In order to define the
actual consumption of the
steel during rolling of the
pipes, all the scrap metal was
weighed. The Deputy Chief
Engineer of Technology Sergey
Besednov reported that the
rolling process was performed
at a high level in each working
area involved, with no
problems. The visual inspection
showed that the quality of the
pipes corresponded to the best
expectations of the pipe mill to
reduce waste and increase the
overall production quality.
First of all, our expectations
following the use of
continuous casting billets,
aimed to obtain pipes of high
quality and to reduce waste.

DANEWS 164

said Sergey Besednov. In this

regard only, in the pipe mill
we hope to achieve savings of
steel not less than 5,000 tpy.
In the wheel making line the
savings could even exceed
11,000 tpy. Moreover, through
the continuous casting billets,
new business applications and
related certifications can be
applied, e.g., production of
corrosion-resistant pipes,
according to American
standard 5CT (steel grade
13Cr L80).
The billets of the new plant
will offer the opportunity to
reach the production level
efficiently and manufacture
pipes in compliance with the
standard API 5L. In a nutshell,
starting production of pipes
and wheels with billets from
the continuous casting
machine opens new horizons
and a new perspective for
Interpipe.
The minimill designed and
built by Danieli on a complete
turnkey basis includes all the
technological production
facilities, the auxiliary plants
and services, along with all the
infrastructure, civil works, and
supporting buildings. The new
meltshop is made of:
> A 160-t FastArc AC EAF,
equipped with chemical
energy injection technology
and HiREG electrode digital
regulations system, for
enhanced furnace operation
and for energy consumption
optimization. The split-shell
EAF operates on 100% scrap
charge.
> Refining station made up of
inert roof-type, twin-station
ladle furnace, and a doubletank VD unit equipped with a
four-stage 400 kg/h steam
ejector vacuum pump.
> A four-strand FastCast
bloom caster and a five-strand
FastCast billet caster, both
equipped with the latest
generation of tundish and
mold design, hydraulic
oscillators, and all means to
enable high-speed casting of
150 to 470-mm- dia quality
round billets and blooms
aimed at production of highquality pipes and railway

wheels. The meltshop includes

all auxiliary plants and
equipment, including material
handling system, fume
dedusting plant, and cranes.
Danieli Automation supplied
all the electrical systems and
an advanced, fully integrated
automation system for the
entire plant, including Level 3
for planning, production
progress control, and quality
management, scheduling, data
warehouse and stockyard
management.
Main figures relating to the
overall man-hours registered
as of December 31, 2011, attest
a total man hours worked in
excess of 6 million, and
monthly Total Safe man-hours
of 367,921. Approximately
332,316 working hours are
foreseen for the completion
of the installation phase (as
of December 31, 2011, the
overall progress of the project
was 98.85%)

1 Doghouse enclosing the 160-t EAF.

2 160-t FastArc AC split-shell EAF,
is equipped with HiREG electrode
digital regulation system.
3 Secondary metallurgy station, with
twin-station ladle furnace, and
double-tank VD unit.
4 Four-strand FastCast round bloom
caster to produce high-quality pipes.

25

FLAT PRODUCTS

DANEWS

Danieli seminar
on Thin Slab Casting technology
in India

India is currently one of the

most active countries in the
global steel industry, with
massive investment plans in
place to increase flatproducts capacity significantly.
Both the public sector and

private entrepreneurs have

already started impressive
development programs to
keep pace with the countrys
internal demand, both in
terms of increased levels
of consumption and product

n order to draw attention to its marketleading position in this field, as well as its
contribution to the development of Indias
steel industry, on December 2, 2011, Danieli
held a technological symposium at Taj Bengal
Conference Center in Kolkata, for the purpose
of showcasing its recent experiences and
consolidated results, as well as its vision for the
development of this technology, to an extremely
qualified audience of more than 120
representatives from 30 Indian organizations,
including private and public sector steel
producers, consulting companies, and
independent experts, representing the elite
of the Indian steel industry.
During a full day packed with detailed
26

diversification, to include
more advanced products
and market niches. Thin slab
casting technology
represents one of the most
suitable technologies to
sustain this market scenario.

presentations, senior Danieli directors and

experts went through the historical development
of thin slab casting technology, starting from
Danielis pioneering experiences in 1984 to the
most recent applications, substantiated and
documented by the concrete results achieved in
Danieli reference plants. The dramatic
expansion in product mix, to include high
added-value steel grades, and in productivity,
were illustrated to showcase Danielis most
recent projects, such as OMK, Russia (the only
thin slab casting and rolling plant in the world
specifically conceived for production of pipe
grades for the oil & gas industry); MMK
Metalurji, Turkey (the most modern minimill in
the Mediterranean region); and the Posco CEM

DANEWS 164

project, Korea (the most productive thin slab

casting and rolling plant in the world), with a
documented outlook of upcoming developments
thanks to the constant R&D activity of Danieli
Group. Danielis original contributions, such as
the vertical curved thin slab caster, and the of
HSM layout concept, with the separation of
stands into roughing and finishing mill groups,
were explained in detail to the audience,
elaborating on the concepts of ultra-high speed
casting, advanced rolling practices (including
real thermomechanical rolling) and ultra-thin
strip production by endless rolling.
Specific presentations were devoted to the fullpackage-approach that Danieli offers its
customers, including the significant

contributions of Danieli Automation and Danieli

Centro Combustion. The Indian market and
customers need to be followed very closely: this
was emphasized in a presentation of Danieli
Indias facilities and team of experts in Kolkata,
Mumbai, and Pune offices, including the first
official presentation of the new Danieli India
manufacturing center, expected to go live in
Andhra Pradesh by the end of 2012.
The successful event attracted the attention of
Indian experts, proving Danielis concrete
interest in India, backed by an active exchange
of information and data with conference
attendees during the Q&A time, the social event
after the technological presentations, and the
contacts that followed the meeting

The fTSR seminar was

attended by more than
120 representatives from
30 Indian organizations,
including private and
public sector steel
producers, consulting
companies, and
independent experts,
representing the elite
of the Indian steel industry.

27

FLAT PRODUCTS

DANEWS

4th-generation Danieli TSC design

applied to existing machines
to improve quality and productivity
at Dongbu Steel, Korea

Danieli Davy
Distington and
Dongbu Steel team
up in a project to
boost caster
productivity (20%
increase over the
design capacity)
by increasing the
casting speed up
to 6 mpm, as well
as to stabilize the
casting conditions
at the highest rate
of productivity,
while improving
automation for
easier process
control.
28

he Dongbu Steel Thin Slab Casters are

an integral part of the 2.6-Mtpy hot strip
complex, the new upstream production
line that Dongbu Steel awarded to Danieli in
May 2007. Dongbu Steel, a leading producer
of CR steel sheet, galvanized, pre-painted and
tin-plated sheets and medium- to large-diameter
pipes, recognized Danielis experience and
knowledge of the minimill concept, for plant
flexibility and low transformation costs.
After the successful final acceptance of the
plant in 2010, Danieli and Dongbu drew up a
program to enhance machine performance,
planning and implementing the road map that
led to the first fourth-generation TSC, namely
the state-of-the-art in continuous thin slab
casting technology.

Main features and results

Starting from an analysis of the root causes that

were limiting productivity, a detailed
investigation was carried out. This resulted in
the decision to focus the upgrade on improving
the machine configuration to eliminate the
dynamic bulging phenomenon -which has to be
considered the key negative factor to avoid in
high-speed production- through the following
actions:

> New roll diagram configuration, with very

tight roll pitches in the top machine section, for
a total containment length of 5.5 m (namely
Segment 0, Segment 1 and Segment 2);
> High-efficiency cooling nozzles from foot rolls
down to Segment 2;
> Improved mold fluid dynamics, through a
detailed study of SENs in combination with the

o
cust mer

sa

tis f a c tio n

1-2 Macroetch on
transversal (1) and
longitudinal (2)
sections of a slab in LC
steel, cast at 6 mpm.
3 Temperature profile and
line scanner
measuring.
4-5 Recording of casting
parameters for 6.0
mpm casting of LC steel
(slab width 1,200 mm)
(4); and MC steel (slab
width 1,230 mm) (5).

Danieli H2-funnel design. All segments were

prepared off line and replaced during the
regular weekly shutdown, with no additional
downtime required for machine modification.
The fixed frame of the machine remained
unchanged and the new segments are
interchangeable with the original ones.
The new automation features also were an
important part of the machine upgrade, with the
dual target of stabilizing process control at the
highest speed, as well as providing the machine
operators with reliable tools to completely
control the machine and even to anticipate and
avoid harmful forecast conditions.
The automation upgrade concerned mold
control using both the level control and the
thermal mapping (MBPS) system:
> Advanced mold level control (AMLC), with
LQG system was installed and tuned. With
LQG system, higher gain in the regulator is
applied, resulting in increased reactivity of the
regulator but keeping it stable without diverging.
This is due to the fact that the LQG regulator
reacts to a model and not to the actual
measured level signal (as PID control is doing);
> Bulging Rejection System, a dedicated
function for mold level control, has been
improved to minimize mold fluctuations;
> Twin sensors for mold level control
(radioactive and eddy-current type) to expand
the measuring capability and to deepen the
analysis;
> Further development of mold thermal
mapping system (MBPS), capable of identifying
mold sticking phenomena and avoiding them in
case of level fluctuations.
During the so-called high-speed optimization
campaigns, the following results have been
consistently achieved on 70-mm-thick slabs:
> Stable casting speed of 6.0 mpm for lowcarbon grades, for widths up to 1,200 mm.
> Stable casting speed of 5.0 mpm for lowcarbon grades, for large widths (1,530 mm), for
a casting throughput of 240 tph (20% more than
the original design capacity);
> Stable casting speed of 5.7 mpm for mediumcarbon steel, for widths up to 1,230 mm,
resulting in a casting throughput of 220 tph
(10% more than the original design capacity).
Dynamic bulging was suppressed in all casting
conditions. Very good results in terms of mold
level control were achieved, with a standard
deviation consistently lower than 1.0 mm.
Furthermore, no breakout occurred during the
high-speed optimization tests -more proof of the
reliability of the modification applied and the
stability of the process. Results show good
internal quality, with no cracks and negligible
centerline porosity. The temperature profile at
the machine exit indicated a slab with very
stable and even temperature.

Conclusions

Danielis design concept is able to guarantee the

highest level of productivity and both surface
and internal quality, resulting from all the
experience gained at OMK (Russia), Tangshan,
Benxi and Tonghua (P.R. China), Ezz Flat Steel
(Egypt), Algoma (Canada).
The same machine upgrades can be applied to
all of the first-generation Danieli TSCs, by
reducing machine modifications and shutdown
time to a minimum, targeting higher TSC
productivity with a limited investment cost. The
automation upgrade plays an important role in
stabilizing and enhancing casting process
control. These great achievements are the result
of the positive teamwork done by Danieli and
Dongbu technicians, which enabled the smooth
completion of this strategic project and its
further enhancement. With this achievement
Danieli Davy Distington once again confirms its
undisputed global leadership as a supplier of
slab casting technology, as well as the capability
to establish successful partnerships with the
customers to match specific needs by
customizing specific solutions

29

FLAT PRODUCTS

DANEWS

Danieli shakes up
the upgrade of Indias first
and biggest hot-strip mill

On January 7, 2012, a
Danieli Team (DWU in
consortium with DIL and
DFE) signed a contract with
SAIL, Bokaro Steel Plant,
for a major upgrade of the
hot-strip mill, including
a new roughing mill.

okaro Steel Plant -the fourth integrated

plant in Indian public sector- started
taking shape in 1965 according to the
terms of an engineering collaboration of the
Soviet Union. It was originally incorporated as a
limited company on January 29, 1964, and in
1978 was merged with SAIL.
The hot-strip mill at the Bokaro Steel Plant was
built in the 1970s with an installed capacity of
1.7 Mtpy, and later expanded to its present
capacity of 3.95 Mpty. The 1,850-mm
(maximum strip width) continuous hot-strip mill
was the first and largest mill in India.
The Danieli Team has been entrusted with this
turnkey upgrade project aimed at increasing the
HSMs capacity from its current 3.95 Mtpy to
4.5 Mtpy.
New equipment to be installed as part of the
upgrade project includes:
> A primary descaler spray station,
> A heavy vertical edger with HAWC and allnew electrical controls and automation,
> A two-high reversing roughing mill, with allnew electrical controls and automation,
> Drive spindles and pinion stands for R3- R5,
> Quick work-roll changing system for roughing
stands R3-R5,
30

> Hydraulic automatic gauge system (HAGC)

in rougher stand R5,
> Passive heat panels between roughing and
finishing mills,
> Roller table and drives in roughing mill area,
> Automation system and interfacing of this
new system with existing electrical /
automation.
Moreover, various equipment along the roughing
mill (e.g. entry side guides) will be modified and
reconditioned.
A new, two-high reversible roughing stand
(RR2) with an attached edger will be installed in
place of the existing continuous roughing stand
R2. This new stand will make it possible to
process slabs up to 250 mm thick and to
increase the average coil weight and net
production rate. The new vertical edger at RR2
and existing vertical edgers at R3, R4, and R5
will be equipped with hydraulic automatic width
control (HAWC), resulting in products with
better dimensional tolerances for demanding
markets. The new passive heat shield at the
delay table after R5 will ensure better
temperature homogeneity of the transfer bars at
roughing mill exit. The revamping work will be
done during an 18-day shutdown (limited mill

1 At the contract signing

ceremony, a handshake
between shared by
P. Tarikere, Product
Manager DWU, and
R.K. Tripathi, SAIL
General Manager,
in the presence of
Executives of SAIL,
CET, and Danieli.
2 Reversible roughing
stand with attached
vertical edger.
3 General layout showing
new (green) and
revamped (red)
equipment.

DANEWS 164

production) for the roughing mill R2, followed

by a 25-day complete hot-strip mill shutdown.
The Danieli Group (and in particular DWU,
whose share of the Indian hot flat product
market is on the rise), in the past few years has
been achieving important results in India (the
Bokaro order is a typical example), consolidating
its position and reliability as a technology
supplier and turnkey project developer

Plant and material data (after revamping)

Production output

4,500,000 tpy

Strip thickness

1.5 - 16 mm

Strip width

700 - 1,850 mm

Coil ID

850 mm

Coil OD

2,300 mm

Max. coil specific weight

20 kg/mm

Max. coil weight

32 t

1 New primary descaler

2 New two-high reversing roughing
mill with vertical edger with HAWC,
and all new electricals and
automation
3 New drive spindles and pinion
stands
4 Quick work-roll changing system for
roughing stands
5 Passive heat panels between
roughing and finishing mills
6 Quick work-roll changing system for
roughing stands

31

FLAT PRODUCTS

DANEWS

New 4.0-Mtpy hot-strip mill started up

at Baosteel Meishan, P.R. of China

On April 2, 2012 -one month

ahead of the contracted
target date- the 1,780-mm
conventional hot-strip mill
installed in Meishan
(Nanjing), successfully began
its ramp-up to the target
capacity of 4 Mtpy.

