Second DRI-based minimill

continues success at
Emirates Steel, UAE.

Aluminium plate stretcher

successful startup at Dalian
Huicheng, P.R. of China.

1.1-Mtpy universal rail and

section mill inaugurated at
Mechel Chelyabinsk, Russia.

Page 12

Page 8

Page 53

Danieli News n.168 October 2013, Danieli Group

DaNews

168

ALSO IN THIS ISSUE

IRON AND STEELMAKING
14 COMMSSIONING ON INDIAS
LARGEST BF AT SAIL RSP.
17 OFFICIAL OPENING AT ACM-ABS
CENTRE METALLURGIQUE
18 SECOND DANIELI NANO MELTSHOP
STARTES UP AT BVK, RUSSIA.
FLAT PRODUCTS
29 FOURTH-GENERATION THIN SLAB
CASTER AT DONGBU STEEL, KOREA.
32 PLATE/STECKEL MILL UPGRADE
PROJECT AT JSPL RAIGARH, INDIA.
36 500,000-TPY PUSH-PULL PICKLING
LINE AT ABUL KHAIR, BANGLADESH.
LONG PRODUCTS
40 EXCELLENT RESULTS FROM DANIELI
CONTICASTERS FOR LONG PRODUCTS.
46 800,000-TPY HIGH-SPEED BAR MILL
AT STEELASIA, THE PHILIPPINES.
54 1-MTPY LARGE-BAR MILL STARTED
UP AT HENAN JIYUAN, P.R. OF CHINA.
HOT AND COLD PROCESSING
70 DANIELI MODERNIZING THE
HISTORY" AT VOLGOGRAD STEEL
WORKS RED OCTOBER, RUSSIA.
+ Highlights AUTOMATION INSERT

PARTNERSHIP LEADS TO SUCCESS

The Final Acceptance for the 4th minimill at Deacero, Mexico, underlines
a successful partnership lasting for over 30 years between two companies
which share the common passion to innovate and perform.

eacero is a successful, dynamic,

and privately owned company that
has achieved its growth by
establishing a highly competitive position
to satisfy the demands of national and
international markets. Deacero is an
important player among steelmakers
supplying long products not only in Mexico
but in 20 countries around the world.
With this 4th minimill Deacero decided
to enter into the market of sections, after
having consolidated its leadership as bars
and wire rod producer. The 1.5-Mtpy
meltshop has been designed both to supply
the downstream flexible merchant mill and

provide the balance of required billets

for the various rolling mills of the Group.
The EAF and the overall layout of the plant
are designed already for the future
installation of a continuous scrap preheating
and feeding system.
Deacero already operates two scrap
preheating systems supplied by Danieli,
in two out of the three existing meltshops.
The skill of their team, together with the
reliability of the equipment, make Deacero
performances a worldwide benchmark:
existing meltshops achieved up to 42 heats
per day, and are performing regularly above
30 heats per day on average.
Page 4

Danieli W+K continuous

improvement approach in
process and design, and the
extensive know-how inherited
from Hoesch, led to state-ofthe-art pipe mill technology.
Design, manufacturing,
modernization, erection and
commissioning of single
machines up to complete
turnkey plants are provided.

DANIELI W+K
WELDED PIPE TECHNOLOGY
TO PRODUCE
LARGE DIAMETER
QUALITY PIPES
> EWR 26 LSAW 64 HSAW 120
> For oil & gas, chemical,
petrochemical, and power applications

Since 1968 Danieli W+K designed and built

35

welded pipe plants

1914 / 2014

Longitudinal and Spiral Welded Pipe Plants

2

DANIELI
CENTURY

DANIELI THE RELIABLE

INNOVATIVE PARTNER
TO BE FRONT RUNNERS

DaNews
DANIELINEWSN.168
OCTOBER2013

/FLATPRODUCTS

1-Mtpy large-bar mill in operation

at Henan Jiyuan, China
> 54

Successful maintenance project

at Chengdu I&S, China
> 83

Q-WIDTH technology proven

successful for slab casters > 26

Fast Learning Curve at CAASA,

Peru
> 56

The fourth-generation TSC

at Dongbu Steel, Korea

Danieli operational equipment

tailored to exploit rolling line
production capabilities
> 84

Danieli H3 wire rod line

starts at Nucor Darlington
(SC), USA

New steel grades for slab

at Yingkou. P.R. of China

> 29
> 30

Two innovations enhance flat

products rolling operations > 31
Plate / Steckel mill upgrade
at JSPL Raigarh, India
> 32
Skin-pass mill inaugurated at SAIL
Bokaro CRM III, India
> 33
Skin-pass mill commissioned at
Risse + Wilke, Germany
> 35

/DANIELIMINIMILLS
Final Acceptance for the new
meltshop at Deacero Ramos
Arizpe, Mexico

>4

500,000-tpy PPP line at Abul

Khair Steel, Bangladesh
> 36

/ALUMINIUM

Six strip finishing lines at Abul

Khair Steel, Bangladesh
> 38

Hot and cold rolling mills

at KUMZ, Russia

>6

Bonderizing line at Wlzholz New

Material (Taicang), China
> 39

Plate stretcher at at Dalian

Huicheng, P.R. of China

>8

/LONGPRODUCTS

Nanshan Aluminium chooses

proven technology, again
>9
TWIN-container press
for General Extrusions, USA > 10
First coil at Taiyuan Jinxi Chunlei
Copper, China
> 11
/IRON&STEELMAKING
Second DRI-based minimill
continues success
at Emirates Steel, UAE

> 12

> 15

Official Opening at ACM-ABS

Centre Mtallurgique
> 17
Second Danieli Nano meltshop
started up at BVK, Russia
> 18
New Nano meltshop
at MTE Finance, Russia

> 19

New integrated EAF charging

system at Sohar Steel, Oman > 20
New EAF roof lifting and swivelling
system at Stefana, Italy
> 21
New VOD station
for Jisco, P.R. of China

> 21

Intense activity drives growth

at Danieli Centro Recycling > 22
Shredder launch ceremony at
Danieli China in Changsu
> 23
Benchmark FTP for Auto Scrap
Shredding at RMB, Italy
> 24

Danieli Training methodology

earns renewed trust
> 85

Bar-mill stacker in operation at

Steel of West Virginia, USA > 57

Capital equipment spare parts

supply Danieli drum shear > 86

Final Acceptance of bar mill at

Dongkuk Incheon, Korea
> 58

Technological revamping
for Steel Dynamics, USA

Commissioning of sheet piles

at Emirates Steel, UAE
> 59

//INSERT:

> 40

Final acceptance of billet and

bloom conticaster at Gerdau
SS NA (MI), USA
> 41
Final acceptance for round bloom
caster at Baotong, China
> 41

Casting of stainless steels at Xining

Special Steel, P.R. of China
> 42

> 87

Highlights AUTOMATION
/TUBEPROCESSING
Next-Generation Cold Pilger Mill
for tube production
> 60
Heat treatment line upgrade
at Jesco, Saudi Arabia
> 62
Heavy wall-thickness tube mill
for TPI, India
> 64
New multicutter for ERW pipe
welding lines
> 65

QDrive - Medium, low and multilevel voltage drives

// 2
Q-Robot MELT / Q-Robot ZINC
How to improve operators' work
conditions
// 3
Billet conticaster modernization
at AM Dabrowa Gornicza,
Poland
// 4
Web reporting system for existing
meltshop at Hadeed, KSA
// 5
Successful Q-MOULD installation
at CMC Arizona, USA
// 5

/HEATINGSYSTEMS

Acceptance for the bloom caster

at Evraz-NKMK, Russia
> 42

Indias largest BF commissioned

at SAIL RSP
> 14
New orders from Chinese
ironmaking operations

Final acceptance for round

bloom caster at Maanshan,
P.R. of China

> 57

Ultra-low NOx walking-hearth

furnace at Hadeed, KSA
> 66
Customized furnace for Orsky
Machine-Building, Russia
> 68
Chain-track bar drawing line
at Marcegaglia Contino,
Italy
> 69
Danieli modernizing the history
at Volgograd Steel Works Red
October, Russia
> 70

State-of-the-art controls for hot

strip mill, at AM Gent, Belgium // 6
Q3Intelligence BI solution at Nucor
Steel Tuscaloosa (AL), USA
// 7
QDrive symposium in India

// 8

QDrive commissioning completed

at Hoa Phat, Vietnam
// 9
E&A equipment for big bar
mill at Qilu, P.R. of China

// 10

Casting new sections of SBQ

at SeAH Besteel, Korea
> 43

/FORGING&EXTRUSION

Finishing mill revamp at CMC

Steel South Carolina, USA
// 11

Repeat order for H3 wire rod

mill technology from Qingdao
Special I&S, China
> 44

Successful commissioning
of a seamless tubing plant
at XinXing, China

HiSECTIONPLUS
at Ferriere Nord, Italy

Danieli Garret Line Technology

at NSSMC, Japan
> 45
0.8-Mtpy bar mill for SteelAsia,
The Philippines
> 46
0.6-Mtpy bar / light section mill
for Mass Global, Jordan
> 47

> 72

// 11

Induction heating furnace

for bar mill at Sovel, Greece // 12
/CUSTOMERSERVICE
Eelectrode arms maintenance
and overhauling package
> 74
DanJoint project accomplished
and a new order received
> 75

Merchant mill modernization

at BSRM, Bangladesh
> 48

DanJoint at Baosteel Meishan,

P.R. of China
> 76

800,000-tpy bar mill project

restarts at Lisco, Libya
> 49

Danieli Service conticasting

knowledge

Ferriere Nord (Pittini Group)

keeps working on innovation > 50

Reduced consumption of EAF

electrodes at NTS, Thailand > 80

Danieli H3 wire rod technology

ordered at AEMZ, Russia
> 51

Cost-effective, small revamping

projects with Danieli Service > 81

Inauguration for the Universal Rail

and Section Mill at Mechels
Chelyabinsk, Russia
> 53

MH Guide Systems technology

at Shanxi Zhongyang,
P.R. of China
> 82

New HiPROFILE at CMC Steel

Alabama, USA
// 13
HelpDesk: better response
and better service

> 78
DanieliPublicityDept.
Tel. (39) 0432.1958244
info@danieli.com
Graphic Design: Polystudio
DTP: Danieli Publicity Dept
Printing: Grafiche Filacorda, Udine
Approved by the Court of Udine
under authorization n.16
dated 21.04.83

// 14

DANEWS 168

Sustainable Entrepreneurship
in Electric Steelmaking
AN OPPORTUNITY TO DESCRIBE OUR COMMITMENT TO INNOVATION

nnovationshouldnotbeseenonlyasa
channelfornewproductsitmustbe
recognizedasacorporatevalue.The
objectiveistotakeadvantageoftheopportunities
thatarisefromacompanysuniqueappealto
customersintechnical,social,environmental,
andthereforealsoineconomicalbases.
OurBestinClassapproachisnotlimitedtoour
technologicalefforts;itisalsoavaliddescription
ofourcost-savingthinkingandourapproachto
environmentalresponsibilities.
Newideasarenottheonlytriggerforinnovation.
Itisresultsfromeffortstobringideastothe
marketandtomakethemsustainablesuccessful.
Onthisbasis,Innovationshouldbeunderstood
asanefforttoaddressproductionchallengesso
thateveryone(employer,employees,customers
andthesociety)maybenefit.
Analyzingouralreadyestablishedtechnologies
forelectricsteelmaking,itappearsthatweare
comingcloserandclosertothetheoretical
minimumlimitsofthatproductionprocess.
Wewilldrawonestepcloserwithournew,
patentedscrap-chargingconceptcalled
HotWind,whichprovidesaproven
technologicalconceptforsustainablelow-cost
conversion,onethatbringsgreaterefficiencyto
thecompleterangeofvariables,suchas:energies
(electricenergy,naturalgas),chargematerials

(scrap,DRI,carbon,etc),andparticularlythe
reliabilityoftheoverallprocessandlogistics.
Thisguaranteesafaststart-upforany
installation,whetheritisagreenfield
developmentorarevampingproject.
Thestart-upcurveofaverage32heats/day
reachedafteroneweekofoperationatthenew
DanieliFastArcEAFatFerriereNord(Italy)is
anoutstandingresultofmoderndesign,precision
manufacturing,detailedplanningfor
construction,andtheopenspiritcooperationwe
sharewithourclients.
Beingawareoftheimportanceofrawmaterials
forNano-,MIDAandMiniMilloperating
results,weproposetechnologiesthatallow
maximumflexibilityintheuseofavailableraw
materials.
Now,havingownlineofscraphandling
equipmentallowsustodefinethemostsuitable
technicalstrategy,fromscrapyardtofinal
product,foreverygeographicalarea.
Also,inthefieldofcontinuouscastingwecanbe
seenastrendsetters;wearecurrentlyachieving
outstandingperformancesinverticalcasting,as
wellinroundcasting(includinglargeroundsof
upto850mmdia),dynamicsoftreduction,ultrahighspeedcasting(>6m/min)withour
revolutionaryPowerMould,anexampleof
continuouslyimprovingprocessparametersfor
ourendlessMIDAtechnology.
Wearedrivenbyapassiontoperform:greater
productivitywithlessequipment,consumingless
energy,andensuringimprovedproductquality:
ourcurrentrosterofinstalledmeltshopsproves
thatwehaveattainedthesetargetsbyworking
together.
Thespiritofsustainableentrepreneurshipat
Danieliisnotlimitedtoabusinessarea.Itisa
sharedattitudeandmutualcommitmentthat
inspireseveryemployee.Weinviteall
steelmakerstobepartofourpassionfor
continuousinnovationthroughoutthecomplete
productlifecyclechain!

THOMASNARHOLZ
EVP DanieliCentroMetSwiss

DANIELI MINIMILLS

DANEWS

FINAL ACCEPTANCE FOR THE NEW MINIMILL

at Deacero Ramos Arizpe, Mexico

fterthesuccessfulstartupofthe
superflexiblerollingmill,thefirstheat
forthenewmeltshopwasexecutedon
March23,2013.ThisnewmeltshopElectricArcFurnace,LadleFurnace,and
conticaster-isdesignedtoproduceupto1.5
Mtpyofbilletsandblooms,aswellasbeam
blanksupto320x400x90mm.Itrepresents
thefourthminimillbuiltandcommissioned
byDanieliforDeaceroinMexico,following
theoperationsinstalledatSaltillo(600,000
tpyofbarsandwirerod),andtwoseparate
plantsinstalledatCelayain1998andin
2006,bothproducingabout2.3Mtpyof
billetsand2.0Mtpyofbarsandwirerod.
Thenewplantisdesignedaccordingtothe
latesttechnologyavailableforsteelplant
machineryandequipment.
Thesteelmeltshopiscomprisedofa150-ton
FastArcEAF(bottomshelldiameter7.7m;
transformerof200MVA;TTT42minutes;
max.productivityof214tph),atwin-type
ladlefurnace,anda6-strandcaster(10/19-m
radius,outfittedforsectionsrangingfrom
130x130to200x240mm).
Thechoiceofthevarioussystemsthatmake
4

uptheplantisdirectlyrelatedtothe
achievementofthefollowinghigh-priority
objectives:
>limitedinvestmentcosts,
>high-qualityproducts,
>highproductivity,
>maximumsimplicityofoperation,
>operationalreliability,and
>maximumflexibilitytomeetvariousmarket
demands.
DanieliAutomationsuppliedtheelectrical,
automation,andprocesscontrolsystemsfor
thewholeplant.
AtbeginningofJuly,130x130-mmbilletsin
A529steelwereproducedatacastingspeed
of5mpm.Aftertheachievementofallthe
contractedperformanceobjectives,theFinal
AcceptanceCertificatewassignedonJuly
11,2013,withfullcustomersatisfaction.
Theplantisnowproceedingwithaquick
ramp-uptowardfirst-classconsistencyin
operationandoptimizationofenergy
consumptionatEAFandLF,tofurther
increasethecompetitivenessonthemarketn

THIS IS THE
FOURTH MINIMILL
COMMISSIONED
BY DANIELI FOR
DEACERO GROUP:
A LONGSTANDING
PARTNERSHIP
CONTINUES
SUCCESSFULLY.

DANEWS 168

Deaceroisasuccessful,
dynamic,andprivatelyowned
companythathasachievedits
growthbyestablishingahighly
competitivepositiontosatisfy
thedemandsofthenationaland
internationalmarkets.The
companyisanimportantplayer

amongsteelmakerssupplying
longproducts,notonlyin
Mexicobutin20countries
aroundtheworld.Continuous
investmentsinstate-of-the-art
millsandplants,withtheir
technologicalimprovementsand
integratedproductionprocesses,

haveallowedDeacerotosatisfy
thecontinuousdemandsofthe
sectorstheyserve:agricultural
products,residentialand
commercialconstruction,and
theindustrialmarketplace.
Deacerohasbeenapermanent
memberofUnitedStatesGreen

BuildingCouncil(USGBC)since
2009asamanufacturerof
sustainableproducts,andtheir
productsachieveLEED
certification(Leadershipin
Energy&EnvironmentalDesign)
forsustainableconstruction
projects.

ALUMINIUM STRIP MILLS

DANEWS

HOT AND COLD ROLLING MILLS

Al

at KUMZ, Russia
TWO CHALLENGING
PROJECTS
BEING TACKLED
BY COOPERATION,
COORDINATION,
AND INNOVATION.

eprojectunder
h
executionforKUMZKamensk-Uralsky
MetallurgicalWorks
encompassestheengineering
andsupplyofaninnovative,
multifunction,all-in-one
double-standhotrollingmill
forhotplatesandcoils,and
coldsheets,plusan
impressive,record-breaking
6-highcoldrollingmill
capableofprocessingwide
coilsupto2,800mm,and
fulfillingtherising
requirementsoftheaviation
andtransportindustries.

Double-standhotrollingmill

Themillsplannedannual
productionof240,000tpy
willbeapportionedas
170,000tpyofHRcoils,
50,000tpyofHRplates,and
20,000tpyofCRsheets.
Thisvarietywillbepossible
thankstothehighrolling
forceavailableatboththe
rougherandthefinisher
(8,000-and6,000-t,
respectively),togetherwith
threeindependentroll
coolantsystems,relative
coolantapplicationheaders,
andindependentfume
treatmentunits.
Thewholemillwillbe
6

managedbyDanieli
AutomationL1andL2
systems.Thehotrollingmill
isinanadvanceddesign
stage,andlong-leadorders
havealreadybeen
purchased.Thebasiccivil
design,andthedesignsfor
auxiliariesandutilitysystems
havebeenhandedoverfor
KUMZtoproceedwiththe
detaildesigningand
constructionofthe
foundations.Currentlythe
buildingframesarebeing
erected,andscheduledtobe
enclosedbeforethestartof
winterinordertocomplete
theinteriorduringthe
wintersmonths.

DANEWS 168

6-highcoldrollingmill

Therewasexcellencetooinaperformance
bytheKUMZemployeeschildren,partoftheRaduga
-TheRainbowGroup.OnJuly4,KUMZandDanieli,
alongwithCityOfficialsorganizedaculturalevent
inJesolo,Italy,wherethechildrenofKUMZ
employeespresentedtraditionalsongsanddances
oftheUrals.TheeventwasattendedbyVladimir
Skornyakov,PresidentofAluminumProducts
ManagingCompany,andGianpietroBenedetti,
ChairmanandCEOofDanieli.

1 Coldmill3Dmodel.
2 Hotmill3Dmodel.
3 KumzandDanieliTeams
duringcoldmill
equipmentinspection
beforeshipment.

4 Hotandcoldmill
buildingunder
construction.
5 Coldmillcivilworks
underconstruction.
6 Firsthotmillshopbays
beingclosed.

Thiswillbetheworlds
widest6-highcoldmillfor
aluminum,andwillproduce
about170,000tpyflexibly,
rangingfromtheminimum
1,100tothemaximum2,800
mmstripwidth.Thiswillbe
madepossiblebythenewest
hydrauliccontrolsystemfor
therollforcecylinders,the
long-strokeshifting,andthe
extra-wideflatness
measurementrollinaclosed
loopwiththecoolantspray
beamheaders,thebending,
shifting,andthetilting
actuators.Asforthehot
section,thewholecoldmillis
managedbyDanieli
AutomationL1andL2
systems.Thecoldmill
machinery,havingbeen
orderedprevioustothehot
mill,isnowfullyengineered
andmanufactured.Currently,
themillcivilworksarebeing
completedforequipment
installation.
Togreatmutualsatisfaction,
alltheequipmentpassedthe
KUMZtechnicalinspection

successfullythefirsttime
around,anditsdeliverytothe
siteisinprogress.Todesign
andmanufactureahotmill
toworkalsoasacoldmill,
andtodesignand
manufacturetheworlds
widest6-highhighcoldmill,
callsuponallthe
experiencesfromKUMZs
fieldexperienceandfrom
Danielisknow-howcenters
(DanieliWeanUnited,
DanieliFrhling,Danieli
Innoval,DanieliAutomation,
DanieliEngineering,and
DanieliHydraulics)
cooperatingtoachieve
excellence.Inthiscontext
ofclosecooperation,thehot
andthecoldmillsare
designedtosetnewstandards
inthealuminumindustry.
Deliveryoftheall-in-one
hot/colddouble-standhot
rollingmillwillstartinthe
firsthalfof2014.Bythat
timethe6-highcoldmill
alreadywillbeproducingthe
wholerangeofalloys(series
1xxx,2xxx,3xxx,5xxx,6xxx,
7xxx, and8xxx)ofitsmix n
7

ALUMINIUM STRIP MILLS

DANEWS

STRETCHED ALUMINUM PLATES

for Dalian Huicheng, P.R. of China

Al

nMarch23rd,
2013,thehot
commissioning
processforthe60-MN
aluminumstretcherwas
concludedthankstothe
DanieliTeamseffortsand
thecustomerssupport:a
5052Faluminumalloywas
successfullystretched,
demonstratingthecapability
ofthemachine.
This60-MNstretcheris
designedtoreacha
productioncapacityof
40,000tpywithaproduct
mixof2XXX,5XXX,6XXX
and7XXXalloys.
Themainapplicationsfor
thickaluminumplatesarein
transportationproducts,
especiallyinaerospace,
automotiveandmarine
industries.

DANIELI WEAN UNITED ACHIEVED

A SIGNIFICANT MILESTONE FOR ITS
STRETCHER DESIGN WITH THE FIRST
ALUMINUM PLATE STRETCHED
AT THE DALIAN HUICHENG SITE.
Therangeofapplications
couldbeextendedtoall
sectorsinwhichlightweight
andhighstrength
characteristicsarerequired.
Incoming Plate Data:
Width

1,000 - 3,600 mm

Thickness

6 - 200 mm

Length

4,000 25,000 mm

Max. weight 14 ton

Thestretchingprocessis
carriedoutasfollows:
dependingonplate

dimensionsandmaximum
plungercompensation,the
fixedheadismovedinto
positionbyahydraulicmotor
andheldusingpins;the
moveableheadismovedbya
quick-movingcylinder.
Thevacuumcranecharges
theplateontofixed
supportingrollersbetween
thetwoheads.Onecarriage
(two forplateslongerthan
10m)supportstheplatein
anintermediatepositionand
hastheeffectofflatteningit.
Theplateiscenteredbyside
guidesandverticalrollers,

andthenclampedbya
gripper.Twomainstretching
cylindersexertthemain
stretchingforceontheplate
andworkuntiltherequired
stretchingforceforthatalloy
isreached.
Asynchronizationcontrol
systemensuresuniform
elongationfortheplate,
preventingheadskewing
duringstretchingforsafety
reasons.Therequired
elongationvariesaccording
toplatematerial,heat
treatmentandtherelated
elasticandplasticstrain
values.Afterstretching,the
plateisunclampedandthe
centeringdeviceopens;the
plateisreadytobe
dischargedbyvacuumcrane.
Theshockabsorbingsystem
willact,withadedicated

DANEWS 168

hydrauliccircuit,incase
ofaluminumplatebreakage,
dissipatingthestretching
energyandlimitingthetravel
ofstretchinghead(inone
direction)andcolumnsplus
fixedhead(intheother
direction).
Thehotteststartedwiththe
firststretchedplate.Since
thestartup,constant
improvementsandfinetuningwereappliedtothe
machineinordertofulfill
therequiredperformance
figures,accordingtothe
EN485-3Standard,which
definesthefinaltolerances
foraluminumplate.
Thetotalnumberofplates
successfullystretchedduring
thestartupphaseismore
than3,000,includingthe
onesforproduction.
Uptonowthemachinehas
stretchedthehardest
aluminumgrades,mainlyof
6061,7075and6082alloys,
andasmallernumbersof
5052plates.
Theseplateswereheat
treatedwithmainlyT651
process,butalsoincluding
someF,H112,andT451
processes,whichmeans
solutionheattreatment
followedbyartificialaging.
Theresultsobtainedduring
recentmonthsconfirmthe
DanieliTeamsabilitytoface
newchallengesand
successfullymeet
profitabilitytargetsinthe
newaluminummarket
segment.
Thefirststretchedplate
representsakeyeventnot
onlyfortheDalianHuicheng
projectbutalsoforother
Danielistretcherprojectsn

Nanshan Aluminium
chooses proven yet advanced
technology, again

Al

CHINAS LEADING PRIVATE

ALUMINUM STRIP PRODUCER
HAS BEEN RELYING ON DANIELI
FRHLINGS CUTTING
TECHNOLOGY SINCE 2003,
AND NOW WILL EXPAND
ITS PRODUCTION FACILITIES
FOR FURTHER GROWTH.

anshanLightAlloyCo.,Ltd.wasfounded
in2001,andhasdevelopedintoamodern
aluminumrollingenterprisewith
productionspacecovering328,000sqm,with
over1,000people,andmorethan60setsof
productionequipmentofallkinds,andatotal
productioncapacityexceeding750,000tpy.
ShandongNanshanAluminumCo.,Ltd.intends
tobuildamodern,large,high-precision
aluminumandaluminum-alloyplateandstrip
productionplantinDonghai(Shandong),which
ispartoftheefforttodiversifyitsproductmix.
In2003,ShandongNanshanAluminumand
DanieliFrhling(DF)becamepartnerswhenthe
firstcontractsforatrimminglineandaslitting
lineweresigned.Furtherorderswereplacedwith
DFfortwomorehigh-speedtrimmersinthe
followingyears.Recently,thecustomerchose
DFtosupplyanothertrimminglineandanew
slittingline,tocompleteitsexpansionproject.

