You are on page 1of 44

siemens-vai.

com

Solutions for long


product rolling mills
Technology, mechanics, automation and electrical
engineering for bar mills, rod mills and section mills

Answers for industry.

Greater production.
Higher quality. Lower costs.

Factors to consider
You should expect a great deal from your solutions partner.
Reliable equipment, process consistency, production
flexibility and waste minimization. All in one package,
managed from start to finish. All of these factors have
to be taken into account in designing the optimal solutions
for your mill.
Maximizing productivity
through process optimization
How much time is needed for each process step? What
temperature profiles are required? How can transfer areas
be made more efficient? For the best answers to these
questions, your rolling mill partner should have expertise
with equipment technology and know-how to optimize
complex plant layouts.
Flexibility comes first
Short delivery times and fast production changeover
are key criteria for you to meet your customers demands.
Thats why you need to be ready to convert your rolling
stands to the next order while still processing the current
one, and change your line from one product to another
with virtually no downtime.

Quality throughout
You can achieve very high precision with rolling stands
designed to withs tand high loads and changing temper
ature r equirements. That same capability, c oupled with
sophisticated control technology, allow a wide range of
process conditions for desired product qualities.
Cost reduction
Cost optimization has many facets, including processcontrolled yield maximization, downtime reduction and
maintenance cost controls. When the entire system is
managed through one source, you benefit from a high
degree of standardization.
Environmental influences
There are sound legal and cost reasons for conservation
of resources within your plant, such as water application
for temperature control. You should also evaluate your
solutions provider by how well they support you in this
area.

For many products, steel must first be processed in a long rolling mill.
Our job is to perfectly coordinate everything to ensure steel quality
and an exceptional level of mill productivity. As the pioneers of key
technologies in long rolling, we have the knowledge and experience
to provide the best solution for your mill.

You expect ...


Consistent reliability of
all units within the mill.
Increased productivity through
intelligent process design.
Maximum plant flexibility,
minimum set up times.
Optimum cost efficiency
through integration of
automatic equipment.
Excellent product quality
with precise tolerances.
Automation systems to
monitor and optimize processes
and mill performance.
Responsible handling of
emissions and recycling.

Our experience in rolling mills dates back to 1886, with the founding
of Pomini in Castellanza, Italy, and 1888, when Morgan Construction
began U. S. operations in Worcester, Massachusetts. Siemens VAI
Metals Technologies continues to innovate all elements of plant
construction: Process, engineering, manufacturing, installation and
commissioning, plus life-cycle management. No other rolling mill
manufacturer can offer a comparable range of products, solutions,
or experience.
Advantages of our
long product rolling mills:
Maximum reliability, thanks
to 250 years of combined
experience
Thousands of roll stands
commissioned
Over 1,000 rolling mills installed
or upgraded on six continents
Verifiable expertise for all
elements of plant design and
construction
Global presence and economic
strength as a part of Siemens AG
Solution providers to cover
all aspects of long rolling:
Mechanical
Electrical
Automation
Fluids
Process and plant services
Metallurgical services
Services
In-house manufacturing
and testing of proprietary
technology equipment
One contact for all questions.

The right starting point:


Siemens VAI Metals Technologies
long product rolling mills
Top quality of all individual rolling components
All components from Siemens VAI Metals Technologies
are designed for high durability and maximum uptime.
The high quality of the components, and a reliable supply
of spare parts thanks to extensive standardization,
ensure we meet or exceed our customers expectations.
SiemensVAI Metals Technologies rolling stands are
suitable for use in a wide range of situations. Our convertible stands, for example, can be switched over from
horizontal to vertical operation at the press of a button.
In the past, set up times were measured in minutes,
whereas now production can be changed in a matter
of seconds.
and in the complete system design
A state-of-the-art rolling mill needs more than just
first-class components. It takes analysis and mapping of
all processes, and possibly their redesign, as part of
an integral system layout, to create a solution thats
not simply a rolling mill.
In concrete terms, that translates into considerably higher
productivity through minimized downtime and seamless
interlinking of production stages.
Automation from the global market leader
All processes of our rolling mills are monitored and
controlled by an integrated automation solution from
SiemensVAI Metals Technologies. Beyond the actual
process control, we also offer:
Standardized mill automation utilizing technological
know-how
Continually developed and partially self-learning
process models for the reproducible manufacture
of steel products of defined quality
A manufacturing execution system solution for
optimized production planning and for minimizing
rejects
A Level 2 and mill management system for maximizing
everyday performance and reliable product tracking
through the mill.

Resource management included


We take care to ensure that your most important resources
are available with absolute certainty, such as efficient
power quality solutions for a dependable and stable power
supply, or with a tailor-made concept for closed-circuit
water treatment to match the process requirements.
Naturally, we also take all current emission levels into
account in the design of a rolling mill and if necessary,
anticipate tomorrows standards as well.
Success from a single source
Our turnkey solutions ensure that all aspects of the mills
design, manufacture, installation and start-up are managed
with close coordination and expertise. This comprehensive
approach is unique. As prime contractor, we handle the
complex details, and monitor all required rules and regulations, so you can concentrate on your core business of
manufacturing long products and marketing them profitably.
Guaranteed performance
throughout the entire life cycle
Knowledge transfer by our training experts, combined
with a dependable supply of spare parts, ensures reliable
operation. A full range of services from Siemens VAI
Metals Technologies helps maintain high mill availability
over the entire life cycle. This is backed by carefully
planned modernizations for cost-effective technical
upgrades.
Wheres the proof?
The numbers demonstrate the success of our concept.
More than 1,000 rod, bar and billet mills all around the
world are Morgan, Pomini, Ashlow and VAI mills, now all
joined within Siemens VAI Metals Technologies. These
mills have set worldwide benchmarks for technological
leadership, reliability and performance, and have captured
the greatest market share in long rolling equipment.
Life-cycle partner for the metals industry
Siemens VAI Metals Technologies is one of the worlds
leading life-cycle partners for the metals industry. A wide
range of products, solutions and services is offered to
ensure that metallurgical plants and the integrated processes and systems are maintained at state-of-the-art
performance levels throughout their entire life cycle.
This is the basis for reliable, cost-efficient and environmentally friendly production, and the long-term success
of our customers.

Mastering the processes SIROLL LR

SIROLL Process Xpert/


Level 2

SIROLL LR
basic automation
system

Mechatronical
packages

Main & auxiliary drives

A precise understanding of all aspects of production is our basis for


developing practical, integrated, standardized solutions for your rolling
needs, developed by systems engineers who understand the mechanical
equipment and process. To insure that individual improvements do not
negatively affect other part of the process, all steps must be understood
within their own context as well as their role in the process chain.
Thats why we give top priority at Siemens VAI Metals Technologies to
developing process-oriented solutions for everything from the mechanical
equipment to the process control. The solution SIROLL LR is part of our
commitment to deliver comprehensive, totally integrated solutions from
a single source. Our process knowledge, combined with Siemens stateof-the-art automation components and software that run on user-friendly
human-machine interfaces, provide operators with simple and efficient
tools to master the processes.

Mill automation and process control

Typical two strand wire rod mill overview screen

Typical diagnostic screen

The combination of process technology, mechanical


equipment, electrical components, and automation
functions is a crucial aspect of Siemens VAI Metals
Technologies solutions, and allows us to deliver
the highest possible performance to our customers.
From initial mill design to maintaining your plant
for years to come, Siemens VAI Metals Technologies
is unique in offering world-class solutions as a
single-source supplier.

The modular design of both hardware and software


ensures flexibility for all customer requirements in
upgrades, extensions, new plants, and very complex
revamps.

Basic automation (Level 1) and


human-machine interface
Siemens VAI Metals Technologies highly modularized
technological control functions are based on extensive
experience in the long rolling industry, and include:
Minimum tension control
Loop control
Cobble detection
Shear and high-speed shear control
Water box control
Intelligent pinch roll control
Coil handling system
Compactor control
Mill setup
Standard interfaces
Mechatronic packages as technological units.
As an integrated and autonomous supplier, we offer
a seamless array of automation functions from a single
source.