32

aosteel Meishans new hot-strip mill will

produce top-quality coils with strip
thicknesses ranging from 1.2 to 19 mm,
and widths from 900 to 1,630 mm, in HS
complex-phase, HS cold-forming, antiatmospheric corrosion, and ULC steels for a
wide variety of applications (including the
automotive industry). The new mill consists
of three reheating furnaces, primary water
descaler, two reversible roughing stands with
vertical edgers, heat-retention panels after the
roughing group, finishing mill area, finishing
mill exit measuring devices, strip-cooling
section, two downcoilers, and coil evacuation
and handling system. Danieli designed and
supplied the mechanical and hydraulic
equipment for the core of the new hot-strip
mill, i.e. the finishing mill area, which includes
adjustable hydraulic entry side guides, crop
shear with max. 50-mm cutting capacity, highpressure water descaler, vertical edger with
automatic width control, seven four-high
finishing stands (with a separating force up to
42,000 kN for F1-F4 and up to 36,000 kN for
F5-F7) equipped with HAGC, heavy bending
(positive up to 2,000 kN and negative up to
1,200 kN) and WR shifting (150 mm),
interstand loopers, roll-bite lubrication, selective
cooling, and quick roll-change system for F1-F7.
Danieli Automation developed and supplied the
latest-generation automation package based on
its HiPAC technological platform, featuring
high-speed, Ethercat FieldBus proprietary I/Os,
covering the entire process line from reheating
furnace exit to the downcoilers and coil
evacuation area. The latest technological and
process control solutions, backed by the
experience gained in the hot-strip mills Danieli
recently supplied in Russia and Turkey,
multiplied by great effort, professionalism and
collaboration by both Baosteel and Danieli
teams throughout all the project phases,
advanced the growth of the plant: one month
ahead of schedule, the plant produced its first
hot-rolled coil during the hot-test ceremony
held in Meishan on April 2, 2012, hosted by
the top management of Baosteel Holding and
Baosteel Meishan. Now, the parties are already
setting ambitious production performance
targets for the new mill and continue to aim
for the highest achievements, of which this mill
is surely capable

From top: Friendly

handshake at the end of
the plant tour between
Jiang YiFeng, VP Baosteel
Meishan (right) and
Georgios Ximeris, EVP
Danieli Wean United.
The first coil was rolled one
month ahead of schedule.
Liu Daide, President of
Baosteel Meishan and
Dario Fabro, EVP Danieli
and Head of Erection and
Commissioning Dept.

DANEWS 164

Plant and material data

Production output

4,000,000 tpy

Strip thickness

1.2 - 19 mm

Strip width

900 - 1,630 mm

Coil I.D.

762 mm

Coil O.D.

2080 mm

Max. spec. coil weight

22 kg/mm

Max. coil weight

33 t

33

FLAT PRODUCTS

DANEWS

First Q&T plate leveled

at SSAB NAD, USA

Hot commissioning
of the heattreatment leveler
started on February
16, 2012.
Performance tests
are in progress and
a successful
project completion
is expected in
agreement with
schedule.

experience gathered by SSAB

and Danieli in the startup of a
similar leveler at SSAB
Oxelsund allowed a smooth
completion of the installation
and commissioning phase of
this new leveler for SSABs
plant in Mobile (AL).
This is the sixth Danieli plate
leveler supplied to SSAB
during the long-standing
cooperation between SSAB
Group and Danieli, confirming
Danielis ability to fulfill
SSABs high standards, as well
as being a key indicator for
success in new projects
1

his leveler is nearly

identical to the one
supplied by Danieli to
SSAB Oxelsund (in operation
since April 2007), this fact
being a confirmation of the
satisfactory performance of
Danieli levelers in the very
demanding application of
high-strength plate leveling.
Key features to meet these
challenging requirements are
Danielis patented
MULTIMOTOR - MULTI
MOre TORque drive system
(to deliver high torque with
very precise control) and the
BUR, whose lifetime
improvement is the result of
the combination between
SSAB experience in ultra highstrength steel production and
Danieli expertise in heavy-duty
machine manufacturing.
Danielis continuously
increasing know-now, due to
several plate levelers
successfully commissioned in
recent years, helped to
simplify the execution of this
project easier and to achieve
the contractual targets.
In addition, the specific
34

Main features of the cold plate leveler

Type

9-roll cold plate leveler

Steel grades processed

A514 Grade B, A514 Grade S,

AR400F, AR450F, AR500F

Material thickness

4.8 - 12.0 mm

Material width

2,100 - 3,100 mm

Material length

6,000 - 15,200 mm

Leveling speed

0.3 - 0.7 mps

Leveling force

18,000 kN

No. of work rolls

4 - top; 5 - bottom

1 SSAB NAD and Danieli

commissioning teams
in front of the highstrength HT leveler.
2 Detail of the bearingtype backup roll system.
3 Danieli high-strength
heat-treatment leveler in
operation at SSAB
Oxelsund, Sweden.
4 Detail of the very first
Quenched and Tempered
plate leveled.

DANEWS 164

This is the sixth Danieli plate

leveler supplied to SSAB
during long-standing
cooperation between SSAB
Group and Danieli.
It is a confirmation of
Danielis ability to fulfill
SSABs high standards,
as well as being a key for
success in new projects.

35

FLAT PRODUCTS

DANEWS

New hot skin-pass mill

with in-line side trimmer
at Gerdau Aominas, Brazil

The contract for the new

facilities to be installed in the
Ouro Branco (MG) works,
signed on November 30, 2011,
strengthens Danieli Wean
Uniteds presence in the
Brazilian market, and advances
its leadership in hot skin-pass
mills with a score of 10 units
supplied in 10 years.

erdau Aominas is one of the largest

suppliers of steel long products in the
world. They operate in 14 countries in
the Americas, Europe, and Asia, with an
installed capacity of over 25 Mt of steel per
year. Gerdau is now entering the flat steel
market and chose Danieli Wean United to
supply its first cold mill for black coils coming
from its Steckel mill. The hot skin-pass mill will
process up to 823,000 tpy (1.2 Mtpy in a second
phase) of hot rolled strip of LC and MC, API up
to X56, shipbuilding, HSLA, pressure vessel,
deep and medium-drawing grades, ensuring full
compliance with final product requirements for
suppressed yield point, improved strip flatness,
roughness transfer, and improved coil shape.
The main features of the mill are:
> Entry coil-handling system, including walkingbeam conveyors, coil car, coil preparation
station, payoff reel, and five-roll flattener;
> Four-high mill stand with long-life work rolls,
36

chocks and bearings, bending blocks, quick

work-roll change device, wedge for pass-line
adjustment, backup roll change, roll cleaning
system;
> Worlds first in-line turret-type, high-speed
(up to 350 mpm) side trimmer and scrap
chopper for heavy gauges;
> Delivery section consisting of hydraulic shear,
strip inspection facilities, double-diameter
tension reel, coil car, and walking-beam
conveyor;
> Equipment electrical control and automation
systems;
> Coil transport car and coil tilter;
> Cranes for coil handling in the storage bay.
Danieli Automation will supply the Level 1 and
Level 2 electrical and automation systems,
including the mathematical models for
presetting and tracking of current conditions, as
well as self-adaptation of the mill. Startup of the
new line is expected by May 2013

1 Souvenir photo at the

contract signing
ceremony.
From left: A. Betzios,
Director, Danieli Brazil;
L. F. Soares, Product
Manager Gerdau
Aominas; L. Mottes,
Danieli VP Key Account
Management; A. S.
Gonalves Campos,
Purchasing Dept. Gerdau
Aominas; P. C. Dias,
Technical Referral Flat
Rolling Mills, Gerdau
Aominas; A. Rigotti,
Executive Product
Manager DWU.
2-4 Kick-off meeting and
site survey.
5 High-tech hot skin-pass
mill in operation at
Tokyo Steel, Japan.
6 3D sketch of a typical
hot skin-pass mill
installation.

DANEWS 164

Plant and material data (Phase 1)

Output

823,000 tpy (Phase 1)

1,200,000 tpy (Phase 2)

Strip thickness

1.5 - 6.5 mm (for skin-passing)

1.5 - 12.7 mm (for recoiling/divided)

Strip width

900 - 2,100 mm

Coil ID

610 - 762 mm

Coil OD

1,100 - 2,100 mm

Max. coil weight

12 - 31 t entry (Phase 2: 12 - 44 t)
5 - 31 t exit (Phase 2: 5 - 44 t)

Piw

21 kgf/mm

Rolling force

15,000 kN

Elongation rate

Max. 4%

Yield strength

200 - 600 MPa

37

FLAT PRODUCTS

DANEWS

Flat products minimill

nearing completion
at MMK-Metalurji, Turkey

flexible Thin Slab Casting and Rolling Line

The Danieli fTSR complex installed at

Iskenderun includes an electric arc furnace,
ladle furnace, vacuum degasser, thin slab caster,
and hot-strip mill, with a nominal annual
capacity of 2.3 Mt of HRC.
The first part of the casting and rolling facility is
a Danieli twin-strand, thin slab caster producing
from 50 to 80-mm-thick slabs (after dynamic
soft reduction), in widths from 800 to 1,570 mm.

38

DANEWS 164

The second part includes two roller-hearth

furnaces (one for each casting line) and a rolling
mill. The furnaces ensure that the slabs are kept
at the right temperature and act as buffers
between casters and mill. Covering less than
137 m, the hot-strip mill consists of 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.
Completing the line is a coil handing system
with circumferential and radial strapping

Following startup, the hot

section (Thin Slab Casting
and hot rolling) is showing
excellent progress, while Final
Acceptance was achieved for
the cold section (continuous
pickling line, 2-stand cold
reversing mill, hot dip
galvanizing line, and color
coating line).

39

FLAT PRODUCTS

DANEWS

machines, weighing scale, marking unit, and

visual inspection station. Danielis scope of
supply includes all the electrical and automation
systems as well as the drive technology. Danieli
Automation tuned all the automation
components and performed the FAT-Factory
Acceptance Tests, thus enabling the
commissioning phase to be completed quickly.
Cold Mill Complex

On January 10, 2012, after the successful

completion of the agreed performance tests,
MMK-Metalurji and Danieli Wean United
signed the Final Acceptance Certificate for all
the cold processing lines installed at the
Iskenderun site. The cold complex includes:
> Turboflo Continuous Pickling Line (CPL).
This line has a production capacity in excess of
1.2 Mtpy, with three pickling tanks and fivestage rinse tank, based on Turboflo technology
(Danieli patent), representing the most
advanced turbulent channel concept for the
highest energy savings and flexible pickling
conditions.
> Two-stand Cold Reversing Mill (CRM) to
produce approx. 0.75 Mtpy of LC, CQ, DQ,
DDQ, and HSLA steels, complete with all the
mechanical devices needed to ensure a flexible
production program.
> Hot Dip Galvanizing Line (HDGL) to
produce 0.45 Mtpy of finished coils for highquality painted applications. It features a double
entry end, horizontal annealing furnace from
Danieli Centro Combustion, and Danieli Kohler
wiping system for precise control of zinc
thickness.
> Color Coating Line (CCL) to produce

40

DANEWS 164

Plant and material data

Production output

2.3 Mtpy

Slab thickness

50/70/80 mm

Slab min-max width

800 - 1,570 mm

Max. slab length

43,000 mm

Strip thickness

1.0 - 20.0 mm

Strip min-max width

800 - 1,570 mm

Coil nominal ID-OD

762 - 2,000 mm

Max coil weight

30.0 t

0.2 Mtpy, for white goods, construction

materials, and general commercial applications.

The plants came on-stream in stages throughout

2010 and 2011, starting with the CCL coating
facilities and ending with the CPL and CRM
rolling facility. The production of the first hotrolled coil on May 4, 2011, concluded the
startup of all the facilities of the new steel
complex. The close interaction between the
mechanical, electrical and automation
equipment supplied by Danieli means
maximum cost-effectiveness and, thanks to our
technological follow-up and customer
assistance, Danieli Wean United reconfirms its
role as a state-of-the-art plant supplier

1 Overall layout of the cold

mill complex at MMK
Metalurji in Iskenderun.
2 Control pulpit of the
two-stand cold reversing
mill (0.75 Mtpy).
3 Turboflo Continuous
Pickling Line (1.2 Mtpy).

4 Hot Dip Galvanizing Line

(0.45 Mtpy).
5 Color Coating Line (0.2
Mtpy).
Previous page: 2+4-stand
compact hot-strip mill.
Insert: twin-strand, thin
slab caster.

41

FLAT PRODUCTS

DANEWS

20-high mill in production

at Chinalco Shanghai Copper. P.R. of China

he newly supplied, 20-high reversing cold

rolling mill for copper and copper alloys
entered the final commissioning phase at
the beginning of 2012. Meanwhile, the mill is in
production and already has reached its target for
minimum strip thickness and maximum design
speed. This has been appreciated by the
customer in a self-explanatory Letter of Thanks
we received:
...on behalf of all the members of my team, Id
like to express our heartfelt gratitude to all DFs
site commissioning specialists for their great efforts
in the commissioning and test running of this
20-high cold-rolling mill. On this mill they have
produced copper at the ultimate minimum
thickness (T2, 0.015 mm x 610 mm) with the
max. coil weight of up to 800 kg, and tried rolling
at the ultimate high speed of 800 mpm. This is
excellent progress for the commissioningof the
20-high cold rolling mill.
We want to say again: thank you!

The newly supplied 20-high reversing

cold-rolling mill for copper and copper
alloys entered the final commissioning
phase at the beginning of 2012.
o
cust mer

Xu Zhengzhe, Team Leader for 20-high Cold

Rolling Mill, CSC Co. Ltd.
These results are based on the close cooperation
between the end-user, Chinalco Shanghai
42

sa

tis f a c tio n

DANEWS 164

Copper Co., Ltd. (CSC), and Danieli Frhling

(DF), as well as Danieli Automation. The
achievement shows again that DFs 20-high
cluster mill design and technology is well proven
and suitable even for producing the thinnest
copper foils. A few years ago, DF supplied a
similar mill to Fujian Zijin (China), which was
the first cold mill in China for rolling copper
down to 10 m. The large number of control
elements in a Danieli Frhling cluster mill is
unique in the world, allowing intermediate rolls
to bend and shift according to the requested
strip properties together with single adjustment
of back-up roller bearings. The common mill
housing design allows tilting of the upper roll
set and quick, closed-loop control of nonsymmetrical strip profiles. The mill at Shanghai
Copper is able to roll copper alloy strips to a
minimum thickness of 0.015 mm at a maximum
strip width of 670 mm. The maximum incoming
strip thickness of 1.6 mm is processed at speeds
of up to 800 mpm. Danielis supply covers all
mechanical and electrical parts, including coiler
stations, entry- and exit side guides, exhaustand media filtering system, and a fire
extinguishing system, as well as related media
systems. In order to assist the customer in its
ambitious effort to be the leading copper strip
and foil producer in Asia, Danieli Frhling will
regularly dispatch its experienced rolling
technologists to CSCs plant. Providing
knowledge on sophisticated rolling technology
during installation, commissioning, and training
courses, is a benefit on top of the equipment
supply. Danieli Frhling possesses dedicated
rolling specialists who support our own on-site
team during essential phases of commissioning
in order to advance the learning curve for the
customers staff

High-speed trimming lines

at Shandong Weiqiao, China
Weiqiao Textile Group, Chinas largest
privately owned aluminium producer,
is expanding its field of business and
investing in a production facility at
Shandong Weiqiao Aluminum & Electricity
Co. in Zouping (Shandong Province).

art of the project is two,

modern aluminium
trimming lines for wide
strips, with high speed, highperformance, and high-quality
capabilities, to be supplied by
Danieli Frhling. The
thickness of the main product
is 0.1-1.2 mm, with widths of
980-2,150 mm at a max. coil
weight of 30 t (without spool).
The maximum strip cutting
speed is 1,500 mpm. The
production capacity for two
trimming lines will be over
460,000 tpy. Mainly, alloys of
series 1xxx, 3xxx, 5xxx, and
8xxx will be processed. The
order includes the complete
system from coil entry side, inline coil preparation,
electrostatic oiling, side
trimming, scrap suction, and
recoiling at high speed.
Furthermore, the auxiliary
systems and electrics and
automation are part of the
scope of supply.

Special features, such as inline preparation with drum

shear (head end cropping) at
200 mpm; CNC trimming
shear for fully automatic
adjustment of width, knife
immersion and cutting gap;
and a reliable scrap suction
and removal system, including
wet washer unit, are included
in the package. With the order,
the customer honors DFs
leading market position for
such equipment and relies on
the proven high-end
technology to meet the
required production schedule,
as well as final product quality.
DF has been the contractor for
nine of such or similar highspeed trimming lines in China
during the last decade.
Further orders from around
the world bring the total to
some 15 lines for speeds of
over 1,000 mpm made by
Danieli Frhling
43

LONG PRODUCTS
Snapshots from the 3-day
seminar and the tour at
DCS facilities in Changshu.
On this page: L. Maestrutti,
EVP, Head of the Section
Mills Division; and
F. Mulinaris, EVP, Head
of the Bar and Wire Rod
Mills Division, making
their presentations at the
Seminar.