Slittingline Thedesignofthisnewlinesisbased
onexperiencesgatheredinalargenumberof
similarlinessuppliedpreviously,aswellasthe
latestimprovementsinsuchoperations.It
providesthecustomerwithahigh-endmachine
abletocutstripstotheclosesttolerances.Atthe
coreofthecuttingprocessisaCNCslittingshear
thataccommodates ahighstandardofdesignand
manufacturing,withpre-tensionedelementsto
reducebacklashinshearadjustment,computercontrolledknifeshaftpositioninginclosed-loop
mode,aswellasanautomaticclampingsystem
fortools.Forbraking,theprovenDFvacuumroll
designwillprovidethesmoothestandmost
uniformtensiontoallindividualstrips.Braking
forceisprovidedwithouttouchingtheupper
surfaceofthematerialandwithverylowfriction
onthebottomofthestrip.Thelinewillbe
completedwithasophisticatedpackinglinethat

SongChangming,Vice
GeneralManagerof
NanshanGroup,andJrg
Schrder,DFManaging
Director.

introducesvacuumstackingandvarious
strappingmachines,aswellasfilmstretcherand
weighingequipment.
Trimmingline Withitsbasicconceptprovenover
severalyears,andreliabilityatstableoperation
speedsof1,500mpmandhigher,thislineis
equippedwithspecialfeaturestoprovide
precisionproductsatmaximumproduction,
suchas:
>High-speedcroppingoftheout-of-tolerance
headandtailendwithintheline;
>Edgetrimmingshearwithautomatic
adjustmentofcuttinggapandimmersion;
>Suctiondevicesforsidetrimmingscrap,
especiallyforhigh-speedapplications;
>Dedicateddesignfortheexitguideunit
downstreamofthetrimmingshear,toestablish
theshortestpossibledistancebetweencutting
andrecoilingzones;
>Tworecoileroutletstomanagetwofinished
stripsatthesametime(maximumspeedinthis
case1,000mpm).

Bothlineswillbecompletedwiththenecessary
hydraulics,automation,electrics,andother
auxiliaryunits.Installationandcommissioning
willbesupervisedbyourexperiencedstaff,
whichensuresafastlearningcurveandoptimal
fine-tuningoftheplantsn
9

ALUMINIUM STRIP MILLS

DANEWS

TWIN-CONTAINER PRESS
at General Extrusions, USA
for higher plant utilization
and lower energy consumption

Al

THE 23-MN PRESS,

THE FIRST
INSTALLATION OF ITS
TYPE ANYWHERE IN
THE WORLD, WILL
BE A MILESTONE
IN THE NORTH
AMERICAN MARKET,
AND WILL CONFIRM
DANIELI BREDA
AS AN INNOVATIVE
PARTNER.

10

eneralExtrusionsInc.
(GEi)produces
standardand
precisioncustomaluminum
extrusionsin3000and6000
seriesalloys.
ThecompanyisISO-9002
certifiedandservices
customersintheappliance,
medicalequipment,
transportation,and
automotiveindustries,
amongothers.
Thenewpresstobe
installedatYoungstown
(OH)plant,accordingtothe
contractsignedinJune
2013,willenableGEito

pursueitsplansfor
productionexpansionand
costoptimization.
Featuringadeadcycletime
40%lowerthanthe
conventionalunitsand
requiring44%lessinstalled
power,theTWINpress
ensuresproductionincreases
withlessenergy
consumption,i.e.improved
operatingmargins.Further
tothe8-in.TWINcontainer,
the2,600-USTpresswillbe
equippedwiththeESED:
EnergySavingElectrical
DriveandBreDanExtr
automationsystems.

Amongtheotherbenefits,
thisplantdesignalsoshows
alimitedimpactconcerning
installation,requiringa
minimalamountofsite
excavationandacompact
footprint.
BothDanieliBredaandGEi
expectthisinstallationto
quicklybecomea
benchmarkforwhat
concernsproductivityand
specificcostonthefinal
aluminumproductn

DANEWS 168

On June 19, 2013, the Danieli Frhling 6-high reversing mill produced
its first coil and quickly proceeded to run at the maximum speed
with the minimum exit gauge, all within gauge and shape guarantee tolerances.

First coil rolled

at Taiyuan Jinxi Chunlei Copper, P.R. of China

hecoilproducedwas
CuZn35withawidthof
420mmandrolledfrom
0.25to0.155mmintwo
passesatspeedsupto450
mpm.Itmetalloftheshape,
gauge,andquality
requirementsofthecontract.
Bythetimethethirdcoilhad
beenrolledthemillhad
achievedmaximumspeedof
600mpm;theminimumexit
gaugeof50mwasachieved
shortlyafter,allwithingauge
andshapeguaranteetolerance.
DanieliFrhlingreceivedthis
orderfromChunleifollowing
theirsuccessfulprojectfora
20-highmillsuppliedinthe
mid1990s,andtomakesure
thateverythingransmoothly
thesamesitesupervisorwas
assignedfortheinstallation
andcommissioningphasesof
this6-highmill.Themillstand
wassuppliedfullyassembled
fromtheDanieliFrhling
workshopsinGermany,with
localsupplyfromDanieliChina
fortheauxiliaryequipmentand
gearboxes.Theelectricaland
automationsystemwas
providedbyDanieliAutomation.
Equipment control functions
Themillcanoperateinfully
automaticorsemi-automatic

modes,withlimitedoperator
intervention.Allthenecessary
permissivesignalsand
interlocksareprovidedforsafe
operation.Driveandmotor
controlsincludehighly
accuratemillspeedmaster,
reeltensioncontroland
automaticslowdowncontrol.
Hydraulic Gap Control (HGC)
Thehydraulicscrew-down
cylindersarearrangedinthe
uppermillhousing.The
positioningofthescrew-down
cylindersisdonevia
independenthydraulicservovalves.Theroll-gappositioning
ismeasuredbyhigh-precision
linearpositiontransducerson
eachcylinder.
Strip thickness control (AGC)
Severalthicknesscontrol
modesareusedtoachieve
reproducible,smallest
thicknesstolerances,using
high-precisionstripthickness
andstripspeedmeasurement:
feed-forwardcontrol,feed-back
control,mass-flowcontrol.
Strip flatness control (AFC)
Stripflatnesscontrolisbased
onthefollowingactuators:
bendingcontrolofWRandIR,
dynamicanddifferential

shiftingcontrolofIR,tilting
control,rollcoolantcontrol.
Theflatnesscontrolpackageis
basedonanextendedLeast
MeanSquareAlgorithmfora
perfectassignmentofshape
errorstothemechanical
actuatorsoftherollingmill.
Inadditiontothisoptimized
'jobsharing'betweenthe
mechanicalactuators,the
flatnesscontrolconcept
comprisesseveraladvanced
featureslikeCoolantSupport
functionality.Essential
highlightsoftheequipment
suppliedthatmakesit
advantageousare:
>Directmeasurementofstrip
entry-andexittensionfor
improved striptensionand
gaugecontrol;

>Symmetricalpositiveand
negativeWRandIRbending;
>DifferentialanddynamicIR
shifting;
>Vibrationsuppressivedesign;
>Easymaintenanceand
minimaldowntime;
>Shortroll-changingtimes;
>Platefilterforhighest-quality
rollingoilfiltering;
>Autocenteringofthecoilat
decoiler;
>3M Squeegeerollstrip
wipingsystem;
>Level2adaptivescheduling
modeln
Firstcoil!Fromleft:SongYinghui,
ProjectManagerChunlei;RalfPtter,
RollingProcessSpecialistDF;
PeiTongwei,mainoperatorChunlei;
WolfgangRathmann,Senior
CommissioningSupervisor,DF.

Mainprocessingparametersofthemill
Typical material grades

Copper: C10200, C11000, C12000,

Copper alloys: C19210, C19400, C 26000,
C26200, C26800, C27000, C70250,

Material condition

CR and soft annealed or CR only, non-sticking,

straight wound, edge trimmed

Strip width

300 - 430 mm

Initial / Final strip thickness

Max. 1.50 mm / 0.05 - 1.20 mm

Max. coil weight

6,000 kg

Max. roll force

4,000 kN (Nominal 3,600 kN)

Rolling speed

600 mpm

11

IRON & STEELMAKING

DANEWS

SECOND DRI-BASED MINIMILL

CONFIRMS SUCCESSFUL PERFORMANCES
at Emirates Steel, UAE

miratesSteelplantsinAbuDhabiare
infulloperatingmodenow,
establishingnewrecordsforsuccessful
performance.
Bothintegratedsteelplants-namely,Phase1
inoperationsincetheendof2009,and
Phase2sincethebeginningof2011-are
runningwithverystableperformancesthat
maintainhighlevelsofproductivity,and
representingremarkableaccomplishments.
OnMay12,2013,thePhase2EAFsafely
achieved38heatsperdaywith5,565tonsof
moltensteel,whiletheconticasterreached
37heatsperdaywith5,466tonsofsemifinishedproductcast(meltingEnergironHot
DRIat94%met-C2.3%),asannouncedby
PaoloRazza,theESSteelmakingPlant
Manager.Theconticasteroutputhas
achievedpeaksabove230tph,with227tph
average,wellabovethedesignconceptof
197tph;thesedataprovethereliabilityof
theinstalledtechnology,entirelysuppliedby
Danieli,andthefinetuningprocesscarried
outbytheESteam.
Evenso,acriticalfactorthatcontributed

Production
ramp-up and very
stable operational
conditions make
Emirates Steels
minimill No.2
the benchmark
in DRI-based
minimill plants.

Cumulativeproductionin1yearofoperation(15Aug201215Aug2013),1,619,388tofhotDRI.
1600

Cumulative production (t*1000)

1400
1200
1000
800
600
400
200
0

Au

Oc
Se
No
J
De
F
Ma
Ap
A
Jul
Ma
J
p
t
c 2 an 2 ebr
r2
v
y 2 un 2
20 ug 2
20 r 201
01
01
01
01 t 201 2012 201
01
01
01
13
13
3
3
3
2
2
3
2
3
3
2

g2

12

significantlytothissmoothoperationofthe
meltshopcertainlyhasbeentheperfect
integrationwiththeupstreamDRplants.
ThesehighperformingEnergironplants,
whichdirectreductiontechnologyhasbeen
developedjointlybyDanieliandTenova
HYL,showtheabilitytofeedtwoEAFs
continuouslywithhigh-qualityhotDRI,
regardlessofthequalityoftherawmaterial.
Inthiswaytheplantmanagerisabletoseek
asignificantcostreductioneasilybychoosing
themosteconomicpelletaccordingtothe
marketconditions,withouteveroverlooking
theprimaryimportanceofthefinished
productquality.Thelatestproductionrecord
achievedbythePhase2EnergironDRPat
thebeginningofAugust,whenthenominal
designcapacityof1.6Mtpyhasbeen
reachedafter12monthsofproduction,
furtherconfirmstheincreasingreliability
ofEnergironplantswithexternalreformer
aswell.
Theseexcellentresultswillbeimproved
furtherwiththeforthcomingcapacity
enhancementofbothdirectreductionplants.
Withamarginalcapitalinvestment,each
plantwillreachproductioncapacityof2
Mtpy,puttingtheentireplantat4.0Mtpy
ofhotDRIcapabilityn

DANEWS 168

Viewofthesecond
EnergironDRplantatthe
minimillcomplexin
Mussaffah,which
togetherwiththefirstDRI
plantinoperationthere
since2009,willenable
EmiratesSteeltoreacha
totalproductioncapacity
ofupto3Mtpyfor
structuralsteellong
products.

13

IRON & STEELMAKING

DANEWS

INDIAS LARGEST BLAST FURNACE

(8,000 THM PER DAY) COMMISSIONED
at SAIL Rourkela Steel Plant

S.S.Verma,EDProjects,
SAILRSP,andP.Zonneveld,
ManagingDirector,Danieli
Corus,cuttingtheribbon.

ecentlyDanieliCoruscommissioned
thegreenfieldBlastFurnaceNo.5
builtforSAIL(SteelAuthorityofIndia
Limited)attheirRourkelaSteelPlant.This
ironmakingvesselwasbuiltbyaconsortium
consistingofDanieliCorusandTataProjects
Limited,andcurrentlystandsasIndias
largestblastfurnace.Thefirsthotmetalwas
tappedafter27hours.Itisanoteworthy
accomplishmentforDanieliCorustohave
builtthelargestoperatingblastfurnace,
accordingtotheHoogovensphilosophy,in
thisimportantmarket.Whilethefurnaceis
namedaftertheHindugoddessDurga,itwas
basedonEuropeantechnologyanddesigned
toEuropeanstandards.Itwasbuiltto
producearound8,000tonsofhotmetalper
dayfora20-yearcampaign,andispartofa
1.75-millionEuroexpansionprogramatthe
RourkelaSteelPlant.
14

DANEWS 168

New orders for Danieli

Corus from Chinese
ironmaking operations
anieliCoruswasawarded
anassignmenttoreplace
threesublancesystems
atthe180-tconvertersofthe
No.1SteelMakingPlant
operatedbyShagangI&S
(Group)Co.,Ltd.Thescopeof
thisprojectincludesdesign,
supplyofsublanceequipment
andtechnicalservices.The
equipmentcomponentswillbe
manufactured inbothThe
NetherlandsandChina.
Deliveryisscheduledfor
December2013,with
installationandcommissioning
expectedtotakeplacein
early2014.

Apoojawasperformedaspartofthe
commissioningofBlastFurnaceNo.5
(Durga)-accordingtoHindutradition,
coconutswerecrackedandthecontents
sprinkledoverthefurnacesshelltohonor
Durga,thegoddessofenergyandcreation.
Thisisthefourthgreenfieldblastfurnace
projectcompletedbyDanieliCorusinIndia
andbasedontheHoogovensphilosophy.
Previously,threesmallerblastfurnaceswere
builtforprivatecompanies,amongwhichthe
oneoperatedbyJindalSteel&PowerLtd.
hasbeenIndiasbestperformingblast
furnaceoverthepastyears.Inaddition,
DanieliCorushasexecutedsubstantial
revampandrepairprojectsontheblast
furnacesoperatedbyTataSteelatits
Jamshedpurplant.Anorderforafifth
greenfieldprojectinIndiawasreceivedfrom
theminingcompanyNMDCin2011.
Thiscompanyisdiversifyingintothesteel
industryanddevelopinganewintegrated
plantatNagarnar.Currently,DanieliCorus
isbuildingtheblastfurnacethere,which
willbelargerthantheDurgafurnace
nowoperatingatRourkela.Thisupcoming
furnaceisexpectedtobecommissioned
in2015n

Thesethreesublancesystems
areintendedtoreplacethree
existingsystemsoriginaly
suppliedbycompeting
Europeanfirms,the
performanceofwhichhasbeen
unsatisfactoryforthe
steelmaker.Onother
converters,Shaganguses
DanieliCorussublancesthat
weresuppliedearlier,achieving

excellentresults.Thisfact
reinforcesDanieliCoruss
globalleadershipforBOF
processcontrolsystems.With
morethan110referencesfor
sublancesystems,especially
operatingwiththeStaticDynamicProcessControlModel
forBOFsteelmaking,Danieli
Corus'strackrecordand
experienceinBOFProcess
ControlSystemsisunrivaled.
Withthisexperience,Danieli
Corushasdevelopedsystems
forfullyautomaticsteelmaking
capability,fromchargetotap.
Thepossibilityofproducing
steelatthetouchofasingle
buttonmakesthesystem
uniqueintheglobalsteel
industry.
DanieliCorushasreceiveda
repeatorderfromPangang
XichangSteel&VanadiumCo.,
Ltd.forthedesignandsupply
ofathirdhot-metal
desulphurizationsystemfor
theirsteelmakingplant.
Thissystemwillbebasedon
co-injectionofmagnesiumand
lime.Equipmentdeliveryis
scheduledforDecember2013,
installationandcommissioning
activitiesareexpectedtotake
placeinearly2014n
15

IRON & STEELMAKING

DANEWS

ON JUNE 25, 2013,

A CONFERENCE ATTENDED
BY NUMEROUS
CUSTOMERS OF ABS
AND END-USERS
OF ITS MAIN PRODUCTS
CELEBRATED THE
OPENING OF THE NEW
ABS R&D CENTER
IN METZ, FRANCE.

16

DANEWS 168

OFFICIAL OPENING AT
ACM-ABS CENTRE MTALLURGIQUE
IN METZ, FRANCE

iththissignificantinvestment,
ABS,thesteelmakingdivision
ofDanieliGroup,reaffirmedits
dedicationtoconstantinnovationandfront
runningspirit,asinthebesttraditionofthe
Group.TheefforttoinnovateisABSanswer
totheEuropeanengineeringsteelsmarket,
amarketthatstillisfarfromafullrecovery.
ABSCentreMtallurgiqueisaninvestment
thatcreateda2,500-sqmlaboratory,
equippedwiththebesttechnologiesfor
analyzingandsimulatingproductsand
processes,guidedbyengineersand
technicianswithadeepmetallurgic
knowledge.TheselectionofMetzisdueto
itslocationinthecenterofEurope,inorder
tobeclosertothecustomers,aswellasto
thetraditionandknowledgeofthe
metallurgicalsciencesnativetothatregion,
inordertoenhancethechancesof
cooperationwiththebestinstitutions
forresearchanddevelopment.
ACMisdividedintwomaindivisions:
processresearchandproductresearch.
EverydivisioncooperateswithABSforthe
innovationandcompetitivenessofthe
steelmakingdivision,withallDanieliproduct
linedivisionssupportingofinnovation;and
withcustomersalongthesupplychain
ofsteelprocessing,includingtheprospect
ofindependentpartnershipatcustomers
service.
Themainfieldsofactivitywillcover
thefollowingareas:
>Mechanical:mechanical,fatigueand
machiningpropertiesofsteelandthe
influenceofmanufacturingprocesses
oncomponentsbehavior;

OnJune25,2013,
aconference
attendedby
numerouscustomers
andend-usersofthe
mainmarketsof
ABScelebratedthe
openingofthenew
ABSR&Dcenter
inMetz,France.

Sinceitsestablishment,ACMhascounted
onacomprehensiveandstate-of-the-artarray
ofequipmentfor:fatiguetestingandDRX
equipment,mechanicaltesting,machining
andmachinabilityequipment,metallographic
characterization,opticalcleanliness
assessment,electronmicroscopy,plastodilatometry,chemicalcomposition
determination,heattreatment,ultrasonic
immmersion,andafullrangeofsoftware
forimageanalysisandprocesssimulation
ofrolling,forging,heattreatment,cooling,
andingotandcontinuouscastingofsteel.

>Manufacturingprocesses:Investigation
ofmanufacturingprocesses,especially
rolling,forging,andheattreatment;

Inordertoguarantythereliabilityofthenew
labsresultsand,moreover,tohavetools
allowingittoreducethedevelopmenttime,
ACMthisyearstartedtheprocessofISO
accreditationbysettingupallrequirements
togainISOTS16949qualitycertificationin
2014.In2015,theISO14001accreditation
forenvironmentalprotectionwillcomplete
thepaneln

>Steelmaking:investigationand
optimizationofsteelmakingprocesses
fromscraptocastproduct.

AlessandroTrivillin,CEOofABS,andPascal
Daguier,Director,ResearchManagerofACM,
givingtheirspeechattheOpeningCeremony.

>Metallurgical:comprehensionof
metallurgicalmechanisms,steeldesign
andcharacterization;

17

IRON & STEELMAKING

DANEWS

SECOND DANIELI
NANO MELTSHOP IN RUSSIA
started up at BVK in Chelyabinsk

THE NEW FOUNDRY,

BASED ON THE
DANIELI NANO
MELTSHOP
CONCEPT, STARTED
UP SUCCESSFULLY
ON MAY 29, 2013,
AND FOLLOWS THE
FIRST ONE
COMMISSIONED IN
2012 AT KULEBAKY,
FOR RUSPOLYMET
SPECIAL STEELS.

VKLLCisanewjoint
venturebetweenItalys
CividaleGroup,oneof
Europeslargestfoundries,and
Konar,onethemostimportant
producersoffittingsandvalves
inRussia,basedin
Chelyabinsk.Designedto
produce25,000tpyofingots,
bloomsandstampings,the

B
1
2
3
4

18

ElectricArcFurnace
LadleFurnace
VacuumDegasser
Ingotcasting.