The operator stations and human-machine interface (HMI)


screens are developed alongside experienced customers
from mills worldwide, offering a practical, user-friendly
look-and-feel.
We achieve world records in commissioning time by
customer-specific concepts, especially during upgrades
and short shutdowns.
Spare-part stocks for our automation components are
available worldwide.
Experienced specialists for programming, training,
and support are available in our regional offices near
you and also at the company headquarters.
Joint mechanical and electrical teams drive our long rolling
technology forward through ongoing research and
development activities and through upgrades to SIROLL LR.
Basic automation and HMI system design:
Standard SIMATIC PLC S7-400 hardware components
centrally installed in the control room or as premanu
factured complete container
Decentralized SIMATIC ET200 I/O modules interface
to plant sensors and actuators for short cable routes
PROFIBUS and SIMATIC NET standard network
components ensure proven communication
MS Windows-based server-client HMI system, PCS 7,
or S7/WinCC both available.
7

SIROLL LR Process Xpert reporting module

Seamless data integration with


SIROLL LR Process Xpert
Consolidation in the global steel industry is bringing new
challenges to the task of managing several plants in different
locations and countries. Business managers may control
overall business performance, but mill floor operations
achieve plant performance. The SIROLL LR Process Xpert
collates the data from Level 1 with all management data
and presents the resulting information in a standardized
format to meet specific mill or company requirements,
including reporting, operations and mill operation tracking.
The comprehensive system prepares and displays complex
KPIs from the operational perspective and provides tools
to analyze and locate areas of opportunity as well as drive
continuous improvement.
Features:
Automates and unifies mill setup and control
Provides operators with comprehensive information
Facilitates use of best operating practices
Enables optimization of mill performance
Eliminates obsolete, stand-alone systems
Interfaces well with SAP
Generates QA certificates.
SIROLL LR Roll Master
SIROLL LR Roll Master is an extension that provides
the following functions:
Easy computer-aided creation of pass schedules

SINAMICS drive panel

Calculation of material spread, mill load and bar


temper-ature based on more than 200 steel grades and
special alloys
Accurate setting of guides for product-dimension changes
Creation of the mill setup considering the actual
condition of all components
Simple management of all key data related to mill grooves,
guides and rolls; available for high-production mills and
special steel grade mills rolling only a few billets per lot
The process automation consists of MS Windows servers
with Oracle database applications.
Mechatronic solutions
Mechatronics merges mechanical, electrical, control systems
and software as an intelligent approach to the design of
electromechanical systems. We use this technology to
integrate our process know-how along with our advanced
equipment. From a single-source supplier, you can get
enhanced products that provide functionality, flexibility
and ease of use, as well as robust and proven systems to
help your operation run smoothly.
When supplying a full rolling mill solution, these systems
are integrated into the mill control SIROLL LR. For moderni
zation solutions, they can be supplied as stand-alone systems
and interfaced with the existing mill control.
Standard mechatronic packages
Can be easily integrated in new or existing systems. When
supplied as part of a full mill control system, the mechatronical
packages are embedded into the SIROLL LR:

Mechatronic solutions
in long rolling mills

Water box control system (HMI)

Water box control system (mill floor)

Shear control

Direct interface with the SIROLL LR mill control system

Temperature control

Integrated tension control

High speed finishing blocks

Easy-to-navigate HMI interface for the pulpit operators

Morgan Reducing/Sizing Mills

Full local and remote control options.

Pinch rolls
Morgan Stelmor conveyor

High speed shear:


Eliminates oversized front and tail ends, reducing
wear and impact stress on downstream equipment

Reform area

Automatic trimming of uncooled product

Coil handling

Synchronized with laying head front end orientation

Compactors

Minimum deflection of rod from cutting position

Cooling bed entry systems

Increased yield by eliminating manual cutting errors

Bar counting

Direct interface with the SIROLL LR mill control system.

Laying heads

Stackers
Tyers and bundlers
Fluid systems
Inline measuring systems
Non-contact measurement systems.
Further stand-alone packages:
Flat Rolling Block
Compact multi-rougher
Rail pre-cambering.
Morgan Bar Reducing/Sizing Mill:
Fully automated control of stand change and roll parting
Fully automated control of drive system clutches
Automated setup

Lubrication systems:
Monitors temperature control and oil cleanliness
Operates under a wide range of ambient conditions
Incorporates vacuum dehydration.
Water systems/product temperature control:
Designed specifically for in-line water boxes
for product controlled cooling
Incorporates specially designed water valves
for high speed operation
Balanced design avoids water hammer
Compact, maintenance-friendly valve stands
Closed loop control
Direct interface with the SIROLL LR mill control system.
9

Our rolling mill products


a well-coordinated ensemble

Coil handling

Morgan Stelmor
Cooling conveyor

Morgan High Speed Laying Head

Morgan Rod Reducing/Sizing Mill

Coil compactor

Cooling bed

10

High speed entry to cooling bed

Bar bundling

Morgan Vee No-Twist Mill

Pouring reel

Endless rolling technology

Red Ring stands

Bar sizing

Crop and cobble shear

Water cooling system

11

Rolling stands

Red Ring stand

Red Ring stands

Red Ring stands


The Red Ring housingless stand design has been a popular
solution for many roughing and intermediate mill
applications.
Red Ring stands are renowned worldwide for their rigidity,
ease of maintenance and load capacity.
Different versions of these stands are available, including
vertical, horizontal and convertible, which allow for
rapid adaptation to a variety of rolled products needed
to fulfill stringent market demands.
With the quick disconnect capability of the spindles and
fluid utilities, the stands can be interchanged very quickly.
Features:
High rigidity
Reduced stress path
Fully automatic operation
Axial roll adjustment
Automatic screw-down system
Adjustment under load available
Roll balance system to eliminate backlash
Self-balancing spindle support for
minimum and positive engagement
Long-life bearings
Automatic utility connections.

12

Convertible stand

Compact roughers
Compact roughers can be used where space is limited
or if higher reductions are required. These roughers are
equipped with special shoe plates and clamps to allow
for minimized centers. Greater reductions are possible
by using the billets own beam strength to help it enter
successive passes. When the centers are close, the stands
can be shifted in and out of the pass line to adjust or
change the guides.
Features:
Small space requirement
High reductions possible
Easy guide change.
Reversing 2-high stands
A group of two stands can roll cast or forged billets in
horizontal-vertical arrangement. Every two passes, the roll
gap is adjusted and rolling direction changes. Reversing
roughers increase the process flexibility. Electrical equipment may be simplified by the use of asynchronous
low-voltage motors with multi-stage reduction units.
Sliding stands
Modern 2-high sliding stands, reversible and fully automated, represent an innovative solution for roughing and
intermediate trains. The rolling line remains fixed, while
pass is changed by the stand sliding movement. The roller
tables and bar manipulating systems are simplified.
The automated change of stand permits the use of off-line
prepared stands, which reduces down-times:

Sliding rougher

Reduced roller table width

Compact cassette rolling stands

Advanced billet manipulation system

Features:
Fast stand and roll change

Automatic roll gap adjustment

Hydraulic vertical and horizontal roll adjustment

Simple foundations

Modular design to reduce crane requirements

Compact multi-rougher arrangement.

Highest stiffness with a housingless design.

Convertible stands
Todays mills can be used in a wide range of configurations
in order to provide an unlimited selection of products
from a single mill layout. Convertible stands allow either
horizontal or vertical positioning, with quick and automatic
selection, and are mainly used in the intermediate and
finishing trains, in accordance with production
requirements.

Compact Cassette Rolling stands


The compact and rigid cassette design is suited to many
special bar mill rolling requirements. The extremely rapid
cassette change facility, in conjunction with a high degree
of automation, allows for flexible and efficient production,
even for orders with a small number of billets.

Features:
Less than two minutes to change position

Features:
Three possible arrangements for twist-free rolling:
horizontal, vertical and 45 (X)
Most compact stand design available on the market

Reduced foundation depth

Automated groove changing

Excellent stand rigidity

Reduced bay height requirements

Quick stand change system without crane requirements.

Open access to top of cassette

Red Ring universal stands


Universal stands are based on the Red Ring concept, and
designed for the rolling of structural shapes. In addition
to the horizontal rolls, the stands are fitted with a set of
idle rolls to work the flanges. Red Ring universal stands can
easily be converted to conventional horizontal rolling,
according to production requirements, thus avoiding the
need for additional horizontal stands.

Possibility for automatic cassette change robot system


Fast roll change, with no need for special equipment
Interchangeable H-V-X cassettes within the same
stand size
Available with monogrooved or multigrooved stands
and also as a reversing block.