DANEWS

>Innovaction< in long products

Technology Seminar in China
The Seminar, organized in collaboration with
the Chinese Society for Metals, was held in
Shanghai, on February 21-23, 2012, and its
target was to present the latest Danieli technology
developments for long product mills to the most
important Chinese producers. Also, it was a
valuable opportunity for our customers to meet
and exchange opinions on the new trends in this
sector. The first day was dedicated to Section
Mills Division with the following presentations:
> Premium-quality rails production;
> Winning technology for medium/heavy
section mills;
> Danieli leadership and innovations in large
SBQ mills;
> In-line heat treatments for large bars and
sections;
> Danieli Automations Q3 suite for section and
rail mills.

More than 150

people, coming from
the most important
Chinese steel
producers for long
products, enjoyed the
technical
presentations in
addition to the
dedicated meetings
organized during the
event.

44

Participants were particularly interested to learn

about the innovations in large SBQ mill
technology aimed at enhancing productivity and
product quality.
The second day was dedicated to the technical
achievements in Bar and Wire Rod Mills with
the following presentations:
> New technology for bearing steel bar
production;
> The new 750,000-tpy superflexible, multi-line
section and SBQ bar mill for Celsa Huta
Ostrowiec in Poland;
> 50 mps on the cooling bed to enhance
profitability in rebar production;
> Danielis latest references and know-how for
stainless steel production;
> Quality and accuracy: a new age of controls
for bar and wire rod mills.
In addition to the technical discussions and
talks, participants were taken on a tour of the
Danieli workshops (DCS) in Changsu, operating
since 2006, where customized meetings have
been arranged and where customers could
appreciate the capabilities, the superior
manufacturing quality, and the wide range of
services Danieli can offer

DANIELI
SOLID
NUMBERS
IN LONG
PRODUCT
MILLS
TECHNOLOGY
From the Danieli
Scorecard:

42

Heavy section
and rail mills

335

Bar mills

164

Wire rod mills

120

Stainless and
special steel mills

118

HTC-High-speed
Twin Channel systems

12

Large SBQ mills

DANEWS 164

45

LONG PRODUCTS

DANEWS

The major achievements and results of

Danielis wire rod mills in terms of:
Speed

> 120 mps on a consistent basis;

> Minimum vibration <1.5 mmps with
Oil-Film Bearing Loop Laying Head;
> Self-adapting speed control by Danieli
Automation to compensate speed drops.
Efficiency

> Roll wear reduced down to 30% thanks

to in-line HiSECTION for cross-section
measurement;
> 900 days maintenance-free at 105 mps
with Delta Wire Rod Block;
> Precise wire rod head positioning
because of synchronization between HSSHigh-Speed Shear and LLH-Loop Laying
Head;
> 92% Mill Utilization Factor thanks to
quick-changing system on the entire line
and free-size rolling process.
Quality

> 0.1 mm with 50% ovality ( 0.075

mm with 50% ovality on 5.5-mm dia.);
> 10 Euro/t saving in production cost with
UGR process;
> Closed-loop control on
Thermomechanical Rolling Process;
> Coil shape and compactness guaranteed
by SUNDCO H, H/V or V systems;
> Maximum one or two loops out of
tolerance on the coil.
Efficiency and Quality

> Danieli Automation control and in-line

sensor to guarantee stability and
consistent product quality.

46

How to obtain
the best product
and performances
with the latest
Danieli equipment
H3 wire rod line:
> High Speed
> High Efficiency
> High Quality

DANEWS 164

Danieli wire rod technologies at the forefront:

a continuous success with 164 plants supplied
worldwide since 1963

anieli Morgardshmmar
launches a new era in
wire rod production for
the benefit of the customer: all
of this newly designed
equipment will make your mill
faster and more reliable than
ever! We can show you how.

WRB/WRBM2 - Pre-finishing or
finishing block

For finishing wire rod in

diameters from 5 to 27 mm,
modular design for flexible
configurations to suit the
rolling layout and metallurgical
process, providing finishing
speeds of over 150 mps
(design 170 mps), size
tolerances down to 0.1 mm
on 5.5-mm diameters, with
ovality of 70%. Quickchanging system and robotized
device for ring changing,
rolling temperature down to
750 C, and single or
multidrive configuration to
enhance ring use.
CSB Compact Sizing Block

A compact system that is

compatible with upgrades to
existing wire rod mills, for
5.0 to 20-mm-dia. wire rod
products at finishing speeds
of over 150 mps (design 170
mps) and tolerances down to
0.1 mm, for all sizes with
ovality of 60%. Rolling
temperatures down to 750 C.
TMB/WRS Wire Rod Sizing
Block

For finishing and sizing of wire

rod diameters from 4.5 to 27
mm, at finishing speeds of
over 150 mps (design 170
mps), suitable for
thermomechanical rolling
(down to 750 C and
normalizing rolling). Provides
excellent size tolerances ( 0.1

mm, with 50% ovality over the

whole range and 0.075 mm
with 50% ovality on 5.5 mm),
single-pass family (all products
finished in the TMB/WRS)
and product changing time
down to 4 minutes.
Also, we have optimized the
WRB Mandrel design using
the One Size Fits All concept
to fit WRB-WRBM2-CSBWRS Blocks (excluding sizing)
based on long-term experience
obtained after more than 900
days of uninterrupted
production, vibration values of
less than 2 mmps, superheavy-duty design, and inhouse manufacturing.
Some improvements have

been made to the LLHPLUS Loop Laying Head, which is

practically vibration-free
during rolling (less than 1.0
mmps at 120 mps) thanks to
our patented oil film bearing,
and low pipe wear resulting
from an optimized pipe shape
and material (5-6 times less
wear than the conventional
system).
Optimal control of last loop
formation and head
positioning, for large-size loops
up to 27 mm and double pipe
arrangement to increase
lifetime and plant utilization
factors. Danielis system for
working at 150 mps is
provided by our Turbo LLH -

Turbo Loop Laying Head. The

newly designed pipeless rotor
does away with 60 worn
pipesmeaning reduced
maintenance and downtimes.
It ensures repeatable loop
formation with steady, regular
laying on the Controlled
Cooling Conveyor, and
reduced noise level (86 dBA
vs. 110 dBA) compared to the
traditional LLH. Further
benefits are diminished
unbalance vibrations due to
axial-symmetrical wearing and
predictable and controllable
wearing results, with no
cobbles due to unexpected
pipe wear. The well-known
DSC Danieli Structure
Control has been upgraded
with the latest fixed, shiftable
and remotely controlled
rotating water cooling lines
with pre-mounted cooling sets
to provide a perfect,
guaranteed alignment with
time savings of 55-58 minutes
for setup changes. The
traditional water cooling boxes
require 60 minutes to change
the cooling elements,
compared to the RotoCoolerTM
which takes only 2 minutes.
Wire rod technologies include
our well-known, reliable
processes and machines to
achieve a perfect coil shape,
such as: LTR - Low
Temperature Rolling for
special steel grades, UGRUltra-fine Grain Refinement
heat treatment for rebar
production, HSS High-Speed
Shear, RRT Rotary Reforming
Tube and Easy-Down systems,
SUNDCO H, V and V/H,
The Art of coil handling
systems by Sund Birsta, DLPP
Danieli Long Products
Predictor - the tool for process
control
47

LONG PRODUCTS

DANEWS

First heavy sections

produced in the Middle East
at Emirates Steel, UAE
Last January 30, 2012, Emirates Steel sold
and delivered the first heavy sections (UC 305
x 305 x 97) produced in the Middle East.

fter the positive hot startup on December

5, 2011, the hot tests of the five
contractual products (UC305x305x97,
UB457x191x98, UB914x305x201,
UB610x229x101, UC356x368x202) were
performed according to the program, and
completed at the beginning of March 2012.
Subsequent to the hot tests, UC356x406x340,
UB914x419x340, UB254x146x31,
PFC430x100x64, and PFC200x75x23 products
were rolled, achieving the ambitious and
excellent figures of DIN tolerances
(dimensional and straightness), and yield of
94%. Thanks to these results, the plant
performance test was scheduled to be
completed by the end of May.
These results are the consequence of the plants
high utilization factor, which is possible thanks
to reduced changing times, high
efficiency/reliability of equipment, high
availability of automation, as well as the
professional approach, collaborative spirit and
mutual efforts by Danieli, Emirates Steel and
McLellan teams.
The new mill is integrated with the 1.4-Mtpy
No. 2 steel meltshop and the associated DRI
plant already started successfully in Autumn
2010. This is the latest stage completed for the
Mussaffah integrated minimill plant, entirely
supplied by Danieli on a full turnkey basis. The
Heavy Section Mill will produce parallel-flange
beams, columns, and bearing piles with web
depths up to 1,016 mm and flange widths up to
419 mm, up to 430-mm parallel-flange
channels, 250-mm angles, 750-mm U-sheet
piles, and 630-mm Z-sheet piles using conticast
blooms and beam blanks as starting material.
The plant, based on the PSP-Profile Sizing
Process, is fed by a 250-tph Danieli Centro
Combustion walking-beam reheating furnace,
directly connected to the Beam Blank
Conticaster for hot-charging operation. The hotrolling area is composed of a single reversing
stand BDM Break Down Mill and the UFRUltra Flexible Reversing pre-finishing /finishing
48

Products already rolled and tested, achieving

DIN tolerances

>
>
>
>
>
>
>
>
>

UC 356 x 406 x 340

PFC 430 x 100 x 64
UB 914 x 419 x 343
UB 914 x 305 x 201
UB 254 x 146 x 31
UB 610 x 146 x 31
UC 356 x 368 x 202
UB 457 x 191 x 98
UC 305 x 305 x 97

mill, made up of three close-coupled universal

stands. After the finishing stand, a HiPROFILE gauge unit (Danieli Automation)
enables the in-line product size measurement
and cloosed-loop control. The mill's finishing
end includes a cooling bed, in-line jumbo-size
straightener, cutting-to-length, automatic
stacking, gaging, repairing, piling and collecting
facilities

Highlights DANIELI AUTOMATION

DANEWS 164 / PROCESS CONTROL, POWER, AND INSTRUMENTATION

Q3INTELLIGENCE
BUSINESS INTELLIGENCE
FOR THE METALS INDUSTRY

MES SOLUTION
AT VIZAG
VISAKHAPATNAM, INDIA

Q3INTELLIGENCE - BUSINESS INTELLIGENCE

FOR THE METALS INDUSTRY
The Q3Intelligence platform combines operational data
with analytical tools to present complex and competitive
information to planners and decision makers
Integrating Danieli Automations extensive
experience in designing, manufacturing,
and commissioning automation systems
for the metals industry, with skill at
designing and developing Business
Intelligence (BI) systems, Q3Intelligence
addresses the need to transform large
amounts of data into useful information,
in order to optimize the metallurgical
production process.

The Q3Intelligence platform interface.

Right: the Q3Intelligence architecture
and data flow diagram.

Web-Report
The Web-Report solution integrates the
most recent technologies for creating and
distributing the various types of reports.
Rapid access to information is provided
through queries and reports. Even
inexperienced users can access this
information without involving the IT
department, with data that is presented
in terms that non-technical business
users can understand readily. Web-Report
is provided with a complete set of
specic reports for each process area to
be covered, to which it is then possible to
add an unlimited number of new reports.

Web-Dashboard
The Web-Dashboard module provides
users with a set of web-based consoles to
monitor Key Performance Indicators (KPI)
that convey how well each process area is
performing; an innovative and complete
KPI library is available, consisting of a
set of advanced KPIs that are structured
and categorized according to the
applicable types of processes.
I2

MOREIntelligence - OLAP
MOREIntelligence is the advanced data
analysis and visualization system for the
metals industry; this is the most powerful
data-investigation tool of Q3Intelligence,
comprising two modules, OLAP and
Analytics.The MOREIntelligence system
is fully integrated with the Level 2 and
MES systems and applications, but it also
provides the opportunity to collect data
from other external sources.
Thanks to its advanced data models and
the interactive interface developed over
several years, MOREIntelligence is a
powerful tool with which to make indepth and exible analyses across the
various plant areas and processes.

MOREIntelligence - Analytics
Some of the most important new entries
of the MOREIntelligence modules are the
Analytics tools, with which users can
increase the volume of information
generated from the data, extracting some
knowledge that was not previously

available. The analytics tools allow:

> Performing advanced statistical analysis
on plant data;
> Evaluating the quality of the production
processes;
> Applying advanced data-mining
algorithms in order to discover the
relationships within sets of data, or to
predict trends and behaviors of the
analyzed variables;
> Perform analyses on different scenarios,
also known as What-If Analysis.

Mobile BI
With Q3Intelligence you also can count on
a powerful mobile extension with which
to obtain instant and highly interactive
access to plant data, from virtually
anywhere. Mobile access to your data
comes with a gesture-driven application
that brings intelligence to the front-line:
this means quick-touch access to trends,
metrics, and plant KPIs.
In addition, the possibilities for
conguring Feeds and Alerts provide
high-value content delivery, making sure
that the right people get the right
information at the right time.

Highlights DANIELI AUTOMATION

Q3Intelligence

MOREIntelligence
OLAP

Analytics

Other sources
s
Data
Warehouse

Tube mill

Casting

Finishing
Hot rolling

Level 2
vel

Level 1
HMI
PLC / H

MES

Cold rolling

O
Other
so
ources
sources

Level 1
PLC / HMI

Process
automation

DRP
Meltshop
p

Data Collector

Multidimensional
Cube

Front-end

Web-Dashboard

Plant
Equipment automation

Web-Report

I3

MES SOLUTIONS AT VIZAG, INDIA

Rashtriya Ispat Nigam Ltd. Visakhapatnam Steel Plant (VIZAG)
selected Danieli Automation to supply a Manufacturing
Execution System (MES) Level 3, including network, for its
new operations.
The state-of-the-art, 6.3-Mtpy
capacity expansion at VIZAG
will produce quality wire rod,
special bar, and structural products for
the ever-demanding Indian market. The
new plant is comprised of:
> Raw material handling plant (RMHP)
area.
> Calcining plant (CRMP).
> Sinter plant (SP).
> Blast furnace (BF).
> Steel meltshop (SMS) consisting of two
LD converters, two ladle furnaces (LF),
RH degasser, desulphurization plant
(HMDP), three 6-strand casters (two for
square billets, one for round blooms).
> Wire rod mill (WRM) with reheating
furnace.
> Structural mill (STM) with reheating
furnace.
> Special bar mill (SBM) with reheating
furnace.
The complexity and dimensions of the
plant forced VIZAG to select the best
available solutions to achieve
manufacturing excellence, from shop floor
to the management suite.
VIZAG has been working with Danieli
Automation solutions since 2007, and
has reinforced its confidence in Danieli
Automation for the supply of automation
and IT solutions with this challenging
MES supply. Danieli also is supplying
mechanical and automation systems for
all casters and the new structural mill.
Full support for production and quality is
vital for efficient management and
provides optimal visibility of the numerous
plant processes.
The MES solution is Danieli Automations
developed Q-MET application, which
ensures the optimal production control
and supports plant operations in
scheduling, production tracking, and
quality operations through:
> Data acquisition that collects
process/product/production and quality
information;
> Order data management to transform
the commercial requirements of an order
I4

into the technical requirements for

production;
> Production planning to issue the
accepted sales orders;
> Production scheduling to detail
scheduling of the different plant units for
optimized plant performance;
> Production progress control to monitor
order progress and product tracking and
genealogy;
> Quality management to collect quality
data for managing information on product
conformity;
> System administration and
configuration to define users, functions,
and related access permissions;
> KPI monitoring to analyze Key
Performance Indicators and compare
measured results;
> WEB-Reports for reporting using a web
browser.
The Q-MET system will integrate
seamlessly with SAP ERP and with the
numerous Level 2 automation systems at
individual plants to provide the automatic
data collection and exchange required for
best management support.
Beside the software supply, Danieli
Automation also will provide a local area
network (LAN) and engineering support
services.
VIZAG will have a fully integrated MES
solution that plans and schedules
production from raw material to dispatch
of finished products.
Q-MET benefits that RINL/VSP can
achieve due to increased visibility
and velocity in their production supply
chain are:
> Machine set-up time reduction.
> Inventory reduction.
> Production lead-time reduction.
> Reduced production costs.
> Maximum utilization of plant capacity,
thanks to optimal scheduling resulting
from the coordinated scheduling across and tighter control of- operations.
> Increased production, by automating
manual processes, and having access to
real-time information.