DANEWS 168

New Nano meltshop

for specialty and stainless steels
at MTE Finance, Russia
meltshopbasicallyconsistsofa
20-telectricarcfurnace(fitted
withthelatestDanieli
FastArcTM technology),aladle
furnacewithinertroofanda
single-tank/single-cover
VD/VODstation,equippedwith
drymechanicalpump.
TheEAFispartofthenew
generationofDanieliEAFNano
series,specificallydesignedfor
smallheatsizesandlow
annualproductionvolumes.
Tooptimizethemelting
processandtheenergy
consumptionbyuseof
chemicalenergysources,a
Roboxconsumableslagdoor
lanceisprovidedandfully
integratedintheprocess
modeloftheautomation
system.TheLFfollowsthe
sameNanophilosophy.
Itisdesignedtoreduceall
necessarymaintenance,andis
fullyequippedwithnecessary
auxiliaries.Thevacuum
degassingandoxygen
decarburization(VD/VOD)
stationisdesignedtotreatthe
entirerangeofhigh-alloy
carbonsteels,andmartensitic,
austenitic,andduplexstainless
steelsnecessaryforBVK
tosolidifyitsmarket-leading
qualitystandards.
Thevacuumpumpisadry
mechanicaltypeoperation,
withsuctioncapacityof
approx.44,000m3/h,textile
filter,anddustseparatorto
removedustcomingfromthe
process.
Thevacuumstationis
equippedwithsupersonic
oxygenlance,splashshield,
undervacuumhopper,
automaticsampler,andwire
feeder.Firstresultsobtained
anticipateafastplant
commissioninganda
successfulprojectconclusionn

7
3
8

2
4

10

11

6
1

MTEFinanceGroup
awardedacontractto
Danielitosupplya
completemeltshop,toproduceupto
115,000tpyofliquidsteel.Itspartofa
programtomodernizethesteelmakingsiteat
Azov,nearRostov.Therenovationofthesteel
complexwillbenefitfromthelongtradition
ofhigh-qualitymetallurgicalindustryinthe
Rostovdistrict,andfromtheplantsstrategic 1
location.Thenewfacilitieswillincludeall
technologicalprocessequipmentformelting
andrefiningofhigh-qualityspecialand
stainlesssteeltobecastasingotsandblanks.
Themainplantunitsare:
>A16-tEAFwithaspout-tappingdevice,
poweredviaan18MVAtransformer;
>A16-tladlefurnacewithahighheating
rateforthehighestflexibilityonproductmix;
>Asingle-tankvacuumdegassingstation
(VD/VOD),withmechanicalvacuumpump;
>Aintegratedmaterialhandlingsystemfor
Fe-alloysandcoarsematerial;
>AFumeTreatmentPlantwithcapacity
ofover300,000Nm3/h;

>EOTcranesforladleandingotshandling
with400/80kNcapacity;
>Aclosed-circuitwatertreatmentplantfor
coolingofthenewlyinstalledequipment.
Whencompleted,thenewprojectwill
estabilishaverticallyintegratedproduction
sequenceforspecialtysteelingots,tofully
exploitthecapabilitiesofthenewlyinstalled
DanieliBredaintegratedopen-dieforging
plant.Theimplementationofameltshop
dedicatedtosuchspecificproductswill
providebenefitsintermofprocess
optimizationonnicheproducts;reduction
ofWIPandstocks;fullcontrolofthequality,
fromscraptofinalproduct;reductionoftotal
OPEX;internalrecirculationofvaluable
processscrap;possibilityofhotchargingof
ingotstotheforgingcycle.Theimproved
plantperformancethatresultswillallowMTE
Financetomeettheneedsofbothdomestic
andinternationalmarkets,competitively,with
significantreductionsinenergyandlabor
costs,andtocreateanenvironmentally
friendlyproductionprocessn
1
2
3
4
5
6
7
8
9

Scrapyard
ElectricArcFurnace
LadleFurnace
VacuumDegasser
Ingotcastingcar
Scrapbuckettransfercar
Ladlerefractory
removalarea
Ladleslagremoval
area
Ladlereliningstation

10 Ladledryingand
preheatingstation
11 Additivesstorageand
chargingsystem
IvanReshetnikov,MTE
FinanceGeneralDirector
(right)andPaoloBurin,
DanieliExecutiveManager
SalesSteelmaking,signing
thecontract.

19

IRON & STEELMAKING

DANEWS

NEW INTEGRATED
EAF CHARGING SYSTEM
at Sohar Steel, Oman

THIS NEW CHARGING

SYSTEM COMBINES
CONTINUOUS
FEEDING FOR BOTH
DRI AND HBI
TO FURNACE
WITH DANIELIS
INNOVATIVE ISAC
SYSTEM FOR
CONTINUOUS
DELIVERY OF
SHREDDED SCRAP,
TO ESTABLISH
THE GREATEST
FLEXIBILITY FOR RAW
MATERIAL SELECTION
AND TO INCREASE
PRODUCTIVITY,
WHILE LOWERING
PRODUCTION COSTS.

DanieliIntegrated
Shreddedscrap
AutomaticCharging
(ISAC)systemwillbe
installedattheSohar
meltshopinPortofSoharto
feedanewDanieli75-t
FastArcelectricarc
furnace,orderedin2012.
Thesystemisanewprocess
solutionforcharging
shreddedmaterialintothe
EAF,andresultsfrom
mergingtheknow-howof
DanieliCentroMetforsteel
meltshops,DanieliProcome
Ibericaformaterialhandling
systems,andDanieliCentro
Recyclingforscrap
shreddingplants.Thesystem
combinessinglebucketand
continuouschargingfor
20

G
Closed scrap bay

Free space for DRI/HBI

charging into bucket

Closed scrap bay

Shredded scrap
belt conveyor

E
C RELINING STATION

DRI/HBI/Lime
belt conveyor
A DanielinewEAF
B Shreddedscrapcharging
C Shreddedscrapbufferstorage
D DRI/HBIcharging
E DRI/HBIstoragesilos
FCommonconveyor
G EAFfeedingfrom5thhole

scraptotheEAFclosedroof
bymeansofaspecial
conveyor,withadedicated
meltingprofileandchemical
energyoptimizationprogram
Inthisway,thescrapdensity
inthebucketismanaged
dynamically,without
impactingthestandard
furnacedesignorthelinked
equipment(i.e.bucket,shell
etc).TheEAFischargedat
thebeginningoftheheat
withonebucketofscrap;
then,themeltingprocess
beginsandwithprecise
timing,determinedbythe
automationsystem,the
ISACsystemstartstofeed
shreddedmaterialthrough
thefifthholetocomplete
thechargerequired.The

ISACsystemprovidesa
completeandaccurate
indicationofthequantityof
materialdeliveredtothe
EAFbydedicatedspecial
weighingsystemsonthe
handlingequipment.This
indication,plustheweighing
ofthescrapbucket,provides
completeinformationforthe
materialchargedintothe
EAF.TheISACsystemis
extremelybeneficialforthe
EAFmeltingprocess,
ensuring:
>anincreaseinmelting
processyield,thankstothe
higherqualitycharge;
>areductionofenergy
losses,duetothefewerroof
openings;
>anincreasedinEAF

productivitywiththesame
Power-Onfactors,thanks
tothereducedPower-Off
period.AtSoharSteelthis
willimproveEAF
productivityfrom92to
105tph(+14%).
TheISACsystemis
integratedwithanew
Danielimaterialhandling
systemforDRI/HBI
continuousfeeding,allowing
thecustomertoselectawide
rangeofrawmaterialfor
chargingandthehighest
processflexibility,tolower
productioncostan
denhanceplantprofitability.
TheISACsystemandthe
DRI/HBIfeedingsystem
willcomeonstreamduring
spring2014n

DANEWS 168

New roof lifting

and swiveling
system for the
140-t EAF
at Stefana
Ospitaletto, Italy

ANOTHER INNOVATIVE VD/VOD PROJECT IN CHINA, FOLLOWING THE

SECONDARY METALLURGY STATION INSTALLED AT XINING SPECIAL STEEL.

NEW VOD STATION

for Jisco, P.R. of China

Thenewequipmentwill
makepossibleaproduction
increase,withsaferoperating
conditionsandless
maintenancerequirements.
hisupgradeproject
forthe20+years-old
DanieliEAF,toinstall
anewdesignroofliftingand
swivelingsystem,aimsto
increaseproductionbyfully
exploitingthe135/162MVA
transformer,acondition
currentlypreventedbythe
designrestrictionsofthe
existingsystem. Inthis
respectthenewsystemis
designedsoastoallowthe
useoflargerelectrodes(from
24to28in.),andthe
consequentincreasedloads
onthesuperstructureby
heavierelectrodemastsand
arms.AtthattimetheEAF
transformerwillrunatthe
maximumpowerofover120
MWbyraisingtheelectrode
currentupto78kA.Asa
resultofthesedesign
changes,maximumEAF
productivitywillbeachieved.
Sincethedesignwill
accommodatetheexisting
hydrauliccylindersand
superstructure,withno
modification,thesystemwill
beinstalledonsitequickly
duringascheduled
maintenancestoppage,
withoutimpactingtheEAF
production.Thestartupof
thenewunitisplannedfor
summer2013n

hevacuumdegasserorderedinMay
2013willcompletethestainless
steelproductionplantthatJiscoJiuquanIron&SteelCo.operatesin
Jiayuguan(GansuProvince).TheVODwill
bededicatedmainlytoproducingstainless
steelgradeswithultra-lowcarbonand
nitrogencontent(C+N<200ppm),andits
innovativefeatureswillallowadramatic
increasetotheproductivityratesforthese
steelgrades.Ladlecapacity,withnew
refractorymaterial,willbe105t,with
1,200mmfreeboard.TheVODdesignisa
doubletank-doublecovertype,equipped
withafive-stagevacuumpumpwithsteam
ejectorsandwaterringpumps,witha
suctioncapabilityof450kg/h.The
innovativedesignofthepumpwillallow
Jiscotoperformtreatmentundervacuum,
atdifferentvacuumlevelsinbothtanksat
thesametime.Danieliwasassignedan
extremelydemandingtask:Jiscorequested
anoperationcapableofsequencingatleast
threeladlestothecasterinaround240
minutes.TheAODconverterisdelivering
ladlestotheVODevery50to60minutes,
andtheslabcasterdownstreamtheVOD
hasacastingtimearound45minutes.
AusualVODstationdesignwouldneed

twoindependentvacuumpumpstofulfill
thisrequirement.Danielidecidedinstead
toofferitsnewvacuumpumpdesignthat
willallowtheoperatorstoreachthetarget
required,savingoninvestmentcostsand
reducingsteamconsumption.
Danieliwillsupplyallthetechnological
equipment,includingthevacuumpump.
Thetanksandthecoversthatwillbe
manufacturedinDanieliChinas
workshopsinChangshu,whilethecritical
controlequipmentwillbesupplieddirectly
fromEurope,thusenablingDanielito
deliveritstraditional,high-qualitysupply
standardsn

Fromleft:CaoShihai,DeputyManagerofTianFeng
StainlessSteelCo.;TianHai,ViceManagerofImportand
ExportTradingCo.ofJisco;GiulioPretini,Manager,Sales,
Steelmaking,Danieli.

21

IRON & STEELMAKING

DANEWS

INTENSE ACTIVITY DRIVES GROWTH

at Danieli Centro Recycling

This year will

undoubtedly be
memorable for
Danieli Centro
Recycling.
The acquisition of
Riverside Products,
Inc., in USA brings
a third major global
brand to the product
portfolio, and
significantly
strengthens the
service capability
and capacity
of the division.
During the same
period, Danieli
Lynxs secured the
order for the worlds
largest aluminum
recycling and
shredding plant,
whilst Danieli
Henschel achieved
notable new
machine orders in
the UK, Belarus,
Middle East, China,
and Australia.

22

nApril2013,Riverside
Productsbecamepartof
DanieliCentro
Recycling.Nowrenamed
DanieliRiverside,the
companyhasbeenactively
supplyinghighlyengineered
scrapshredderrotorsand
wearpartstothemetals
recyclingindustryworldwide
formorethan50years.Its
reputationforengineering
excellenceandthenumber
ofpatentsitholdswasa
decisivefactorbehindthe
acquisition.Innovativerotor
designsdevelopedbyDanieli
Riversidewillbe
incorporatedintospecialty
shredderapplicationsoffered
byDanieliLynxs.Spring
2013sawDanieliLynxs
awardedthecontractto
constructthreeshredding
andseparationlinesforthe
worldslargestaluminum
recyclingplant,under
constructioninGermany.
Theclient,aprominent
supplierofaluminumsheet
totheautomotiveindustry,
choseDanieliLynxsdueits
superiortechnologyand
flexibilityindesign.Fasttrackmanufacturingwill
allowinstallationofthefirst
shreddinglinetobeginin
January2014,withhandover
ofthecompleteplant
scheduledforthirdquarter
2014.Theintegrationof
DanieliHenscheloverthe
past12monthshasbrought
newprocessingsynergiesfor
steelmakingcustomersof
DanieliandDanieliLynxs.
InAustralia,Sell&Parker
(Pty)Ltd.choseDanieli
Henschelasitspreferred
supplierforanewCIB
1400-10Lstatichydraulic
sheartocomplementa

DANEWS 168

3,000-kWDanieliLynxs
shredderinstalledand
operatingattheirSydney
processingfacilitysince
2002.
Similarly,NatSteelHoldings
inSingaporeandUnited
SteelIndustrialCo.(Kuwait
Steel)appreciatedthe
importanceoftheirlong
associationwithDanieli
whendecidingonthe
supplierof,respectively,new
CIB1400-10LandCIB
1250-10Lstatichydraulic
shears.Theprominenceof
DanieliHenschelasoneof
theworldsforemost
suppliersoflargehydraulic
shearsbroughtfurtherorders
fromEnablelink, UKand
BelvtormetinMinsk,
Belarus.Aspartofanew
Nanomillprojectawardedby
ArabianGulfSteel(Taybah),
DanieliLynxswillsupplya
1,050-kWDCR1822
shredderandDanieli
HenschelaCIB1000-8L
statichydraulicshear.Asone
oftheworldsleading
technologycompanies,
Danielibringsnewsolutions
toallitsproductlines.
DuringSpring2014,a
1,050-kWDCR1822scrap
shredderplantwas
commissionedbyDanieli
LynxsforMetalesde
Navarra,S.A.(Medenasa),
Pamplona,Spain.Themain
shreddermotorrepresents
theworldsfirstapplication
ofalow-voltageinverter
driveforthistypeof
equipment.Thetechnology
wasdevelopedexclusivelyby
DanieliAutomationand
providessignificantsavings
intotalenergycosts.The
perennialproblemofpower
supplyflickerisovercome
andsignificantlysmaller
demandsaremadeuponthe
incomingpowersupply.
Othernotableproject
completionsinthisperiod
havebeenthe1,500-kW
DCR1827shredderplant
withadvancedTOCFume
TreatmentforRMBSpA,
Brescia,Italy,andthe1,050kWshredderplantforMag
Ferum,NowySacz,Polandn

DCR6290 shredder launch ceremony

at Danieli China in Changsu (DCS)

nMay29,2013,inparallelwith
theBIRconventionheldin
Shanghai,aneventwasorganized
atDCStopresentthenewlyfinished
DCR6290scrapshreddertoaselected
groupofpotentialcustomers.
Duringtheplanttour,theguestswere
showntheexcellentlevelofproduct

LiJun,EVPofDanieli
China,deliveringthe
welcomespeech.

Thegeneralsecretaryof
CAMU,LiShubin,the
EVPofDanieliChinaLi
Jun,andtheVPGlobal
SalesofDCR,Andreas

manufacturingandofproduction
managementavailableatDCS.
Theguestsexpressedadeepinterestinthe
advancedtechnicalpointsoftheshredder
(e.g.theuniquebasesectiondesign,spider
rotorwithcap,hydraulicfastenunit,
appropriatelysizedwearingparts,etc.)and
ofdownstreamsystems.Suchinterestmakes
usconfidentthatabroadmarketappreciation
willbeshown,andwillbepursuedthrough
dedicatedvisitsanddiscussions.
Furthertothepositiveresponsesofguests
atDCS,leadersoftheChinaAssociation
ofMetalScrapUtilization(CAMU)that
attendedtheceremonystatedtheirbelief
thatthelaunchofthenewshredderwell
representsthecommitmentofDanieli
totheChinesemetalrecyclingindustry,
andwillleadthemarketdemandforgreen
recyclingtechnologyn

Zoellner,cuttingthe
ribbontounveilthe
brand-newshredder
together.

QinLinsheng,Vice
ChairmanofCAMU,and
DavideBraga,Sales
ManagerofDCRpropose
thetoasttotheguests.

23

DA N

BENCHMARK PERFORMANCES
FOR AUTO SCRAP
SHREDDING FUME TREATMENT

EL

EL

DANEWS

TE

IRON & STEELMAKING

I GR EN S
E

at RMB Brescia, Italy

A new Danieli-patented system
for gas cleaning and controlling
Volatile Organic Compounds
(VOC) emissions was
commissioned successfully
this past March.

The innovative solutions

achieved all the project targets,
with total VOC emissions lower
than 5 mg/Nm3, advancing this
new technology as the new
benchmark for dedusting
systems for automotive recycling
4

heshredderatRMBtreatsamixed
chargeofscrap,includingcompacted
vehicles;forthisreasonaneedwas
identifiedforafume-treatmentplanttotreat
theVolatileOrganicCompounds(VOD).
Itshouldbenotedthattheabatementof
VOChasbecomemandatoryonlyrecentlyin
thecarrecyclingindustry,andthis
requirementinvolvesotherpollutants,too.
OnesuitabletechnologyforVOCcontrolis
oxidationathightemperature,butthis
methodisnoteconomicallyviableinthis
casebecausetheVOCconcentrationisso
lowthatitcannotsupporttheselfcombustionofVOC,thusexternalfuelmust
beusedtoincreasethefumetemperatureto
approx.900C.
Itisnotpossibletotreattheairdirectlywith
abedofactivatedcarbonduetotheriskof
watervaporcondensationfromthepretreatmentstageinvolvingawetscrubber
(whichisnecessaryfordustabatement).Dry
pre-treatmentwithabagfilterisnotfeasible
duetothepotentialfirehazard(flying
burningmaterialsmustbequenchedwith
thewatersprayedinthescrubber).
TheDanielitechnologyinvolvescontrolling
VOCwithabedofactivatedcarbonand
processingtheprimaryairflowfromthe
24

Pollutants Target Measured

values values
(mg/Nm3)
(mg/Nm3)
Dust content

10

4.5

Oil mists

10

Cr, Co, Cd, Ni, As

0.1

Pb, Mn, Cu, V, Sn

0.5

HCl

10

HF

0.2

0.01

0.001

PCB

0.1

0.001v

VOC

30

1Activecarbonboxes
2Cyclone
3Demisterandscrubber
4Bagfilter
5Burner
6Stack-Fan
Targetvaluesofthefume
treatmentplant,expressed
aspollutantsatchimney,
comparedwiththe
measuredvalues.

DANEWS 168

Danielifumetreatment
technologywithbedof
activatedcarbontocontrol
VOCatRMB,Brescia,Italy.

shredder,togetherwithasecondaryflow
comingfromtheairseparationequipment
installedatthefluffseparator.Theprimary
fumesarededustedwithacycloneandthen
withawetscrubber.Thesecondaryflowis
pre-filteredwithabagfilterandheatedbyan
externalfuelburnerpriortomixingwiththe
primaryairflow(fromtheshredder).The
temperatureofthemixedflowishigherthan
ambienttemperature,thustheriskof
condensationinthecarbonbedisprevented.
Theadvantageofthistechnologyisthata
freeflamecanbesafelyusedtoheatonlythe
secondaryflowofair,whichdoesnotcontain
VOC.Theflowrateofairtreatedbythe
activatedcarbonbeddoesnotincrease

significantlybecausethesecondaryflowis
onlyonefifth(approx.)oftheprimaryflow.
Thecombinationofthetwolines(primary
flowfromtheshredderandsecondaryflow
fromairseparationunit)iseconomically
advantageousbecauseitallowsusingonly
oneinduceddraftfanandonestackinstead
oftwo,asitwouldberequiredwithtwo
independentlines.
Theprojectwassuccessfulandallthetargets
havebeenreached,withtotalvolatileorganic
compoundslowerthan5mg/Nm3.
Duetotheinnovativesolutionthis
technologywillbecomethenewbenchmark
fordedustingsystemsforthecarrecycling
industryn
25

FLAT PRODUCTS

DANEWS

Q-WIDTH TECHNOLOGY:
PROVEN SUCCESS FOR HIGHER-FLEXIBILITY
SLAB CASTING OPERATIONS
Danielideveloped
the3Qprocess
technologiessuite
toaddressthree
criticalprinciples:
deliveringhighest
productQuality,
intherequired
Quantity,with
theQuickness
ofresponse
requiredfortodays
castingmachines.

-WIDTHisa
combined
mechanicaland
softwaresolutionthatmakes
itpossibletochangetheslab
widthwithoutinterrupting
theoperationoftheslab
caster,therebyprovidingthe
casteroperatorwith
maximumoperational
flexibilityinlinewith
customerrequirementsand
theproductionschedule.
Itiswellknownthatproper
controlofthetaperminimizes
theriskofexcessivenarrow
sidebulginganddepressions
intheslabcornerarea,
whichultimatelywillleadto
productdown-gradesoreven
rejections.Q-WIDTH
addressestheseissuesby
continuouslyadjustingthe
narrow-sidetaperaccording
toslabwidth,castingspeed,
steelchemistry,andsuper
heat.Hence,Q-WIDTH
ensureshigh-productquality,
26

whilstmaximizingcaster
availability.Q-WIDTH
utilizesstate-of-the-art
technologytoachievethe
narrow-facetaperand
positionaccuracyrequired.
Theelectro-mechanical
systemconsistsofahighcapacityrollerscrewjackin
eachadjustmentram,fitted
withagearboxtodrivethe
narrow-sideassembly
forwardandback.Aposition
transducer,insidetheroller
screw,andanencoderonthe
gearboxprovidetheaccurate
positionmeasurementofthe
narrowsideassembly.The
drivecomesfromanelectric
motorfittedtoit,positioned
eitheroffthemoldor
integratedintothemold.
Thisarrangementguarantees
thatthesystemwillnotbe
affectedbyanymechanical
backlashand,asthesystem
isequippedwithastationary
brakingdevice,any
movementscannottake
placeifnotrequestedby

Q-WIDTH.Comparedtoa
hydraulicsystem,QWIDTHhastheadvantage
ofnotlosingitspositioneven
intheeventofapoweror
electricalfailure.Duringa
slabwidthchanges,the
controlsoftwarewillconduct
real-timecalculationsofthe
optimalnarrow-sidetaper,
considering castingspeed,
narrow-sidewidthadjustment
speed,andnarrow-sidewidth
adjustmentacceleration.
Basedonthiscalculationthe
movementofthemold
narrowfacesisacombination
oftranslationandrotation,
whicheliminatestheriskof
anairgapbetweentheslab
shellandthemoldnarrow
sidecopperplates.QWIDTHisaproven
technology,astestifiedbythe
resultsrecentlyachieved
duringperformance
guaranteetestsatTangshan,
P.R.ofChina,and
ArcelorMittalTubaro,Brazil,
whereawidthchangeofup

to300mmwasachievedina
singlestep.Q-WIDTHcan
beappliedtonewcasting
machinesorretrofittedto
bothconventionalslab
castersandthinslabcasters,
workinginatypicalrangeof
castingspeedsfrom0.5-7.0
mpm.Sincethereisno
limitationforcastingspeed,
thewidthchangecanbe
operatedinanycondition
thatallowsoptimizingthe
taperedslablength.The
projectpaybackperiodis
typicallylessthan12months,
withthefollowinganticipated
benefits:
>Increasedflexibilityin
satisfyingtheproduction
schedule;
>Improvedslabqualityand
shape;
>High-speedwidthchange,
reducingdownstreamyield
loss;
>Reducedmachinedown
time;and
>Reducedpotentialfor
breakoutsn

THE COMPREHENSIVE RANGE OF 3Q TECHNOLOGICAL PACKAGES

>Q-LEVEL+foraccuratemoldlevelcontrol
system;
>Q-MAPformoldthermalmonitoringsystem;
>Q-INMO+highestquality,lowmaintenance
hydraulicoscillator;
>Q-COOLthehigh-efficiencydynamic
secondarycoolingtechnology;
>Q-COREfordynamicsoftreduction;
>Q-WIDTHmoldwidthadjustmentsystem;
>Q-PULSEtheinnovativesystemforliquidpool
endpointmeasurement;
>Q-MIXmodelcalculatesinrealtimethe
chemistryofthesteel;

>Q-MODmonitorsthemoldoscillatormovement
performanceduringproduction;
>Q-OPTIMUMisDanielisuniquesegment
design,todelivertheultimateinoperational
performance,withreducedmaintenance.
>Q-ARTisacomputer-basedcastproduct
qualityassessmentsystem
>Q-ROLLisbasedonlong-standingexperience
incasteroperationandmaintenance;
>Q-CUTmaximizesthequantities
ofprimequalityslabs.

DANEWS 168

1 TypicalQ-Widthassembly.
2 Narrowfaceplatemovement
positionduring50-mmwidth
decreaseandincrease.
3 SchematicdiagramofQWidthequipmentfittedtothe
mold.
4 ExampleofMWAtests
performedatTangshan,P.R.
ofChina,andArcelorMittal
Tubaro,Brazil.Width
increaseanddecrease(per
strand).

Motor 1
Right top

Motor 3
Left top

Reduction
gear

Number of MWA test

Resolver brake
90
80
70
60
50
40
30
20
10
0

85

52
45
32 34
21 23
16

TOTAL

11 14

12

3 2
INCREASE DECREASE

Motor 2
Right bottom

Strand 1
Strand 2

74

4 5

4 4

6 3

INCREASE DECREASE INCREASE DECREASE INCREASE DECREASE INCREASE DECREASE

0-49 mm

60-99 mm

100-199 mm

200-300 mm

Motor 4
Left bottom
4

27

FLAT PRODUCTS

DANEWS

WITHIN THE LONG-TERM

COOPERATION
ESTABLISHED BETWEEN
DONGBU AND DANIELI,
THE PAPER UPGRADE
TO FOURTH GENERATION
OF THIN SLAB CASTER
WAS JOINTLY PRESENTED
AT THE AISTECH2013
CONFERENCE
IN PITTSBURGH (PA).