13

Bar sizing technology

4-stand Morgan Bar Reducing/Sizing Mill

High precision rolling coupled with process flexibility


and equipment durability describes the Siemens VAI
Metals Technologies bar sizing technology. Based on the
two-roll arrangement, various solutions are available,
which meet every need for size, load capacity and
productivity.
The two-roll design
The two-roll design offers user-friendly operation as well as
simplified maintenance. It produces superior surface quality,
high dimensional precision and ultimate processing flexibility. The two-roll design can use multi-groove rolls, which
significantly lowers the investment and conversion costs
as well as reduces operation downtimes.
Pass schedules provide reduction rolling in the first stands
followed by high precision sizing in the final stands.
The rigidity and load capacity of the equipment permit
the processing of a wide range of steel grades, with both
conventional and low temperature, such as thermomechanical, rolling practices. Under-load remote adjustment
of roll gap is also possible.
Features:
Single family rolling capability
Free size rolling capability
3-stand or 4-stand configuration
Pre-loaded stands with under-load remote
adjustment of roll gap
Automatic couplings of service utilities

14

3-stand Morgan Bar Reducing/Sizing Mill

Inline quick change of stands


Off-line quick change of rolls
Easy preparation of rolls and guides with off-line
presetting for plug & play rolling campaign
Single or multi-groove rolls
Possibility to use both cast iron rolls, tool steel and
tungsten carbide rings
Unique and patented pass designs
Possibility of automatic gap control
Over-driven stand arrangement provides minimal
impact on foundation works.
Sizing for bar-in-coil products
The Morgan Bar Reducing/ Sizing Mill (BRSM) is the
preferred solution for rolling small- to medium-diameter
product typical of bar-in-coil production.
Features:
Compact arrangement to minimize space
Single or double groove to reduce roll cost
and downtimes
Guideless rolling
High speed capability
Symmetrical mechanical preload
Split roll housing design for fast roll changes.

3-stand Pre-stressed Sizing Group

4-stand Pre-stressed Sizing Group

Sizing for straight bar products


The Pre-stressed Sizing Group (PSG) is the preferred
solution for rolling medium- to large-diameter product
typical for straight bar mills. The available stand sizes
cover a range of finished bar diameters up to 150mm.

Mechatronic solution
Fully featured mechatronic packages provide complete
and effective control of Siemens VAI Metals Technologies
bar sizing technologies to ensure guaranteed performance.

Features:
Higher mill utilization with multi-groove rolls

Features:
Full local and remote control options
Fully automated control of stand change and roll gap

Hydraulic preload systems for both radial and


axial directions guarantee very high rigidity

Fully automated impact compensation and stand


speed referencing

Automatic gap control

Automatic setup

Motorized adjustment of guides and axial roll


movement.

Automatic under-load gap control

Other solutions
The Cantilever Sizing Stand is the simple solution for
a quick and economical project, to improve the size
tolerance at 90 to the last finishing stand.

Integrated tension control

Features:
Easy and economical installation in existing mills

Direct interface with mill control system


Straightforward, easy-to-navigate HMI interface
for the pulpit operator
Electro-mechanical systems fully tested prior to
shipment for shorter site commissioning times
Fully integrated into standard SIROLL solution.

Small dimension and weight


Easy positioning close to finishing stand
Stand, gearbox, motor and hydraulic unit are
contained in a single transferable block
Can use cast iron rolls, tool steel and tungsten
carbide rings.

15

Technologies for rails and sections

idRHa+ system 3-D rendering

Continuous finishing mill for rails and sections with Red Ring stands

Red Ring universal stands


As with the 2-high Red Ring stand, the Red Ring universal
stand has no requirement for a standby stock of chocks.
Instead, a robot system performs roll changes, which
mechanizes the assembly/disassembly of roll chocks. The
process of disengaging a Red Ring universal stand from the
rolling line, such as for stand clamping or spindle holding,
is exactly the same as for a normal 2-high Red Ring stand.
Features:
Easy conversion to conventional horizontal stands

Automated roll change operation:


Significantly reduces roll assemblies changeover time
Operation with hydraulic unit.
Pre-cambering systems
Rails may require an additional pre-straightening operation
thats applied at the cooling beds entrance. Asymmetrical
cooling in the cross section of the rail tends to bend it
inwards on its head side. Pre-cambering compensates for
this, and promotes an effective post-cooling straightening.

Four-row cylindrical bearings with separate thrust


bearings allow maximum load carrying capability

Features:
Rails hydraulically clamped and lifted

Fast roll and stand change

Individually programmable travel strokes allow


application of different pre-camber patterns.

Vertical frame separates from tie rods for quick assembly


Hydraulically adjusted horizontal and vertical rolls.
Increased life span and cleaner operation:
Main bearings and labyrinth seals have extended life
with oil/air lubrication instead of automatic grease

Stacking systems
The layers of sections arriving from the straightening
and cold-cutting area are properly braked and buffered
onto the first transfer table of the stacking area.

Flume water contamination reduced.

Aligning rolls and stoppers give bars an orderly disposition.

Counterbalanced spindle support:


Wrapped bearing design eliminates hub wobble,
reduces wear

idRHa+ rail hardening


The use of high-speed trains for long-distance passenger
transport calls for excellent quality of the rail head surface.
On the other hand, the high axle loads created by freight
traffic are placing increasing demands on the track bed and
rails, with wheel loads of over ten tons often imposed on rail
contact areas of just a few square centimeters. This requires
rails that can not only withstand these high contact stresses
but also have a high resistance to wear.

Generous tapers on hub entry and roll ends allow


stand changing without moving spindles.

16

Medium section straightening system

The Injector Dual-phase Rail Hardening (idRHa+) is suitable


for installation in new plants as well as for integration into
existing mills, and it enables rails to be produced with
improved resistance to contact fatigue and wear. The final
rail performances may be optimized according to the
different grades of steel, which may be processed reliably
and flexibly. The idRHa+ also allows the simulation of
various cooling strategies for different grades of rail steel
prior to the start of production. This enables run-up times
to be reduced, nominal capacity to be attained more quickly
and relevant performance parameters to be fulfilled
consistently and reliably.
Features:
Special system directs out-of-tolerance bars to
separate cradles

Rail pre-cambering system

Working sequences of stacking and binding fully


automated and interfaced with the other areas of
the rolling mill.
Straightening systems
When sections are cool enough, below approximately
100120 C, they must be individually straightened
before being cut to their final length. This is necessary
to remove the deformations caused by the asymmetrical
cooling effects. The sections have to be subjected to
a mechanical deformation to reach the yield tensile
strength (YTS) value.
Other types of straightening systems are designed for
rail and special sections processing.

Disappearing stoppers and variable-speed devices


form and separate individual layers

Features:
Rigid frame contains two sets of double-supported
horizontal rollers

Synchronized operation of suitable devices ensures correct


sequence of straight and 180-degree rotated layers

Top rollers position is vertically adjusted according


to bar size

Electromagnets equip devices for firm grip on bar

Hydraulic counterbalance eliminates vertical


movement backlashes

Adjustable width roller table transfers stacks to


binding area

Axial adjustments for rollers

Horizontal and vertical rollers maintain good stack


alignment in transit

Rollers mounted in removable cassette for quick


changing operation

Operations all fully automatic and computer-controlled

Special combing devices or pinch rolls ensure


bar separation for effective straightening process

Divisible design provides flexibility needed to process


different stacks of different lengths for greater productivity
Combined mechanical-magnetic type processes small
to medium sections

Magnetic rollers at straighteners exit prevent


bars slipping
Suction system removes scale during straightening.
17

Slitting and high speed cooling


bed entry systems

Rotary Entry System

4-slit rolling

Multichannel braking system

Slitting systems
Siemens VAI Metals Technologies powered slitters provide
highly accurate and consistent dividing. They allow rebars
to be rolled in multiple strands, significantly improving
the productivity of small size rebars, without increasing
their finishing speeds. Slitting rolls have ten times the
life of slitting guides, while offering higher speeds and
better accuracy. Divided strands may be finished in the
same rolling stands or individually, for better product
quality and tolerance.

Benefits:
Bar maximum delivery speed: 50m/s

Benefits:
Reheating furnace and rolling mill can also be operated
to full design capacity for small size rebars, which
become less costly to produce

Benefits:
Bar maximum delivery speed: 28m/s

Easily applicable to most bar mill configurations.


High speed cooling bed entry systems
High speed finishing maximizes rolling operation over
the entire product mix. To meet these requirements,
Siemens VAI Metals Technologies provides the Rotary
Entry System (RES) and the Multichannel Braking System
(MBS). Both RES and MBS allow the smooth discharge of
one bar per notch for better alignment, separation and
counting. They can be installed along with conventional
run-in roller table and brake slides for large size rebars.
Rotary Entry System
Each strand has a pair of rotating drums, where bars are
indexed after being braked by the high speed pinch rolls.