> Quality assurance.

> Integration: tight integration with SAP
and shop floor computing thanks to
automatic data collection of production
results and KPI data gives VIZAG
complete data integration in all levels
(Level 1, Level 2, Level 3, and Level 4).
The project has just started and will go
live in the Q4 of 2013.

Contract signing, from right: B.N. Rajeshwar Rao,

Deputy Gen. Mgr., Sunil Kumar Gupta, Gen. Mgr,
S.K. Srivastava, Chief Manager (from Vizag
Steel), R. Treu, Sales Area Manager, A.
Baracchini, Sales Engineer, S. Chakraborty, Sales
Manager (from Danieli Automation).

Highlights DANIELI AUTOMATION

DANIELI AUTOMATION

Additional direct orders

New HiPROFILE
PR84120F

New HiPROFILE
PR86300 C/M

Q-Zinc Robot
systems for HDGLs

AT GERDAU MOGI
DAS CRUZES, BRAZIL

AT ONESTEEL WHYALLA,
AUSTRALIA

AT MARCEGAGLIA
RAVENNA, ITALY

Gerdau Group conrmed again its

preference for Danieli Automation, signing
the contract for the supply of a new, stateof-the-art HiPROFILE PR84120F for the
rolling mill plant in Mogi das Cruzes, Brazil.
The PR84120F model has been selected to
measure at bars from 50 to 106.6 mm
wide and 5.4 to 51 mm thick, produced at
the Mogi rolling mill, but it has been
specially designed to measure also rounds,
squares, and hexagons up to 80 mm, equal
and unequal angles up to 80 x 50 mm, and
channels and H beams up to 70 x 35 mm.
Its innovative construction will provide online certication for the entire range of
products of Gerdau Mogi.

The rst HiPROFILE has been sold in

Australia, where OneSteel, Australias
largest steel producer, awarded Danieli
Automation with the order of one
HiPROFILE PR86300 C/M. The gauge will
be installed at the exit of the last nishing
stand and will measure in hot condition
and without contact all of the customers
product mix: equal angles, unequal angles,
parallel ange channels, universal beams,
universal columns, and rails. Thanks to this
order, OneSteel Whyalla will benet by the
operator-independent production check,
the continuous dimensional monitoring
against previous operator spot-check, the
automatic warning for mill adjustment to
compensate size deviations, the
achievement of a close to minimum size
practice, and the quality certication report
for total production of each customer order.
The HiPROFILE PR86300 C/M and the
SM3100 Speed meter sold with it will be
installed during summer 2012.

Danieli Automation Q-Zinc Robot systems

will be installed on each of the four Hot-Dip
Galvanizing Lines of the Marcegaglia
Ravenna works. The rst unit, installed on
HDGL No. 2, has been working without
interruption since January 2011. During the
rst nine months of operation, the system
also showed it can pay for itself in less than
ve months by saving up to 24% of dross,
compared with previous years when the
same work had to be done by the operator.
This also means better conditions and
workplace safety for the workers.
Installation and commissioning of the other
three systems on HDGL No. 3, No. 1, and
No. 4 are scheduled between June and
August 2012.

Handshake during HiPROFILE kick-off meeting

at Whyalla. From left: E. Bennet, Operations
Manager, C. Toso, Sales Executive Manager,
Special products & Instrumentation; P. Rostig,
Manager Steel Products; A. Nonini, Product
Engineer, Special Products.

I5

Highlights DANIELI AUTOMATION

1
0

AT RIVA ACCIAIO VERONA,

ITALY

Circular diagram of electric network

characteristics of the HiREG electrode regulator.

The new automation systems for LF2 ladle

furnace and for the upgrade of ladle
furnace LF1 will implement the Danieli
Automation 3Q technology concept.
The same concept was successfully applied
at the same plant for the unied control
pulpit for two casting machines.
Comparable to the installation for the
casters, both control systems will be
located in a single pulpit.

RIVA ACCIAIO

I6

At the 3rd International Conference on Automation and Information

Technology in Iron and Steel Making (AITSM) dedicated to Process
Improvement and Energy Efciency, Danieli Automation presented
its process automation solutions for sustainable resources and energyefcient electric steelmaking.
The use of PC controllers, process simulation, the knowledge-based
approach developed for the 3Q systems, and the use of robots, were
described to the qualied audience.
Danieli Automation presented its technology suite for EAF steelmaking,
consisting of Scrap Optimizer, Slab-building Optimizer, Off-gas
Analyzer; HiREG PLUS Electrode Regulator, and the integration of DRI
plant and transport of Hot DRI to EAF.
Scrap Optimizer is meant for use of worst grade scrap and saving
good quality scrap, and the DRI/HBI requirements for melt dilution.
Slab-building Optimizer provides optimal generation of slag for arc
coverage, and minimal requirements of dolomite to produce slag, and
to lower phosphorous content of steel. Off-gas Analyzer measures the
content of CO, CO2, and O2 in the fumes. HiREG PLUS was developed
to regulate the operation of electrodes to maximize energy utilization in
the melt and to reduce electrical energy consumption. The integration
of DRI plant and the system for transporting Hot DRI to the EAF saves
electrical energy consumption.
Additionally, in order to supervise and control power consumption,
a Power Demand Control has been developed by Danieli Automation.

Danieli Automation at AITISM 2012

in Ranchi, India
New automation
for ladle furnace

0
0

Highlights DANIELI AUTOMATION

Plant commissioning

DANIELI AUTOMATION

New HiREG

OneSteel selected Danieli Automation to

supply a new HiREG control for the ladle
furnace of its Laverton plant. Despite the
particular situation, resulting from the need
to keep the old regulator working in parallel
with the new one, the startup has been
smooth and fully functional. A simple and
user-friendly interface permits the user
to review the data in the form of trends,
perspective charts, and statistical bar
charts. A ltering system allows more
detailed investigations of either a single
process phase or an individual electrode,
or any combination of these two.
The professionalism of Danieli Automation
has been positively valued. Moreover,
thanks to the after-sale services granted
by Danieli Automation Global Service,
the customer is supported 365 days/year
24 hour/day.

New speedmeter
SM300 for Exacut
technology

AT RIVA ACCIAIO VERONA,

ITALY

AT ONESTEEL LAVERTON,
AUSTRALIA

3Q unified control
pulpit for two
conticasters

AT GERDAU COSIGUA SANTA

CRUZ, BRAZIL

The challenging task assigned by Riva

Acciaio to design a single pulpit, based
on 3Q concept to control two, 6-strand
billet conticasters ended with complete
success. The startup was smooth and very
fast, accomplished in only 10 days.
Just the rst day after the startup, the
two casters produced 34 heats in total,
maintaining the required index of sequence.
Important targets, such as the reduced
number of operators needed to supervise
the machines, the improvement of the
ergonomics of the control pulpit, and the
level of the knowledge of the automation
system, have been totally achieved. As a
sign of satisfaction, immediately after the
startup the customer signed the Final
Acceptance Certicate, and an additional
order for a new automation system for the
ladle-rening furnace. As another mark of
3Q success, Rivas Thy Marcinelle branch
in Belgium chose 3Q Technology to revamp
its steelmaking plant (EAF and LRF).
The startup is foreseen in August 2012.

The optical speed meter SM3100 was

installed in Santa Cruz (RJ) rolling mill
No. 3 to measure production speed and
length of round bars and proles. The
application of the meter has been very
challenging because of the huge variety of
rolled material, surface types (mirror-like
or opaque), and section types (channels,
I-beams, U-beams, angles, rounds).
The specic details of this plant required
a change in the automation software that
was successfully executed successfully
on-site. The precise speed and length
measurements provide the customer with
improved cut-to-length precision, thus
realizing the Danieli Automation Exacut
technology.

RIVA ACCIAIO

I7

DANIELI AUTOMATION PRODUCT LINES

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

DANEWS 164

January 30, 2012:

A truck is loaded with the new
mills first beams to be sold.
Breakdown Mill and the
3-stand UFR-Ultra-Flexible
Reversing pre-finishing /
finishing mill.
UB 914x419x340 profiles
on the cooling bed.

49

LONG PRODUCTS

DANEWS

Excellent Combi-caster startup

at IDC, Turkey

Innovative Danieli technologies

for the mold, the containment
rolls, and the supporting zone,
promote extended component
life and minimized
maintenance downtime.

fter a quick installation

and commissioning at
the beginning of
January 2012, perfectly
according to schedule, IDCs
new 9-m radius billet / bloom
caster successfully started the
hot test at the Izmir facilities.
After two weeks, full
production was transferred
from the old installation to the
new machine, casting 140-mm
square billets on low- and
medium-carbon steel grades at
high speed. The new six-strand
50

DANEWS 164

>FastCast <

Final Acceptance
of revamped conticaster
at SAM Neuves Maisons
(Riva Group), France

FastCast caster, which will

reach a capacity of 1.5 Mtpy of
billets, blooms and beam
blanks, incorporates innovative
Danieli technologies for the
mold, as well as for the
supporting zone, making it
possible to install or remove
the mold and the supporting
zone in a single operation
without losing the alignment
between equipment and
machine radius.
As a consequence, no
alignment is required in the
maintenance workshop.
Also, the containment rolls
unique design ensures a
perfect product and tight
control of both internal and
surface cracking, all promoting
extended roll life and
minimized maintenance
downtime.
The performance tests are
proceeding smoothly, and a
successful project conclusion
is expected

he Final Acceptance Test of the phase 1

revamping project for the 12-m radius
billet conticaster at SAM Neuves
Maisons was signed on March 21, 2012. The
caster produces 155-mm square billets of LC,
MC, HC, and peritectic grades.
This initial phase of the revamping project
included the installation of Danieli FastCast
Cube and Power Mold on one strand. The
successful performance tests were executed for
all the relevant grade families and proved that
the strand productivity was increased by up to
40% compared to the original configuration.
Billet quality and copper tube mold life also
registered excellent results.
This first successful step achieved by Danieli
and Riva teams is the beginning of a long-term
cooperation, which will continue in August
2012, with the installation of FCC and PM on
three additional strands at SAM Neuves
Maisons caster

Signing of the Final

Acceptance Certificate at
SAM Neuves Maisons.
From the left: M. Bourdon,
SAM Steel plant electrical
responsible; D. Zenarolla,
Danieli Site Manager; F.
Bresciani, Riva Group
Investment responsible;
C. Duhamel, SAM Steel
plant manager.
Left: Assembly of a
FastCast Cube mold and
hydraulic oscillator.

Souvenir photo at the new

conticaster. From left:
Gkhan zaksoy, IDC,
Lorenzo Libanori, Danieli,
Deniz atan, IDC, Levent
Akboy, IDC, Claudio
Capecchi, Danieli.

51

LONG PRODUCTS

DANEWS

Danieli H3 high-tech wire rod mill

at Nucor Steel Darlington (SC), USA

After the successful installations

in P.R. of China, Danieli
Morgrdshammar will supply
Nucor with rolling and treating
lines for special engineering
steels featuring -first in the USAthe TMB/WRS-Wire Rod Sizing
Block technology.

ith a production capacity in excess

of 26 Mtpy, Nucor is the largest
producer of steel in the U.S.A.
But more than a steelmaker, it is the worlds
foremost steel recycler and one of the largest
recyclers of any kind.
In order to remain one step ahead of its
competition and to enter new market niches, in
February 2012 Nucor Corporation assigned to
Danieli the order to upgrade rolling mill No. 2
by installing the H3 wire rod line, where H3
stands for High Efficiency, High Speed and
High Quality. The line produces CHQ grades,
low-, medium,- and high-carbon grades, spring
steel, bearing steel, micro-alloyed grades, and
free-cutting grades.
The state-of-the-art plant will implement all the
latest Danieli technologies and high-tech
equipment available in rolling, on-line
processing, and heat-treatment of wire rod and

10

More and more

top wire-rod producers
around the world choose
Danieli Morgrdshammar
technology.
164 installations since
1973, proving our
leadership in high-speed
wire rod plants.

52

DANEWS 164

bar-in-coils, including LTR-Low Temperature

Rolling process. The project basically foresees:
> A new-concept wire rod line fitted with two,
2-stand, independently-driven wire rod blocks
and 8-stand heavy-duty Delta-type high-speed
block acting as pre-finishing mill; 4-stand
TMB/WRS-Wire Rod Sizing Block high-speed
finishing block; latest-generation OFB-Oil Film
Bearing loop-laying head; a DSC-Danieli
Structure Control system, including water
cooling line and CCW-Controlled Cooling
Conveyor; and a RRT-Rotary Reforming Tube
and Easy-down system for a perfect coil
formation. A future provision for QTR-Quenching
and Tempering process for wire rod is included.
> An ultra-modern bar-in-coils line, designed for
2.5-t coil handling, composed of a modern
CCB-Controlled Cooling line for Bars, two
Garret coilers, and a walking-beam coil
conveyor fitted with hoods and fans for slow,
natural, and fast cooling treatment. The two
lines will be served by the latest-generation V-H
SundBirsta coil handling equipment in order to
satisfy the new working conditions.
The mill will be fed with 178- and 207-mm
square billets, 8.2 and 10.7-m long. The wire
rod lines product mix includes 5.5- to 25-mm
wire rod and 6-to 12-mm rebars, produced at
speeds of up to 115 mps. Coiled bars will cover
19 to 51 mm rounds and 16 to 51 mm hexagons
produced at speeds of up to 13.5 mps in coils of
up to 2,700 kg. Electrical and automation
equipment will be supplied by Danieli
Automation, including the latest-generation
HiProfile section gauges and HiTest laser units.
Also, Darlingtons rolling mill No. 1 (which
produces round bars from 41.1 to 114.3 mm)
will undergo a major modification, consisting of
six SHS roughing stands in H / V configuration,
suitable for handling the new starting billets, six
loopers on the finishing mill, and a new cooling
bed connected to the cutting-to length facilities
supplied by Danieli in 2002. The plant startup
is scheduled by the end of 2013

Rolling Mill No. 1

1 SHS stands and loopers
2 Cooling bed

6
7

Wire rod line

3 Two, 2-stand,
independently driven
wire rod blocks
4 Eight-stand heavy-duty
Delta-type high-speed
block
5 Four-stand TMB/WRS-

Upgrade
of NNII
rolling mill
at Nucor
Steel Norfolk
(NE), USA

n February 2012, Nucor

Steel assigned to Danieli
Morgrdshammar the order
to revamp its NNII rolling mill
at Norfolk, Nebraska. The
project is a continuation of the
plan to expand Nucors SBQ
production capabilities over
the next two years. The scope
of supply includes a new
dividing shear, cooling-bed exit
table with automatic layer
preparation, 10-roll multistrand straightener, and 1,100sht cold shear to process
angles, channels, flats,
squares, SBQ rounds, and
hexagons from A36 to AISI
52100. Automation and
electrical equipment will be
supplied by Danieli
Automation. Startup of the
new facilities is scheduled for
late 2013

Wire Rod Sizing Block

OFB-Oil Film Bearing
loop-laying head
DSC-Danieli Structure
Control system

Bar-in-coils line
8 Garret coilers
9 Controlled cooling coil
conveyor
10 Coil handling
equipment

53

LONG PRODUCTS

DANEWS

SBQ bar mill modernization

at Gerdau Special Steel NA, USA

The project follows

the contract signed
last year for the
new secondary
metallurgy and
bloom casting
facilities, and aims
to strengthen
Gerdau Special
Steels leadership
in the North
American SBQ
market, improving
quality, throughput,
and transformation
costs.