28

DANEWS 168

SUCCESSFUL STARTUP OF THE

FOUTH-GENERATION THIN SLAB CASTER
at Dongbu Steel, Korea

SAE1008M (LC) - 4.3%

SPHC (LC) - 42.7%
SPHT2 (LC) - 2.4%
SPHT3 (LC-HSLA) - 2.4%
API X52 (LC-HSLA) - 0.9%
SS400 (MC) - 17.7%
API J55 (MC) - 2.0%
SS490 (MC-HSLA) - 1.3%
JS 45C (HC) - 0.7%
SPECIAL STEEL (HS, VAG) - 18.9%
CHECKER PLATE - 6.7%

hestepsperformedinthismachine
modification,aswellasthefinal
resultsachievedbyDongbuSteel,
werejointlyexhibitedastheaccomplishments
ofthehigh-speedcastingandhighquality
targets,amodelforfastandreliablecaster
upgradesandtuningofthefourthgeneration
fTSC.Danielistechnologicalpackageswere
fundamentaltoachievingtheproduction
targets,aswellasthehighest-qualityproducts.
Inparticular,twoofthesepackageswere
furtherdevelopedspecificallyfortheDongbu
project:theMouldBreakoutPrevention
SystemwithThermalMapping(Q-MAP),
andtheAdvancedMouldLevelControl(QLevel+).TheQ-MAPmappingviewerwas
improvedandthealgorithmsforfasterand
morereliabledetectionofdefectswere
furtherdeveloped,customizedtoaddress
specificcustomerdemands.Furthermore,
theQ-Level+wassuccessfullyimplemented
forhighlyaccurateperformancesinmold
levelcontrolandleveldiagnosticsat

Thepaperdescribes
theachievements
ofthelatestDanieli
TSCtechnology
andtestifiestothe
factthathardwork,
flexibility,and
acooperativespirit,
arethekeysto
achievinghigh-end
resultsandcustomer
satisfaction.
KwangYeolKim,VPofDongbu,
SuperintendentofHotRollingMills,
DangjinWorks;YoonJaeLee,
TechnicalDirector,DanieliDavy
Distington.

maximumcastingspeed,andevenadopting
doublesensor(radioactiveandeddycurrent
type)monitoring.ThetwoDanielifTSCflexibleThinSlabCasterscommissionedin
2009arecurrentlyproducingawidevariety
ofsteelgrades,spanningfromlow-carbon
gradesforhigh-qualitygalvanizedproducts
(DongbuSteelisthemarketleaderinKorea
forcoldrolledproducts),toAPIJ55for
casingandX70gradesforpipeapplications.
High-carbongradesareproducedinarange
ofcarboncontents,from0.35%to0.85%.
Dependingonmarketdemand,thehot
complexexceeds190,000-200,000tons
permonthofHRcoilsproduced,smoothly,
andwiththehighestqualitystandards.
DongbuSteelpreviouslyexpressedits
satisfactiontoDanieli,highlighting
theattainmentofthetargetsthatwere
theresultofthemutualcooperation
betweenbothparties.Andco-operationstill
continues,targetingmoreandmorenew
achievementsn
29

FLAT PRODUCTS

DANEWS

COMMISSIONING OF NEW STEEL GRADES

FOR 350-MM THICK SLABS
at Yingkou. P.R. of China

roducersofsteel
platefacean
increasingdemand
forhigh-quality,highthicknessplateproducts.
TheYingkouslabcaster,
withits11-mradiusandthe
abilitytocastslabsfrom
250upto350mmthick,
wasdesignedtomatchthis
requirement.Currentlythe
casterisinthetuningphase,
inordertosolidifythe
achievementofdefect-free
productsthatcanberolled
withoutpriorconditioning.
Toaddressthemarkets
expectations,prioritywas
giventotheproduction
ofthehighestthickness
(350mm)andthewidest
dimensions(2,000-
2,200mm.)
Theproductmixconsists
ofabout80%ofmediumcarbonandmedium-carbon
HSLAsteelgrades,asmall
amountofspecialsteel
grades,andabout18%of
high-carbongrades.
Ofparticularinterestamong
themedium-carbonsteel
gradesisthecastingof
boron-addedsteelgrades.
Itiswellknownthatsteels
gradeswithboronaddition
areextremelysensitiveto
cracking.Particularattention
hastobepaidtocorner
cracks.Itiscrucialto
preventedgetemperatures
fromfallingintorangesin
whichthereisareduction
ofductilityofthematerial,
therebypromotingcrack
formation.Theapplication
ofthepropercoolingstrategy
isfundamentaltoobtaining
aproductfreefromdefects.
Forthesecondarycooling
systemoftheYingkoucaster,
eachloopiscapableof
30

2
1 Internalqualityachieved
intermsofcracksand
segregationisatthe
highestlevel.
2 InspectedslabofMC
B-addedslabof350
mmthickness,no
subsurfacedefects
found.
3 Dimensionaltolerances
areeasilywithin
contractuallimits,in
particularthebulging
ofthenarrowfaceisless
than4mm,acritical
pointforthehigh
thicknessslabs.
3

independentflowcontrolfor
eachwidth,ensuringinthis
waypropertemperaturefor
anycastingcondition.
Asresultoftuningactivities
ithasbeenpossibletoobtain
medium-carbonboron-added
slabsfreefromsurface
defects.
Dimensionaltolerancesare
easilywithincontractual
limits,inparticularthe
bulgingofthenarrowface,
acriticalpointforthehigh
thicknessslabs,islessthan
4mm.
Anotherfundamentalaspect
toconsiderwhenproducing
slabsforplateapplicationsis

theinternalquality.Applying
softreductioninthecorrect
positionisacriticalpointto
achievetherequiredinternal
soundness.Softreduction
andsecondarycoolingare
controlledbyamathematical
modelcalculating
temperatureacrosstheslab
width,regulatingwaterflow
andsoftreductionendpoint.
Toverifyaccuracyandtune
themodelwhennecessary,
agreatcontributionismade
bytheDanieliQ-Pulse
system(patentpending)
thatdetectsandconfirms
theendoftheliquidcone.
Intermsofcracksand

segregation,theinternal
qualityisatthehighestlevel.
Productiontuningactivities
arestillinprogressbut
resultsobtaineduptonow
provetheYingkoucaster
capableofmeetingthemost
demandingrequestsinthick
slabcastingn

DANEWS 168

Hot strip mill innovations

to enhance rolling operations
in North America
Newguillotine-typecropshearfortransferbar

A SUCCESSFUL
HOT STRIP MILL
UPGRADE PROJECT
IN THE USA
PRESENTED
AN OPPORTUNITY
TO DEVELOP TWO
INNOVATIVE
SOLUTIONS,
FOR TRANSFER BAR
CUTTING AND FOR
THE WORLDS FIRST
AUTOMATIC
SAMPLING STATION,
MAKING IT POSSIBLE
TO EXTEND THE
MILLS PRODUCT
RANGE TO INCLUDE
HIGH-STRENGTH /
HIGH-THICKNESS
PRODUCTS.
Fromtop:GuillotineshearpreassembledatDanielisworkshops.
Saw-typesamplingstationpreassembledattheDanieli
workshop,andinoperationinline.

Theshearoperatesinconjunctionwith
anexistingrotarydrumcropshearsoas
toincreasetherangeofproductscutupto
3in.transferbarthicknessforAPIX80grade
strip.Thiswillmakeitpossibleforthehot
stripmilltoprocesshigh-strength,1-in.thick
APIX80linepipegrades,whilemaintaining
theabilitytoprocessallofthecurrentproduct
mix.
Thetransferbarsrangeinsizefrom1.5to
3in.inthickness,and24to78in,inwidth,
andhaveaminimumtemperatureof900C.
Theguillotineshearsquaresofftheheadend
ofthetransferbartoimproveitsinletinto
thefinishingmill.Theshearisadown-cut
leverdesignwithhydraulicactuators,
designedwithahydraulicsynchronization
system.Hydraulicsynchronizationofthetwo
sidesoftheshearisperformedthrougha
closed-loopcontrolusingthehydraulic
cylinderlineartransducersignals.Theentry
pinchrollisprovidedtoclampthetransfer
barduringthreadingandcutting,
respectively.Themachineiscompletedwith
entrypinchrollsandknife-changing
mechanismsforquickremovaland
replacementofshearknivesandpinchrolls.
Worldsfirstautomaticsamplingstation
forAPIX80,1-in.stripthickness

Thenewautomaticsamplingstationarea
consistsofacoilloadingstation,coiltransfer
car,unbandingmachine,sawdisk-typeshear
withpeeler,circumferentialandradial
strappingmachines,coilremovablestation
andscrapandsampleevacuationequipment.
Thisnew,compactmachineisabletocut
scrapsandsamplesfromhigh-resistancecoils
of0.31to1in.thickand24to78-in.wide
strip,insemi-automaticmode,consistently
reducingthecompletecycletime.
Thecuttingisdonebyacarbide-tippedsaw
disk.Samplesarecollectedinautomatic
modeinamovablebasketinanordinate
sequence.Theperformancetestwas
completedsuccessfully,confirmingthe
soundnessofDanielisinnovativeconcept
forboththeguillotineshearandthesaw-type
samplingstationn
31

FLAT PRODUCTS

DANEWS

PLATE / STECKEL MILL UPGRADE TO ACHIEVE

BETTER QUALITY AND HIGHER PRODUCTIVITY
at JSPL Raigarh, India
On July 25, 2013,
Jindal Steel and
Power Ltd. and
Danieli agreed to
a contract for the
supply of design,
engineering, and
equipment supply
to upgrade the
existing JSPL
plate/Steckel mill
plant, a project that
will increase the
finished product
quality as well as
the mill capacity
from its current
production to
1.2 Mtpy.

indalSteelandPowerLtd.
(JSPL)isoneofIndia's
largeststeelproducers,
withasignificantpresencein
mining,powergenerationand
infrastructuresectors.JSPL
hasasteelmakingplantat
Raigarh,Chhattisgarh,that
featuresdownstreamathick
slabcasterandaplate/Steckel
milltoproduce3.5mwide
platesandcoilsof3mwidth.
Thisisanoldplate/Steckelmill
thathasbeenrelocatedto
Raigarh,startingitscurrent
commercialproductioninApril
2007andhavinganactual
productioncapacityof1Mtpy.
32

Projectfeatures
Toensuretheproductivity,
reliability,consistencyandthe
satisfactoryoperationofthe
existingplant,themain
objectivesoftherevampare:
>Supplynewdrivemotors(2x
7,500HP)withbaseframes
andbearingsforthe4-high
finishingSteckelmillstand,
andrelocatedexistingdrive
motors(2x5,000HP)with
baseframesandbearingsto
the2-highmill.
>Generalrefurbishmentofthe
4-highmillstandto
accommodatenewmillentry
anddeliverystrippersand
guides,newWRheavybending
system,existingHAGCwith
newservovalvesandbuilt-in
electronics,newrollbite
lubricationsystem,newWR
ThermalCrownControl(RTC),
newdustsuppressionsystem,
newon-boarddescaling
system,andintermediate
laminarcooling.
>ImplementationofDanielis
patentedfullyautomatic
AcceleratedCoolingsystem,
tooperateaccordingtothe
laminar-flowprinciplewithlowpressurewatertocoolthestrip
/platescomingfromthemill,
andalsotoimprovethe
mechanicalcharacteristics

ofthethermo-mechanical
rolledplates.Anedge-masking
functionisprovidedtoprevent
plateedgeovercooling.
>Installationofapowerful
Danielidowncoiler,customdesignedtocoil25.4x2,500mmstripinAPIX80grade,
matchingtheextremerolling
conditionsandthedemanding
requirementsofcoilingspeed
andstripformationforthose
oil-and-gasproducts.Three
wrapperrollsprovideexcellent
tensioncontroltoprevent
telescopingcoils.
>Additionofacompletecoil
handlingsystemwithin-line
facilities(suchas
circumferentialandradial
strappingmachine,weighing
andmarkingmachine)aswell
asoff-linesamplecollecting
andinspectionline.
>Implementationofanew
automationsystemforthemill
zoneandforthenew
equipment,providedbyDanieli
Automation.

expertisewithrevampprojects,
encompassingtheabilityto
analyzealltherequirements
andthepossiblecritical
aspects,andtocustomizeand
optimizetheproposal,also
respectingtheneedto
minimizethe
intervention/modificationand
theplantshutdown.So,it
shouldreiteratetheincreasing
confidencesharedbyflatproductsproducersworldwide
inDanielisreliability,including
theIndianmarket,where
previousinterestingand
challengingupgradeprojects
(Bokarohotstripmill,and
JSPLRaigarhplate/Steckel
millatglance)havebeen
awardedtoDanieliduring
recentyears,beyondturnkey
completeplantslikeNMDCs
QSP-2andSAILRSPs
platemilln

Theproposedsolutionthus
incorporatesoptimalplant
configurationandlayout,taking
fulladvantageoftherationality
ofmaterialhandlinginthe
plant.Infact,thisorder
confirmstheDanieliteams

SarojJain,President
(Projects)ofJSPLand
MatteoBulfone,Product
ManagerofDanieliWean
United,exchanging
contractdocuments.
Right:The4-highfinishing
Steckelmillstandasitis
now,beforetheupgrade.

DANEWS 168

DANIELI SKIN-PASS MILL INAUGURATED

at SAIL Bokaro CRM III, India

hisstate-of-the-artskin-passmill-the
firstunittobeinauguratedatthe
BokaroCRM-IIIcomplex-will
processabout860,000tpyofcoldrolled
annealedcoils(stripthicknessof0.25to2.0
mm;stripwidthof800to1600mm)ata
maximumspeedof1,200mpminawide
spectrumofgrades(CQ,DQ,DDQ,EDDQ,
HSLA,IF,BH,etc.,withyieldstrengths
from140to400N/mm2)targetingthe
automotive,whitegoods,andappliance
sectors.ThisSPMwillbeabletoprocess
verysoftmaterials,likeIFgrades,andvery
high-strengthsteelswiththenecessary
elongation,hardness,flatnessandstrip
roughnessstandardsrequiredmainlyfor
automotiveapplications.Designedasan
elevatedmillstructurewithstripflowfrom
lefttoright,itconsistsmainlyofthe
followingequipment:
>Entrysection,includingwalking-beam
conveyors,downcoilers,coilcars,coilpreparationstation,payoffreelwithpupcoil
removalsystem,entrybridleunit,automatic
de-bander,etc.
>Millstandequipmentconsistingofmill
standwithrolls,chocksandbearings,
bendingblocks,quickwork-rollchanging
device,hydraulicwedgeforpass-line

ON JANUARY 18,
2013, C.S. VERMA,
CHAIRMAN OF
STEEL AUTHORITY
OF INDIA LTD.,
INAUGURATED
INDIAS MOST
ADVANCED SKINPASS MILL,
A STATE-OF-THEART LINE SUPPLIED
BY DANIELI FOR THE
1.2-MTPY CRM III
NEW COLD ROLLING
MILL COMPLEX.

adjustment,backuproll-changesystem,wet
skin-passingheadersandnozzles,anti-crimp
roll,cobbleguards,rollpolishingdevice,etc.
>Deliverysectionconsistingofstripblow-off
unit,thicknessgauge,shapemeterroll,
hydraulicshear,electrostaticoilerunit,
tensionreel,beltwrapper,exitcoilcar,
bandingmachine,andexitwalking-beam
conveyorsystem.
Danielisscopeofsupplyalsoincludedallthe
auxiliarysystems(hydraulic,pneumatic,
lubrication,fumeanddustextractsystems,
etc.)andcompleteelectricalandautomation
systems,whichwereimplementedbyDanieli
Automationn

Fromleft:T.Suresh,Director,Projects,SAIL;H.S.Pathi,
Director,Personnel,SAIL;S.S.Mohanty,Director,Technical,
SAIL;C.S.Verma,Chairman,SAIL;A.Maitra,CEO,BSL;
UmeshKumar,ED(Projects),BSL.

33

FLAT PRODUCTS

34

DANEWS

DANEWS 168

FINAL ACCEPTANCE FOR SKIN-PASS MILL

at Risse + Wilke, Germany

heRuhrareaisknownasthe
birthplaceofthecoldrollingindustry
inGermany,and10%ofGermanys
totalcold-rolledsteelstripoutputissupplied
byRisse+Wilke,locatedatIserlohninthe
heartoftheRuhrregion.Thecompanyhas
about350employees,withanannualturnover
of160MEuro.45%oftheoutputisdedicated
totheautomotiveindustry,andtheremaining
55%toawideselectionofapplicationsfor
othercustomers.Anexampleofthecompanys
specialproductswithuniquefeaturesare
ultra-hardsawblades,suppliedtoBrazilfor
largechainsawsusedtoharvestlumber,orto
Italianstonequarriesforsawstocutmarble
blocks.MostoftheseproductsgetafinalCR
passonthenewDFskin-passmill,designed
forsteelgradesrangingfromcarbonsteelup
tohigh-strengthmicroalloyedsteel,ata
maximumstripwidthof820mmandstrip
thicknessbetween0.2mmand6.0mm.
Themillisacombined2-high/4-high
configuration,forstripelongationand
reductionrangingfrom0.2%and15%,using
eithera2-highor4-highrollstack.Special
constraintsfortheequipmentdesignhave
beenfollowedclosely,togetherwiththe
customer,asthenewmillwasinstalledinan
existing buildingandinfrastructure.
Specialfeaturesofthemill

>Top-mountedHAGCcylinderswithlow
hysteresisforhighlydynamicroll-gap
adjustmentandthicknesscontrol.
>4-highworkrollsequippedwithpositive
andnegativerollbendingtoallowawide
productmixatareducednumber
ofdifferentrollcrowns.

IN MAY 2013
RISSE + WILKE
SIGNED THE FINAL
ACCEPTANCE
CERTIFICATE FOR
THE 2-HIGH/ 4-HIGH
SKIN-PASS MILL.
THE EVENT MARKED
THE SUCCESSFUL
COMPLETION
OF THE LARGEST
INVESTMENT
IN THE HISTORY OF
RISSE + WILKES.
THIS PROJECT ONCE
AGAIN SHOWS THE
STRONG MARKET
POSITION OF
DANIELI FRHLING
FOR NARROW
SPECIAL STEEL
ROLLING MILLS

>Twin-drivegearboxforseparately
controlledtopandbottomrolls.
>Dryrollingandminimumlubrication
rollingmode.Theminimumlubricationuses
aspecialdesignforconstant,reproducible
applicationofverylowquantitiesofoilonto
thesurfaceofthestrip.Thesystemuses
pressurizedairtoatomizethelubrication fluid
tothesmallestdrops.Additionally,theair
buildsupachanneltoavoidfluidparticles
splashingtosurroundingareas.
>Rollpolishingunits,usingDFinnovative
designfordryandwetpolishing.Fordry
polishingthedustparticlesarevacuum
exhaustedandaircleanedbyahighefficiencycyclonefilter.
>Completelyenclosedhousingforthecore
equipment,forincreasedsafetyatworkand
compliancewiththestrictGermannoiseand
fumeemissionregulations.
>Fullyautomatedmanipulatortoremove
pupcoilsfromthepayoffreel,forfastcoil
changesequenceandhighyield.
ThemillisequippedwithACdrives
ofatotalinstalledpowerof1.6MW.Special
attentionispaidtosustainable,energyefficientdesignbynetregenerativedrives
withminimizedharmonicfeedbackand
adjustablereactivepowercompensation,as
wellastomotorsofthehighestefficiency.
Theautomationsystemprovidesastate-oftheart,real-timecontrolsystemwith
automaticthickness/elongationcontrol
andadditionalstripprofilemeasurement.
Thelinewasofficiallyinauguratedduring
thispastspring,andsincethenhasbeen
operatingatfullproductionn
35

FLAT PRODUCTS

DANEWS

NEW 500,000-TPY PUSH-PULL PICKLING LINE

at Abul Khair Steel, Bangladesh

nJune13,2013,DanieliIndiaLtd.
signedacontractwithAbulKhair
StripProcessingLtd.fordesign,
engineering,supply,andinstallationofa
500,000-tpypush-pullandsemi-continuous
picklingline,tobeinstalledattheAbul
KhairSteelfacilityinKadamrasul,Sitakund,
Chittagong.
Thisnewpush-pull/semi-continuouspickling
lineisonepartofastrategiccapacity
expansionprojectbyAbulKhairforitsflat
productproductionfacilities.
Danieliisresponsibleforsupplyingthe
entiremechanical,electricalandcontrol
systems.Accordingtoitswell-proven
strategy,Danieliwillmanufacturethe
mechanicalequipmentatitsownworkshops
inItaly,Thailand,China,andIndia.Thefirst
coilfromthislinewillbeproducedwithin
10.5monthsofthecontractseffectivedate.
Thelinewilltreatlow-carbonsteelswith
max.UTSof550N/mm2,andYSof170to
400N/mm2,atmax.processspeedof200
mpm.Stripthicknessandwidthwillrange
from0.8to4mm,andfrom800to1,270
mm,respectively.Thisstate-of-the-artPPPL
willhaveadouble-passentrysection,a
stitcherforsemi-continuousoperationto
processthinnerstrips,aDanieliTurboflow
acid-picklingsection,sidetrimming,and
recoiling.Theelectricalandautomation
systemsuppliedbyDanieliAutomationwill
bebasedonstate-of-the-arttechnologyand
widelyacceptedindustrystandardsinorder
toensurereliability,user-friendlinessand
easeofmaintenance.Easylinediagnostics

36

PPPL TECHNOLOGY
HIGHLIGHTS
> ECONOMICAL
PLANT SIZE FROM
1.0 MTPY DOWN
TO 0.25 MTPY.
> ABILITY TO
PROCESS MUCH
HEAVIER GAUGES
COMPARED
TO CONTINUOUS
LINES, UP TO
16.0 MM.
> HIGHER
FLEXIBILITY IN
OPERATION
COMPARED WITH A
CONTINUOUS LINE.
Photographofthecontract
signingonJune13,2013,
atChittagong.Fromleft:
WazadandMukesh
AggarwalfromAbulKhair,
SanatBhaumik,
MassimilianoSvetina,
SudiptaRayandSiddartha
BanerjeefromDanieli.

willbeanintegralpartoftheoverallsystem
architecturedesign,providingtheoperators
withinformationneededtotakequickand
decisiveaction.Fromthemainpulpitonthe
HMIscreen,allthemachineoperationsand
set-upvaluescanbemonitoredand
supervisedbytheoperator,whichhelpsto
simplifyoperationoftheline.
Thisplantisexpectedtobeprocessingstrips
bythemiddleof2014,estabilishinganew
benchmarkforDanieliinthemarketofsuch
push-pullpicklinglinesinBangladeshand
neighboringcountries.Oneofthemain
highlightsofthelinewillbeitsabilityto
processultra-thinhotrolledstripsdownto
0.8mm.Withproductionofthinnerand
thinnerhotrolledstripsbymodernthinslab
castingandrollingplants,demandsforsuch
innovativepush-pull/semi-continuous
picklinglineswillcontinuetorisefrom
customersinthesteelsector.Suchlines
willsupplynotonlypickledcoilstocold
rollingmillsbutalargenumberofHRPO
coilstohotskinpassmillsforskin-passed
HRPOcoilsn

DANEWS 168

37

FLAT PRODUCTS

DANEWS

ORDER FOR SIX STRIP FINISHING LINES

from Abul Khair Steel, Bangladesh

Maindataofthefiverecoilinglines
Material

CR LC steel coils

Thickness

0.09 - 0.4 mm (for line nos. 1 &2);

0.20 - 1.0 mm (for line nos. 3 & 4);
0.25 - 2.5 mm (for line no.5)

Width

650 to 1,250 mm

Coil data

ID: 508 mm, OD: 2,000 mm (max)

Weight: max 25 t, PIW: max 20 kg/mm

Line speed

600 mpm max

Line functions

Uncoiling, edge trimming, top and

bottom side inspection, coiling, coil
strapping and weighing, spool loading /
unloading, etc.