Accommodates 2-way slitting into high speed finishing


blocks for consistency of section and quality
Modular design.
Multichannel Braking System
The system can be used to discharge single strand, multistrand, and up to 4-slit rebars. The bars are braked by
pinch rolls into channels which open over the cooling bed.

Applicable with all sizes of both cold (low carbon


quenched) and hot material (microalloyed steel rebar)
Hydraulic system allows easy off-line removal for
maintenance.
Mechatronic solutions
An integral part of the bar mills high speed capability
is the specialized mechatronics package developed by
Siemens VAI Metals Technologies for this application.
This includes:
Coordinated speed control for powered slitter and
rolling stands or Morgan No-Twist Mill
Divide shear control
Bar cut length optimization
Braking pinch rolls control
Bar positioning system on cooling bed
Fully integrated into standard SIROLL solution.

18

Cooling beds

Cooling bed for large rounds

Cooling bed for rebars

Cooling beds
Siemens VAI Metals Technologies cooling beds are
designed using standard elements that can be combined
in accordance with plant product mix requirements
and production capacity. Full mechanical component
standardization assures constant equipment quality,
as well as high performance levels.

Features:
Perfect repeatability of braking cycle, at any speed

The design features cover a variety of applications:


rounds with diameters from 8 to 300mm, light, medium
and heavy sections up to 1,000mm and rails.

Bar separation during braking, if required by layout


and speed
Pack annealing device available for spring steel flats
Bar alignment by rollers
Bar layer prepared by chains and transferred by cars.

For special applications, the cooling beds offer slow


cooling with insulated covers and forced cooling through
water spray systems or water tanks.
At the end of the cooling bed, bars are aligned by rollers,
separated into orderly layers and transferred onto exit
roller tables.

Aligning rollers, chains and transfer cars

19

High speed finishing blocks:


Morgan Vee No-Twist Mills

10-stand Morgan Vee No-Twist Mill

Morgan Vee No-Twist Mill rolling stands

High speed, high production capacity and reliability are


critically important on the finishing end of your mill.
The rolling equipment must have flexibility to produce
a wide range of sizes and steel qualities, while providing the best possible product dimensional accuracy.
Scores of rolling mills throughout the world have installed
Siemens VAI Metals Technologies finishing blocks, as they
have set the standard for successful mill operations.
Available in a variety of stand combinations, these blocks
can satisfy virtually any need on the finishing end.
Rolling load capacity and pass design are tailored to the
product requirements.
Morgan Vee No-Twist Mills are capable of sustained, reliable
operation at speeds of up to 120m/s. This results in production in excess of 150 tons/hr achieved under everyday operating conditions at mill installations worldwide.
When it comes to versatility, the Morgan Vee No-Twist
Mill can roll grades ranging from carbon steels to tough
to roll, heat-resistant alloys, using roll units having a
capacity of more than 470 kN. Mills can be supplied with
pass reduction of anywhere from 10% to 25% per stand.
Morgan Vee No-Twist mills can be built with four, six, eight,
or ten roll stands. The mills can be configured with any
combination of 250mm, 230mm or 160mm ultra heavyduty housings, depending on your mills requirements.
These housings are interchangeable between a Morgan
Vee Mini-Block and a Morgan Reducing/Sizing Mill. All
housings have provisions for remote adjustments under
load. Moreover, they can be equipped with monitoring
facilities for bearing condition.
20

Features:
All major drive components are below floor level,
thus reducing noise, improving visibility and providing
convenience for mill crews
New entry end drive arrangement allows easier access
to the motor and no restriction on motor size
Entry end drive enables disconnection of finishing line
shafts when not in use to minimize wear on high-speed
components
High-quality sealed roll housings provide reduced
maintenance and long life
Roll housings are easily lifted out for quick change times
Designed for thermomechanical rolling, with capacity
for low rolling temperatures
Capable of rolling to tight tolerances
Tungsten carbide rolls give better rod quality and longer
roll life.
Morgan Modular Vee No-Twist Mill
This patented new design enables the changing of pairs
of roll stands in a few minutes, so that size changes can
occur very quickly.
Stands not used on larger sizes are disconnected, thereby
extending the overall life of the equipment and reducing
maintenance costs. This design also minimizes power
consumption and thereby reduces operating costs.
Used in conjunction with a Morgan Reducing/Sizing Mill
and single family rolling, the Morgan Modular No-Twist
Mill maximizes utilization in the rolling mill.

Mini-blocks

Mini finishing block

Morgan Vee Mini-Blocks as pre-finishing mills

The Morgan Vee Mini-Block is an innovative 2- or 4-stand


mill expandable up to an 8-stand unit, with a host of
benefits for rod and bar producers. In numerous existing
installations around the world, mini-block mills have
increased productivity by as much as 50%, permitted the
rolling of various diameter rod and bars, and achieved
thermomechanical rolling properties.
Features:
Small footprint makes it ideal for retrofit situations
Can be used as a pre-finishing mill, usually in 2-stand
or 4-stand configurations
Can be used as a mini-finishing mill after an existing
finishing block to increase speed and productivity

Mechatronic solutions
The performance and reliability of the Morgan Vee
No-Twist Mill and Morgan Mini-Blocks can be enhanced
with the application of specialized mechatronics
packages, including:
Bearing temperature monitoring:
Provides temperature status for bearings in the block
Issues warnings of high temperatures that can be
caused by bearing wear or lubrication problems
Constant monitoring improves performance and
prevents system downtime
Fully integrated into standard SIROLL solution.

Capable of improving tolerance of feed sections to


an existing block

Lube oil water content:


Continuously monitors for any water ingress

Increases finishing speed when used after an existing


finishing block

Specifically monitors water content in the


lubrication system

Can be used to roll finished sizes from 4.0mm up to


as large as 35mm

Real time trending of water content and


lube oil temperature

Able to roll at low temperatures

Historical logging

Perfect for retrofit applications in both bar mills and


rod mills

Fully integrated into standard SIROLL solution.

Can be used upstream or downstream of existing


finishing blocks
250 mm, 230 mm and 150 mm roll housings available,
interchangeable between a Morgan Vee No-Twist Mill
and a Morgan Reducing/Sizing Mill.

21

Rod sizing technology

Morgan Rod Reducing/Sizing Mill with off-line units

Morgan Rod Reducing/Sizing Mills


With over a decade of operational know-how on more
than 60 installed strands, our engineers have advanced
the Morgan Rod Reducing/Sizing Mill into the most
versatile, sought-after rolling technology available.
There is no other rod sizing system on the market today
that can compare with this technology.
The advantages of the Rod Reducing/Sizing Mill are
nearly unlimited. It can be integrated after a conventional
finishing block, boosting mill productivity on small sizes
by up to 60%. Its extreme precision has been proven
in many practical applications.

22

Product dimension features::


Produces all sizes to ultra-precision tolerances
Tolerances as low as +/0.1mm
Ovality at 0.12mm about the nominal size and within
2sigma statistical limits
Flexibility to produce a size range from 4.2mm to 26mm
Free size rolling capability.
Improves the operation
The patented pass design enables true single family rolling
from the first stand after the reheat furnace to the last
stand of the block ahead of the Morgan Reducing/
Sizing Mill. Added after a conventional rod finishing block,
the patented unit can significantly increase finishing
speeds on smaller sizes.

Morgan Rod Reducing/Sizing Mill in single strand high speed rod outlet

Rolling stands

Productivity features:
Single family rolling dramatically increases utilization

Mechatronic solution
The Morgan Rod Reducing/Sizing Mill mechatronics
package is a proven system on dozens of mills around
the world.

Productivity on small sizes increases by as much as 60%


Quick change transfer car ensures rapid and
error-free setup
Roll parting adjustment under load d
irectly from
the operator station with roll gap feedback
Patented built-in bypass troughs provide immediate
setup for dummying roll units
Guideless rolling in sizing stands allows for
fast parting adjustments and free size rolling.
Increases product quality
The combination of advanced technologies allows very
low-temperature rolling. This results in a more refined
microstructure that can eliminate additional processes.

Features:
Full local and remote control options
Direct interface with mill control system
Straightforward, easy-to-navigate HMI interface
for the pulpit operator
Automated product change increases productivity
Incorporates Siemens VAI Metals Technologies
mechanical e
xpertise in gear change strategy
Electro-mechanical system fully tested prior to
shipment and commissioned on site
Fully integrated into standard SIROLL solution.

Features:
Grain refinement possible with thermomechanical
rolling results in improved properties
Unique oval-round-round-round pass sequence
delivers high-reduction rolling for internal quality while
enhancing surface quality and extending roll life.