1
2
3
4
5

Walking-beam reheating furnace

Six-stand breakdown mill
Water cooling box
Cooling bed
Disk saws

s the plant modernization -and in

particular for the SBQ section- (the
meltshop project is progressing well
toward completion during Q2, 2012) Gerdau
Special Steel NA decided also to modernize the
rolling mill facilities, choosing Danieli Group
once again as its reliable technology partner.
The project foresees installation of a new, 140tph Danieli Centro Combustion walking-beam
reheating furnace in order to:
> Increase starting billet section size -and
corresponding weight, from current 6 to 210
and 280 mm.
> Increase the mills hourly capacity from 110 to
140 tph in case of cold charging.
> Increase flexibility in charging different billet
lengths: up to 12.2 m in one row, or from 5 m to
6.1 m in two rows, hence maximizing the mill
metallic yield.
> Optimize fuel consumption, with respect to
specific length and steel grade of the product,
with automatic control of reheating curves by
means of Level 2 automation.
> Flexibility in adjusting billet residence time
inside the furnace, with respect to specific steel
grade and desired discharging temperature.
> Flexibility in charging different steel grades
and control of the discharge temperature.
In order to feed properly the existing continuous
mill with the new working conditions, Danieli
will provide a 6-stand continuous breakdown
mill fitted with SHS Star Housingless stands in
alternate V-H configuration, a crank shear, and a
cooling bed for billet production. Additional
water box and finishing area modification (with
insertion of disk saws, and cooling bed facilities)
are part of the supply. The purpose of this
Souvenir photo at the contract signing
ceremony. From left: R. Spessot,
Danieli; J.R. Borsato, Procurement
Manager, Gerdau; L. Mottes, EVP Key
Account Management, Danieli; V.F.
Moura, Procurement Dept. Gerdau
Group; A. Betzios, Director, Danieli do
Brazil; G. Giordani, DCC.
3

54

equipment is to treat and cut-to-length the

entire range of bars for the production rate of
140 tph, with a minimum weight of 4,000 kg
per bundle in 6.1 to 9.5 m length. A new scale
pit and water-treatment plant for direct cooling
for a capacity of 2,200 m3/h will complete the
order. Danieli Automation will supply all the
electrical equipment and the L1 and L2
advanced automation and process control
system package, including the material tracking
function. The startup of the plant is scheduled
by the Q2 of 2013

DANEWS 164

Danieli
SHS stands
for rolling mill
upgrading
at Gerdau
Siderperu,
Peru

Since their original

development
in the mid 40s, SHS
stands continue
to be a Danieli
Morgrdshammar
success, with over
7,600 units having
been installed.
n December 2011,
Siderperu (part of Gerdau
Group) awarded Danieli
Morgrdshammar the order
to modernize its roughing mill
with three latest-generation
SHS-Star Housingless Stand
units. This will lead to optimized
rolling mill operation and
reduced downtimes. The mill
processes 98-mm billets
to produce up to 150,000 tpy
of 28-mm dia rounds

55

LONG PRODUCTS

DANEWS

Latest Danieli wire rod

technologies will put
Ferriere Nord one step
ahead with 1.25 Mtpy.

56

DANEWS 164

Further wire rod mill modernization

at Ferriere Nord, Italy

hree years after the last modernization

project of its wire rod mill, Ferriere Nord
(part of Pittini Group), initiated a further
development project that will cover different
areas of the mill, including mechanical and
electrical equipment installations.
The core of the project is to modify the
intermediate mill and services, and the finishing
mill area, with the insertion of two, 4-stand
individually driven wire rod blocks for a sharp
and precise intermediate rolling operations;
some new-generation water-cooling boxes along
the existing DSC-Danieli Structure Control
line; plus two newly-designed 3-stand CSBCompact Wire Rod Blocks acting as finishing
stands on the two lines. This implementation
will set the mill into high gear, enhancing
product quality, and increasing production,
material and plant yield, and implementing a
fast changing program at high finishing speed.
Robotized ring-changing equipment will be
installed at the 4-stand WRBs, at the 10-stand
blocks, and at the 3-stand CSB units,
accordingly. The two 3-stand CSB-Compact
Wire Rod Blocks have been operating smoothly
and reliably since mid January 2012 at 120 mps
of industrial production speed.
The new water-cooling boxes will make it
possible to use Danielis UFG and UGR
innovative processes (patent pending) for lowcost production of seismic concrete
reinforcement steel.
UFG-Ultra Fine Grain and UGR-Ultra Grain
Refining rolling make it possible to achieve the
resistance requirements for construction-grade
steel used in earthquake-prone regions, starting
from low-carbon and low-manganese steel

Souvenir photo at the contract

signing ceremony. From left, for
Danieli: E. Paron, Proposal
Engineer, A. Mestroni, Executive
Manager Sales, Tech-Team
Automation; E. Francescatto and
N. Redolfi, Executive Product
Managers, Bar & Wire Rod Mills;
and for Ferriere Nord: G. Fior,
Group Plants Director; L. Del Pin,
Rolling Mill Manager; D. Furlan,
Rolling Mill Manager Assistant.

1 WRB intermediate stands

2 New Danieli Automation
HiPROFILE gauges
3 Existing 10-pass DWBs
4 New-generation water-cooling boxes
5 CSB-Compact wire rod Blocks
finishing stands
6 New Danieli Automation
HiSECTION gauges
7 Existing HSS-High-Speed Shears
8 Existing OFB-LLH - Oil-Film
Bearing Loop Laying Heads
9 Robotized ring-changing equipment

through low-surface temperature rolling.

In this way, the low mechanical properties that
result from poor chemistry are balanced by the
microstructure obtained via UFG and UGR
processes. Additional advantages are the
reduced need to install quenching and
tempering systems, and an increased rolling
speed production.
Electrical and automation equipment will be
supplied by Danieli Automation, including the
latest-generation HiProfile laser units

ECIDOC

ECIDOC

CODICE

CODICE

57

LONG PRODUCTS

DANEWS

New 400,000-tpy rebar mill

for Abhijeet Group, India

The Indian market

once again relies on
Danieli technology
for long products
mills: this will be the
10th rolling mill
supplied (five of
which were for
engineering and
special steels) in the
last five years, out
of a total of 17.

entirely made up of heavy-duty SHS housingless

stands, will make use of an advanced multistrand slit-rolling system (four-strand slitting
for 8-mm-dia; three-strand slitting for 10-mmdia, and two-strand slitting for 12-mm-dia),
and the on-line QTB-Quenching and Tempering
process will be provided at the finishing stand
delivery side.
A 66x10 m cooling bed with associated cold
cutting-to-length shear, a gauge beam, an
automatic bar counting and forming station with
short bar recovery, tying machines, and bundle
collecting station for bundles of up to 2,500 kg,
will complete the supply. Plant startup is
scheduled for the Q3, 2013

1 Conticaster outlet
2 80-tph reheating furnace
3 18-pass rolling mill with
SHS stands

Handshake at the contract signing

ceremony between Arun Gupta, CEO,
Abhijeet; and A. Diasparro, VP, Sales
Danieli. In the front row, from left: T.
Pattanayak, AGM Procurement,
Abhijeet, S. Jain, GM Purchasing,
Abhijeet; R. Mahajan, Dy. GM
Manager, Sales, DIL; and P.
Sathishkumar, VP, DIL.

n early November 2011, Abhijeet Group

assigned to Danieli Morgrdshammar the
order for a new, 400,000-tpy rolling mill for
production of deformed bars. Danieli Group
affirmed its leading position in India with 17
rolling mills supplied or under supply, four of
which include a bar slitting system.
The new plant will be supplied with the latest
Danieli technology equipment to guarantee
quality and efficiency for finished products that
will be sold in Indias domestic market.
The product range will be 8 to 40-mm-dia
rebars produced at rates of up to 75 tph, starting
with 130x12,000-mm square billets in low- and
medium-carbon steel. The 18-stand mill,

tying, and collecting area

7 Main electric cabin
8 Roll shop and stand
preparation area

4 QTB Water quenching

and Self-Tempering line
5 66x10-m cooling bed
6 Cut-to-length, bundling,

58

DANEWS 164

New production records

at BSRM, Bangladesh
Sold for a capacity of 300,000 tpy, the plant
is now producing at up to 600,000 tpy

The multi-strand
slit-rolling process,
developed and
launched by Danieli
in the early 80s, has
become a standard
for high-capacity
merchant bar mills.
Danielis scorecard
counts 115 plants,
supplied worldwide.

n April 2012, at BSRMs

Chittagong facilities, the most
modern bar mill of its kind in
the region (started up in 2008)
set new production records, as
stated in a congratulatory letter
we received from Sunil Kumar
Das, Head of Operations, BSRM
Group.
regarding the mill performance,
we can say our best performance
so far was in the month of
January 2012, with a net
production of 54,740 t, with a
monthly average of 85.21 tph
productivity, 88.21% efficiency,
0.08% cobbles, 97.46% yield,
and lowest power consumption of
68.33 kWh/t . Even in the month
of April we have run the mill nonstop without any interruptions,

with an average billet-to-billet

gap of 2 seconds for 11 hours
continuously, while rolling 3x12
mm April the 3rd.
These performances are being
demonstrated once again thanks
to solid cooperation between
BSRM and Danieli, consolidating
for the BSRM Group its
undisputed leadership in rebar
production in the South Asia,
obtained through the stable and
well-known MSR-Multi-Strand
Rolling system developed by
Danieli Long Products Division

59

LONG PRODUCTS

DANEWS

Fast-track commissioning
of super-flexible bar mill
at Deacero Ramos Arizpe, Mexico

17 months
from groundbreaking to the first bar produced,
confirming Danieli Groups leadership in greenfield
project management and implementation

n February 17,
Deacero started
operations at its third
Danieli steel production
complex at Ramos Arizpe,
which follows those in operation
in Saltillo and Celaya. Smiling
faces and a friendly handshake
marked the completion of the
greenfield, super-flexible rolling
mill project, implemented in
only 17 months from the
project start. Installation of
the annexed steel meltshop
is progressing well toward its
expected startup by summer
2012, i.e. six months after the
rolling mill startup. Once
completed, the minimill will
produce 1.5 Mtpy of finished
products -mainly sections and
profiles - confirming Deacero
as a successful, dynamic
company that has achieved its
growth by establishing a highly
60

competitive position to satisfy

the demands of national and
international markets. This
aggressive posture has helped
the Mexican steelmaker to
become a major player in
Mexico and in almost 20
countries around the world.
Its recent investments in its
third new steel plant and into
the existing production plants
have allowed the Deacero
Group to offer the "latest and
greatest" in high-performance
quality products.
These state-of-the-art mills
and plants, thanks to the close
cooperation with the Danieli
Group and its process and
technology knowledge, permit
Deacero to satisfy the
continuously evolving
demands from agricultural,
building and construction,
and industrial marketplaces

First bars rolled on February 17, 2012, onto the cooling bed. The 102x11.5-m
cooling bed is also able to treat the small and medium sections to be produced
in the Danieli super-flexible rolling mill.

DANEWS 164

Overview of the full steel

complex area and related
infrastructure as of January
2012. The new flexible rolling
mill is complete with shipping
warehouse (bottom), and the
steel meltshop under
construction at the top.

61

LONG PRODUCTS

DANEWS

Work in progress on the 1.1-Mtpy rail

and section mill
at Mechel Chelyabinsk, Russia

Thanks to the advanced technologies

applied, the new plant will be one
of the most modern rolling mills of its
type in Europe, and in the whole world.
More than 50% of the product mix will
be dedicated to high-quality rails of up
to 65 kg/m, for railways and other
applications (including special rails,
vignoles, cranes, tram, etc.)

The delivery of the

equipment to
Chelyabinsk
Metallurgical Plant
for the new
Universal Mill to
produce 100-m long,
in-line hardened
rails, and up to
600-mm wide
parallel flange
beams, structural
shapes, and sheet
piles, has been
completed, and
now the installation
phase is in progress.

62

he project foresees the

installation of a new,
240-tph Danieli Centro
Combustion walking-beam
reheating furnace for blooms
and beam blanks.
The hot rolling area features the
re-use of an existing BreakDown Mill stand (BDM1), a new
Break-Down Mill stand (BDM2),
an UFR-Ultra Flexible Reversing
mill with three close-coupled
stands, and a separate Universal
Finishing stand with SCC-Stand
Core Concept super-heavy duty
design to perform the PSPProfile Sizing Process.
Downstream of the cooling bed
and the horizontal/vertical roller
straightening line, dedicated
cold processing and finishing
facilities are provided,
respectively for rail and for
structural shapes.
The rail-finishing end is

provided with end-straightening

presses, NDT center, sawing and
drilling units, final inspection,
collecting stations, and special
overhead cranes for final
placement of 100-m long rails.
The structural shapes finishing
end includes cold sawing,
automatic stacking, and
collecting facilities.
With the goal of a smooth
installation and commissioning
on site, during summer 2011
complete assembly and
integrated tests were performed
in the Danieli workshops for the
UFR mill equipment and the
relevant automation system
developed and supplied by
Danieli Automation.
Currently, the steel buildings,
the EOT cranes, the civil works,
and the electric cabinets are in
progress.
The installation of the reheating

furnace, BDM2, UFR mill, and

UF stand, as well as electrical
and auxiliary equipment, is
ongoing. Finishing ends for both
rails and structural sections will
begin shortly.
Through a professional
approach, collaborative spirit,
and mutual efforts by both
Mechel and Danieli teams, the
Universal Mill project moves
toward the commissioning,
scheduled in the Q4 of 2012

DANEWS 164

Final Acceptance
Certificate for rebar
and light section mill
at Chico, Sri Lanka

In February 2012, the Final

Acceptance Certificate
(FAC) of the Ceylon Heavy
Industries and Construction
Co Ltd.s (Chico) new, hightech 250,000-tpy rolling mill
was signed and released, with full customer
satisfaction. Now, the plant is producing on a
constant basis.
The plant, located in Oruwala (Athurugiriya,
Colombo state) features all of the most up-todate technologies in rolling rebars for
construction applications.
It is basically comprised of the latest-generation
SHS housingless-type rolling stands with multistand slit-rolling process and on-line QTBQuenching and Tempering process, a rake-type
cooling bed, and associated cutting-to-length,
bar counting and bundling services, short bar
recovery, tying, and final collecting facilities.
Automation and process control systems were
supplied by Danieli Automation

63

LONG PRODUCTS

DANEWS

Danieli TMB technology in operation

at Zhejiang Qingtian Ruipu, P.R. of China

TSINGSHAN

TMB/WRS
confirms the reliability
and enhanced
performances
for special steel
wire rod processing,
strengthening Danielis
presence in the Far
East markets

he 4-pass Danieli TMB-Twin Module

Block, installed at Zhejiang Qingtian
Ruipu S.T Co. Ltd., in the new Danieli
wire rod and bar-in-coil mill, started operation
successfully at the beginning of 2012.
This unit is designed to produce 5 to18-mm-dia
smooth wire rod and 14- to 22-mm-dia bar-incoil, in 2,450-t coils. The steel grades produced

64

through the line include austenitic, martensitic,

and ferritic stainless steels, welding steel, lowalloy, and cold-heading steel.
Finishing rolling of the entire product size range
is performed on the Twin Module Blocks at
speeds of up to 105 mps, with very strict endproduct size tolerances

Top: AC-driven 4-pass TMB-Twin

Module Block wire rod finishing
mill area. Left: The 24-stand
rolling mill with SHS-stands ahead
of the wire rod and bar-in-coil
lines. Right: AC-driven 10-pass
DWB wire rod pre-finishing block.