Maindataofthecut-to-lengthline

bulKhairStripProcessingLimited
(AKSPL) isanewlyestablishedmetal
stripfinishingplantfortheAKGroup
inBangladesh,plannedtoproduceawide
rangeofsteelproductslikeverythincoldrolledcoils,galvanizedplainandcorrugated
sheets,color-coatedplainandformedsheets,
etc.Becausetheminimumthicknessofcoldrolledorgalvanizedsheetswillbeaslowas
0.09mm(90m),AKSPLneededvery
specialfinishinglineequipmenttoensure
properedgetrimmingatveryhighspeeds(600
mpm), shearingandproducingthefinished
coils/sheetswithoutanyscratchmarkson
thestripsurfaces.Beingimpressedwiththe

ContractsigningonAugust23,2013.Fromleft,from
AbulKhair:ZakirAhmedSuman,DeputyManager,
SupplyChainManagement,MukeshAggarwal,
DeputyGeneralManagerFlatProject,A.N.M.Wazed
Ali,GeneralManager,SupplyChainFunction;for
DanieliChinaDNFBU:ZhangChang,EVP,and
HuangZhenyan,SalesManager.

38

AbulKhairSteel
Limitedisan
affiliateofAK
Group,whichisa
oneofthelargest
Bangladeshi
industrial
conglomerates.
AKGroupwas
establishedin1953
byAbulKhair,
apioneerinthe
privateindustrial
sector.Themarkets
servedbythis
conglomerate
includecement,
steel,consumer
goods,tobacco,
foodproducts,etc.

Material

LC steel coils, cold rolled,

galvanized and color-coated

Thickness

0.2 to 2.0 mm

Width

750 to 1250 mm

Coil data

ID: 508 mm, OD: 2,000 mm (max),

Weight: max 25 t, PIW: max 20 kg/mm

Line speed

100 mpm max

Line functions

Uncoiling, leveling by 6-high, 21-roll

leveler, shearing by double eccentric
flying shear, stacker for 4-m-long sheets

state-of-the-artequipmentproposed,AKSPL
selectedDanielitosupplythesefinishing
lines.OnAugust23,2013DanieliAKV
ChinasignedacontractwithAKSPL
coveringthedesign,engineering,supply,
andinstallationofsixfinishinglines(five
recoilinglinesandacut-to-lengthline)
tobeinstalledatitsflat-rollingfacilityin
Kadamrasul,Sitakund,Chittagong.
Thecontractforthesestate-of-the-art
finishinglinesisonestepofastrategic
capacityexpansionprojectforAbulKhair
atitsflat-productfacilitiesinChittagong.
Danieliisresponsiblefortheentire
supplyofthemechanical,electricaland
controlsystems.AsperDanieliswell-known
strategy,manufacturingofallmechanical
equipmentwillbedoneinDanieli
workshopsinChina.Thefirsttworecoiling
linesandthecut-to-lengthlineareexpected
tobeoperationalbythethirdquarter
of2014,creatingalandmarkfor
Danieliinthemarketofsuchfinishinglines
inBangladeshandIndian

DANEWS 168

New bonderizing line

at Wlzholz New Material (Taicang), P.R. of China

THIS IS ANOTHER
HALF TURNKEY
PROJECT
ASSIGNED TO
DANIELI CHINA.

nJune17,2013,
WlzholzNewMaterial
(Taicang)Co.,Ltd.and
DanieliChinasignedanorder
forinstallinganewbonderizing
lineatitsproductionsitein
Taicang,JiangsuProvince.The
scopeofthecontractcovers
thedesign,manufacturing,
installation,andcommissioning
ofthestripprocessingline,a
processalsoknownas
phosphatingorphosphatizing.
WlzholzNewMaterial
(Taicang)Co.,Ltd.isawholly
ownedsubsidiaryofGermanys
CDWGroup.AtCDWmorethan
180yearsofexperiencein
workingwithsteeliscombined
withmoderntechnology.Today
thecompanyisamarketleadingsupplierofsteel
productsforcomplex
applications,worldwide.
Bonderizedsteelstriphas
someexcellentproperties:itis
capableofextrememetal
formingwithminimaldrawing
stepsandwithoutintermediate
annealing,forallendproducts.
Thenewbonderizinglinewill
bedesignedtoproduce650mmwidecold-rolledsteelstrip.
Thelinesprocesstechnology
includesatravellingshearto
cutoffthestitcheswithout
stoppingtheline.Thefinished
stripcanberecoiledeitherto
thetoporthebottom.Thisline

ispartofthesecond-phase
expansionprojectatWNM,by
whichthecustomeraimsto
produce70,000tpyoftreated
material.Thecontractshows
theconfidenceofan
internationallyrenowned
customerinDanieliChina
regardingthehigh-quality
engineering/manufacturing,
andfast,reliableexecutionof
theproject. Italsoopensthe
doortofuturecooperation
betweenthetwocompanies
worldwiden

Top:WaelzholzNewMaterial(Taicang)
worksite.Left:JuergenJentsch(right),
GeneralManagerofWaelzholzNew
Material(Taicang)andZhangChang,
EVPDanieliChinaNonferrous
BusinessUnit,shakehandsafter
signingthecontract.

39

LONG PRODUCTS

MA STEEL

DANEWS

FINAL ACCEPTANCE FOR ROUND BLOOM CASTER

at Maanshan, P.R. of China

nMay2013,Danielisuccessfully
completedtheperformancetestsonthe
conticasterforroundblooms,andthe
FinalAcceptanceCertificatewasreleased
withthemutualsatisfactionofthe
equipmentbuilderandthecustomer.The
15-mradius,five-strandcasterisdesignedto
produceupto800,000tpyof380-,450-,and
600-mmbloomsinhigh-qualitycarbonand
alloyedengineeringsteels.
Thecasterisfedwithliquidsteelfrom120-t
ladles,andfeaturesallthetechnological
packagesneededtoachievetop-levelquality
products.Around50%oftheoutputisused
toproducerailcarwheels,whilethe
remaindergoestowardfabricationofrings,
pipes,spring,tirecord,andbearings.
Anexampleoftheexcellentqualityresults
achievedispresentedinthefollowing
table,concerningsixheatsofC50Mntrain
wheelsteeln

Equiaxial
zone

Max.difference
ofCcontent

Carbon
segregation

Guarantee
figure

55%

0.03max.

1.06

heat 1

60%

0.03

1.04

heat 2

56%

0.03

1.00

heat 3

56%

0.03

1.05

heat 4

55%

0.02

1.05

heat 5

56%

0.02

1.02

heat 6

55%

0.01

0.96

40

1 Macroetchofa380mmroundbloom,steelgrade16Mn.
2 Macroetchofa600mmroundbloom,steelgradeIDC35E.
3 Exampleoftheexcellentqualityresultsachievedforthesteelgrade
C50Mn.

DANEWS 168

Finalacceptance
ofbillet
andbloom
conticaster
atGerdauSSNA
(MI),USA

Final acceptance for the new

conticaster
for large round blooms

FOLLOWING
AN EXCELLENT
STARTUP,
THE PROVISIONAL
ACCEPTANCE WAS
RELEASED IN JUST
FIVE DAYS, ONLY
29 DAYS AFTER
THE FIRST HEATS
OF ALL GRADES FOR
ALL SECTIONS WERE
SUCCESSFULLY
TESTED AND
APPROVED.

hisnewfour-strand,
10-mradiuscaster
(alreadyreadyfor
expansionwiththe
additionofafifthstrand),
iscapableofcasting6-in.
and7-in.roundbilletsof
254-and325-mm
diameter.Itstarted
operationinNovember
2012,andtheFinal
AcceptanceCertificatewas
signed,withtotalcustomer
satisfaction,onMay13,
2013.Thissuccessful
accomplishmentrepresents
anotheradvancementfor
bothDanieliandGerdau.
Phase2oftheproject
beganinAugustand
includesinstallation
ofanewtwin-tankvacuum
degasser(VD)stationwith
amechanicalpump
system,andaconversion
oftheexistingVAD,for
serviceasaladlefurnacen

SouvenirphotoaftersigningtheFAC.
Fromleft:L.Pontoni,Danieli
Erection&CommissioningEngineer;
U.Pupp,EngineeringManager;
K.El-Rassi,andC.Andre,Meltshop
Sr.ProcessEngineers,forGerdau.

at Baosteel Nantong, P.R. of China

hegreatspiritofcooperationand
teamworkestablished
betweentheDanieliand
Baosteelteamshavebeen
vitaltothesuccessachieved
inthechallengingtaskof
bringingthisnew
conticastrertoitsfull
performancecapability.
Infact,only29daysafter
thefirstheatallgradesforall
sectionshadbeentestedand
approved.Asaresultofthis
remarkablework,theFinal
AcceptanceCertificatewas
releasedonFebruary27,
2013,withmutual
satisfaction.
Thefour-strandcaster
produces300-,370-,430mmroundbloomsinlowandmedium-carbonand
alloyedsteels,forfinal
applicationsintubingand
casing,tubesforhighpressureboilers,machinery,
gascylinders,petrochemical,
andpipelineapplicationsn

SigningoftheFAC,fromleft:ChenKaijun,BaosteelCommercialManagerof
EngineeringEquipmentDept.;GuWenBin,BaotongAssistantGeneralManager;
MarcoCozzarolo,DanieliProjectManager;LiBin,BaotongDirectorofSteel
MakingPlant.

41

LONG PRODUCTS

DANEWS

FINAL ACCEPTANCE
FOR THE REVAMPED
BLOOM CASTER
FOR RAIL QUALITY
at Evraz-NKMK, Russia

Casting of stainless
steel grades
at Xining Special Steel,
P.R. of China
Xiningsmain
objectiveistoreplace
theingot-casting
routebyprogressively
addingstainless
steels totheproduct
mixofthenewbloom
conticaster,supplied
byDanieli.

IT IS THE FIRST
CASTER FOR THESE
FINISHED PRODUCTS
INCLUDING SOFT
REDUCTION
TECHNOLOGY

nMay24, 2013Evraz
ConsolidatedWest
SiberianMetallurgical
PlantandDanielisignedthe
FinalAcceptanceCertificate
fortherevampedNo.1largebloomconticasteratthe
Novokutnetskfacility.The
casterisproducinghighqualitybloomsof300x360
mm,inlow-andmediumcarbongrades,andrailsteel,
thelatterrepresentingmore
than90%ofthecasters
output.Thesuccessful
42

performancetestswere
executedforallthegrade
familiesandprovedthatthe
strandproductivityincreased
byabout40%comparedto
theoriginalconfiguration,
reachinganaverage
productionrateof140tph.
Atthesametime,thequality
ofthebloomsshoweda
significantimprovementfor
centerporosity,axial
segregation,andequiaxial
zone,ifcomparedwiththe
resultsthatcouldbeobtained
priortotherevamp.The
performancetestsalso
exhibitedatotalabsenceof
internalcracks(bothaxialand
corner),nowhiteband,and
noedgecontamination.The
surfacequalityexceededall
therequiredstandards
andproductdimensionswere
withintherequiredrangesn
Top:Detailofthenewwithdrawaland
straighteningunits.
Right:TopviewoftheoldW&Sarea.

iningCompany,located
intheQinghaiProvince,
isamongthemost
qualifiedproducersofspecial
steelsinChina,andoverthe
comingmonthsitwillstartupa
Danieliconticasterforlarge
bloomsofspecialengineering
andtoolsteels.Recently,a
decisionwastakentoadd
stainlesssteelstothe
conticasterproductmix,in
ordertoprogressivelyreplace

thecurrentproductionof
stainlesssteelingots.
Consequently,anadditional
contractwasplacedwith
Danielitosupplythefurther
equipmentneededforthose
newproducts.Theoriginal
three-strandcasterfeaturesa
16.5-mmainradius,andthe
castsizesare250x280and
410x530mm,whereasferritic
andmartensiticstainlesssteel
gradeswillbecastinthe
250x280mmbloomsizeonly.
Customizedarrangementshave
beenmadeforthedesignof
thecasterequipment,
specificallyforstainless
grades,suchasnewmolds
withdifferenttapervalues,
newsecondarycoolingspraying
nozzles,differentpositionof
F-EMS(FinalElectromagnetic
Stirrer),andspecificsolutions
toavoidexcessivefrictionof
thebloomintherunoutarea,
detrimentaltothebloom
surfacequalityandsubsequent
processes.Thecommissioning
ofthenewequipmentis
plannedforSpring2014n

DANEWS 168

CASTING NEW SECTIONS OF SBQ

AT SEAH BESTEEL, KOREA

eAHBesteel,a
steelmakerthat
specializesin
engineeringandautomotive
SBQgrades,assigneda
contracttoDanieliforthe
supplyofthreenewround
formats-150,170,210
mm-tobeproducedon
theexistingDanielibillet
conticasterNo.3.This
caster,originallysuppliedin
2011,followedthetwo
otherbilletcastersanda
bloomcasterfromDanieliwhicharecurrentlyin
productionatGunsan-si
Works,solidifyingthelongtermpartnership
establishedbetween
DanieliandSeAHBesteel.
Thefive-strandNo.3
casterfeaturesa9-m

radius,witha150-tladle
capacity.Itwasoriginally
arrangedtocast130,160,
and180-mmsquarebillets,
and200-mmroundbillets.
Themachinewasequipped
withadvancedfacilitiesto
copewiththemoreand
moredemandingcustomers
inthespecialsteel
business,includingamold
andfinalEMSsystem,airmist cooling,andan
advancedautomationand
processcontrolsystem.
Acriticalfactorforthe
successofthisprojectwill
betheveryshortperiod
requiredfordelivery-less
thanfivemonths-whichwill
allowSeAHtobevery
responsiveinmarketingits
newproductsn

43

LONG PRODUCTS

DANEWS

Repeated orders for H3 wire rod mill technology

from Qingdao Special I&S, P.R. of China

Contract signing ceremony with,

from left: Hu Naizhi, Plant
Director of WRM #2, Jiang Gong,
President of Imp. & Exp.
Company of QDIS, Antonello
Colussi, EVP, Danieli China,
with managers and executives
of both companies looking on.

There has been a high level of activity for the

Danieli Group in Chinas wire rod mills market: in
addition to the new assignment from Qingdao,
some prestigious orders have been recorded from
Yunnan Yuxi Xianfu Steel Rolling, and
Shangdong Guangfu Group, and new plants have
been started up successfully at Shanxi Jianbang,
Jiangyin XingCheng and Tianjin Metallurgy Group
Zhasan Youfa.

ingdaos new twin wire rod mills were

assigned to Danieli on June 24,
2013. Its primary products will be
tire cord and high-carbon steels grades, at a
rated capacity of 500,000-tpy. The state-ofthe-art plant will be installed at Qingdao, in
Jiaonan, and outfitted with all of Danielis
latest technologies for rolling, on-line
processing, and heat-treatment of wire rod.
This list will include the LTR-Low
Temperature Rolling and UFG-Ultra Fine
Grain rolling processes. The project basically
foresees two rolling mills, each made up of
16 H/V alternate stands.
The new design for the mill outlet includes
a wire rod line with two-pass wire rod
44

Following previous
mills supplied in
2001 and 2003,
Qingdao
once again
turns to Danieli
for its twin
high-speed plant
lines 2 and 3.

pre-finishing equipment, eight-stand prefinishing block, DSC-Danieli Structure

Control System, including water cooling lines
and CCW-Controlled Cooling Conveyors,
four-stand TMB-Twin Module Block highspeed finishing blocks, and OFB-Oil Film
Bearing loop laying heads.
Sund Birsta will supply the entire finishing
end, from the reforming tube with distributor
and Easy-down systems for perfect coil
formation, to the SundCo-V vertical coil
collecting station and the horizontal coil
transporting, tying, and final collecting
system.
The product range starts with 150-mm
conticast square billets, anticipating finished
products from 5 to 16 mm dia wire rod, in
coils weighing up 2,050 kg.
Danieli Automation will supply the
automation and process control systems
for the main equipment, including two
Hi-PROFILE laser gauges for rolled stock
dimensional control.
The startup of the twin lines is scheduled for
the end of 2014 n

DANEWS 168

DANIELI GARRET LINE TECHNOLOGY

at NSSMC, Japan

To upgrade
the finishing end
of the rolling mill
at the Muroran
Works, Nippon
Steel & Sumitomo
Metal Corporation
are relying
on the worlds
leader in bar
coiling technology,
with 123 machines
installed for
60 customers
worldwide.

Assembly of high-tech Garret

coilers at Morgrdshammar
workshops at Smedjebackens,
Sweden. These machines ensure
accurate product control,
and produce scratch-free
material at the highest possible
speeds and coil weights.

n April 2013 Danieli

Morgrdshammar, Sweden,
was chosen to supply two
new coilers that will be
integrated into an existing
rolling mill at the Muroran
Works, to improve the product
quality and productivity of the
line. Most of the products
made by the Muroran Works
are intended for automobilerelated applications.
Particularly, they are used for
important safety-related parts
that require the highest levels
of strength and durability. To
achieve such critical targets,
Morgrdshammar developed
a unique coiler design, based
on its over 45-year experience
in designing and
manufacturing plants and
equipment able to ensure
accurate product control,
and to produce scratch-free
material at the highest possible
speeds and coil weights.
With the NSSMC order, our
reference list now tops 120
coilers, with 44 units supplied
just in the last 10 years n

45

LONG PRODUCTS

DANEWS

NEW 800,000-TPY HIGH-SPEED BAR MILL

for SteelAsia Manufacturing Corp.,The Philippines

3
4
5
2

3
6

1 Reheating furnace
2 16-stand roughing and
intermediate mill
3 Six-pass finishing blocks

4 Double Twin Channel

system
5 90x10 m cooling bed
6 Cold finishing services

Were raising
the bar is
SteelAsias motto,
in reference
to the level of its
performance
standards.
Simply put,
it means doing
things better.
True to this
statement of
purpose, SteelAsia
selected Danieli
to supply
a new flexible bar
mill.
Souvenir photo at the contract
signing ceremony. From right:
Leslie Corker, Project Manager,
SteelAsia; Tony Lorenzana, COO
of SteelAsia; Benjamin Yao,
President of SteelAsia; Franco
Alzetta, COO of Danieli; Andrea
Nardone, VP Danieli; Carlo
Pagano, Director Sales, Danieli.
Left: handshake between
Benjamin Yao and Franco Alzetta.

46

stablished in 1965, the private

company known now as SteelAsia is
the largest steel bar manufacturer in
The Philippines, with a capacity of 1.75
Mtpy, and it supplies rebar to around 70% of
the infrastructure and critical building
projects in that country. Continuing with its
modernization program, SteelAsia selected
Danieli to supply a new flexible bar mill with
a design capacity of 800,000 tpy.
The product range will be 8- to 36-mm
rebars produced at rates of up to 120 tph,
starting from 130- and 165-mm billets. The
16-stand mill -entirely made up of SHSPLUS
housingless stands, plus two 6-pass finishing
blocks- will use a two-strand slit- rolling
system to produce 8, 10, 12 and 16- mm
rebars at finishing speeds of up to 29 mps.

Souvenir photo at the contract signing ceremony. From right:

Leslie Corker, Project Manager, SteelAsia; Tony Lorenzana,
COO of SteelAsia; Benjamin Yao, President of SteelAsia;
Franco Alzetta, COO of Danieli; Andrea Nardone, VP Danieli;
Carlo Pagano, Director Sales, Danieli.
Left: handshake between Benjamin Yao and Franco Alzetta.

The supply also will include on-line QTB

for the Quenching and Tempering process
of deformed bars, double HTC-High speed
Twin Channel systems, and a 90x10 m
cooling bed. Associated cold cutting-tolength, automatic bar counting and bundling
(up to 2,500 kg) forming, tying and collecting
services complete the rolling mill. Danieli
Automation will supply the Level 1 and Level
2 equipment automation and process control
systems. Plant startup is scheduled for the
first half of 2015 n

DANEWS 168

FOLLOWING A MINIMILL PROJECT IN 2011, MASS GLOBAL INVESTMENT ONCE AGAIN

RELIES ON DANIELI GROUPS TECHNOLOGY FOR ITS EXPANSION PROJECT

New 600,000-tpy flexible bar / light section mill

for Mass Global Investment, Jordan

his new flexible mill will be designed to

produce 600,000 tpy of bar and light
section. The 18-stand continuous rolling
mill will be made up entirely of SHS housingless
stands in H, V and H/V arrangements.
The rolling mill being supplied also will include
automatic quick-changing facilities in the prefinishing and finishing stands in order to
establish the production flexibility and the
shorter size/section changing times required to
respond quickly, and competitively, to market
demand. The bar finishing facilities will feature
a 90-m-long cooling bed fitted with water-spray
cooling, start/stop-type in-line straightening and
cut-to-length services, a 24-m-long single-head
magnetic stacker, plus bundling, tying, and
collecting facilities.
The extremely wide range of products will
include rebars from 16 to 40 mm dia, plain
rounds from 20 to 40 mm dia, squares from
20 to 40 mm, equal angles from 30x4 to
100x12 mm, flats from 40x5 to 100x10 mm,
channels from 40x20 to 100x50 mm, and tees
from 30 to 50 mm. A 120-tph walking-hearth
furnace supplied by Danieli Centro Combustion
will reheat billets and feed the material
to the rolling mill. Danieli Automation will supply
the electrical, automation, and process control
systems. Plant startup is scheduled for the end
of 2014 n

Handshake between Ahmad I. Saleh, President of Mass

Global Investment (right) and Paolo Baldo, VP Key Account
Management, Danieli, after contract signature.

47

LONG PRODUCTS

DANEWS

New merchant mill modernization

at BSRM, Bangladesh

IN ORDER TO
MAINTAIN ITS
LEADING POSITION
IN THE
BANGLADESHI STEEL
MARKET, BSRM
WILL CONTINUE
EXPANDING WITH
A PROGRAM
TO REBUILD
A 450,000-TPY
ROLLING MILL
AT CHITTAGONG,
INCLUDING NEW
INVESTMENTS IN
DANIELIS
INNOVATIVE
TECHNOLOGY
AND EQUIPMENT.

he new contract that was signed in

April will be carried out as a two-stage
project that aims to increase plant
production capacity to over 1 Mtpy,
expanding the product range, and improving
the finished product quality. Further targets
are to reduce current product change-over
times and downtime, and possibly to recover
and reuse the mechanical and electrical
equipment for the new working conditions.
Because of this the supply includes 20 rolling
mill stands (of which 10 with be SHS type
and 10 will be re-utilized and adapted to the
new rolling condition), a QTB water
quenching system for reinforced bars, a
66x7-m walking-beam cooling bed with a
water-cooling system for forced bar cooling,
and a multi-strand straightener with
associated cold cutting-to- length facilities.
An automatic counting / bundling / stacking
station with associated finishing, and final
collecting systems for bundles and stacks,
also will be included. Danieli Automation
will supply the electricals and the advanced
automation system. A water-treatment plant
from Danieli Engineering is included in the
supply, too.
In the first stage, starting from 130-, 160and 170-mm square billets, the plant will
produce rebars from 8 to 50 mm, channels
up to 125x65 mm, and equal angles from
25x3 to 100x12 mm.
In the second stage the product mix will
be extended to rounds up to 65 mm, flats
up to 100x15 mm, unequal angles from

1 20-pass rolling mill

with new SHS stands
2 QTB water quenching system
3 66x7 m cooling bed
4 Multistrand straightener
and cutting to length
5 Automatic counting / bundling /
stacking station
6 Water treatment plant

From left: E. Francescatto, Area Sales Manager, Danieli;

F. Mulinaris, EVP, Danieli; Aameir Alihussain, Managing
Director, BSRM; F. Albanese, Sales Engineer, Danieli.

30x20x3 to 100x75x12 mm, and Tee profiles

up to 50 mm. One detail worth mentioning is
that BSRM will produce small rebars with
the Danieli 5-strand slitting system (5x8 mm)
- a worlds first! Development work is
expected to begin soon, and startup
of the redesigned rolling mill is scheduled
for the end of 2014 n

5
2

48

DANEWS 168

800,000-TPY HIGH-SPEED
BAR MILL PROJECT RESTARTS
at Lisco, Libya

stablished in 1979, the

Libyan Iron and Steel
Company is one of the
largest industrial companies
in Libya, designed to
produce 1,324,000 ton of
liquid steel annually. The
company is situated near the
coastal city of Misurata,
about 210 km east of Tripoli,
on site covering 1,200
hectares. Since its
establishment, Lisco has
pursued a policy of
continuous facilities
improvement by upgrading
existing plants and
introducing new production
lines, with the dual aim of
meeting increasing domestic
demand and diversifying its
product mix, to increase its
share of overseas markets.
Following this focused
vision, two major upgrade
projects were assigned to
Danieli Group: the twostrand wire rod mill in 1995,
and the high-speed bar mill
in 2008. During the
fulfillment of the latter
project, Lisco chose Danieli
Morgrdshammar to supply a
new 800,000-tpy high-speed
rolling mill to produce 8 to
40-mm-dia deformed bars, a
contract assigned on a
complete turnkey supply
basis.
Due to Libyan revolution in
2011, work that had been
underway was abruptly
stopped and, consequently,
all the related activities. In
early 2012, immediately
after the conclusion of the
hostilities in the country,
Danieli was ready to restart
the project, demonstrating
its strong, continuous and
proactive customer support.
To this end, the Lisco and

From left: Ali A. Sasi, General Manager Expansion Lisco; Dr. M.A Elfigih,
Chairman of Lisco; F. Roman, EVP TK Projects Danieli; Eng. Nagi M. Abunaama,
Director Technical Affairs, Lisco; Marai Almalki, Legal Manager, Lisco.
Bottom: M.A. Elfigih, (left) and F. Roman, sign the contract reinstatement.