23

Morgan high speed laying heads


and intelligent pinch rolls

Morgan High Speed Intelligent Pinch Roll and Laying Head

Morgan High Speed Laying Head with patented tail end control

The laying head and intelligent pinch roll system


is capable of high speeds with smooth operation,
while providing well-shaped rings correctly positioned
on the conveyor.

Mechatronic solution:
Laying head and intelligent pinch roll mechatronic
system provides:

Our patented intelligent pinch rolls and laying heads


are proven for sustained operation at high speeds and
for flexibility across a large range of product sizes.

Speeds coordinated with pinch rolls for error-free


operation on tail ends

Repeatable front end positioning of each coil

Fine adjustment to allow control of coil diameter

Features:
Durable drive for reliable high speed operation

Wobble adjustment for varying ring diameter

Universal design fits all installations

Closed loop control of pinch force and pinch roll


drive motor

Closer calibration of pinch force


Faster set up after roll change

Servo control of pinch force and position

More compact installation

Self-regulated system to avoid roll slip and remove


user input from the pulpit

Novel pipe design extends life to record levels

Fully integrated into standard SIROLL solution

Easy-change pipe support

Rapid roll closing times (0.1 to 0.15 seconds)

High quality bearings for reliability and


minimized vibration

Repeatable roll close times, within +/- 5 milliseconds.

Front end orientation to eliminate snags


on the conveyor
Tail end control for good coil package.
Improving the ring pattern
The laying head design with patented tail end control
helps improve the ring pattern on the conveyor for both
small products at speeds up to 150 m/s and large products
at lower speeds. It allows increased production, improved
yields and consistent product quality.

24

Laying head capabilities:


High speed capability proven over 120 m/s
Ability to lay plain rounds, rebar and quenched and
tempered rebar
Handles rod sizes from 4.0 to 26.2 mm
Pipe change times of 15 minutes or less
Interchangeable vertebrae and rollerized pipe features
available for surface-sensitive grades
Twin pipe design available for different coil dimensions
Pipe bending services available.

Morgan Stelmor controlled cooling


conveyor and reform ring distributor

Morgan Stelmor controlled cooling conveyor

High capacity fans on Morgan Stelmor conveyor

Morgan Stelmor conveyor exit end

The Morgan Stelmor controlled cooling conveyor


system enables processing in a wide range of conditions, including both fast and slow cooling modes
within a single system.

Other system possibilities


Optional capabilities that can be incorporated into
the Morgan Stelmor system include:

This capability enables mills to produce a broad spectrum


of plain carbon and alloy steels, as well as stainless steels
and other specialty grades. The results are improved asrolled rod properties. This enables the production of more
grades in a directly usable condition, thus reducing or
eliminating downstream processes, such as spheroidize
annealing.

In-line heat treatment

Controlled cooling capabilities:


Forced air cooling with high capacity fans gives
fast cooling rates
Excellent cooling uniformity in fast cooling mode,
accomplished with either the traditional Optiflex
system or the newer patented Optimesh system
Slow cooling with insulated covers
Hybrid cooling with combined fast, natural and slow
cooling for customized cooling of special grades.
The more than 350 Morgan Stelmor lines installed at
mills throughout the world have established this systems
reputation as the best for product quality, processing
versatility and equipment performance.
The robust design includes durable drives for reliable
high speed operation and high quality components for
reduced maintenance downtime and cost.

Slow cool pots


Water quench baths.
Mechatronic solution
To ensure the greatest benefits from processing and
production, a mechatronic system provides for:
Automated product cooling setup
Conveyor speed control
Automated fan cooling control
Full integration into standard SIROLL solution.
The ring distributor
The patented ring distributor collects rings high in the
reform tub using a rotating blade for optimal placement.
This system shortens the coil package, easing shipping
and storage space concerns, which in turn reduces costs.
Improved collection also results in better-shaped coils
for fewer tangles and snags at payoff.
Features:
Simple, low maintenance coil forming design
Allows for increased coil weight capacity
Works with new or existing horizontal hook and vertical
pallet coil handling systems
Permits removal or change of blade in 5 minutes or less.
25

Coil handling and compactors

Vertical stem pallet coil handling system

Horizontal hook system for coil handling

From complete handling systems to system upgrades,


Siemens VAI Metals Technologies has many solutions
to every coil handling need.
Vertical or horizontal
Both the vertical stem pallet and horizontal hook
carrier systems are of modular design, providing for
unique configurations with standard components.
Features:
Standard modules can be arranged in highly
customized installations
Individually driven and controlled modular conveyor
system offers high productivity and ease of maintenance
System movements provide scratch-free handling
of the coils
Blowing stations available for accelerated cooling
of selected grades
Patented heat retention tunnels available for slow
cooling of sensitive grades.
Mechatronic solution
For maximum benefits in the coil handling system,
a mechatronic system provides for:
Fully-automated coil transport system
Minimized installation and start up times

26

Horizontal coil compactor

Individual AC drive motors


Customized coil distribution and storage
Automatic pushing and pulling strategies to
maximize cooling time and product throughput
Recipe driven system
Coil tracking.
Compactors
Both the horizontal compactor and the vertical compactor
systems provide a wide range of capabilities for all coiled
products, with either wire binding or strapping.
Features:
Standard compactor design allows for easy retrofit
from wire to strap, or vice versa
Unique wire binding unit design with quick-replace
wear cassettes
Low operating and maintenance costs.
Mechatronic solution
The automation of the compactor system includes:
Automated compression of coils into compact bundles
for efficient transport and storage
Automatic wire feeding and monitoring of
coil compression
Different press force settings.

Bar in coil

Pouring reel

Pouring reel coil

Pouring reels
The Siemens VAI Metals Technologies pouring reels enable
the production of bar products in coiled form, typically
for bar sizes of approximately 10mm to 60mm.

Interface with coil handling


The coiling line can be provided with a new coil handling
system or interfaced with an existing vertical pallet or
horizontal hook system.

Features:
Interchangeable entry spouts accommodate a wide
product size range

Interface components:
Downenders

Multiple pinch rolls assist the bar into the tub and
control tail ends

Trimming stations

Traversable pinch rolls allow for quick groove change


between sizes
Elevating coil plate for easy coil removal
Collapsing inner fingers minimize damage to rings
on coil inner diameter
Wear strips prevent damage to rings on outside
diameter of coil
No direct water cooling required, reducing maintenance
Designed for minimum foundation depth.
Coil removal and transfer
A pivoting mast supports a boom assembly for transporting the coil from the elevated coil plate to a pallet or coil
conveyor. Depending on the configuration when using a
pallet system, elevators may transfer the pallets between
levels in the mill.

Transfer cars
Inspection stations.
The coil handling system can be shared with a rod mill
or rod outlet on a combination mill.
Process capabilities
In addition to forming a well-shaped coil with excellent
surface quality, the bar-in-coil system is designed for
optimal metallurgical and scale characteristics.
Features:
Coiling temperature can be controlled with upstream
water boxes
Blowing stations available for accelerated cooling
Insulated tunnels available for slow cooling of
critical grades
System length and operational practice designed
to give optimal final coil temperature.

27

V+coil bar spooling system

V+coil bar spooling system layout 3-D rendering

V+coil bar spooling system unloading operation 3-D rendering

The V+coil bar spooling system is the latest innovation in


bar-in-coil production.

Features:
High productivity also for small diameters,
e.g. 75tons/hr for diameter 10 mm at 35 m/s

It creates a twist-free winding of round, flat and square bars.


Unlike with the conventional pouring reel, the bar is
distributed in sequential, regular, homogeneous and
compact layers, producing large weight coils with small
overall dimensions, which can be easily transported
and stored.

Overcomes conventional pouring reels speed limitation


Processable round diameters from 8 to 32 mm
Applicable also to squares, hexagons and flats
Fixed height and inner diameter
Coil weight up to 3,500 kg, controlled by outer diameter

As the coiled bar has no residual torsion, the de-coiling


operation is smoother and faster.

Great compactness with very high filling factor

The innovative spooling system is a considerable technological step forward in bar-in-coil production, offering
bar producers the opportunity to be more competitive
by offering final users a reduction of post-rolling costs,
as well as a better product appearance with easier
transportation and storage.

Significant savings in coil transportation


and storage

28

Easy de-coiling operation

Higher material yield in post-rolling cold processing lines


Uniformity and consistency of final product properties
Absence of residual internal torsional stresses.