DANEWS 164

Successful
startup
of the
HSS-High
Speed Shear

Final Acceptance
of the wire rod line
at Shandong Laigang Yongfeng,
P.R. of China

at Diler
Demir elik
Turkey

he equipment is part
of a 400,000-tpy wire
rod mill originally
supplied by Danieli in 2005.
The rolling mills product
range is 4.5 to 25 mm dia;
maximum operating speeds
reach 105 mps. The Danieli
HSS shear, enabling
automatic wire rod head and
tail cropping before the laying
head, is an ideal solution for
reducing manpower and
cutting production costs in
modern wire rod mills. To date
the Danieli scorecard includes
21 HSS shears supplied
and installed successfully
worldwide since 1994

DILER

he release of the Final

Acceptance Certificate
follows an excellent
and fast startup, learning
curve, and performance tests.
The new, 1.5-Mtpy plant for
engineering and special steels
wire rod in coils is comprised
of two independent high-speed
wire rod mills, each with a
capacity of 750,000 tpy, to
produce 5- to 25-mm dia plain
(6- to 16-mm dia deformed
wire rod) finished at up to 115
mps in coils weighing up to
2.3 t. The range of steel grades
includes structural, engineering,
and special steels, tyre cord,
cold heading, spring, and
bearing qualities. The Danieli
scope of supply for each of the
two lines includes advanced
technology equipment for the
finish-rolling and on-line
controlled cooling areas,
namely: a two-pass DWB pre-

finishing miniblock, a highspeed finish-rolling line (eightpass DWB block plus fourpass TMB finishing block for
Mill No. 1 and 10-pass DWB
finishing block for Mill No. 2),
CCW-Controlled-Cooling line
for Wire rod, and OFB-OilFilm-Bearing type loop layers
with associated auxiliaries.
This makes it possible to
achieve an increased
operational flexibility and high
yield for the mill, as well as
high mechanical and
technological characteristics
to the finished product

Laigang wire rod line A. DWB

wire rod finishing block area.
Signing of the Final
Acceptance Certificate.
From left: Zheng Rong,
Project Manager DME;
M. Lirussi, Project Manager
DMH; Wang Huidong, Plant
Leader; Liu Guoqi, Equipment
Director; P. Saccavini, DCS
Workshop Director.

65

LONG PRODUCTS

DANEWS

Mission accomplished:
commissioning of section mill
completed successfully
at CMC Zawiercie, Poland

The result was

achieved in 10 days,
starting from the
cold commissioning
up to full production.
This is one of 12
plants that have
been successfully
commissioned
and completed
since January 2012
by the Construction
and Commissioning
team of Danieli
Long Products
division.
Flat bars on the 96x11.6-m rake-type cooling bed.
Automatic cold finishing services, with single-head
magnetic stacker, and SundBirsta tying machines.

66

MC Zawiercie S.A.
(part of the American
CMC Group) started
the rolling activities for its new
section products mill at the
beginning of February 2012,
rolling 800 t of 40x5 and 40x4
mm angles without
complications during the hot
test. This goal was achieved
thanks to a good relationship
established between Danieli
and CMC Group. The
superflexible section and SBQ
bar mill is designed to produce
16 to 80-mm-dia quality plain
bars; 14 to 40-mm-dia rebars;
35 to 200-mm flats; 50 to 180mm angles; and corresponding
channels. The mix of grades
includes LC, MC, HC, and
low-alloyed construction and
engineering steels.
Considering the successful
involvement of the Danieli
Team, CMC has officially
requested our presence and
assistance also during the test
of other light sections, to be
carried out in June

DANEWS 164

New bar finishing services

started up
at Acciaierie Valbruna, Italy
he Acciaieria Valbruna special steel bar and
light section mill was upgraded with the
installation of new finishing facilities for
processing stainless steel rounds, ribbed rounds,
flats, squares, hexagons, and equal angles, with
the aim of maximizing plant efficiency, material
yield, and final product quality.
The new, state-of-the-art line, in operation since
early 2012, is made up of a newly designed,
hyper-quenching line with water-cooling boxes, a
cooling bed and associated cutting-to-length saws,
with gauge beam, a combined bundling/stacking
station with strapping and tying equipment, final
weighing, and an automatic labeling and collecting
station for specialty steel stacks and bundles

Fast ramp-up
of EWR billet welding line
at Cape Gate, RSA
Following a timely and smooth
installation, the FAC was released
two weeks after the start of hot testing,
reconfirming Danielis undisputed
leadership in long products equipment.

n March 2011 Cape Gate

(PTY) Ltd. awarded Danieli
Morgrdshammar the order
for a new EWR-Endless
Welding Rolling line to be
installed ahead of a 18-pass
Danieli bar mill with ES
cantilever stands, originally
supplied in 1984 and
revamped in 1995 and 2007.
Thanks to the good cooperation
established with the
customers team, installation
and hot tests were carried out
according to schedule, and the
hot tests started on January 10.
The results were extremely

positive, leading to the release

of the Preliminary Acceptance
Certificate on January 23 and
of the Final Acceptance
Certificate two days later, and
delivered with the customers
full satisfaction. This is the
first EWR unit operating in
the Republic of South Africa
and the fourth supplied in the
African continent.
It is designed for automatic
continuous welding of 115and 130-mm, 10.3-m long
billets of low- and mediumcarbon steels at rates of up
to 50 tph

67

HOT & COLD PROCESSING

DANEWS

68

DANEWS 164

In-line hot-slab
inspection
and conditioning plant
at Posco, Korea
30+ years of
cooperation
between Posco
Group and Danieli
Centro Maskin, the
undisputed leader
in grinding
equipment and
technology,
continued with the
installation of 27
grinding units, 16
of which are
designed to treat
hot and cold slabs.

Two high-speed
drawing lines
at Ningbo
Powerway
Alloy Material Co.,
P.R. of China

N
P

osco Group, the largest steel producer in

Korea and one of the 10 largest steel
manufacturing firms worldwide, assigned
to Danieli Centro Maskin an order for a stateof-the-art slab inspection and conditioning line,
which will be a milestone in the hot-slab
inspection and conditioning technology process.
The plant configuration will include three new
grinders featuring 315-kW main motor power, in
line with the slab caster. The facility will
include advanced solutions recently developed
by Danieli Centro Maskin and Danieli
Automation, such as:
> Hi-grind system for pressure automatic control;
> e3 system for surface quality enhancement
and grinding wheel life optimization;
> Level 2 automation system;
> Intelligrinding system for semiautomatic
surface-defect detection in both cold and hot
temperature conditions, and automatic defect
removal.
All this, in addition to operating mainly in hot
conditions -up to 700 C for a wide range of
stainless steels- will lead to remarkable
advantages, including:
> Higher productivity;
> Energy savings (conditioned slab can be sent
directly to mill still hot);
> Reduced storage and handling;
> Improved final surface quality

ingbo Powerway, one of the largest

processors of brass alloys in China,
has ordered two chain-track
drawing lines from Danieli Centro Maskin
as part of a brand-new production facility.
Producing calibrated, cut-to-length, and
chamfered bars in diameters ranging up to
12 mm, the two fully automated lines will
greatly increase Powerways production of
high-quality cold finished bars. Reaching
speeds of up to 250 mpm, the two drawing
lines will incorporate significant new
technology developed specifically for this
extremely demanding application.
Fundamental for the process, the Danieli
chain-track pulling units will ensure the
high-speed performance required to ensure
the best productivity for these very small
bar sizes. The new facility will be in full
production in 2013

Contract signing at Posco. From left:

H.Y. Sohn, Danieli agent; Chang JiNyeong, Posco E&C, Automation Dept.,
Steelmaking plant; Jung-Ki Kim,
Posco E&C, General Manager
Steelmaking plant; Marco Coldebella,
Manager Sales, DCMK; Kang
Cheolwon, Posco E&C, Steelmaking
plant group.

69

TUBE PROCESSING

DANEWS

Two Extreme Performance Cold Pilger Mills

at Elemash-Spetstrubprokat Ltd., Russia

emographic changes, greenhouse gas

regulations, and energy security are
particularly important drivers of innovation
in tube and pipe production. Two examples of
these trends are constant efforts to develop
innovative, premium connections specifically
designed for horizontal drilling in the Marcellus
Shale area (in the U.S.) and renewed interest in
nuclear power. Therefore, Danieli decided to
concentrate know-how related to tube and pipe
finishing in the Danieli Centro Tube Division
(DCT) to ensure opportunities for growth in a
dynamic environment are maximized. Now,
three families of Cold Pilger mills with a
common interface are available for rolling highly
sophisticated materials for critical applications,
a wide portfolio of solutions for coupling and
tube threading, pipe beveling, tube straightening,
hydrostatic pipe testing, and cutting.
Any company has an obligation to establish
customer relationships that are beneficial to
both parties, thus guaranteeing a better
understanding of specific needs with the aim
of providing just-in-time support and offering
state-of-the-art, cost-effective technical solutions.
A critical factor for the success of this strategy
is the close coordination with other Danieli
Groups divisions, such as Danieli Breda, our
specialists in stainless steel extrusion and pipe
upsetting, and Danieli Centro Combustion for
heat treatment furnaces. The first important
result using this strategy came in November
2011 with a contract awarded in collaboration
with JSC Institute Tsvetmetobrabotka to supply
two Extreme Performance Cold Pilger Mills, to
produce seamless stainless steel tubes for
nuclear applications. The two mills will be
installed in the Elemash-Spetstrubprokat plant
in Electrostal, where a complete spectrum of
precision thin-walled tubes of corrosionresistant steel and alloys required for nuclear
fuel production are manufactured.
In a nuclear reactor, uranium-dioxide fuel
pellets are sealed into metallic tubes (fuel rods)
grouped into fuel assemblies. Tube material may
be stainless steel or zirconium alloy, depending
on the design of the reactor. For these
70

EPCPM main
characteristics
Mill sizes: 20-40-60-80-110150-200-280-350-450.
Extensive production range:
OD from 4 to 450 mm; WT from
0.12 to 30 mm.
Materials: Stainless steel; Ni; Ti;
Zr; Cu; Al.

The two units will

incorporate cutting-edge
technology, know-how,
and experience
in cold forming to
produce ultra-thin,
stainless steel seamless
precision tubes
for nuclear applications.

Sophisticated products:
Tubes for heat exchangers,
furnaces, boilers,
instrumentation, and
mechanical hollow bars.
High-tech applications:
Nuclear, aerospace, energy,
OCTG, automotive, chemical,
umbilical systems, for critical
operating conditions (corrosion,
high temperature, high pressure,
maximum strength under
alternate loads).

DANEWS 164

applications, high-quality tubes are essential,

therefore exceptional OD and WT tolerances
are required, including an extremely high
surface quality, minimal defects, extremely
uniform grain microstructure, and high
mechanical properties. Elemash is integrated
into the TVEL Fuel Co., a division of Rosatom
State Corp., and a major Russian manufacturer
of nuclear fuel for power stations and also a
world leader in fuel vending. The company also
produces cold rolled, thin-walled titanium and
stainless steels tubes. This order is especially
important as an introduction for DCT to the
market of cold pilger mills for nuclear
applications. With the support and experience
of JSC Institute Tsvetmetobrabotka Danieli is
also extending its market position into cold
forming of highly specialized niche products.
The aim is to play a leading role in the future
and establish high standards for design,
manufacturing, and supply of modern, highperformance, state-of-art equipment destined
for use by top market players. The two mills,
installed side-by-side, will produce tubes in
difficult-to-roll materials with max. strengths
up to 1,000 MPa, OD from 4 to 24 mm, WT
from 0.2 to 2 mm (two/three roll configuration),
WT from 0.12 - 2 mm (two / three roller
configuration) and finished tube tolerances
of 0.5% on OD and 3% on WT. The mill
design, which foresees a movable stand and
cassette with lever-type synchronization, is the
optimal solution for the production of ultra-thin
wall precision tubes. To maximize product-mix
flexibility, interchangeable stands with two or
three rolls/rollers may be used to produce
round, square or hexagonal high-precision
tubes. Continuous shell feeding, broken
mandrel and head-to-tail sensors, and mandrel
internal lubrication are additional features of
these two mills. Danieli boasts a long history
as the reliable partner in steelmaking and tube
rolling, and guarantees direct attention to all
customer requests and priorities for selecting
the right solution among a wide spectrum of
standard and customized EPCPMs available
in three different configurations: "Quarto" for
difficult-to-roll materials, "Duo" for ductile
materials, and "Precision for ultra-thin wall
thickness tubes

1 Three-roll movable stand

and cassette with levertype synchronization for
Precision ultra-thin
wall thickness tubes.

Mill data
Number of mills:

2 (left / right)

Mill type:

Movable stand and cassette with lever-type synchronization,

for extra thin wall precision pipes.

Stand / cassette types:

Two and three rolls, two and three rollers

Materials:

with ultimate strength up to 1,000 MPa

Hollows:

OD 10 - 26 mm, WT 0.5 - 3 mm, length 0.8 - 4 m

Finished tubes:

OD 4 - 24 mm, WT 0.2 - 2 mm, with two and three rolls,

WT 0.12 - 2 mm, with two and three rollers, length 3 - 8 m

Hollow tolerances:

1% on OD, 5% on WT

Finished tube tolerances:

0.5% on OD, 3% on WT

Finished tube type:

Ultra-thin wall thickness, round, square and hexagon, finned

2 Shell carriage with

brushless servo motors
for a continuous
adjusting of feeding and
turning.

71

HEATING SYSTEMS

DANEWS

72

DANEWS 164

Horizontal CGL revamping

at ArcelorMittal Eisenhttenstadt,
Germany

10

12

12

11

It is the first order

on a turnkey basis
from the worlds
leading producer
of steel strip
for automotive
applications.
1
2
3
4

New entry sealing

New recuperative room
No. 12 new burners
New tube treatment No. 40 new burners
5 New jet coolers
6 No. 3 new cooling fans, ducts,
and diffusers
7 New FF combustion air fun
8 New FF dilution air fan
9 New FF exhauster
10 New TT combustion air fan
11 New waste gas damper
12 New connection throat

1
2
3

Detail of DCC jet coolers.

Longitudinal furnace section,
including modifications.
Souvenir photo at the kick-off
meeting held in DCC Genoa
offices. From left, for
ArcelorMittal: S. Wochatz,
Process Engineer, G. Fritz,
Project Manager, D. Lwenberg,
Head of Engineering Department,
L. Kockzius, Plant Engineer
Mechanics; and, for DCC,
F. De Santi, Process Engineer.
Internal view of the furnace.

n December 2011, ArcelorMittal

Eisenhttenstadt, known in the industry as
being an unparalleled partner to automotive
manufacturers, placed an order with Danieli
Centro Combustion (DCC) to revamp its
continuous galvanizing lines horizontal
annealing furnace. Included in the contract are
the supply of both basic and detail engineering,
with May 2012 as the contracted deadline. Step
2 of the investment, expected for Summer
2013, includes equipment supply, installation
and commissioning on a turnkey basis.
The plant revamp will expand total annual
production from the current 405 kt up to 474 kt.
DCC shall implement the following improvements:
> Increasing of the RR zone.
> Increasing FF zone thermal power (new
burners and fans).
> Increasing TT Zone thermal power (new
radiant tube burners, adding a fan). This
significant modification will be executed using
DCCs proprietary auto-recuperative burners
installed inside single-end radiant tubes made
of APM (Advanced Powder Metallurgical,
dispersion-strengthened, ferritic FeCrAl alloy
used for radiant-tube temperatures up to 1,250
C). The new tube treatment zone will be
equipped with state-of-the-art solutions for the
application.
> Installing modern, custom-built, more
powerful jet-coolers. This section is used to cool
the strip quickly down to the treatment
temperature of 460 C. Maximum cooling rate
is 30 C/s.

