IN THIS ISSUE: DANIELI NEWS FOR THE TRUE GREEN METAL INSERT

Danieli is steadily evolving to usher the customers into a new era: breakthrough technologies
to preserve the environment. Renewable sources, H-MIDA, QSP-DUE are just some of the
concepts behind Danieli’s push to be a step ahead in tools for a greener future.

DaNews 184 SEPTEMBER 2020 Danieli Group

DANIELI NEWS
N.184 SEPTEMBER 2020
DANIELI GROUP

DaNews 184

A STEP AHEAD
TECHNOLOGY
TO HIT RECORDS
Jumbo size beam blank cast.
119.6 m/s 6-mm wirerod
average production speed.
Greenlit 3.5-Mtpy QSP
thin slab casting
and rolling commissioning.
Excellence in thick slab caster
to produce ULC
and IT steel grades.
DANIELI A step ahead technology to hit records danieli.com
[The new Danieli advertising campaign] [The new Danieli advertising campaign]

TWENTY DANIELI TECHNOLOGY ANSWERS TWENTY DANIELI TECHNOLOGY ANSWERS

TO BE A STEP AHEAD TO BE A STEP AHEAD

Danieli
03 Danieli
10

ANSWER

ANSWER
Answers Answers
to be to be
a step a step
ahead ahead

Danieli DIGI&MET Danieli Turboflo+OSRT

benchmark technology benchmark technology
Efficient, quality pickling
and strip cold–rolling

An Intelligent Plant is a manufacturing organization The coupled Pickling Line and Tandem Mill installed at
strongly supported by digital assets (systems, sensors, Yildiz Demir Çelik, Turkey, is the most advanced PLTCM,
equipment, etc.) which are fully integrated for the best and allowing unmatched ease-of-operation and product quality.
most efficient synergy between humans and machines.
The Turboflo® pickling line with energy-saving patented
Processes are automatically and autonomously improved, technology and preceded by a powerful scale breaker
and decision-making supported by data and statistics. improves efficiency and flexibility.
3QPulpit is Danieli Automation’s innovative and proactive
pulpit for a no-man-on-the-floor approach. The Danieli Wean United 6-high tandem mill features
original Danieli OSRT control for superior strip flatness and
From one 3QPulpit the whole production line or even Danieli Automation mathematical models.
multiple lines can be safely and efficiently controlled by a Final strip thickness of 0.20 mm and widths up to 1,550
few operators. 3QPulpit enriches, simplifies and empowers mm are achieved for DP600, DP1000, IF and HSLA
the operators’ experience, providing the right information at automotive products.
the right time by collecting Big Data directly from the plant,
with 360° video monitoring so operators can safely navigate Ultra-low hysteresis HAGC, X-Dry for 20x greater strip
dangerous or inaccessible areas, even analyzing past drying capacity, and D-Rec automatic eccentricity
events. Events requiring user interaction are conveniently compensation algorithm are featured too.
Twenty 09. Quality slab casters proposed as questions directly on the Operator Assistant. Strip thickness tolerance down to ± 0.6%, head/tail off-
Danieli answers 10. Pickling and cold mills gauge length lower than four meters, and strip flatness less
Twenty 09. Quality slab casters
to be a step ahead 11. Galvanizing / Air knives The result is a sustainable plant where Key Performance Danieli answers 10. Pickling and cold mills than 6IU are achieved.
12. Billet casters Indicators are measured, energy consumption is optimized, to be a step ahead 11. Galvanizing / Air knives
01. Sustainability 13. Billet welders 12. Billet casters One week after commissioning the newly suplied PLTCM
02. CO2 reduction 14. Wirerod mills
and quality is monitored and adjusted in order to produce
more with less. 01. Sustainability 13. Billet welders already was producing at more than 60% nominal capacity,
03. 4.0 intelligent plant 15. Rail and section mills 02. CO2 reduction 14. Wirerod mills
danieli.com 04. MIDA ECR 16. The Drawer sizing block 03. 4.0 intelligent plant 15. Rail and section mills
and after 2 weeks 20,000 tons were produced in first
05. QSP DUE 17. Reheating systems 04. MIDA ECR 16. The Drawer sizing block quality, for almost all contractual steel grades.
06. Digimelter 18. Seamless tubes 05. QSP DUE 17. Reheating systems
07. Energiron DRI 19. Extrusion lines 06. Digimelter 18. Seamless tubes
08. Long-life BF 20. Aluminium mills 07. Energiron DRI 19. Extrusion lines
08. Long-life BF 20. Aluminium mills