Flat Rolling Block

Flat Rolling Block

Flat Rolling Block


The Flat Rolling Block is the perfect instrument for
the economic production of flat bars in any lot size.
Flat bars can be rolled in a wide range of sizes with
tight tolerances and sharp corners. Product size can
be changed automatically within seconds.
Features:
Grooveless rolling of an infinitely variable product
size range

Mechatronic solution
To ensure the greatest benefits from processing and
production, a mechatronic system provides for:
Roll gap control with servo motors
Mill load control using load cells
Fully automated system integrating the roll pass set up
(RollMaster) with the Level 1 control system.

Product size changes within seconds


Sharp product edges
Fulfillment of highest product tolerances, reducing
downstream machining requirements.

Flat Rolling Block detail

29

Mill shears and saws

Sawing unit

Crop and cobble shear

Hot shears
Siemens VAI Metals Technologies offers a full line of
hot shears for a wide variety of requirements, such as:

Cold shears
Siemens VAI Metals Technologies designs flying and
static cold shears, with direct drive or clutch and brake.

Pendulum, toggle or snap shears, which prevent the


flow of material through the rolling line

Features:
Cutting table width up to 1,800 mm

Shears for billets, blooms and larger sections, for bar


cropping and dividing
Rotary, crank and convertible shears along the rolling
mill, for flexible operation according to bar size and speed
Bar cut length optimization, for sending only multiples
of saleable length to the cooling bed.
High speed trimming shear and shear control systems
Enables inline rod trimming of out-of tolerance head and
tail ends in the finishing train. Used either ahead of a
post-finishing block or immediately before the pinch roll
and laying head, this results in substantial operational
cost savings.
Features:
Synchronized with laying head control for front
end positioning
Trimmable sizes from 5.0mm to 26.0mm

Cutting speed up to 2.5 m/s


Direct start-stop drive for reduced maintenance
and shorter cycle time
Very precise cutting
Compatible with high strength steels, as quenched
rebar and high-alloy grades
Flat or profiled blades according to use
Fully automated cutting procedures
Quick-change device for blade replacement.
Sawing units
For rails, medium-large sections, large bars, and special
steel grades, where sawing is preferred over shearing,
these units provide better cut quality and precision,
eliminating bar end deformation.

Maximum operating speeds of 120m/s

Features:
Metallic or abrasive disc technologies available

Minimal disturbance of the rod path

Pendulum or linear disc movement

High speed motion controller to minimize delays


between tracking system and servomotor control

Automatic removal of nose and tail crops

Dynamic positioning of shear blades to ensure cut


length accuracy.

Dust removal and filtering system

30

Collection of sawing swarf


Fully automated sawing procedures.

Bar finishing components

Bar counting area

Bar counting system

In addition to the wide array of rolling stands, finishing blocks and cutting-to-length systems for every
bar product, Siemens VAI Metals Technologies has an
extensive portfolio of equipment to cover the complete
range of final processing needs. From counting to
bundling and stacking, and then unloading bundles
everything can be arranged for a smooth final
production process.
Bar counting
Fully-automated counting of bars moving from the
cooling bed to the bundling station assures that customer
orders are filled accurately and completely. The system
is capable of high production rates and is accurate for all
types and sizes of bars. Current count and end-of-batch
signals can be output to downstream equipment and to
the mill tracking system for full control and information
on the process. Both contact and non-contact counting
systems are available.

Bar bundling system

Bundling system
Siemens VAI Metals Technologies provides bundlers for
round and flat bars together with bar counting for rounds
and small bundle processing systems. The packaging form
can be round, square, rectangular and hexagonal shapes.
Binding systems
Automatic binding of the packages and bundles are
available with strap or wire.
Weighing, labeling & unloading
All bundles can be automatically weighed and further
labeled for quality-assured delivery of the finished
products at the bundle unloading station. With accurate
product tracking systems provided by Siemens VAI
Metals Technologies, such as the SIROLL LR Process Xpert,
tagging accuracy and reliability of the final shipment
are assured.

31

Water boxes and in-line thermal


processing

Water cooling system

Rebar quenching system

The Siemens VAI Metals Technologies water cooling


systems make a significant difference in the operation
of a bar or rod rolling mill, from improved utilization
to better product quality. Available cooling elements
include conventional solid injector and cooling pipe
to the more advanced split nozzle design.

Martensitic self-tempered outer surface, with


ferrite-pearlite core

The high cooling efficiency in these water box systems


results in reduced water usage and increased lifespan
of pumps, valves and other critical components.
Features:
Sturdy water box construction
Replaceable wear parts within the cooling nozzles
Less water contact with the product reduces the
tendency for cobbles, enabling higher rolling speeds
Improved split-style nozzles are retrofittable replacements for previous-generation split nozzle
design water boxes
Optional lift-out headers and traversable water box
design minimize change times.
Rebar quenching systems
Water quenching systems with stationary, lift-out or
traversable water boxes provide efficient cooling of ribbed
products in straight lengths to a cooling bed or in coil
form to meet virtually any worldwide specification for
quenched and tempered rebar.
Features:
High yield strengths
32

Controlled values of tensile strength/yield strength


ratio and elongation
Elimination of micro-alloying elements in melt shop (V,Nb)
Elimination of expensive post-rolling treatment
(e.g. cold drawing or stretching)
Excellent weldability due to low carbon content
Up to 4-slit rolling.
Mechatronic solution: Temperature Control System
The Temperature Control System provides monitoring and
control of stock temperature to guarantee the correct
mechanical and metallurgical properties throughout the
process. By monitoring product speed and temperature,
along with cooling water pressures and temperatures,
the system can provide real-time feedback for closed-loop
control of cooling zones.
Benefits:
Consistency of properties
+/10C accuracy
Standard operating practices
Recipe systems for fast and consistent setups
Minimizes uncooled rings
Reduces disturbances to water system
Historical and real time logging
Improves detection of problems
Event sequence analysis.

Thermomechanical rolling

High speed rod rolling mill for thermomechanical rolling

Effect of finishing temperature on rod microstructure

Thermomechanical Rolling (TMR) requires a combination of properly arranged rolling and cooling equipment, adequate load capacity in the rolling stands,
and intelligent rolling and cooling practices. The result
is a refined microstructure in the product that has
superior as-rolled mechanical and metallurgical
properties.
By improving as-rolled properties and microstructures of
rod and bar products, subsequent downstream processes,
most of which are done in-house by the major steel producers, can be eliminated or significantly reduced, therefore lowering the conversion cost.
TMR in a rod mill
Although high productivity and efficiency remain the main
attraction of the Morgan Rod Reducing/Sizing Mill to most
plain-carbon unalloyed steel producers, metallurgical
processing flexibility is becoming an equally important
benefit to the specialty steel and cold heading quality
producers.
Through an engineered combination of high load design
of the patented mill and proper mill layout, thermo
mechanical rolling at low temperatures becomes a practical
production process. Siemens VAI Metals Technologies
has developed a successful combination of equipment
design and process design, demonstrated by more than
60installed and operating post-finishing mill blocks in
a variety of mill configurations, from existing two-strand
rod mills to new high speed, high production rate singlestrand rod mills.

Fine grain rebar


Demand is rising to produce concrete reinforcing material
with enhanced properties through thermomechanical
processing. This reduces alloying and simplifies and even
increases production and thus can be a viable alternative
to quenched and tempered rebar:
Low rolling temperatures reduce hardenability,
promote ferrite formation and retard the evolution
of bainite and martensite
More uniform grain size from surface to core
Reduction in as-rolled tensile strength
Increased ductility
Improved heat treat response including a reduction
in spheroidize annealing times
Increased work hardenability.
With respect to rod structure, the refined structure
associated with reduced rolling temperatures improves
diffusion during heat-treating and can result in reduced
heat treatment times and temperatures. For those rods
which are not heat-treated, the refined and complex
structures resulting from low temperature rolling increases
tensile pickup during cold deformation.

33

The MORSHOR accumulator system

MORSHOR installation

MORSHOR accumulator system 3-D rendering

The MORSHOR accumulator system is designed to


optimize the overall utilization and efficiency of the entire
mill train by matching rolling capability with furnace
capacity. This system can upgrade a rod or bar mill
to increase the production rate of smaller sizes by up to
100percent from a single strand feed roughing and
intermediate mill.

Key design features:


Coiler and entry pinch roll receives material from
intermediate mill and feed to accumulator

This revolutionary system serves as a buffer between a high


production rate roughing/intermediate mill and a lower
production rate rod or bar outlet. A coiler unit forms rings
that are collected on a drum, which rotates in conjunction
with an exit pinch roll that traverses along the drum.
The exit pinch roll controls the speed of ring payoff to
feed the downstream outlet.