Roll

Single-end radiant tube

> Installing three cooling fans (one movable,

two fixed) in the tower, to cool the strip down to
treatment temperature of 230 C.
Materials processed in the galvanizing line are
cold-rolled carbon steel, in an impressive range
of grades: soft, mild, UHSS for cold forming,
UHSS IF, BH, microalloyed, multiphase,
P-alloyed, and isotropic steels
73

HEATING SYSTEMS

DANEWS

Revamping of a tube heat-treatment line

at Vallourec & Mannesmann, Brazil

his new order emphasizes the

establishment of an important
partnership with the V&M Group (one
of the worlds leaders in steel pipe production),
thus confirming Danieli Centro Combustions
(DCC) undisputed technological leadership in
heat-treatment lines.
The order, to be carried out on a turnkey basis,
includes the supply and installation of two new
furnaces (PHF & SF) and the revamp of two
existing ones (HF & TF) geared toward
expanding and optimizing current quenching
and tempering processes for pipes, with product
dimensions ranging between 114.3 and 370
mm, widths between 5 and 38 mm, and in the
following API grades: L80, P110, C95,
VM110HC, VM125HC, VM110SS, L8013Cr,
X52, X60, X65. Production of reference pipes
will be increased from approximately 44 tph to
64 tph thanks to a reduction in the cycle time
from the current 86 seconds to the future 60
seconds. The reheating furnace (PHF), installed
upstream of the actual austenizing furnace
(HF), will decrease power consumption by more

To date, this is the sixth

order placed by V&M,
the globally recognized giant
in steel pipe production.

Layout of the heat-treatment area at V&M.

1
2
3
4
5
6

Charging grid (existing, relocated)

Pre-heating furnace (new)
Hardening furnace (existing, revamped)
Quenching machine (existing)
Tempering furnace (existing, revamped)
Soaking furnace (new)

74

DANEWS 164

Pusher reheating furnace

to Tecpro Systems Ltd., India

entro Combustion Furnaces Ltd.

(CCF) was awarded a contract to
design and supply a pusher-type
furnace, to be installed in Tecpros
100,000-tpy section mill. Construction
of the reheating furnace in Alwar,
Rajasthan, is expected to take eight
months. This furnace project will be the
very first to be managed and executed in
its entirety by CCF. Mr. Aditya Gabrani,
Managing Director of Tecpro Systems
Ltd., described this contract as an
important part of the companys growth
strategy toward backward integration of
large-scale business operations for Tecpro
in India. Mr. Loganathan Jayaram, VP,
CCF, also expressed the strategic
importance of this contract for growing
CCFs market share within this particular
segment. CCF is already building a
70-tph walking-beam reheating furnace
for Sunflag Iron & Steel Co. Ltd. at
Nagpur, in the state of Maharashtra,
which is in the advanced stage of
commissioning. Also, CCF is in the

C
V&M and DCC delegation at kick-off meeting.

than 20% thanks to the use of thermal energy

contained in the HF furnace combustion waste
gas. This waste gas will be pumped by an
exhauster fan situated between the two furnaces
and then injected into the PHF combustion
chamber to maximize heat exchange with the
pipes, and thus allowing waste gas evacuation to
the stack at temperatures well below 200 C.
The new equalizing furnace (SF) situated at the
end of the tempering process immediately
downstream of the existing furnace (TF), not
only will allow an increase in productivity but
also an improvement in temperature uniformity,
during and at the end of treatment.
Equalizing heat will be supplied using an
important amount of waste gas that is kept
in circulation and injected onto the tubes via
eight fans. Maintaining the correct recirculating
temperature will be possible because of the use
of eight burners (DCC) positioned in the
combustion chamber outside of the
recirculating chamber.
This process will guarantee temperature
uniformity equal to 3 C during heating and
2.5 C on the product exiting the furnace

process of constructing reheating

furnaces for major companies in India,
such as SAIL (Vizag Steel Plant),
Jayaswal Neco Industries (Siltara), and
Mittal Corporation (Indore). A recent
example of success is the Bhushan Steel,
Angul furnace, which was put into
operation recently and is considered to
be one of the best operating furnaces in
the country. In recent years, growth in the
Indian steel industry not only has been
encouraging for the country, but also has
demonstrated consistency. This trend
is predicted to continue over the coming
years. The growth strategy for CCF is
closely aligned with expected growth in
the Indian steel industry.
By following our standards for success we
can definitely see the company becoming
a market leader in reheating furnaces in
the not-too-distant future

Contract Signing on
March 2, 2012 in the
CCF offices in Pune,
India. From left, for
CCF, S. Bianchi, VP
Purchasing, L. Jayaram,
VP Sales. For Tecpro:
Aditya Gabrani,
Director, C.B. Kumar,
General Manager
Purchasing.

Main milestones
of the turnkey project
> Contract signing:

November 2011
> First shutdown (PHF installation):

October 2012
> Second shutdown (SF installation):

August 2013
75

FORGING & EXTRUSION

DANEWS

New integrated forging plant

at MTE Group, Russia
The Danieli Breda
forging plant,
consisting of a
25-MN forging
press and two
manipulators,
will be installed
at Donpressmash
facilities in Azov
City, Rostov.

he Russian Group
MTE was founded in
2003, and its first
operating unit, CJSC MTE
Finance, became known in
the market as one of the
leading specialists for leasing
equipment to projects in the
areas of mechanical
engineering, power engineering,
and aviation. MTE Finance
was the basis for the
development and growth of
the Group. In 2009, MTE
made the decision to combine
the competencies it had
accumulated during the initial
years of the organization as the
foundation for developing its
own industrial project. A team
of managers was formed and
MTE Manufacturing was
created. The production area,
managing the assets of
Donpressmash (MTE DPM)
is located in Azov City, near
Rostov. The company was
founded in the early 60s, and
operates on a site area of 35.6
ha, served by a 7,500-m long
internal railway network.
76

The 2-column press,

integrated with two 20/60-t
manipulators (one mobile and
one rail-bound) will produce
up to 35,000 tpy of low-carbon
alloyed steel forgings, with
diameters ranging from 400 to
830 mm, lengths up to 12 m,
and weighing up to 20 t.
In addition to the new
integrated forging plant,
modernization plans for DPM
involve the iron casting

facilities, to produce up to
15,000 tpy of castings
weighing from 600 kg up to 15
(30) t (including cylinder
barrel products for diesel
engines), and metalworking
facilities in support of
construction, power plants,
and power transmission line
products.
Plant startup is expected 12
months after the contracts
effective date

Contract signing. From

right: D. Voekov, Plant
Director, Donpressmash;
D. Volkov, General Manager,
MTE; M. Mancini, Sales
Manager, and P. Fraternale,
EVP, for Danieli Breda),
and A. Eremin, Danieli
Moscow.

DANEWS 164

Successful startup
of double-stroke pipe upsetting plant
at Tenaris Tamsa, Mexico

The Final Acceptance

Certificate for the doublestroke pipe upsetting line
was released in March 2012.

enaris supplies an extensive range of

seamless and welded line pipe products,
complete with coatings and accessories
for use in onshore, offshore, and deepwater
pipelines, with on-site, ready-for-installation
delivery. Tamsa is a major player in the offshore
markets (mainly deepwater and ultradeepwater) of South America, West Africa, Far
East, United Kingdom, and Scandinavia.
In contrast to the existing mechanical upsetting
machine designs, the new Danieli Breda model
is fully oil hydraulic: the main advantage of this
solution is greater flexibility, lower scrap and
higher production, and lower maintenance and
investment cost.
The above-mentioned advantages convinced
Tamsas management to change the pipe
upsetting technology from mechanical to
hydraulic.
The technical solutions adopted for this
machinery allow high operating flexibility, in
order to cover a wide range of processes and a
very simple set up that will reduce the
downtime between the upset cycles.
The upsetting machine is able to forge a single
pipe with a double stroke. According to the
required thickness of the pipe end wall, one or
more upsetting strokes may be required

1 Section sample of a pipe

end processed with the
double-stroke hydraulic
press.

2 Pipe upsetting area at

Tenaris Tamsa facilities
in Veracruz, Mexico.
3 Pipe upsetting sequence.

77

CUSTOMER SERVICE

DANEWS

Condition Monitoring System

Case history and return on investment analysis
for long product rolling mill stands
Gear box vibration
monitoring and
data analysis can
result in cost savings
of 120,000 Euro.
Danieli provides
equipment-monitoring
services through
customized technical
assistance packages for early
detection of critical breakdowns.
The Danieli monitoring systems
allow plant preventative
maintenance teams to detect
incipient failures, either before
they occur or before they develop
into major defects, avoiding
costly equipment failure and
production losses. As an example,
bearing defects, shaft problems,
and gear wear all can be detected
before critical failure occurs.
The application of such Danieli
technical assistance packages,
has demonstrated how periodical
vibration-data acquisition and
analysis produces cost-savings in
equipment maintenance and
reduced down time.
Gearbox of cartridge-type rolling
stand No. 10 (vertical) at
Ferriere Nord bar mill, Italy
First measurement session,
February 2011
The outstanding issues
addressed were:
> On the velocity spectrum, a
very high peak of the entry shaft
fundamental frequency was
detected, with maximum
magnitude of 15.85 mm/s in RMS.
> On the time domain diagram,
the presence of periodical signal
in the waveform was reported.
78

Diagnosis
The vibration spectrum and
waveform shape indicate defect
of unbalancing related to the
input shaft.
Corrective action
Danieli Service recommended
a verification of the operating
conditions of the spindle
between the vertical gearbox and
the bevel gear, jointly, as well as
a general inspection of the whole
equipment.
Maintenance action, March
2011
The spindle of the entry shaft
was found in poor condition and,
during the alignment verification
by means of laser
instrumentation, a residual radial
misalignment was detected.
In addition, the visual inspection
of the vertical gearbox revealed
damage to the cage of the thrust
bearing of the entry shaft.
The bearing failure was
determined to be the result of
improper running condition of
the vertical gear box input shaft,
which was loaded by the spindle
being significantly out of balance.

Second measurement session,

June 2011
The relief carried out after
replacement of the damaged
bearing, and substitution and
alignment of the spindle,
highlighted a great improvement:
> The magnitude of the entry
shaft RMS velocity peak dropped
from 16 mm/s down to 1.45
mm/s.
> The acceleration waveform in
time domain did not show any
evident periodical oscillation

(B)

(A)

Inspection of the gearbox

of a cartridge-type rolling
stand: some broken bearing
cage fragments (A) are
present, and the bearing (B)
is clearly damaged as also
shown in the detail (left).

DANEWS 164

With vibration analysis

Without vibration analysis

Damage type
Detected in initial phase

Unexpected

Action
Gearbox visual inspection

None (problem miss-detection)

Damage description
Bearing cage damage

Heavy failure of the bearing. Debris of the cage

and rolling elements dropped into the machine
body, damaging the pinion and the bearing housing

Effects
Bearing replacement and spindle
alignment during the first available
plant shut-down. Possibility of preparing
and organizing all activities, tools,
and manpower.

Gearbox repair during unplanned plant shut-down

Necessity to replace pinion and repair by welding
the bearing housing.
Unscheduled downtime and possible lost
production

Necessary corrective actions and time requested (hours)

Gearbox inspection (1h)

Gearbox inspection (1h).

Damaged bearing replacement (6h)

Gearbox removing from the line and complete

disassembly of the machine (11 h)

Alignment (1h)

Bearing housing repair, assembly and final

installation of the gearbox (9h)
Final alignment (1h)

Total downtime 8 hours

3
0.6

Total downtime 22 hours

11/02/2011

20/06/2011

Acceleration in Gs

0.3

Cost comparison
Lost production cost (*)
63,600 Euro

174,900 Euro

-0.6

Maintenance cost (spares and manpower)

700 Euro (bearing)

700 Euro (bearing)

-0.6

400 Euro (bearing)

4

3,000 Euro (entry pinion)

0.09

0.27

Measurement date
11/02/2011
20/06/2011

4,900 Euro (gear wheel)

672 Euro (manpower)

0.18
Time (sec)

2,772 Euro (manpower)

Total cost
64,972 Euro

186,672 Euro
1 Maintenance procedure
and cost comparison
with or without vibration
analysis.
2 Detail of entry shaft
defect frequency (1x)
that shows how the
magnitude of the
vibration is reduced after
refurbishment.
3 View of the rolling stand
after refurbishment.
4 Comparison of the
vibration measurement
sessions carried out
before and after gearbox
refurbishment.

(*)
Market price: 265 Euro/ton; Plant productivity: 30 t/h

RMS velocity (mm/sec)

19.69 Hz

1.45

0
0
2

100

200
300
Frequency (Hz)

400

500

79

CUSTOMER SERVICE

DANEWS

Danieli Service Centers

expansion projects
in Russia and India

The new
investments aim
to meet the
increasing demand
for high-quality
equipment and
services from the
expanding markets
in those countries.

Danieli Engineering
Polska, Poland

80

Danieli Volga
Nizhny Novgorod, Russia
Danieli Service Center,
Vyksa, Russia

Morgrdshammar
Sweden
Morgrdshammar
Germany

Danieli Service Center

Magnitogorsk, Russia

Danieli Service
Center, UK
Danieli Corporation
USA

Danieli Procome,
Spain

Danieli Service Center

Ukraine
Danieli Anatolia
Turkey

Daniel
Headquarters
Italy
Danieli Service
Center, Mexico

Danieli Volga, Russia

Russia is becoming a highly
demanding market. Steel
producers are moving toward
more sophisticated products, and
outdated plants need to be
modernized to meet the demands
for higher efficiency, better
quality, and lower consumption /
running costs. These market
developments have led Danieli,
in line with its plan for
internationalization, to build its
first Service Engineering
Workshop in Russia. The new
company has already been
registered as Danieli Volga. The
plant will be located on a 25-ha
site within the industrial area of
Nizhny Novgorod.
The first stage of investment
foresees a building of 8,500 m2
for the workshop, 1,800 m2 for
the offices, and the installation of
a first-class fleet of machine tools
and fabrication facilities that will
deliver products and services to
customers according to Danielis
quality standards.
The range of core products and
services provided (e.g., spare
parts as per original design,
consumables, refurbishment of
core equipment/parts, technical
assistance, total maintenance
contracts) will make Danieli Volga
a reference for the local market.
Construction for the building
began in April 2012, aiming to

Danieli Engineering
and Service, Austria

Danieli Service Center

Argentina

Danieli Service Center

Korea

Danieli Engineering
Japan

Danieli Service
Center, Egypt

Danieli Changshu
Metallurgical Equipment
and Services, China

Danieli Service
Center, Saudi Arabia
Danieli Service
Center, UAE

Danieli do Brasil
Brazil

Danieli Metallurgical
Equipment, Beijing
China

Danieli Service Center

Malaysia
Danieli India Ltd,
Mumbai, India
Danieli India Ltd,
Kolkata, India
Danieli India Ltd,
Chennai, India

Danieli Far East,

Thailand
Danieli Service Center,
Vietnam

Companies
Branch offices

start manufacturing activities

within December 2012. The
hiring of 150 technicians over
two years is foreseen. Specific
training courses for local senior
staff, some expatriates with a
long-standing experience, and an
agreement with the local
university to select the most
talented graduates, will make
Danieli Volga an example of
management focused on
customer satisfaction.