danieli.com

You can learn about these winning 01. Sustainability

02. CO2 reduction
11. Galvanizing / Air knives
12. Billet casters You can learn about these winning 01. Sustainability
02. CO2 reduction
11. Galvanizing / Air knives
12. Billet casters
technology solutions from 03. 4.0 intelligent plant
04. MIDA ECR
13. Billet welders
14. Wirerod mills technology solutions from 03. 4.0 intelligent plant
04. MIDA ECR
13. Billet welders
14. Wirerod mills
the advertising pages published 05. QSP DUE
06. Digimelter
15. Rail and section mills
16. The Drawer sizing block the advertising pages published 05. QSP DUE
06. Digimelter
15. Rail and section mills
16. The Drawer sizing block
in the international steel and 07. Energiron DRI
08. Long-life BF
17. Reheating systems
18. Seamless tubes in the international steel and 07. Energiron DRI
08. Long-life BF
17. Reheating systems
18. Seamless tubes
nonferrous metals magazines. 09. Quality slab casters
10. Pickling and cold mills
19. Extrusion lines
20. Aluminium mills nonferrous metals magazines. 09. Quality slab casters
10. Pickling and cold mills
19. Extrusion lines
20. Aluminium mills

DANIELI.COM DANIELI.COM
DaNews Danieli News No. 184 September 2020 Contents

Edited by
Danieli Advertising Dept. — EDITORIAL 3
(39) 0432.1957969
info@danieli.com
Rolando Paolone

Graphic Design
polystudio.net
Francesco Messina
Andrea Morandini
Fabio Toscano
— IRON & STEELMAKING 14
Photographs
Alessandro Paderni
(Eye Studio)
Archivio Danieli

Printed in Italy by
Grafiche Antiga
Crocetta del Montello — FLAT PRODUCTS 26
Treviso

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

— LONG PRODUCTS 57

— AUTOMATION 82

— CROSS PRODUCTS 92

— ORDERS & STARTUPS 122

— DANIELI NEWS FOR THE TRUE GREEN METAL

Insert
DANEWS 184

2
 EDITORIAL

Danieli research into emissions reduction

and innovations in energy savings promotes the goals
of an environmentally responsible industry

DEVELOPING TECHNOLOGIES
TO SUPPORT
SUSTAINABLE STEELMAKING

Edited by n the past, steel producers around essary to advance steadily and quickly to-
Rolando Paolone I the world were focused mainly on
increasing productivity and product
wards such goals.
Carbon dioxide (CO2) is the main issue
quality, as a way to either strengthen or in- when thinking about greenhouse gas emis-
Chief Technology crease market share. sions.
Officer, A plant's output, with focus on transforma- This is gas that is commonly present in
and Member tion costs, is key for the producer's Return nature: it is emitted by animals, human
of the Group on Investment (ROI) for capital expenses beings, plant respiration and decomposi-
Executive Board (CapEx) and operating expenses (OpEx). tion, and it is regularly transformed through
Danieli In this century, and mainly for the Western different natural processes, such as plant
Hemisphere, arguments like workers’ safety photosynthesis: to foster their growth, they
and environmental issues have become absorb CO2 and release oxygen instead.
more and more important for steel industry Industrial activities have increased CO2
sustainability. emissions, using fossil fuel to produce en-
Proper use of resources, circular econom- ergy, resulting in an unbalanced system.
ics, and reduced emissions are concerns The diagram in (Figure 1) shows the per-
that regularly rise on the list of companies’ centage of greenhouse gases emitted by the
top priorities. different sectors, while (Figure 2) highlights
Individual nations have grown to under- the trend versus the target fixed by the Paris
stand the importance of environmental Agreement.
sustainability and have defined emissions The 2020 target was reached in Europe
targets from 2020 to 2050 (starting with in 2016, while the next target is extremely
the Kyoto Protocol in 1997 and, in greater challenging: assuming the current trend
detail, with the Paris Agreement in 2015). remains steady, the 2030 objective will be
The action plan outlined objectives and missed.
dates for steps needed to reduce green-
house gas emissions (GHG), keeping tem- “On average, 1.85 tons of CO2 were emit-
perature increases below the 2 °C thresh- ted for every ton of steel produced in 2018:
old, with a target of zero emissions by 2050. The steel industry generates between 7%
To do so, the EU has been asking industrial and 9% of direct emissions from the global
organizations to develop technologies to use of fossil fuel”. (Source: worldsteel.org).
help reach this ambitious goal, while help-
ing fund relevant research activities. The main routes for crude steel production
Structural changes require decisions and (Figure 3), depending on raw material (iron
strong actions: in recent years the steel ore or scrap) and process (for iron ore: BF-
community understood that, because the BOF or DRI-EAF) have completely differ-
defined dates are inching closer, it is nec- ent CO2 emission rates.