Mechatronical solution
A critical part of the accumulator is the mechatronics
system, which provides for:

The patented technology can also be used to convert a


single high-capacity roughing and intermediate mill into a
multiple-outlet mill. The MORSHOR accumulator system
offers plant flexibility for the production of coiled rod and
many bar products in straight or coiled form.

Drum stores rings of rolling stock


Exit pinch rolls control payoff of material to downstream pre-finishing and finishing mills.

Front end positioning of incoming product on the coiler


Speed control for the coiler drum
Position and speed control for exit pinch roll for feeding
product at required production rate to downstream
finishing end.

Advantages:
Increases production of smaller sizes, which greatly
improves mill utilization
Optimizes product quality by allowing all products
to be rolled through a single strand horizontal-vertical
roughing and intermediate mill
Reduces by 50% roughing and intermediate mill stand
gearbox torques over two-strand rolling mills
Increases production and flexibility through multiple
outlets.
34

MORSHOR use in two rod outlet configuration

WinLink direct rolling technology

WinLink is an innovative technological process for the


endless production of long products from liquid steel.
Through the direct linking of a high-speed billet caster
to a rolling mill with high availability in a very compact
production line, producers benefit from energy efficiency
and low environmental impacts, at minimum investment
and production costs.

Main advantages over a conventional minimill


Capital expenditures:
Smaller footprint and reduced civil works
Fewer equipment and lower infrastructure requirements.
Operation expenditures:
Lower consumption of energy, fluids and consumables

A WinLink-based minimill can produce between 400,000


and 500,000 t/a of billets of which 300,000-400,000 tons
are directly rolled to rebars and 100,000 tons are available
for external sale.

Higher yield and reduced incidence of cobbles

Long, uninterrupted casting/rolling sequences recover


thermal energy from the cast billet and maximize yield.

Finished rolled products produced from scrap in less


than 2 hours.

A typical layout would include:

Environment:
Energy savings

EAF and ladle furnace state-of-the-art meltshop


for the adjustment of the required composition and
temperature before casting
High-speed billet caster for the direct feed of rolling mill.
High-efficiency induction furnace to equalize
the temperature of the billet before rolling. Replaces
conventional gas or oil re-heating furnace
High-availability rolling mill equipped with Red Ring
stands, high-performance quenching and tempering,
quick change devices, stand pre-setting and gap
control systems
Comprehensive electrics and automation for smooth
plant operation, maximum availability and integrated
process control, along the complete production line.

Lower scale formation, no short bars or bar crops


Lower inventories and working capital
Fewer operating personnel

Lower CO2 emissions and water consumption


Less land usage, smaller buildings and reduced visual
impact.
100%

Conventional
minimill

80%
60%

WinLinkbased
minimill

40%
20%
0%
Natural gas Manpower
Plant
consumption
footprint

Material Electricity
losses consumption

Comparison of cost factors


35

ERT-EBROS endless rolling technology

ERT-EBROS system in operation

Defect-free burr remover

In recent years, markets demand bigger billets to increase


material yield and produce higher weight coils.

Features:
No inter-billet time

Siemens VAI Metals Technologies solution is based on


JPSteel Plantech Co.s EBROS.

Improved yield by reducing losses at both head and


tail ends

The welding system is installed between the reheating


furnace and the first rolling stand to weld together
consecutive hot billets and therefore provide a continuous
rolling process.

Lower risk of cobbling

The system operation consists of two main phases:

Reduced maintenance costs

Phase 1 Billet welding


Billets are clamped in the welding machine, which is
moving at a speed to follow the entry speed of the rolling
mill. Incoming billets are joined by flash welding, through
rapid heating of billet ends, followed by application of
a counter force to complete the joining.
Phase 2 Burr removal
The welding machine has an efficient burr cutting system at
the exit to completely remove the burr from the welded zone
and to avoid potential defects during rolling operations.

Welded joint
36

Before deburring

Possibility of producing higher and customized coil


weights, without increasing billet size, for better
product marketability
High quality of the flash process weld, so that the
joint area does not affect final rolling quality
Able to weld rough and oxidized surfaces
Welded joint area free from inclusions, filler metal or
other impurities, for homogeneous and consistent
product quality
Highly efficient operation, for reduced energy
consumption.

After deburring

Turnkey solutions
Success from a single source

There are many requirements involved in building or


modernizing a rolling mill, including on-time and cost
guarantees, reliable start up and rapid achievement of
expected production volumes and product qualities.
To ensure that these requirements are met, Siemens
VAI Metals Technologies offers a turnkey solution.
We take on complete responsibility for project implementation and start up production, so you can concentrate
on your core business of manufacturing long products
and marketing them profitably.
Our responsibility, not yours
Most projects require the coordination of a large number
of suppliers on timing, technology, and logistics. Given
the number of players involved, we offer a solution as
prime contractor:
We work through all technical interfaces so that all
components work efficiently together in the overall plan
We work in partnership with all subcontractors, and
guarantee overall quality
We ensure on-time completion and a smooth start-up,
so you can pay down debt on schedule
We construct your plant for a fixed price.

Secondary processes are no minor matter


We provide our own solutions for nearly all processes
associated with production, from the power supply to
water treatment, and from fire protection to railway
siding. And everything is backed by services from our
local partners. This comprehensive approach is unique.
Cross-functional concepts such as totally integrated
automation and totally integrated power provide synergies
and a high degree of standardization.
Your security: Our financial strength
and project expertise
In a turnkey project you profit from the global strengths of
Siemens: Our sound financial base as well as our ability to
plan projects with foresight and implement them reliably.
We bring to each project many years of experience in
complying with all rules and requirements, from customs
regulations to approval conditions.
Another benefit is the enthusiasm of our engineers,
fitters and start-up engineers, all eager to work together
with you to create a world-class system.
If youre planning to invest in a long product rolling mill,
we can provide the comprehensive product, system,
integration and service expertise you need for success.

37

Across all processes:


Expertise, automation, services

Total engineering

Every rolling mill is different, varying in design accord


ing to the desired products, qualities and volume.
Siemens VAI Metals Technologies offers you the right
solution for every requirement for high-speed
production, for precise microstructure qualities, for
the shortest possible change-over time from one
long product to another and much more.

Total engineering
Accurate planning that addresses everything from energy
supply and raw materials logistics to throughput targets
is a prerequisite for a successful start of your plant.
We provide all the up-front necessities to make sure
your project gets off to a safe start, including technical
consulting as well as simulation of all processes.

Automation SIROLL LR
From mill management, supervisory and control systems,
all the way to motors, drives and individual component
and sensor controls, Siemens offers a complete solution
to your rolling mill automation needs from Level 1 to
Level 3. With a full array of mechatronic packages for
equipment units throughout the process, a totally
integrated automation solution is available from the
factory floor to upper management.

Commissioning
In supervising installation and start-up of electrical
and automation, the task is to reach full production and
consistent operation in the shortest possible time.
That requires experienced automation and electrical
engineers knowledgeable in long products to support
the customer. For easier and quicker trouble-shooting,
the automation system is prepared for remote access.

38

Automation SIROLL LR

Services and life-cycle management


Ongoing availability calls for a well-designed service
concept, up to and including around-the-clock monitoring
of the plant by Siemens. Clearly defined processes,
uniform manuals, assured parts availability and a globally
available team of specialists wensure minimized shutdown times and high performance throughout the life
cycle of the plant.

Commissioning

Services and life-cycle management


39

Our services
For the best performance of your plant throughout its lifetime

Long rolling services from Siemens VAI Metals


Technologies enables you to take advantage of
the combined experience of our people and deliver
comprehensive life-cycle support for your mill.
The rolling mill is a long-term investment, and
therefore you want a long service life, along with
productivity and high utilization, profitability,
and product quality.
The range of services we offer is comprehensive and
covers every aspect of your operation.
Mechanical and lube system audits
With detailed studies by our mill experts, we can
determine whether the components are meeting
current demands and look for ways to improve their
performance.
Predictive maintenance
Through vibration monitoring, the operating conditions
of your critical bearings and gears are tracked and
trended to allow for planned maintenance. Eliminating
unplanned down-time also provides cost control and
allows the equipment to operate to the full life-cycle
of the mill bearings.
Reconditioning and rebuilds
Get the most from your initial mill investment without
the capital expense of full replacement. Many critical
machines can be upgraded to newer technologies that
feature increased reliability and design capacities.