Danieli Indias new facility

in Chennai
Danieli India (DIL) is increasing
significantly its presence in the
Indian steel market and, in
support of this objective it has
decided to establish its own
manufacturing and assembly

facility in Chennai (Southern

India). It will expand the current
capabilities of its sales and
engineering offices in Mumbai
and Kolkata, as well as the
existing manufacturing unit for
electrical and automation control
boards, and will give DIL direct
control over the supply of hightech equipment, quality products,
and timely delivery from its own
fabrication facilities.
The project involves construction
of 45,000 m2 of covered area
with offices and workshops
equipped with state-of-the-art
facilities for machining, assembly,
after-sale refurbishment, steel
fabrication, heat treatment, sand
blasting, and painting, able to
provide the finished products
according to customer needs,
and with quality according to

Danielis standard. Construction

work has already started and the
first factory-assembly activities
are expected in July 2012, while
full factory activity, including
machining, will start in January
2013.
Staff hiring is already in progress
and more than 60 persons are
being trained already in other
Danieli facilities around the world
to be ready for the startup.
The Chennai facility will involve
up to 400 persons.
Besides the engineering and
production of core equipment for
metallurgical plants, DIL will
provide service activity, like
refurbishment, caster segment
rolls, mandrels, shears, spare
parts as per original drawings,
technical assistance, and
maintenance contracts

DANEWS 164

Handshake between V.P. Shantsev, Governor and

Chairman of the Nizhny Novgorod Region
Government (left), and V.V. Lurye, General Director
of Danieli Volga. On March 21, 2012, Danieli Volga
signed a three-party agreement with regional and
local governments of Nizhny Novgorod and
Dzerzhinsk, and placed a cornerstone on the site to
mark the beginning of construction. Groundwork
and foundations started on April 2.

Below: a rendering of the new Danieli India Ltd.

facilities located in Sri City Industrial Area, 50 km
from Chennai, in a 32-ha land area.
Raising of the first column took place on January
19, 2012, with the celebration of Indian traditional
well-wishing Pooja ceremony. The full factory
operation is forecast at the beginning of 2013.

81

CUSTOMER SERVICE

DANEWS

Danieli Service >ResinTech<

Resin technology for the revamp
of a 4-high reversing plate mill
at Marcegaglia, Italy
During a maintenance shutdown lasting just four days,
Danieli Service completely
revised the rolling stand
geometry, improving
competitiveness for the plate
mill.
With the global crisis affecting the steel
sector, many steel makers had to freeze
capital investment plans for rolling mill
modernizations; now many are looking
for inexpensive but effective solutions to improve
rolling performances. Today, rolling mill flexibility,
efficiency, and rolled product quality are the critical
factors for gaining competitiveness. Marcegaglia
Group, well aware of those key points, assigned to
Danieli Service an order for ResinTech mill stand
recovery, in order to improve those capabilities on
its 4-high reversible plate mill, located at San
Giorgio di Nogaro. The activity was carried out in
August 2011 during a maintenance shut-down that
lasted only four days, during which time Danieli
Service completely revised the rolling stand
geometry by means of its proven Resin Technology,
and improved not only the rolled product quality
and mill flexibility, permitting it to roll longer and
thinner plates, but also optimized production by
reducing downtimes that followed from the need for
continuous realignment of the transfer bar to the
rolling mill centerline. As all revamping activities
were carried out, Marcegaglia gained the following
advantages from the ResinTech technology:
> Widening the rolled product range by reducing
minimum plate thickness to 14 mm and increasing
plate lengths to 18 m;
> Restoring rolled-product geometrical qualities;
> Optimizing production by reducing downtimes
that were necessary to realign the plate to the
centerline;
> Reducing human errors due to reduced use of
side-guides;
> Simplification and speed-up of the roll stack
changing operations;
> Increasing main bearing service life by reducing
side forces;
> Creating a stainless property layer that will protect
housing surface from future corrosion (due to
SuperMetal chemical properties).
The aim of this project was to recover all wear outs
and damages on the housing as well as the chocks,
82

DANEWS 164

Increase [mm]
-2

-1

BUR
Top 1

12

backup top 1

125

200
125

125

work top 1
liner type e
work top 2
work bottom 1

125

125

backup top 2

liner type f
work bottom 2
backup bottom 1

Before revamping (real housing

displacement detected after survey)
Operator side

0.041

design
housing
position
3.280

liner type g

After revamping (new mill window

with offset and restored perpendicularity)

on -site machining

real
housing
position
new
chock liners

backup bottom 2
liner type h

3660

WR
Top 2

11

125

WR
Top 1

10

125

BUR
Top 2

WR
Bottom 1

new offset

WR
Bottom 2
415

0.655

3.308

BUR
Bottom 1
BUR
Bottom 2
Clear. due to Housings without Liners
Clear. of Housing A Liners ( Exit side)
Clear. of Housing B Liners ( Entry side)

new housing liners

Clearance of Roll Chock

Clearance of Roll Chock Liners
Total increase

Technical report of the clearance increase at the motor side (compared

with drawing values): a critical geometric condition of the rolling stands
could generate bad control of WR crossing and cause out-of-tolerance
product dimensions.

which led to an increase in the rolling stand

operating gaps. This increase generates different,
unwanted phenomena (roll crossing, chattering,
and plate deviation) that force the customer to
reduce the product range in order to minimize their
effects. Such operating gap increase is generated
by many years of rolling stand use, and results from
a combination of corrosion, wear out and imprinting
of the mill window and chock liner surfaces, plus
the misalignment between operator- and drive-side
housings due to foundation assessment.
The only way to solve all these problems is to
reestablish the correct alignment between all
operator and drive side sliding surfaces, together
with all chocks. This activity is also a good occasion
to create some small improvements to the mill

Diagram of the stand refurbishment with highlighted major intervention

carried out to restore the designed operative conditions.

window design concept, similar to those that were

carried out in Marcegaglia:
> differentiation of mill window openings between
operator and drive side, in order to simplify the
alignment between roll stack and stand;
> modification of the design of operator-side
housing liners, in order to reduce the cost of future
spares;
> realization of adjustable operator-side chock
liners for clamping, in order to compensate for the
future wear-out of the clamps, as well as to reduce
maintenance costs.
All the advantages stated here set the ResinTech
application as the most convenient, simple, and
non-invasive process for recovering old rolling
stands in a very short time

Warm handshake for the

successful completion
of the revamping project
between F. Fasoli, Plant
Manager, Marcegaglia,
and M. Zawadzki, Site
Manager, Danieli Service.

83

CUSTOMER SERVICE

DANEWS

Safer, faster, more accurate

CRM equipment alignment
thanks to BUR de-chocking machine

Successful execution
of Danieli Service project
for the five-stand tandem
cold rolling mill at AMSAArcelorMittal South Africa.

The installation of the custom-designed

BUR de-chocking machine was
completed successfully in December
2011. The addition of the new dechocking machine resulted in the safer, quicker,
and more accurate mounting and dismounting of
BUR chocks, while also avoiding accidental
damage to bearing components, when compared to
the previous manual assembly techniques using
the overhead crane.
The machine itself is comprised a central hydraulic
lifting platform with roll diameter compensation for
accurate positioning of BURs. This main platform is
complete with four wheels, two of which are driven,
for controlled rotation of the BUR to assist in the
alignment of keyways.
The BUR chocks are precisely positioned by using
two hydraulically controlled platforms specifically
designed to accommodate both top and bottom
BUR chocks. The movement of the chocks can be
carefully monitored to an accuracy of 1 mm
through the widescreen, digital display mounted on
the control unit. Roll supports, chock-clamping
mechanisms, and the positioning of the main
control unit vastly increase the safety of the roll
shop personnel during the mounting and
dismounting procedures. After several weeks of
successful operation and positive feedback from
the customer, stating their complete satisfaction of
overall performance of the system and the
realization of benefits obtained through this
investment, the Final Acceptance Certificate was
released on January 25, 2012. Such is the success
of this project that other mills within the
Vanderbijlpark plant are being considered for future
investments in Danieli de-chocking machinery

Snapshots from Danieli

Service de-chocking project
at AMSA five-stand CRM.
Souvenir photo with

84

A. Romanek, Senior
Engineer of AMSA,
and M. Falcomer, Senior
Engineer of Danieli Service.

DANEWS 164

SRW-E the new benchmark

for high-speed guides

The SRW-E guide is

available now to the
market. This new
guide series has been
developed on the basis of the
well-known SRW guide, a bestseller among high-speed guides.
Supporting the development of
this new guide were reports from
end-users and Danieli
Morgrdshammars unmatched
experience and know-how with
high-speed rolling mills.
The main improvements
featuring SRW-E are:
> Zero clearance system to
improve stability and control
at high speed;

Contact your MH guide representative

for further information.

> Increased rigidity thanks to

improved preload on roller
holders;
> Increased service life for each
component to reduce operating
cost (example roller holder shaft
is now installed on bushings);
> Optimized, V-shaped base to
improve reliability and
repeatability of guide installation;
> Increased guide capability
thanks to the new version with
a 40 mm roller;
> Improved roller installation.
These features add to the
characteristics of the previous
SRW guides, namely:
> Simple and heavy-duty design.
> Stainless steel material to
withstand the severe environment
of high-speed blocks.
> Individual adjustment for each
roller holder.
> Simultaneous fine adjustment
of all rollers, through single
central screw
> Independent vertical
adjustment for all rollers
> Minimized need of spare parts
and maintenance. Common
components between different
guides types
> Available with shorter roller
height to be installed closer to

the rolling rings to improve

guiding capability.
> Special design for bearing preloading, to achieve contact
between ball bearings and races.
> No media supply (air/oil
lubrication and water cooling)
through external pipes.
> Long intervals between
maintenance activities, granting
long operational time.
The new guides, installed with
titanium-carbide Ferrodur rollers,
will allow unbeatable

performances that withstand

existing demand, to increase
rolling speed and finished
product quality. Guide setting
could eventually be performed
with Danieli Automation Hiline
IFB, for unbeatable precision.
Two reference plants -the highspeed wire rod mill of Ferriere
Nord, and the stainless steel mill
of Cogne Acciai Speciali, where
the new guide has been testedproved the advantages of new
SRW-E guides
85

CUSTOMER SERVICE

DANEWS

Unicoils cold mill complex

produces up to 250,000
tpy of pickled, cold rolled,
galvanized strip in CQ,
DQ/LFQ, FH, and structural
steel grades.

OMKs Danieli QSP-based

minimill complex produces
up to 1.2 Mtpy of hot rolled
coils of thin strip (down to
1 mm) in a wide variety of
grades that include
peritectic and up to API
X70 steels. Center: friendly
handshake after LTSA
contract signing between
Mr. Fedotov, Plant Manager
(OMK), and Mr. M. Di
Giacomo, EVP Danieli
Service.

86

DANEWS 164

Danieli Long-Term Service Agreement

for flat product plants maintenance,
signed at OMK, Russia, and Unicoil, KSA

Danieli Service signed

a new Long-Term
Service Agreement
(LTSA) with OMK
Steel (Russia) for on-site support
for the maintenance and
operation of the meltshop, slab
caster, hot strip mill, and mold
and segment workshop area.
Over a two-year term covered by
this contract Danieli Service will
provide supervisory services for
equipment maintenance,
operation, and practical training,
to support OMK Steels staff in
its efforts to improve plant
performance and maintenance
results. Moreover, besides the
on-site services, for a quick
solution to technical issues and
to reduce the causes of
equipment stoppages, Danieli
Service and Danieli Automation
will provide a remote maintenance
service (Teleservice package) to
detect faults and malfunctions,
and to support the customer with
a call service. The benefits of the
LTSA, where over the duration of
the contract a minimum number
of man-days is guaranteed, is to
provide the customer with a
faster response and to fix
problems at advantageous rates.
Another LTSA contract was
signed with Unicoil (KSA) for
operation and maintenance
support of the Danieli cold mill
complex there, which is
comprised of a push-pull
pickling line, cold rolling mill,
and hot-dip galvanizing line.
The target for this backup
support is to provide specialized
assistance in the most critical
equipment (furnace, pickling
section, etc) that requires a high
level of knowledge in process
and special materials, in order
to reduce maintenance costs
and increase production
performances.
Moreover, many other LTSAs
are under discussion
87

Danieli Partners in Front Running

Worldwide Offices
and Service Centers

Danieli
Headquarters

Worldwide
Danieli Companies

Via Nazionale, 41
33042 Buttrio (UD) Italy
Tel (39) 0432.1958111
Fax (39) 0432.1958289

info@germany.danieli.com
Tel (49) 208.3780000

info@spain.danieli.com
Tel (34) 94.4872800

info@canada.danieli.com
Tel (1) 905.3049337

info@russia.danieli.com
Tel (7) 495.9819073

info@thailand.danieli.com
Tel (66) 2.6933520

info@netherlands.danieli.com
Tel (31) 251.500500

info@usa.danieli.com
Tel (1) 724.7785400

info@brazil.danieli.com
Tel (55) 11.35085900

info@russia.danieli.com
Tel (7) 351.2674632

info@korea.danieli.com
Tel (82) 2.5626622

info@austria.danieli.com
Tel (43) 4232.51440.6101

infodme@china.danieli.com
Tel (86) 10.58082828

info@mexico.danieli.com
Tel (52) 81.83781055

info@russia.danieli.com
Tel (7) 3519.244043

info@japan.danieli.com
Tel (81) 45.6517077

info@sweden.danieli.com
Tel (46) 240.668500

infodcs@china.danieli.com
Tel (86) 512.52267088

info@egypt.danieli.com
Tel (20) 2.26379229

info@ukraine.danieli.com
Tel (38) 056.7904301

info@switzerland.danieli.com
Tel (41) 61.8368310

info@uk.danieli.com
Tel (44) 114.2800300

infodfe@thailand.danieli.com
Tel (66) 38.955888

info@uae.danieli.com
Tel (971) 2.6812268

info@india.danieli.com
Tel (91) 22.39917100

info@france.danieli.com
Tel (33) 1.49722269

info@india.danieli.com
Tel (91) 33.39847777

info@ksa.danieli.com
Tel (966) 3.8993145

info@taiwan.danieli.com
Tel (886) 7.3358655

www.danieli.com
info@danieli.com

Vallourec & Mannesmann

Arvedi, Italy

OMK, Russia

Riva Acciao, Italy

Four reheating and heat

treatment projects for
seamless pipes over five
years, mostly on a turnkey
basis, in Europe, North
and South America.

The ultimate vertical

furnace for DP and TRIP
GI, equipped with
proprietary pre-mix burners,
self-recuperative burners
in 2P Inconel radiant tubes
and rapid cooling (100
C/sec @ 1-mm thickness).

200-m-long, 300-tph roller

hearth tunnel furnace
and heat transfer table
for thin slabs, processing
alloy and carbon-manganese
steels up to 90 mm thick
and 1,800 mm wide.

Turnkey, 350-tph walking

beam furnace equipped
with MAB Flameless low
NOx burners installed in
one of the worlds largest
hot-strip mills (6 Mtpy).

FOUR LATEST REFERENCES

AMONG A TOTAL OF 231

DANIELI CENTRO COMBUSTION

ULTRA-LOW NOX HEATING SYSTEMS
FOR AN EFFICIENT
AND SUSTAINABLE STEEL INDUSTRY

Reheating systems

STATE-OF-THE-ART REHEATING AND HEAT TREATMENT SYSTEMS COVERING A WIDE RANGE OF FURNACE TYPES
FOR SPECIAL AND COMMERCIAL STEEL PRODUCTS (BILLETS,
BLOOMS, BEAM BLANKS, THIN AND THICK SLABS, COILS, TUBING AND CASING).

DANIELI ENVIRONMENTAL SOLUTIONS

FOR A SUSTAINABLE INDUSTRY
> WATER TREATMENT PLANTS <

Danieli Engineering supplies

reliable solutions for water
treatment plants to the steel
industry, including:
> primary treatment to obtain good quality for make
up purposes;
> no contact cooling circuits;
> heat recovery for desalination units;
> contact cooling circuits,
with complete cleaning treatment of dirty water;
> blow-down water treatment and recovery,
up to zero discharge option
(ZLD);
> wastewater treatment;
> chemical conditioning advisory and assistance.
More than 135 water treatment plants, with
a cumulative capacity of circulating more
than 370,000 m3/h of water for indirect cooling systems, and more than 200,000 m3/h of
water for direct cooling systems

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 the 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.

ENVIRONMENT