Danieli teams started again

with a thorough review of
the actual status of the
works, plants and
equipment, and planned the
resumption of the project.
Thanks to a strong effort by
both teams, even in a stilldifficult situation, the parties
were able to finalize a
contract reinstatement that
was signed on May 30, 2013.
This allowed a prompt kick-

off of the project,

representing one of the first
major jobs started in Libya
after the revolution.
The new plants main
highlights will be the high
production capacity and the
very high-speed finishing for
small-size bars, to be
delivered through the
Double Twin-Channel
system to the cooling bed at
up to 37 mps.

To this end, the revised plant

layout is arranged as a 16stand continuous mill plus
two 6-pass, high-speed twistfree finishing blocks, fed by
two- strand slit-rolled stock
coming from the upstream
intermediate mill.
In this way, smaller bar sizes
will be produced on two
strands at very high speeds,
fully exploiting the mill's
capacity for the entire
product range (over 140 tph
already with 10-mm and
larger-dia bars).
On-line water quenching
and self-tempering of rebars
will be performed by two
QTB lines, located at the
finishing blocks delivery
side.
Danieli Automation will
supply electrical and fully
integrated automation
systems, while Danieli
Centro Combustion will
supply the 150-tph walkinghearth reheating furnace.
The complete turnkey supply
will include all auxiliary
plants and systems, auxiliary
equipment, cranes and
transport devices, buildings,
civil works and general
coordination by Danieli
Engineering. The project
completion, followed by
commencement of the
commercial production at
the plant, is planned within
first half of 2014.
The successful conclusion
of the challenging course
described here reconfirms
the strategic commercial
relationship between Lisco
and Danieli, one that will
guide further technical and
commercial resources to
support this very important
customer n
49

LONG PRODUCTS

DANEWS

Ferriere Nord (Pittini Group)

keeps working on innovation:
EWR, SHSPLUS, Spooler
An extensive restructuring program
will bring Danielis latestgeneration rolling technology to the
existing bar mill, increasing
efficiency and reducing operational
and maintenance costs across the
entire operation thanks to the
simplified, standardized
engineering of the equipment
produced by the Danieli Long
Products Division.

he existing bar mill will be rebuilt with

newly designed SHSPLUS stands, the
EWR - Endless Welding Rolling
system, and a newly designed bar spoolers that
will deliver the heaviest, compact coils ever
produced. Following the successful startup of
the new EAF and the completion of the wire
rod mill in January 2013, Ferriere Nord
decided to implement the latest Danieli
technology to upgrade its existing bar mill,
making considerable structural changes in
different technological areas, such as:
> Adding 20 SHSPLUS new generation
housingless stands (for a total of 42, including
the spare units for changes in production) for
billets up to 170 mm square, to feed the
existing HTC-High Speed Twin Channel line
supplied earlier by Danieli. The intention of
this part of the plant improvement is to reduce
the maintenance costs and mechanical failures;
> Installation of a new billet EWR-Endless
Welding Rolling line- for continuous billet
rolling with no time gaps between charged
materials, and the associated front/back ends,
for uninterrupted production of bars and barsin-coils;
> Installation of two, new-generation spooler
units to produce compact heavy coils, with
new water-cooling boxes placed along the line.
Electrical and automation systems for the
entire installation will be supplied by Danieli
Automation.
The plant will be in operation by Q1 of 2014.
Thanks to this new project, Ferriere Nord will
be first in the world producing these heaviest
coils with the EWR system, further
establishing its leadership in the production
of concrete reinforcing bar products n
50

DANEWS 168

DANIELI H3 WIRE ROD TECHNOLOGY ORDERED

at AEMZ, Russia

The ultra-modern,
600,000-tpy wire
rod mill for AEMZAbinsk Electric
Steel Works will
incorporate all
Danielis latest
technological
innovations for
high-speed rolling
and on-line heat
treating of superiorquality wire rod
products.

n March 30, 2013

-the day of the plants
third anniversary- AEMZ
selected Danieli as sole
supplier for a new 600,000tpy, high-tech rolling mill that
will be installed at Abinsk,
Krasnodar Region, to produce
wire rods in commercial and
engineering steel grades.
AEMZ started its business in
2010 and the geographical
location and transportation
infrastructures (motor and
railway transport, port of
Novorossiysk) make its products
attractive for the entire
Southern Federal District. The
new plant will produce a wide
range of steel grades, such as
tire cord, low-, medium-, and
high-carbon, microalloyed and
reinforcement grades, spring
steel, bearing steel, welding

wire, and CHQ grades. The

finished product sizes will
range from 5.5 to 25-mm-dia.
wire rod and 6 to 16-mm-dia.
deformed wire rod in coils
weighing up to 2.0 ton. The
starting material will be
150x150-mm billets in lengths
of 12,000 mm, and weights up
to approximately 2,050 kg.
The new plant will be
comprised of a 150-tph Danieli
Centro Combustion walkingbeam reheating furnace
equipped with the latest
generation flat MAB flameless
burners -that will ensure ultralow NOx emission below 150
mg/Nm3, 16 SHS housingless
stands in H and V
configuration, on-line water
cooling boxes, an H3 (High
productivity, High efficiency,
and High quality) 110-mps
wire rod production line with a
two-pass wire rod pre-finishing
unit, 10-stand pre-finishing
block, DSC-Danieli Structure
Control system including QTRWire Rod Quenching system

and CCW-Controlled Cooling

Conveyor, OFB-Oil Film Bearing
loop-laying head, RRT-Rotary
Reforming Tube and EasyDown system for perfect coil
formation. Sund Birsta (a
Danieli Group company and
global leader in its field) will
supply a Sundco V/H system
for finishing wire rod coils.
With this new project, Danieli
confirms its leadership in the
production of rolling mills for
long products, following
successes with similar plants in
operation at MMK and
Berezovsky, Shandong Laigang
Yonfeng, Angang Steel,
Xincheng, and Tianjin in the
P.R of China, and Ferriere Nord
in Italy. It also anticipates the
next such plants to come into
operation in the CIS countries,
at the Severstal Balakovo
Works in 2013 and BMZ in
2014.
At AEMZ, Danieli Automation
will supply all the electricals
and the Level 2 automation
system for the whole plant,

including its new QDrive

solution of MV drive for highspeed finishing block, and HiPROFILElite and Hi-SECTION
measuring devices for in-line
tracking and product
monitoring. Also part of the
supply will be a Danieli CMSConditioning Monitoring
System, to improve equipment
efficiency and reduce
maintenance costs through
continuous equipment status
monitoring and diagnostic
information. The startup of the
new AEMZ plant is scheduled
for the beginning of 2015 n

Handshake between
D. Homchenkhov (right),
AEMZ General Director,
and L. Tambosco, EVP,
Danieli Bar & Wire Rod
Mills, after signing the
contract for the wire rod
mill. Attending the
ceremony were, standing,
from left: A. Eremin and
A. Londero for Danieli,
and S. Danilenko, S. Volos,
M. Zhigarev, and
V. Luchinets for AEMZ.

51

LONG PRODUCTS

52

DANEWS

DANEWS 168

OPENING CEREMONY FOR MECHELS CHELYABINSK

1.1-MTPY UNIVERSAL RAIL AND SECTION MILL
The Russian plant is designed to produce
100-m long in-line heat treated rails

ON JULY 16,
IN THE PRESENCE
OF THE RUSSIAN
FEDERATION PRIME
MINISTER, DMITRY
A. MEDVEDEV,
THE OPENING
CEREMONY FOR
THIS NEW
UNIVERSAL RAIL
AND SECTION MILL
TOOK PLACE,
ALONG WITH
A CELEBRATION
OF THE 70TH
ANNIVERSARY OF
THE FIRST HEAT
AT THE
CHELYABINSK
METALLURGICAL
PLANT.

ocal, regional, and state authorities,

as well as representatives of steel,
administration and finance sectors,
have been impressed with this huge facility,
which extends more than 1.3 km long, as
well as with the plant systems and the
equipment supplied there.
Appreciation was expressed by the Mechel
and Danieli executives for the cooperation
demonstrated by the project and the
commissioning teams, and the example they
have set for an integrated partnership.
Danieli also honored the Mechel groups
innovative approach to steelmaking and to
infrastructure development in the Russian
Federation. The commissioning of the
Universal Rail and Section Mill supplied to
ChMK to produce up to 1.1 Mtpy of 100-mlong hardened rails, up to 600-mm-wide
parallel flange beams, structural shapes, and
sheet piles, started in April 2013 with the hot
rolling area and the structural shapes
finishing end, and then moved forward to
include the rail finishing end.
The project featured a 240-tph Danieli
Centro Combustion walking-beam reheating
furnace for blooms and beam blanks. The hot
rolling area is comprised of an existing breakdown mill stand, a new break-down mill
stand, an UFR-Ultra Flexible Reversing mill
with three close-coupled stands, and a
separate Universal Finishing stand using

SCC-Stand Core Concept super-heavy duty

design to perform the PSP-Profile Sizing
Process. Downstream from the Universal
Finishing stand, the in-line Rail Head
Hardening (RH2) system developed by
Danieli will be used to manufacture
premium-quality rails. Such rails, featuring
high fatigue- and wear-resistance and highimpact strength for very low temperature
applications, will be supplied to the Russian
Railways OAO for the upgrade of existing
tracks as well as the construction of new
railways all over the country.
Further downstream, the dedicated cooling
bed and the Horizontal/Vertical roller
straightening line facilities are provided,
respectively, for rail and for cold processing
and finishing of structural shapes.
The finishing end for structural shapes
includes cold sawing, automatic stacking,
and collecting facilities.
The rail finishing end is provided with endstraightening presses, a Non-Destructive Test
center, sawing and drilling units, final
inspection, collecting stations, and special
overhead cranes for final handling of 100-mlong rails.
Danieli Automation supplied the associated
electrical and the automation system, too.
Also included in the Danieli supply were two
water treatment plants, a workshop and rollshop facilities, and a laboratory n
53

LONG PRODUCTS

DANEWS

1-MTPY LARGE-BAR MILL STARTS OPERATION

at Henan Jiyuan, P.R. of China

The cooperation
between Danieli and
Henan Jiyuan I&S
Group began in 2007 with
the supply of a 600,000 tpy
bar-in-coil mill, and now
includes another significant
achievement following the
succesful startup of the new
large-bar mill designed to
produce 1 million tpy of
high-quality steel bars.
The first bar was rolled on
June 20, 2013, less than 19
months after the contracts
launch date. The official
ceremony held on July 10
included participation from
54

important members of the

local government, as the
Henan provincial Vicegovernor Mr. Wang Tie, and
from the Italian Embassy
Economic Counsellor, Mr.
Livio Spadavecchia.
The plant -a complete rolling
mill, including reversing
roughing stand (BDMBreakDown Mill), 8-stand
continuous finishing mill,
hydraulic shear with 1,500-t
cutting capacity, and
collection facilities that
allow quick bar removal at
high temperature for slow
cooling (a critical step for

DANEWS 168

special steel production) incorporates Danielis most

up-to-date large bar mill
technology and equipment.
The installation produces
round bars up to 300 mm
and square billets up to 240
mm for the automotive,
machinery and equipments,
railway and power generation
industries.
This project was
implemented by Danieli
Italy, Danieli China, and
Danieli Automation as the
main suppliers of equipment,
engineering, automation, and
process control systems n

1 The first billet is rolled

by the reversing break
down mill.
2 The continuous finishing
mill is made of eight
Danieli Star Housingless
stands.
3 Collecting table for slow
cooling with first rolled
specialty steel bars.

This new rolling mill is the core element

of Henan Jiyuans 12th five-year plan
to achieve total production capacity
of 4 million tpy, becoming one
of the largest producers in central Chinas
Henan province. Demand for large bar
products is expanding in China,
and Danieli confirms its leadership in the
design of such plants, with nine orders
acquired in less than two years.

GUOTAI

55

LONG PRODUCTS

DANEWS

FAST LEARNING CURVE

at CAASA, Peru

ust three months after

rolling the first billet on
April 12, 2013, the new
high-speed rolling mill at
Corporacion Aceros
Arequipas plant in Pisco,
has test-run all the products
successfully. Various sections
(e.g., rebar 6 mm, 8 mm,
3/8-in., -in., etc.) have
been produced smoothly and
successfully on the Double
Twin Channel line, with
stable and constant process
speeds of up to 35 mps
More than 40,000 tons have
been rolled during the first
month of operation and over
120,000 t in the first three
months, surpassing the
56

ANOTHER SUCCESS
WITH HIGH-SPEED
BAR MILLS:
THE DANIELI
STARTUP TEAM
SET ANOTHER GOAL
AND STRENGTHENS
THE COOPERATION
BETWEEN THE TWO
COMPANIES.

contracted monthly
production program, with
the customers full
satisfaction.
This target has been
achieved thanks to the full
and strong co-operation
between the CAASA and
Danieli teams. The next step
for the high-speed bar mill
will be to install and start the
new QTB quenching line.
That QTB line will treat
rebars from 6.35 to 32 mm
at operating speeds of up to
14 mps, producing rebar
with high mechanical
properties, good weldability,
and high ductility, starting
from common, low-carbon

steel without the use of

microalloyed steels, for
substantial production cost
savings. The installation is
scheduled for the end of
this year, in order to give
customer more flexibility
in quenched rebar
production, aiming for high
efficiency and productivity,
and the best quality rolled
bars and sections n

Augusto Cornejo, Plant Manager of

CAASA, and Emanuel Roiatti, Danieli
Site Manager, with the joint CAASA
and Danieli Team that carried out the
plant startup and commissioning.

DANEWS 168

New bar-mill stacker

operating now
at Steel of West
Virginia, USA

DANIELI H3 WIRE ROD

SPECIALTY STEEL MILL
STARTS SUCCESSFULLY
at Nucor Darlington

From the good results in P.R. of China to the

new line installed at Nucor Darlington, these
H3 wire rod lines will be the benchmark for
high-speed, high-efficiency, and high-quality
wire rod production.

100-tph automatic Winstack

stacking station has been operating
at the SWV No. 2 bar mill in
Huntington, since January 20, 2013, when
the Provisional Acceptance Certificate was
released. The 16-m-long, magnetic stacker
is designed to process over 100 products in
regular stacks weighing of up to 500 kg/m.
The option to extend the systems handling
capability up to 80 ft. has been provided, to
increase its overall productivity. Danieli
Automation supplied all the electricals and
the automation system for the new finishing
area. With this stacking machine, 136
Winstack stations have been installed
worldwide since 1970, confirming Danieli
Morgrdshammars absolute leadership
in this field n

(SC), USA

iding the wave of the

success that resulted from
a series of orders in P.R of
China, and the installations and
successful startups that followed,
this upgrade to the No. 2 rolling
mill at Darlington benefitted
from an especially positive legacy
that continued with the
installation and the fast startup
of the 6-stand roughing mill on

May 30, 2013. A few of days

later, the first bars were tested
and produced through the bar-incoil line. The installation
schedule has been fully
observed, and the new wire rod
line started operations at the
beginning of September 2013 n

57

LONG PRODUCTS

DANEWS

Final Acceptance
of the 1-Mtpy high-speed bar mill
at Dongkuk Incheon, Korea

n May 14, 2013

Dongkuk released
the Final Acceptance
Certificate for the ultramodern high-speed rolling
mill for rebars built by
Danieli and installed at
Incheon Works. The mill

has an output capacity of

1,000,000 tpy for 10- to 57mm dia rebars, but currently,
the main products are D10,
D22 and D25, while the
remaining diameters are less
frequently produced due to
market conditions.

The mill has shown an

impressive, fast learning
curve, and lately the
production has surpassed
650,000 t rolled, aiming
toward full production
capacity within the end
of the 2013 n

900

90
83.353
Production
on three shifts
started on Sep. 4
Monthly production (ton*1,000)

800

H
700

63.216
57.266

56.931

49.243
August
dedicated to
Performance Tests
(4 sizes)

50

40

J
30

20

June and July

dedicated to
Hot Commissioning

500

J
400

300

Top, left: the 17-stand

continuous mill.
Right: The cooling bed,
equipped with HTC-Highspeed Twin Channel
system.
Left: the impressive
Learning Curve recorded
in the first 12 months
of operation.

200

16.008
10.050

10

600

Progressive production (ton*1,000)

Hot Commissioning
and Performance
Tests performed on
a daily single shift

76.845

75.352

Monthly avg. target considering

1.0 Mtpy of mill productivity

60

83.333

80.811 79.712
79.094

80

70

85.315

100

1.615
0
June

August

October

December
Month

58

February

April

June

0
monthly average
target

Monthly production
Cumulative production

COMMISSIONING OF SHEET PILES

at Emirates Steel, UAE

mirates Steel has been increasing its

product selection on a continuing basis,
and as of today more than 140 different
types and sizes of beams, columns, and
channels have been rolled.
Now, Zed piles (EZ 18) represent the latest
production challenge. The combined ES and
Danieli team is completing the commissioning
program for this product using the latest
available technologies available in this product
segment, and together are establishing new
standards for rolling sheet piles: for the first time
anywhere in the world it will be possible to roll
EZ18 with only one BreakDown Mill plus the
three-stand UFR finishing mill. Based on the
successful preliminary tests, we are confident
that the commissioning of EZ 18 will be
completed soon.
This represents only the latest challenge that
Emirates Steel and Danieli teams have addressed
successfully, thanks to their collaborative spirit,
professional approach, and mutual efforts n

ROLLING OF EZ18 SHEET PILES WITH ONLY ONE BDMBREAKDOWN MILL STAND PLUS UFR-ULTRA FLEXIBLE
REVERSING FINISHING MILL WILL BE A FIRST-OF-ITSKIND ACHIEVEMENT, AND JUST THE LATEST OF THE
CHALLENGES SUCCESSFULLY OVERCOME THROUGHOUT
THIS PROJECT.

59

TUBE PROCESSING

DANEWS

NEXT-GENERATION COLD PILGER MILL

for tube production

vercapacity is quickly becoming the

rule in the actual market situation,
especially where commodities are
concerned. The pressure on pricing is
increased daily by new producers settled in
BRIC countries. Simultaneously, new
opportunities are arising for producers of
highly specialized niche products.
In such a challenging market situation it is
fundamental for equipment designers and
manufacturers to completely change their
approach to customer requirements and in
particular understand the necessities not only
of tube producers but also of tube end-users by
anticipating market trends and developing new
innovative technological solutions.
A major challenge in the energy market is
increasing tube operating temperature in
power plants in order to increase process
efficiency. Consequently, more sophisticated
stainless steel grades (duplex and super
duplex) are needed. Aerospace applications
demand a large amount of non ferrous metal
tubes (aluminum 2024 and 7075 alloys, nickel
alloys and titanium alloys). In larger countries
such as P.R. of China and India, the growing
population and changing life style tends to
increase energy demand and consumption,
therefore the installation of new nuclear power
plants is seriously considered as the most
realistic and reasonable option available thus
new fuel complexes for zirconium tube
production are planned. In some applications,
e.g. OCTG submersible pumps, mechanical
tubes with extremely tight geometrical
tolerances are requested as a starting material
for the production of equipment components.
The production of such a wide range of
different products is possible only using tube
Cold Pilger Mill technology now available in
Danieli thanks also to cooperation established
in 2010 with JSC Institute Tsvetmetobrabotka
which combines respective know-how and
experience in tube cold rolling.
The target of this ambitious R&D project plans
to answer two fundamental requests arriving
from tube producers:
60

Mill data
Number

2 (Left / Right)

Type

Lever

Stand/cassette type

2 and 3 rolls; 2 and 3 rollers

Finished tubes

OD 4-24 mm
WT 0.2-2 mm, with 2 and 3 rolls
WT 0.12-2 mm, with 2 and 3 rollers
Length 3-8 m

Finished tube type

Ultra-thin wall thickness, round, square and hexagon

Detail of a Extreme Performance Cold

Pilger Mill equipped with movable
stand and cassette with lever-type
synchronization; 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.

> Accessibility of new innovative state-of-theart Cold Pilger Mills at a reasonable price;
> Accessible solutions to increase the
performance of existing Cold Pilger Mills with
limited investment costs.
Nowadays thousands of Cold Pilger Mills are
installed worldwide and hundreds of tube
producers are using the technology considered
fundamental for some specific materials and
especially when demands for tube quality are
key. The majority of these Cold Pilger Mills
were installed in traditional tube producer
countries before the 1980s; therefore some of
these machines are now technically or
economically obsolete.
To compete on the global market means tube
producers need to seriously consider whether
advantages of new technologies now available

DANEWS 168

Three families of
Cold Pilger Mills
for rolling highly
sophisticated
materials for
critical applications
are now available
in three different
configurations:
"Quarto" for
difficult to roll
materials, "Duo"
for ductile
materials
and "Lever for
ultra-thin wall
tubes, all with
a common
interface.

justify an investment into new equipment or

whether revamping existing ones is a more
viable option.
Danielis line of approach is to assist tube
producers in understanding their specific
needs and develop custom-built solutions in a
spirit of teamwork to offer a win-win
partnership. Several options are available to
maximize or increase productivity:
> Using a continuous Cold Pilger Mill instead
of a non-continuous one;
> Using a roll-type Cold Pilger Mill instead of
a roller one,
> Changing the feed and turn section of an
existing mill,
> Changing the roll path (roll and mandrel
design, number of feeds and turns per stroke,
feeding per stroke),
> Changing the product mix (increasing OD
and WT range).
Several options are available to increase
produced tube quality:
> Increase stand rigidity using a different stand
design;
> Increase feeding and turning section
precision.
All these options are already available from
Danieli but need to be evaluated by the

customer together with the specialist to ensure

the right solution is selected.
An additional benefit of working with Danieli
Centro Tube is the possibility to develop
vertically integrated projects including stainless
steel tube extrusion (Danieli Breda), tube cold
rolling, bright annealing (Danieli Olivotto
Ferr) and tube finishing.
Examples of this approach are the two Cold
Pilger Mills for nuclear applications developed
for a Russian customer which are now under
testing in our workshop. In this project cuttingedge technology, know-how and experience in
cold forming is utilized to produce ultra-thin
stainless steel seamless precision tubes.
To maximize product mix flexibility
interchangeable stands with two or three
rolls/rollers can be used to produce highprecision round, square, or hexagonal tubes n
61

TUBE PROCESSING

DANEWS

1 Straightening machine exit area

2 Hardening and tempering
furnaces
3 Quenching head
4 Quenching tank
5 Sample cut-off and exit area

62

DANEWS 168

HEAT-TREATMENT LINE UPGRADE

FOR THE 16 SEAMLESS PIPE MILL
at Jesco, Saudi Arabia

A NEW CONTRACT TO UPGRADE

THE TUBE HEAT-TREATMENT LINE (HTL)
IN OPERATION FOR THE MIDDLE EASTS
FIRST SEAMLESS PIPE MILL AT JUBAIL
INDUSTRIAL CITY RECONFIRMS
THE EXCELLENT COOPERATION
ESTABLISHED BETWEEN DANIEL
AND JUBAIL ENERGY SERVICES CO.

production size range.