40

Equipment upgrades
Benefit from the latest design technologies, improving
overall equipment and mill performance with targeted
upgrades. Planned repair or reconditioning work is
the prime opportunity to incorporate some of the latest
designs in the mill to align with current operating
parameters and market demands.
Spare parts management
Custom spare planning allows for minimum inventory
levels to control operating cash flows. Critical spares are
readily available in stock in our warehouses around
the world to ensure key components are available when
needed most.
Guides
Backed by our comprehensive process knowledge,
Siemens VAI Metals Technologies expertise in guides
provides solutions for all long rolling applications.
A wide array of designs for mounting and ancillary guiding
equipment, is available to meet every challenge.
Training
A wide range of training programs are available for
maintenance, operations and processing. To handle
special requirements, we can develop customized
training for your people.

Life-cycle management
Partnership never ends

I nvestigation/inspections & feasibility study


Design
Layout
Construction
Installation
C ommissioning

S ervice contracts


Spare parts and components
Consulting and training
Online and offline
maintenance
M aintenance contracting
Operation

t
stmen
inve
w
e
N

Consulting | Planning | Financing


tion
rniza
Mode

Recycling

M igration packages


U pgrading and
modernization

As a plant operator, you have conflicting needs.


On the one hand, your performance is measured each
quarter against short-term profitability expectations.
On the other hand, you have to plan on a totally
different timescale when compared with capital
markets. Depending on the lifetime of your plant,
you have to consider the next 15 years or more
at the very least, that is 60 full quarters.

Siemens VAI Metals Technologies life-cycle services


Thanks to our comprehensive expertise and integrated
approach to solutions, you can benefit both short-term
and long-term from our life-cycle services.
In the short term: Backed by our extensive experience
with many reference plants, we provide you with the
certainty of fast, dependable production, start-up and
shorter amortization periods.
In the long term: Our master plan guarantees competitive
performance for your plant in every phase of its life cycle.
Whether were providing 24/7 technical or spare parts
service, optimizing maintenance, or making permanent
plant improvements, were always working to ensure
the cost-effective operation of your plant.
Peace of Mind maintenance
This program maximizes mill utilization by focusing on
your most critical mill assets. With a balanced approach
of predictive and preventative maintenance, spare parts
management training, and audits you can achieve
optimal operating conditions.

41

Excellence through experience


Selected success stories with rolling mills

Profitable expansion for rapidly growing market

Customer:

V izag Steel, Visakhapatnam (Andra Pradesh), India, part of Rashtriya Ispat Nigam Ltd.

The task: Expand production to 6.3 million tpy, improve prductivity and optimize costs of its production line.
Our solution: A new mill with 18 Red Ring rolling stands followed by a 3-stand Pre-stressed Sizing Group, with a double
finishing area with cooling bed and three pouring reels. Initial mill capacity of 750,000 tpy.
The result:

 lexible and reliable operation in expanded modern facility that profitably positions Vizag in one of the
F
worlds most rapidly developing areas.

Achieving huge capacity, productivity gains

Customer:

V illares Metals, Sumar (So Paulo), Brazil, part of voestalpine AG

The task:

Expand product portfolio, increase rolling capacity and productivity, and optimize operation costs.

Our solution:

 new multiline mill, including a straight bar line with 16 compact cassette rolling stands, a rod line with
A
two finishing monoblocks and a line with a flat rolling block.

The result:

 olling capacity increase of approximately 40%, with optimized costs and an installation schedule that
R
eliminated potential impact on existing production.

Meeting speed and quality goals

Customer:

Votorantim Metais, Resende (Rio de Janeiro), Brazil

The task: Add capacity for coiled rebar and other rod products to support growing South American market on
greenfield site with the best technology for high production rates and quality.
Our solution: New single-strand rod mill with roughing and intermediate train, pre-finishing Morgan Mini-Blocks,
finishing Morgan Vee No-Twist Mill, in-line quenching, Morgan High Speed Pinch Roll and Laying Head,
Morgan Stelmor conveyor, reform and coil handling system. Provisions for future second strand.
The result:

42

 igh quality rod and coiled rebar produced at finishing speeds up to 110m/s for at least 500,000 tpy on
H
single strand. Mill has rolled HYQST quenched and tempered rebar products at highest speeds in the world.

World-class slit rolling bar mill

Customer:

Tata Iron & Steel Co. Ltd., Jamshedpur, India

The task:

 s one of the largest steel producers in the world, Tata wanted to expand capacity in India to support growA
ing infrastructure with latest techniques for rolling rebar, and remain best-quality construction supplier.

Our solution:

 ew single-strand bar mill with 16 stands for roughing and intermediate trains, two-way slitting unit, two
N
6-stand Morgan No-Twist Mills, water boxes for HYQST processing, dividing shears, patented high speed
Rotary Entry System to the cooling bed, cold shear, plus bundling and strapping equipment.

The result:

 esigned to produce 600,000 tpy, mill exceeded production targets several times at commissioning.
D
One of the fastest and most efficient mills in the world for slit rolling in straight lengths, with rolling line
yields above 95%.

Modernization yields production growth

Customer:

Global Steel Wire, S.A., Santander, Spain, part of the Celsa Group

The task: As a renowned supplier of high quality rod products, Global Steel Wire needed to expand product size
range, increase production and improve quality for changing markets, including new bar-in-coil market.
Our solution: 
Series of mill modernizations: Equipment improvements and additions to 2-strand rod mill to increase
production rate and productivity, including Morgan Mini-Blocks, Morgan No-Twist Mills, Morgan Rod
Reducing/Sizing Mills, rod outlet; bar-in-coil outlet with water cooling and Morgan Bar Reducing/Sizing
Mill for high quality bar products.
The result:

 ver 10 years of mill modifications, Global Steel Wire has increased production from 570,000 tpy
O
to more than 900,000 tpy, with increases in coil weight, product size range and quality.

Longer long products

Customer:

Corus, Scunthorpe, UK, part of Tata Group

The task: As part of companys overall investment program, mill revamp needed to improve Corus production
capability and cost-effectiveness.
Our solution:

 new finishing mill with 7 in-line Red Ring universal stands, cooling area with rail precambering, and
A
handling equipment.

The result: The mill enables Corus to roll rail lengths up to 120 meters in an in-line continuous finishing mill.
It offers unsurpassed flexibility to process both rails and sections, with minimized change operations
and improved tolerances.

Highest productivity in the Middle East

Customer:

Habas Sinai Ve Tibbi Gazlar Istihsal Endustrisi A.S., Aliaga, Turkey

The task:

 ne of the leading players in the Middle East, Habas needed a greenfield rebar rolling mill,
O
with high productivity and equipment reliability.

Our solution:

 state-of-the art fully automated multi-slitting rolling mill with 25 Red Ring stands, including a double
A
finishing train, with in-line bar quenching, multichannel braking system for high speed delivery to a 120m
cooling bed and handling areas. Bars ranging from 8 to 42mm diameter rolled in up to 4-slit process.

The result: Designed for 1,185,000 tpy, one of the most productive rebar plants in the world. Production exceeds
4,500 tons per day, equivalent to an average rebar production of 180t/h.

43

Competence Centers
Siemens Industry Inc.
50 Prescott Street
Worcester, MA 01605-2615, USA
Phone: +1 508 755-6111
Fax: +1 508 849-6678
E-mail: longrolling.metals@siemens.com
Siemens S.p.A.
Industry Sector Metals Technologies
Via Luigi Pomini, 92
21050 Marnate (VA), Italy
Phone: +39 0331 741211
Fax:
+39 0331 741386
E-mail: longrolling.metals@siemens.com
Headquarters
Siemens VAI Metals Technologies GmbH
P.O. Box 4, Turmstr. 44
4031 Linz, Austria
Phone: +43 732 6592-0
E-mail: contact.metals@siemens.com
siemens-vai.com
Order No. E10001-M3-A325-V1-7600
Dispo No.: 21661 K-No.: 20254 | Printed in Germany
GB 120208 WS 06131.0 | 06.2013, Siemens VAI Metals Technologies GmbH

The information provided in this brochure contains merely general


descriptions or characteristics of performance which in actual case of
use do not always apply as described or which may change as a result
of further development of the products. An obligation to provide the
respective characteristics shall only exist if expressly agreed in the
terms of contract.
All rights reserved. Subject to change without prior notice.
SIROLL is a trademark of Siemens AG.
No-Twist, Stelmor, MORSHOR, idRHa+, V+coil, WinLink, ERT-EBROS,
and Red Ring are trademarks of Siemens AG and/or one of its
subsidiaries.
EBROS is a trademark of JP Steel Plantech Company.