The capacity will be
increased by approximately
+35%, however.
HTL upgrade description

emand for seamless

tubular products
continues to rise, as
demonstrated by the growth
in orders assigned to Jesco,
and the buyers increasing
demands for heat-treated
pipes and higher grades also
has had a significant
influence on the companys
decision to boost HTL
production capacity, even
though the line (part of the
original turnkey contract)
had only just been
successfully commissioned
in 2010. Danielis design
offers fewer modifications /
replacements to equipment
in this project, and so the
upgrade will have no impact
either on operating time or

Although the main target of

Jescos contract was to
increase production capacity,
the project also was
developed to improve the
flexibility of the HTL,
meaning, to allow quick
tube-size changeovers.
Several areas of the line will
be subjected to upgrade /
modifications:
HTL production capacity
increase will include:

> Modifications to the

straightening machine exitside handling system and a
software upgrade to reduce
the tube-straightening cycle
time;
> Installation of additional
burners (hardening,
tempering furnaces);
> Re-distribution of preheating zones capacity
(hardening, tempering

furnaces);
> New quenching head
configuration: installation of
a fourth module and redistribution of quenching
capacity modules.
HTL flexibility improvements
will include:

> Installation of a quenching

tank by-pass system: a chaintype frame, including quick
connecting/disconnecting
system;
> Re-location of the sample
cutting saw (off-line) and
installation of a new tube-

collecting cradle.
The design concept for these
upgrade solutions was based
largely on the objective of
limiting installation and
commissioning activities,
thus avoiding any
unscheduled plant
shutdowns. Installation of
new equipment is expected
to commence during the
plants annual shutdown and
weekly maintenance
activities n

63

TUBE PROCESSING

DANEWS

HEAVY-DUTY, THICK-WALL TUBE MILL

for TPI, India

anieli W+K delivered a new specialty

rolling mill to Tube Products of India
(TPI), located in Chennai, and
designed to produce precision tubes in hightensile strength materials, with diameters
ranging from 2.5 to 7 in. and a maximum wall
thickness of 0.5 in. The challenge for Danieli
W+K was to design a customized special
tube mill because the line will produce
mainly precision tubes for hydraulic cylinders
used for earthmoving and construction
machines, and hollow sections for steel
construction. The complete line consists of a
fully automatic strip preparation section, a
forming, welding and sizing section, and a
newly developed flying saw -the multi-cut.
The finishing line, also provided by Danieli
W+K, consists of a run-out section, sample
tube-cutting device, and an integrated flushout station to flush out the inside scarf. A
chopper to cut the inside scarf and a blowout station is incorporated into the flushing
station. The system also is equipped with an
automatic bundle station and a magnetic
portal packaging device for assembling
hexagonal and rectangular bundles of round
tubes and hollow sections.
The enhanced multi-cutter consists of two
individually driven saw blades on an orbital
rotation system that enables it to cut in two
64

The complete line

consists of a fully
automatic strip
preparation
section, a forming,
welding and sizing
section, and a
newly developed
flying saw -the
multi-cut.

Forming stands section

of an ERW line for
precision tubes.

Workshop assembly of a
Multicutter for maximum
pipe OD 220 mm.

modes: one is the HSS saw blade for tubes

ranging from 2.5 to 3.5 in., and another is the
two-mode system consisting of two tungstencarbide saw blades to cut round and
rectangular sections up to 7in. The saw blade
drives are water-cooled and well protected
against the particular environmental
conditions. Special gearbox design and
patented clamping devices guarantee almost
vibration-free cutting and long life for saw
blades. With this new line TPI plans to
penetrate new market segments, and in
particular the market for thick-walled-tubes
for special applications.
Production is scheduled to commence in
March 2014 n

DANEWS 168

Danieli W+Ks successful

development of a new
multicutter for ERW pipe
welding lines

he machine produces almost burr-free cuts

of pipes between 60 and 220 mm OD,
with WT between 1.0 and 14.0 mm at a
maximum tensile strength of up to 850 N/mm.
The new Multicutter is distinguished by the
fastest tool change-over, high protection classes
for the AC servomotors, extremely short cutting
cycles, excellent quality of the cut, and
automatic process optimization by the newly
developed control system. Depending upon the
pipes and profiles to be cut, the Multicutter can
be operated either with one saw blade (HSS) or
with two saw blades (TC tipped). The single-saw
blade cutting mode is selected for pipes up to
100 mm OD and up to 5 mm WT. In this cutting
mode it is guaranteed that the inside scarf is cut
as well. The two-saw blade cutting mode is used
to cut profiles and pipes of more than 90 mm
OD, and guarantees high cutting speeds, high
performance, and a high-quality, low-burr cut.
Also, Danieli W+K has developed a new
special clamping system that ensures tight
clamping of the pipes and profiles during the
cutting process. The clamping units are mounted
to both sides, close to the saw blade at a
maximum distance of 10 mm. This reduces any
vibrations during the cut-off process, thereby
achieving longer service life for the saw blades.
All motors in the working area of the saw are
water-cooled and in the highest protection class
to guard the motors safely against emulsion, dust
or chips. Special attention should be given to the
easy access for the operator when exchanging the
clamping tools and saw blades. For this purpose,
the exit-clamping unit is locked hydraulically.
The unique design of Danieli W+Ks new
Multicutter allows for easy integration into
existing pipe welding lines n

65

HEATING SYSTEMS

DANEWS

NEW GENERATION ULTRA-LOW NOx

WALKING-HEARTH FURNACE
at Hadeed, Saudi Arabia

n 2009, Sabic Hadeed contracted

Danieli to supply a second wire rod line,
similar to the one commissioned in
2004. The new line features a Danieli Centro
Combustion (DCC) heating furnace that
duplicates the one supplied in 2004, i.e. a
walking-hearth type furnace (radiant-roof
type) with a maximum production rate of 120
tph. The 25-long, 14.8-m wide furnace heats
130- and 150-mm billets in lengths ranging
from 8.8 to 14 m. The furnace is equipped
with four moveable and five fixed hearths.
Considering the predominant maximum
billet width, it is also equipped solely with
radiant burners to ensure uniform thermal
feedstock heating, and discharging
temperatures ranging from 1,050 to 1,150
C. Burners are fed with natural gas and air
preheated from 400 to 450 C via a central
recuperator installed in the waste-gas flue.
During the five-year period between the two
orders, Saudi Arabia introduced stricter limits
on pollutant emissions: in particular, the
allowance for nitrogen oxides has been
reduced from 86 g/GJ to 43 g/GJ (based on
gross calorific values), corresponding
respectively to 260 and 130 mg/Nm3 @ 3%
02, considering wet waste gas.
However, DCCs R&D department has made
considerable advances since 2006, especially
in the field of combustion, and two new
types of radiant burners designed and tested
for the new Hadeed furnace guarantee NOx
emissions lower than 100 mg/Nm3 @ 3% 02
with a furnace chamber temperature of
1,250 C, fed with combustion air preheated
to 450 C, and requiring use of flameless
combustion. The following burners are
installed on the furnace roof:
> Pre-heating zone: 27 RAD-FL6 burners
(three rows of nine), with maximum power
of 610 Mcal/h;
> Heating zone: 27 RAD-FL6 burners
( three rows of nine), with maximum power
of 750 Mcal/h;
> Equalizing zone, right and left: 15 + 15
(on three rows) RAD-VGL4 ULNOx burners
66

LIMITATIONS
TO NOx
CONCENTRATIONS
IN EXHAUST FUMES
ESTABLISHED
BY NATIONAL
AND INTERNATIONAL
REGULATIONS
IMPOSE
A REQUIREMENT
FOR SUBSTANTIAL
REDESIGN
OF NEW BURNERS.

Tests in the DCC Lab: RAD-FL6 in flame mode (top) and

in flameless mode (middle).
Zone 1 Shortening: RAD-FL6 burner in flameless mode
in the third row (first two rows switched off).

THE CHALLENGE
IS TO ACHIEVE
OPTIMAL
EFFICIENCY
AND AT THE SAME
TIME TO ENSURE
THAT EMISSIONS
PRODUCED REMAIN
WITHIN THE SET
RESTRICTIONS.
DANIELI CENTRO
COMBUSTION
ACCOMPLISHED
THIS TASK IN ITS
DEVELOPMENT
OF THE REHEATING
FURNACE FOR
HADEEDS NEW
WIRE ROD MILL.

DANEWS 168

Customer inspection at DCCs R&D center. From left:

C. Iernetich (DMH); D. Astesiano (DCC - R&D); Tawfeek
Shammasi, Hadeed Environmental Dept.; M. Rocca (DCC).

with maximum power of 200 Mcal/h.

Each zone is equipped with a single airfeeding line and two gas-supply lines, one
dedicated to the flame mode function, the
other to the flameless mode. Once the
combustion zone reaches automatic ignition
temperature (800-850 C), gas flame
alimentation closes automatically and
switches over to flameless mode. Registered
toxic waste, and NOx emissions in particular,
are extremely low and the percentage of
unburned hydrocarbons (CO) is virtually nil.
In the preheating zone there is an option to
switch off first- and second-row burners
according to thermal request in the zone, and
to further reduce fuel consumption when the
furnace is functioning in low production mode.
Furnace performance tests were carried out
from March to April 2013, with extremely
successful results:
> Specific consumption: 219 kcal/Nm3 against
242 kcal/Nm3 of contractual requirements,
discharging temperatures of 1,050 C with
150-mm billets;
> Billet temperature uniformity: DeltaT less
than 10 C on the section and less than
15 C on the length; contract requirements
of 25 and 30 C, respectively.
> Scale loss: 0.55% on total weight with
150-mm billets discharged at 1,150 C
compared to 0.7% in the contract.
The outstanding performance regarding
nitrogen oxides must be highlighted, too.
Considering the limit of 43 g/GJ @ 3% 02,
29 g/GJ (equal to 93 mg/Nm3) was recorded
in flameless mode, that is 33% less than the
guaranteed limit -- also considering billet
discharging temperature of 1,150 C.
In flame mode this value was 63 g/GJ
equivalent to 202 mg/Nm3.
By way of comparison, the furnace installed
in 2004, at a billet discharging temperature
of 1,050 C, produced NOx emissions
of 61 g/GJ, equivalent of 194 mg/Nm3 n
67

HEATING SYSTEMS

DANEWS

CUSTOMIZED FURNACE
for Orsky Machine-Building Plant, Russia

The Orsky Machine Building Plant

(TMK Group) in Orsk produces
a wide range of forged parts and drill
pipe joints, supplied to both Russian
and foreign consumers.
It is the only plant in Russia authorized
by the American Petroleum Institute
to manufacture drill pipe joints
in compliance with the API Spec 7
international standard.

68

Maximum productivity

3 tph

Residence time in furnace

6.2 h

Total cycle time

7.2 h

Gas consumption
at maximum capacity

200 Nm3/h

the roof, promoting high

waste-gas recirculation, and
heat exchange. After heating
and soaking at a temperature
of 860 C, the treated parts
pass through the controlled
cooling phase, which reduces
the temperature down to
approximately 600 C before
transfer into the forced-air
cooling chamber. The forced-air
cooling chamber is equipped
with two recirculating
centrifugal fans (located on the
roof) and one injection of cool
ambient-air deriving from a
third fan managed by an
independent temperaturecontrol loop. Material
temperature is lowered to
approximately 300 C before
transfer to the final waterspray cooling chamber. This
strategy, combined with
appropriate fan management,
ensures temperature control at
any point on the material within
a range of less than 5 C n

Core temperature trend for a 30-mm forged component

900
800
700

710

832 842 846 852 856

788 814
736 762

620

600
520

500
420

400
310

300
200

200

Furnace recorded temperature

Core recorded temperature
Theoretical interpolated avg. temperature

100
0

30
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150

itself is equipped with 26

burners (80 kW each) for
material heating. The furnace
is divided into 10 control
zones, each of which is
outfitted with independent
temperature loop monitoring
and control. The last four
zones also are equipped with
cooling systems (fed by
combustion air) in order to
perform smooth, combined
heating / cooling control
during the final portion of the
thermal recipe (soaking and
cooling phases). Temperature
uniformity and optimized heat
transmission in the furnace
heating and soaking chamber
are guaranteed by eight
centrifugal fans located on

Performances achieved

Temperature (C)

n June 2013 Danieli

Olivotto Ferr successfully
commissioned the
annealing line installed there
recently to treat forged
parts/tool joints. The fully
automatic line includes a rollerhearth annealing furnace, a
roller-hearth air-cooling
chamber, a roller-hearth watercooling chamber, and a
complete handling system for
loading / unloading forged parts
for treatment in a special
basket. The annealing furnace

Time (min)

DANEWS 168

HOT & COLD PROCESSING

DANEWS

Chain-track bar drawing line in full operation

at Marcegaglia Contino, Italy
he Marcegaglia plant in
Contino (Mantova) is one
of Italys top three
producers of cold-drawn steel
bars. The plant owners decided
to increase their output by
investing in a new, high-speed
chain-track drawing plant,
chosen over the alternative of a
traditional cam-based drawing
line. Processing bar diameters
up to a finished size of 28 mm,
this new line is now in full
operation, capable of a 180-

mpm maximum speed, which

is 50 per cent higher than the
best previous drawing
technology available on the
market.
With a bar length tolerance
of 0/+1 mm and up to 48 bars
drawn per minute, cut to
length, and chamfered, the
Danieli chain-track technology
is yet again proving to be the
winning solution for maximum
productivity, with best finished
product quality n

Marcegaglia Open Day - June 7, 2013

Souvenir photo at the end of plant tour. From left: G. Dorscheid, SaarBlankstahl; D. Meyer, Steeltec; M. Liedlich, Deutsche Edelstahlwerke;
I. Robin, Deutsche Edelstahlwerke; E. Christau, Bessey Przisionsstahl;
S. Liebetanz, Stahlwerk Ergste Westig; E. Sittaro, Danieli; A. Sieber,
Steeltec; P. Rdiger, Danieli; E. Ceresetti, Plant Director, Marcegaglia
Contino, G. Pasquali, Production Engineer, Marcegaglia Contino.

he chain-track technology is usually associated

with the drawing of copper tubes. More and more,
the chain track is used to draw solid steel too, since
this type of drawing has significant advantages compared
to the cam-driven machines. In recent years Danieli has
delivered only chain tracks for drawing of steel.
Now, customers are showing a greater interest in the
chain-track technology. With the kind permission
of Marcegaglia Contino, a Danieli chain-track line
in operation could be demonstrated to technical,
production, and maintenance managers from Germany
and Switzerland. All the participants were very impressed
with the speed, quiet running, and bar length tolerances
achieved by the Marcegaglia drawing line n

69

HOT & COLD PROCESSING

DANEWS

DANIELI MODERNIZING THE HISTORY

OF SPECIAL STEEL PRODUCTION IN RUSSIA
at Volgograd Steel Works Red October

Danieli Breda open-die forging

complex
The first stage of this program has been
contracted to Danieli Breda. It calls for
a new forging complex based on a 25-MN
push-down open-die forging press integrated
with a 20-t rail-bound manipulator and a
20-t diesel mobile manipulator.
Thanks to the Danforge automation system,
the plant will process ingots of high-quality
alloys, such as tool steel, HS steel, stainless
steel, Ni-based, and titanium grades, with
maximum efficiency and reliability toward an
average production target of 35 ktpy. The
new forging plant will commence production
in Q1 of 2014.
Equipped with advanced features for opendie forging technology, developed earlier by
Danieli Breda, it will ensure a wider product
mix for the customer, increasing production
quality in order to match the demands of an
70

even more challenging and competitive

market. Danieli and Red October also are
cooperating to optimize plant layout.
The first step of this task already started with
the award of a contract for existing forging
plant modernization. In that project the
target is to optimize the hammers shop by
removing the outdated steam drive and
converting the power supply to a modern,
centralized unit to drive a group of hammers
ranging from 20 to 50 kJ. The project will be
in operation before the end of the year.

Fume Treatment Plants

Danieli Environment was selected as sole
technology supplier to design, manufacture,
and supply the new fume treatment plant
(FTP) for the steel meltshop, to control
fumes and dust emissions from the primary
and secondary lines of the 200-t electric arc

Dmitry Petrovitch Gerasimenko,

Executive General Director of
JSC Volgograd Steel Works "Krasny
Oktyabr", and Franco Alzetta, COO
and Member of the Board Danieli,
signing the contract for the plant
modernization project.

DANEWS 168

Volgograd Steel Works

Red October has always
been a leader in metal
industry. The mill is
considered to be Russias
largest producer of highquality special steel grades
for the automotive industry
and aircraft producers, and
for chemical, oil and
power engineering
programs. The mill was
established in 1897.
Production capacities
increased and new steel
grades were adopted up
to 1941. Almost destroyed
during WW2, it was fully
restored, and by 1949 the
production had increased
to its pre-War volume.
By 1986 the Mill had a
production capacity of 2
Mt of liquid steel, with the
ability to produce about
500 steel grades
according to the main
international standards.
In summer 2013
Volgograd Steel Works
decided to proceed with
a modernization project
for its meltshop, forging
complex, and finishing
lines, with the target of
minimizing meltshop
emissions, reducing
production costs, and
improving product quality.

L1 and L2) systems. Also included in the

supply will be a dust separator and textile
filter (to remove the dust coming from
process gas), all necessary shut-off and
control valves, spectrometer-type gas
analyzer, and a hydraulically-actuated
vacuum switch to serve both the vacuum
tank for degassing and the vacuum ingot
chambers, managed with same dry pump
system. Startup of the new mechanical dry
pump is scheduled for the end of 2014.

New bar straightening

and peeling plant
furnace and ladle furnace.
The design of these new facilities will ensure
high-efficiency fume capture and fume
filtration, as well easy maintenance and long
service life for the components.
A thorough design was required to comply
with the space limitations and other
constraints of the site, and to minimize
meltshop shut-down required for the
installation. The FTP will treat about 80,000
Nm3/h at 1,100 C as EAF primary off-gas
extraction and 2.75 Mm3/h of secondary
fumes, ensuring a dust content emission at
the stack of less than 10 mg/Nm3, with noise
levels less than 85 dB(A) at the stack outlet
(less than 45 dB(A) at 300 m distance from
the stack). FTP technology is based on pulsejet filters 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 the filter, thus occupational
health and safety are not compromised.

Danieli Centro Maskin will delivery a new

peeling plant to process hot-rolled bars up
to 250 mm in diameter and 6,500 mm long.
This system will be installed downstream
from the straightening machine for large bars
supplied in 2004. Bars will be prestraightened on a new Danieli RL250 tworoll straightening machine (one of the largest
such machines in the world) in-line with the
new peeling machine, all with fully automatic
settings/adjustment and recipe programming
systems for maximum production flexibility.
Processing a wide range of steel grades,
including nickel alloys, bearing steels, and
stainless steels, this high-performance plant
will be capable of producing up to 90 tph of
100% surface defect-free material with
excellent h9 dimensional tolerance. The very
tight dimensional tolerance combined with
the bar straightness of 1 mm/m and defectfree surface will allow the Volgograd
Steelworks to supply all specialty engineering
customers in Russia and abroad where only
the very highest bar quality standards are
acceptable, as guaranteed by the best Danieli
cold-finishing technology developed over
more than 50 years n

Mechanical dry pump system

for vacuum degasser
Danieli Centro Met will supply a new
mechanical dry pump system to replace the
existing steam ejectors vacuum pump serving
the VD/VOD unit. Mechanical
dry pump systems offer the same
performances as the steam ejectors vacuum
pump, but without the active costs for steam,
steam generation plant, and maintenance.
The number of mechanical dry pump
installations is rising, and Danieli is further
solidifying its leadership in the field thanks
to the stable results achieved in numerous
reliable solutions developed worldwide.
These results are supported by the
continuous development of the metallurgical
process target and control philosophy, and
the complete automation control (including
71

FORGING & EXTRUSION

DANEWS

SUCCESSFUL COMMISSIONING
OF A SEAMLESS TUBING PLANT
at XinXing, P.R. of China

oth XinXing and Danieli Breda teams

involved in the commissioning of this
plant proved to be particularly skilled,
and the startup was conducted smoothly and
with very good performances in terms of time
and quality, leading to the release of the Final
Acceptance Certificate with mutual
satisfaction. The core technological
equipment supplied by Danieli Breda
included the 25-MN expander press, where

72

WITH THE PERFORMANCE TEST

OF THE 60-MN EXTRUSION PRESS
CARRIED OUT IN APRIL 2013, DANIELI
BREDA SUCCESSFULLY COMPLETED
THE STARTUP OF THE SEAMLESS
TUBING PLANT AT XINXING PIPES,
LOCATED IN HANDAN.

DANEWS 168

1 Overall view of the extrusion plant.

2 Xing Derun, Plant and Production
Manager, XinXing Pipes, with the
joint Team that carried out the
plant commissioning.
3 The 60-MN extrusion press.
4 Wang Li Hui, XinXing Pipes,
and Domenico Samele, Site
Manager, Danieli Breda.

XinXing Special Steel Pipes

has a production capacity
of 180,000 tpy of bimetal
composite pipes and highalloy steel pipes and other
high-end seamless steel pipes,
widely used in power
generation, petrochemical,
chemical industry, etc.

the billet is upset and the pre-hole is

expanded to a value higher than the final
diameter of the pipe to be produced.
The downstream 60-MN extrusion press
-the heart of the process- is equipped with
an active piercer, and forms the expanded
billet into the hot finished tubes.
The extrusion process requirements are very
demanding, with total extrusion times of less
than 5 seconds, and product exit speed of 2

to 8 mps. This means that extrusion speeds

between 50 and 300 mmps are required
(with a tolernace of 3% extrusion speed
variation during one push at 300 mmps).
The new plant is designed to produce pipes
of different diameters and lengths
with a targeted production capacity of
50,000 tpy, and a product mix that includes
plain quality special steel grades and double
metal pipes n
73

CUSTOMER SERVICE

DANEWS

MAINTENANCE AND OVERHAULING PACKAGE

FOR DANIELI SERVICE EAF/LF'S ELECTRODE ARMS

The electrode arms

are one of the most
critical components
of the meltshop area, and
must be monitored
constantly and maintained
to avoid possible accidents
and unscheduled plant
stoppages. These
components must be always
available in stock and ready
to be installed in case of an
emergency. Accordingly,
Danieli is supporting its
customers with a specific
Electrode Arms Package,
in which we analyze the arm
condition and, if needed,
overhaul the arms, drastically
74

reducing the costs of

replacing the equipment
with a new set of arms.
This package is now
proposed as an option to new
spare parts arms supply, or to
customers who seeking to
optimize costs by rotating
and refurbishing the present
sets of arms. The first part of
the package consists of an
annual specialized arms
survey, in which we monitor
the condition of the arms to
define the maintenance
plan, and agree to a
customized overhauling
program to restore the
complete arm condition.

DANEWS 168

According to the above

analysis, specialized actions
will be planned directly onsite, such as:
> Bimetallic plates
machining;
> Arms tail machining;
> Pusher refurbishing;
> Other updates.
In case this approach is
determinated to be
insufficient, a complete arm
overhauling will be carried
out in Danieli workshops,
where we complete the
following:
> Cleaning, disassembling,
and shot blasting;
> Inspection to identify any
possible defects in the arm
structure or welding damage;
> Bimetallic plates
replacement and checks;
> Power cables connecting
area inspection and possible
machining;
> Endoscopic internal
inspection and flushing;
> Final pressure test and
painting;
> Components reassembly.
The Electrode Arms Package
is tailored to the customers
needs and maintenance
policy, and aimed at
preventing the more invasive
-and expensive- action of
complete electrode arms
overhauling, that thus
becomes the very last solution
to the problem. These
services improve the
electrode arms service life,
saving money and time,
needing just a simple
scheduling to check the
proper arms condition and
to replace any worn critical
parts n

After the successful startup of DanJoint spindles at their hot strip

mill, Thailands Sahaviryia Steel Industries (SSI) confirmed its
confidence in DanJoint technology with another order for spindle
supply and HRM stand powertrain upgrading.

DanJoint project accomplished

and a new order received
High-performance,
oil-lubricated gear
spindles were
commissioned successfully
for stand F7 during the
December shutdown at SSI
in Bangsaphan. During that
period from December 16 to
28, the following activities
were accomplished:
> The existing greaselubricated spindles were
removed from the stand,
> The pinion stand was
dismantled and the two
pinions shipped to Danieli
Thailand, where the existing
drive-side hubs that were
shrunken on the pinion shafts
were removed. The new driveside hubs for the new spindles
were installed on the existing
pinions, and properly secured
in place;
> The pinions with the new
hubs were shipped back to SSI
and installed in the existing
pinion stand housing;
> A new oil-collecting tank
was installed and grouted on
the foundation;
> New spindles were installed,
and then cold- and hot-tested;
> Properly adjusting all
lubrication parameters and
recording all technological
working parameters completed
the commissioning.
All activities were properly
scheduled and carried out in
order to complete all actions
within the planned shutdown.
Then, a new order was
discussed, concerning new oillubricated spindles for stand
F6. During one year of work for
finishing stand F7 with the

new DanJoint oil-lubricated

gear spindles, SSI had the
opportunity to verify all the
advantages of DanJoint
technology:
> Drastic reduction of
damages typical for gears with
grease lubrication (like pitting,
abrasion wear, bonding and
fusion),
> High efficiency in terms
of power transmission,
> Low friction between contact
surfaces,
> Increased lifetime of geared
elements, and
> Main economic advantages
(easy maintenance design
concept to reduce operating
costs, drastic reduction of
lubricant consumption and
relevant storage costs, no risk
of human error during
lubrication that may cause

equipment failure, no need

for lubrication maintenance
personnel).
All these reasons convinced
SSI to also replace the
spindles of finishing stand
F6 with the DanJoint oillubricated gear spindles n

Souvenir photo after successful

conclusion of the DanJoint installation.
From left: P. Bootsri (S.MMD),
M. Rugo (Sr. Engineer, DS),
T. Khaengkhan (S.MMD), M. Rovere
(Sales Mgr., Danieli Thailand),
M. Persoglia (Mechanical Engineer, DS).

75

CUSTOMER SERVICE

Baosteel Meishan reconfirms trust in Danieli technology

for high-torque transmission drives

DANJOINT FOR VERTICAL EDGER

In July 2013 Danieli
Service was assigned
a critical order by
Baosteel Meishan, China,
relating to the cardan
spindles for the edger main
drive. The reversing roughing
stand and the edger were
originally designed and built
by a reputed local producer;
recently, cracks appeared in
the key seat at the interface
between the roll side hub
and the spindle yoke. Then,
DanJoint was requested to
analyze the issue and to
propose a new solution to
the problem. Highlights of
the new design are as
follows:
> In order to increase the
service factor, newly
designed spindles feature an
increased size, from 700- to
900-mm rotation diameter;
> Cast yokes were replaced
by forged yokes, made in
HS, Q&T steel;
> Different materials and
designs for yoke and flange
frontal teeth were installed,
to achieve better
performance and longer
service life;
> Very high performance,
case-hardening steel was
used for the cross, in order
to achieve high quenching
effects and high surface
hardness at the surface in
contact with bearing rollers;
> Newly designed cardan
joint, with toothed-type
serration to replace the
keyed connection, thus
avoiding dangerous stress
concentration at the key seat;
> An advanced bearing
design was adopted that
includes inner and outer
rings to prevent yokes and
76

Top: detail of the existing spindles that

shows critical details at the key seat.
Bottom: FEM analysis showing how
the heavy torque load creates heavy
stresses in the key seat that induce
cracks on the spindle flanges.

crosses from any scratches

due to possible overloads or
cobbles;
> Customized maintenance
tools were selected for the
specific application, to be
delivered along with use and
maintenance manuals;
> An optimized grease
lubrication system was
chosen, for more effective
and ergonomic;
> All spindle items are
forged and compliant with
the strictest European
quality standards.
The new order includes two
new 900 S spindles

Souvenir photo at the contract signing, involving Mr. Yang Rui, Meishan Import &
Export Co. Director; Mr. I. Picco, Area Manager, Sales, Danieli Service; and Mr.
Wu Suo Tuan, Meishan HSM Plant Chief Engineer.

DANEWS

FRUITFUL COLLABORATION
DANIELI SERVICE HSM'S
KEY SPARE PARTS SUPPLIES
CONVINCE HIGH-PROFILE
CUSTOMER

MILL STAND

complete with serratedflange frontal teeth on the

drive side and roll side hubs
and one spare spindle.
The new design has been
calculated both for pulsating
and reversing loads and to
ensure high service and
safety factors for the spindle
and all the related
components. This important
order highlights DanJoints
competence in heavy-duty
drives for rolling mills, and
confirms Danielis longlasting, satisfactory
relationship established
with Baosteel n

In November 2009 Danieli was awarded a contract to supply

equipment and service for a complete 1,780-mm hot strip mill
with a capacity of 4.0 Mtpy of HRC.
Two contracts were awarded to Danieli Service to supply
HAGC, bending blocks, shifting devices, and DanJoint geared
spindles for finishing stands F1-F7.
At the end of 2012 another order was assigned to Danieli
Service, to supply additional HAGC and geared spindles
DanJoint for finishing stands. The quality of the equipment
and the project execution capabilities shown by Danieli Service
were so well appreciated that the customer asked
us also to supply the spindles for the No. 1 vertical edger,
modified according to Danielis know-how.
Danieli Service is providing good service and support
to the Meishan hot strip mill and Baosteel Group, and the
target is to continue this cooperation for several more years.

PASS LINE

Baosteel delegation visiting Danieli HQ.

Friendly handshake between Mr. Wang Qiang Min, VP, Baosteel,
and Mr. M. Di Giacomo, Danieli EVP, Danieli Service.

77

CUSTOMER SERVICE

MOLD COPPER TUBE CONDITION MONITORING SERVICE

FOR UNINTERRUPTED CASTING QUALITY

Danieli Service casting knowledge

The ability to analyze

the state of wear of
the copper tubes
during their operating life,
and also to check the correct
taper at delivery time, is
essential in order to ensure
consistent cast product
quality. Danieli has
developed a new laser
instrument to compare
different measurements
made during a copper tube
lifecycle, providing the
ability to monitor the
progress of wear related to
this core element of the
continuous casting machine.
The instrument is useful for
testing the copper tubes
dimensions and geometry,
either before the tube is put
into service or during
operation, to check its wear.
In both cases, when the
measurements do not
comply with the
requirements, or the wear
could be too much, the tube
could be preventively
replaced to avoid product
quality problems. The
instrument, which requires a
single operator, both in the
workshop and on the casting
78

1,995 casting strands designed,

manufactured, and put in
operation worldwide are the solid
basis on which stands our process
knowledge for casting steel.
This is what customers gain from
our consultation on molds
> copper tubes
> and copper plates
condition monitoring
and operations setup support.

DANEWS

1 Main characteristics of laser-based copper tube section measurement tool.

Measuring range

Square sections: from 130 mm to 160 mm;

Copper tube length: from 780 mm to 1000 mm

Accuracy

0.01 mm on tube side; 0.5 mm on tube length

Resolution

0.005 mm on tube side; 0.2 mm on tube length

Repeatability

0.01 mm on tube side; 0.5 mm on tube length

floor, is comprised of a
handle equipped with a
control panel at one end; on
the other end is a rotating
measuring head with a
double laser sensor that
detects the internal
dimensions and geometry of
the copper tube.
Using wireless technology
the tool moves all the
collected data to a portable
PC equipped with dedicated
software to visualize the
measurements of mold taper,
shape, and squareness, in
the form of graphs and
tables.
Moreover, at any time these
values can be compared with
those related to the design
drawings loaded in the
software. Loading the
measurements related to a
copper tube in the Q-mold
package, a historical
database could be created
with all significant data
belonging to a single copper
tube n

2-3 Danieli Service

technicians support
for mould
maintenance and
monitoring of copper
tubes wearing and
working conditions.

3
4 Example of inner-outer bow / left-right measurements: meniscus wear is shown,
the report grants to act process setup adjustments as to preserve casting
quality.
X profile

Y profile

79

CUSTOMER SERVICE

DANIELI SERVICE REDUCES

EAF ELECTRODE CONSUMPTION
at NTS, Thailand
1

Technical support
agreement
once again
demonstrates
the Groups
commitment to be
a reliable partner
for on-site
customer support.

NTS, a company of Tata Steel Group

in Thailand, and Danieli Service
signed a six-month service contract
agreement for the supply of technical support
in order to reduce EAF graphite electrode
consumption. The project started in February
2013 with the arrival of Danieli Service
specialists to conduct a technical site survey,
and to provide practical advice for the
optimization of three major components of
the EAF:
> Danieli Melting Profile;
> Danieli HiRegPLUS electrode regulation
systems;
> Danieli More injection system.
Not only has the intervention achieved an 8%
reduction of electrode consumption, but also
helped to cut electrical energy consumption
by a remarkable margin, with no machine
revamping, to the full satisfaction of the
customer. Danieli specialists will continue to
provide technical support remotely from
Danieli Thailand headquarters, and to give
advice on activities through periodic site
surveys n

%MgO

Chart of saturation isotherm

4
1-2 View of EAF and detail
of the calibration of
flow meter for
electrode cooling.
3 Implementing HiReg
harmonic analyzer and
HiRegPLUS electrical
regulation.
4 Slag analysis and
adaptation for good
slag foaming.

80

20
18
16
14
12
10
8
6
4
2
0

MgO-FeO and
2CaO-SiO2
saturation
liquid
phase
2CaO-SiO2
saturation

10

20

EAF main data

MgO-FeO
saturation

30
%FeO

40

Type

Full platform, AC, EBT

Shell diameter

5,900 mm

Transformer capacity

72 MVA

Tapped steel

75 t

Electrode regulation

Danieli HiRegPLUS

Burners

Oxygen lances

3 x 2,000 Nm3/min

50

EAF Performance

Mar-13

Apr-13

May-13

Jun-13

Electrode consumption (kg/ton)

1.82

1.75

1.66

1.67

Electrical energy consumption (kWh/ton)

386

398

398

378

Average Power-On time (min)

39

39

39

39

Average oxygen consumption (Nm /ton)

34

34

34

34

Average production (ton, on-peak)

44,000

44,000

44,000

44,000

DANEWS

Cost-effective revamping projects

by Danieli Service

In a period of global
financial straits that
continues to have
consequences for the steel
market, revamping projects
are often the best solution
for many steelmakers to
improve productivity and
quality while saving on
investments in new
technology.
Following this perspective,
Danieli Service acquired two
new orders to revamp
existing bar mills, at Aceros
Alfa, Honduras, and at Abul
Khair, Bangladesh.
Aceros Alfa, Honduras

This revamping project

developed for Aceros Alfa is
the first step of a two-phase
program that will upgrade
the rolling mill production
capacity, from 25 to 60 tph,
and increase the plants
functionality without
completely changing the
existing configuration. In this
first phase, the layout of the
plant will be modified to
produce squares and angles
as well. The modifications
include the supply of two
new gearboxes for stands
No. 7 and No. 8, with a new
crop shear between the two
stands; in the finishing mill,
two new stands, No. 11 and

No. 13, will be supplied. In

the finishing area, a new
cold shear will be installed.
Abul Khair, Bangladesh

The project for Abul Khair

will introduce some
important changes in the
actual plant configuration:
with the installation of two
new roughing stands prior to
the existing rolling mill, the
maximum billet size will
increase from 130x130 up to
160x160 mm. In the
finishing mill, new guides
and conveyors will be
supplied, in order to perform
the four-strand slitting. The
installation of a new water
quenching line will improve
the material properties; the
QTB is already designed for
a future five-strand slitting
configuration.

Souvenir photo after successful conclusion of the technical meeting, from

left: Mr. L. Zampa (Senior Engineer, Danieli Service), Mr. A.J. Kattan
(Aceros Alfa owner), Mr. E. Guarini (Danieli Service Mgr. South America),
Mr. E. Kattan (Aceros Alfa Director) and Mr. M. Odorico (Senior Engineer
Technical Assistance, Danieli Service).

These two projects will

require strong cooperation
between Danieli Service and
customers, to provide the
best solutions for a proper
integration of the new
machines in the existing
layouts; in order to obtain
the best results possible, the
teamwork approach taken by
Danieli Service will be the
most important factor for
success n

Aceros Alfa rolling mill revamping project:

Existing equipment
New equipment - Danieli supply
New equipment - Manufacturing
at the customer direction.

81

CUSTOMER SERVICE

MH GUIDE SYSTEMS TECHNOLOGY

at Shanxi Zhongyang Steel, P.R. of China
Left: souvenir photo at the
contract signing ceremony,
with Bao Qing Wang, Steel
Rolling Factory Director;
Bai Junhong, Rolling
Guides Sales Supervisor,
Danieli China; Qi Jun Ying;
S. Capra, Product
Responsible, MH Guide
Systems.

On September 30, 2011 Shanxi

Zhongyang Steel assigned an important
contract to Danieli for modernization of
its obsolete bar mill to the current 700,000 tpy
capacity, with the update to high-quality
production bar mill. After that contract the
customer decided to continue its collaboration
with Danieli for special guide systems, trusting in
the quality of our products and our experience,
as well as in our assistance. Then, the contract
signed with Danieli China covers the supply of
guides for a half-year production (especially for
the 4-slitting process). In order to certify the
global quality of our guide systems, Shanxi
Zhongyang Steel visited Danieli Austria
workshops, where the guides are manufactured.
During the visit, the customer stressed the
importance and desire to work with quality
products made according to European standards,
such as those made in Danieli Austria. The visit
was extremely satisfactory and the customer
expressed again an appreciation for the quality
and professionalism on our guide system
products department n
82

Right: Shanxi Zhongyang

delegation visiting MH
Guides manufacturing
center at Danieli Austria.
Yuan Yu Ping, VP Shanxi
Zhongyang; S. Capra,
Product Responsible,
Danieli MH Guide Systems;
Qi Jun Ying, Intl. Dept.
Manager; S. Bergamasco,
Operation Manager, Danieli
Austria.

DANEWS

Successful maintenance project

at Chengdu Iron & Steel, P.R. of China

CHENGDU I&S, PAN GANG

GROUP, RECOGNIZES DANIELI
SERVICE CHINA AS A RELIABLE
PARTNER FOR ADVISORY
SERVICE FOR IN-HOUSE CAPITAL
EQUIPMENT MAINTENANCE.
Pangang Group Chengdu I&S Co. is
an important source of construction
steel in Sichuan Province. As of
March 2013, the imported wire rod mill
equipment has been running continuously
for nearly four years. As part of a preventivemaintenance program, the steelmaker
organized an annual maintenance schedule,
and urgently requested Danieli Service to
visit to the production site and provide
advisory services. Danieli Service responded
positively, organizing a squad of experienced
professional and technical personnel that
hurried to the customers site, and delivered
high-level technical support to ensure that
the client would complete all maintenance
tasks within the stipulated time.
The main maintenance activities were carried
out on critical components of Danieli
equipment of the WR mill, namely:
> 8-pass DWB wire rod block;
> 4-pass TMB high-speed finishing block;
> Oil-film bearing-type loop laying head;
> Shear.
Key aspects of Danieli technicians support
have included:
> Equipment inspection on site
> Analysis of the issues with the customer
> Fix detailed maintenance actions
> Refurbishment on-site
> Final check of the equipment startup
> Detailed plan for effective solution to the
customers spare parts shortage problems.
Once more, Danieli Service confirms
its role as a valuable resource for qualified
technical support and 24/7 troubleshooting
capabilities n
Although the customer planned a three-week maintenance
period for this wire rod line, Danieli completed all the
activities, one week earlier than originally planned.
For any refurbishment project, Danieli China is completely
self-sufficient thanks to its state-of-the-art workshops that
support customers on a 24/7 basis.

Customer compliments Danieli Team:

...Allow me to express my sincere thanks to your company, who attached
great importance to the WRM annual maintenance, actively preparing for
the deployment of manpower in this busy schedule, and sent three
comrades to our factory for tracking and technical guidance! The three
comrades arrived at the scene and went to work immediately. They give up
the rest of their holidays to work alongside our on-site personnel. The
atmosphere of cooperation was very smooth and pleasant. Your company
gave full technical support for equipment inspection and installation, and
enhanced our understanding of the equipment. Therefore, for this
technical support we express thanks to your company! I hope we may
work together again in the future to help each other, learn from each
other, for mutual benefit and to seek common development, working
together and achieving better results.
Pan Gang Group Chengdu Iron & Steel Co., Ltd and Wire Plant

CUSTOMER SERVICE

DANIELI OPERATIONAL EQUIPMENT

adapted to exploit rolling line
production capabilities
Customized Danieli Service operating
equipment is the reliable foundation
on which to build production flexibility,
so as to satisfy the increasingly strict
market standards for a wide product mix
availability, and a fast response to any
supply request.

Successful workshop
tests and inspections
were carried out for
two new cartridge stands at
the Hadeed rolling mill.
Both stands were
successfully tested in the
Danieli workshop under
direct supervision of Hadeed's
Roll Shop Long Products
Superintendent: every
critical component and every
alignment measure was
checked and approved by the
customer. Additional tests
were required by the
customer during an
inspection visit, such as dyepenetrant inspection on the
chocks. Particular care was
84

taken to set the correct

alignment between the rolls
and the rest bar, so as to
minimize the effect of the
wear on the guides and to
align the stand perfectly;
additional improvements
have been added to the
cartridge stands in order to
optimize the customers
workshop activities n
Snapshot of the commissioning stage
in Danieli HQ workshops. Friendly
handshake after successful test
conclusion, in the presence
of Mr. Khalid Al-Suhail (roll shop
superintendent of the long product
plants, Hadee), Mr. K. Emam (Danieli
Service Area Mgr.), Mr. S. Lucchetta,
(Project Mgr., DS) and Mr. L. Zampa
(Senior Engineer, DS).

ELIAL
I
N
DA IGIN ARTS
OR ARE P THS
SP RENG
ST

> Flexible supply structure,

offering:
- LTSA Long-Term Service
Agreement to minimize
delivery time and spares
storage requirements.
- Emergency spare
assistance as a troubleshooting service.
- Spares, for preventive
maintenance.
- Capital parts spares
contracts, to reduce repair
time.
> Plant engineering and
startup, maintaining
continuous feedback, and
able to lead continuous
improvement on spare
selection and
manufacturing.
> Spares implemented
by a new solution in order
to improve equipment
performances.
> Maintains equipment
value through the years.
> Danieli proprietary brand
technological products.
> Consulting service to
optimize spares
management to avoid

hidden production costs.

> Warranty
> Asset preservation
> Enhance the value
of equipment
> Reduce inventory n

DANEWS

Danieli Training earns renewed trust

thanks to its learning methodology

AS A RESULT OF THE LONGSTANDING PARTNERSHIP

WITH ITS CLIENTS,
CONTINUING
AFTER PLANT STARTUP,
DANIELI HAS RECEIVED
TWO IMPORTANT ORDERS
FOR TRAINING ACTIVITIES.
Following the conclusion of three
customized training projects for their
engineers, during which Danieli
provided 150 man/days of training in
classroom and selected similar plants,
for a total of 990 trainee/days, Saudi Iron
& Steel Company (Hadeed), the largest steel
producer in Saudi Arabia (fully controlled by
Sabic) placed an open order with Danieli
Service for future training packages
that will cover all the disciplines and
technological areas.
This will allow Sabic to place orders
immediately, to cover their training needs,
and will guarantee the immediate
programming of the training, as all terms and
conditions have already been defined.
In June 2013 EZZ Dekheila placed an order
for a complete training package for its
engineers and supervisors. A detailed training
program (total duration, 35 weeks) was
designed to include theoretical and practical
courses to cover each plant area for a total
of 175 instructor man/days and 1,050
trainee/days.
The entire training program was developed
for different groups:
>
>
>
>
>

Rolling mill for long products,

Meltshop area,
Slab caster,
Rolling mill for flat hot products,
Academy training for plant managers.

Each course will consist of theoretical

classroom lessons and training at similar
plants n
85

CUSTOMER SERVICE

Capital equipment spare parts supply

Danieli drum shear

Danieli designed and manufactured

a complete drum shear cassette to be
installed in an existing hot-strip mill.
The shear cassette underwent the final tests at
Danieli workshops, in the presence of one official
from the customer. Special tools designed to
simulate the operational dynamics are used to
guarantee the cassette performance. The testing
plan, as agreed with customers maintenance
and production staff, included rotating drums
to measure the main gear action path, knives
clamping/unclamping, and knife-gap adjustment.
All the structured testing sequences have been
performed and completed successfully, and
the signature of the dispatch clearance
certificate gave a green light for packing
and transport to the plant. The shear is designed
to cutting/chopping strips of API pipe grades,
HSLA, and carbon steels in the thickness range
from 25 to 40 mm. The supply also includes
Danieli manufactured knives in DanCut 510.
As part of the sales contract, Danieli Service also
will provide advisory service for the first
installation of the cassette into the rolling mill,
to follow the cold and hot commissioning up to
full customer satisfaction n

For capital equipment spare parts,

Danieli Service carries out in-house
functional tests, sharing results and
final commissioning with the customer.
This approach guarantees both
a dramatically reduced installation
and on-site testing period, as well
as a truly "ready to go" startup.

86

DANEWS

TECHNOLOGICAL REVAMPING

DANIELI KOHLER
NON-CONTACT EDGE
BAFFLES FOR HDGL
AIR KNIVES:
STRIP-COATING
QUALITY WITH
MINIMAL CAPITAL
INVESTMENT.
Today's steel
industry has a
limited need and
capability for expansion,
which makes it extremely
important to improve
product quality with minimal
capital investment. Steel
Dynamics, Inc. of Butler
(Indiana) has two galvanizing
lines whose pot areas are
identical except for the style
of wiping equipment
supplied by Danieli Kohler's
predecessor, Kohler Coating
Machinery Corporation.
CGL1 is used to coat
heavier-gauge materials,
mostly hot rolled product,
while CGL2 is for lightergauge cold rolled product.
Due to the combination of
low line speed and heavy
coating weight SDI
experienced edge
overcoating on CGL1, which
was the source of customer
complaints. SDI approached
Danieli Kohler to make a
proposal for Danieli Kohler's
NTLT non-contact edge
baffle for CGL1.
In conjunction with Danieli
Service, Danieli Kohler
analyzed the request and
suggested including CGL2
as well, even though that
line had shown no problems
with edge overcoating, thus

taking advantage of a
common design and shared
maintenance strategy, and
standby equipment, which
made the proposal
economically attractive. The
system improves zinc coating
uniformity by avoiding air
turbulence generated by
opposing knives airflow
crossing at the strip edge,
and reduces noise. A
dedicated automation
control system dynamically
controls the baffle position,
referring to the non-contact

strip position sensor, and

the dedicated automation
is interfaced to the line
automation. Maintenance
software tools are anticipated
to help calibrate and
diagnose the
mechanical/electrical
system.
The design is tailored and
focused to supply preassembled and precommissioned components
for an easy
and quick installation
and commissioning at site n

Danieli Kohler edge baffle

equipment:
1 Baffle plate.
2 Edge baffle mechatronics
drive.
3 Sensor for strip position.
4 Elevator positioner
(existing).
5 Tomahawak mechanism
(for maintenance).

Quality for galvanized

strip production

for Steel Dynamics, USA

DANIELI
THE
RELIABLE
INNOVATIVE
PARTNER
TO BE
FRONT
RUNNERS

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@brazil.danieli.com
Tel (55) 11.35085900

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

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

info@russia.danieli.com
Tel (7) 903.6001990

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

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

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

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

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

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

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

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

info@turkey.danieli.com
Tel (90) 232.4355577

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

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

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

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

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

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

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

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

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

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

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

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

www.danieli.com
info@danieli.com

88

Danieli Centro Tube seamless

pipe plants are equipped with
cone-type piercing mills,
original FQM-Fine Quality
Mill (3-roll retained mandrel
mill) and sizing/stretch
reducing mill to roll tubes with
close dimensional tolerances.

DANIELI CENTRO TUBE,

SEAMLESS PIPE TECHNOLOGY
TO PRODUCE
UP TO 28 DIA API GR 1 TO 5
AND UP TO 160 PIECES/HOUR

Since 2004 Danieli Centro Tube designed and built

12

Seamless pipe plants

1914 / 2014

Seamless Pipe Plants

DANIELI
CENTURY

DANIELI THE RELIABLE

INNOVATIVE PARTNER
TO BE FRONT RUNNERS

800 -MM ROUND BLOOMS

IN SPECIAL ENGINEERING STEELS
CAST ON A 5-STRAND CASTER
at Laiwu Steel Co. Ltd. PR of China

MORE THAN
20,000 TONS
OF BLOOMS
IN SECTIONS
OF 500-650-800 MM
PRODUCED
IN JUST ONE MONTH
AFTER
THE FIRST HEAT

This is the only Continuous Casting Machine in the world that features five strands and 16.5-m radius,
equipped with all the most advanced technological packages, and designed for the production of demanding
steel grades such as automotive, spring, free-cutting, bearing, and gear steel.