3
DANEWS 184

Pollution world map:

by steadily improving
steelmaking processes,
it'll be possible to
reduce the spread of CO2
emissions.

Bunker fuels
Energy
Land-use change 2 Manufacturing
and forestry and construction
6 12.4
Waste Electricity
3 and heat 31

72
Agriculture 11 15 Transportation

6 5.2
Industrial Fugitive
8.4
processes emissions
Other fuel
combustion

6,000
2. Greenhouse gas
emission trends: emissions,
projections and targets for
5,500
the EU compared against
1990 levels (million tons
5,000 of CO2 equivalents). Source:
-23% in 2016* European Environmental
Agency.
4,500

4,000

3,500 Emissions.
2020 goal: −20%* 2030 goal: −40%*
Projections with existing
3,000 measures based on member
states’ submissions.

1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 (*) compared to 1990 levels.

4
 EDITORIAL

DEVELOPING which is the Q-ONE for the DDM (Danieli

TECHNOLOGIES Digital Melter, our evolution of the EAF).
TO SUPPORT The original MIDA itself, thanks to a pro-
SUSTAINABLE cess that does not need intermediate heat-
STEELMAKING ing, is able to cut almost to zero the direct
CO2 emissions after the melt shop.
Grey electrical energy for motors and arc
furnace electrodes represents indirect
CO2 emissions minimized thanks to the
H-MIDA.
All of this means that, while a conventional
minimill melting scrap will rate close to 400
In this context, processing iron ore into kg CO2/ton of steel, the MIDA will drop
steel through the BF-BOF route results in emissions down to 300 kg CO2/ton steel,
< 1. Global man-made the most pollution, with around 2 tons of with H-MIDA representing another step
greenhouse gas emissions CO2 for each ton of liquid steel, while the towards greater reductions, to approx. 230
by sector.
EAF (from scrap) produces less than 0.4 kg CO2/ton steel.
ton of CO2 for each ton of liquid steel. This rate also can be maintained with iron
In this issue of DaNews a dedicated section ore as the raw material, using our DRI-
will explain how the DRI-EAF route is able DDM using hydrogen (Figure 4).
to cut CO2 emissions in half; and, using hy- Danieli’s approach to environmental issues
drogen instead of natural gas as a reducing is to prioritize solutions that avoid the use
atmosphere, lower the relevant emissions of fossil fuel before investing in energy-
close to zero. recovery processes.
As iron ore represents 75% of the raw ma- This happens thanks to the use of big data
terial in steel production, it is clear how to improve process control, while increasing
fundamental is the transition from the overall efficiency at the same time.
BF-BOF traditional route to the Direct On the other side, in the last 50 years the
Reduction plus EAF. steel industry saw a significant reduction in
Danieli is well present in this scenario energy consumption, resulting in a plateau
with its Energiron technology, a “H2 ready” for the past 15 years, which makes it appar-
process. In the sector, everybody now con- ent that additional and different efforts are
siders H2 a dramatic step ahead for steel required.
production from iron ore.
H2 introduces a transformative shift in Circular economics is a strong asset for the
emissions reduction, comparable to the Group: different solutions are available to
deep change that electrical mobility is reduce the waste, and maximize the reuse
bringing to transportation (from cars to of resources in every area of the steel plant.
trucks, trains etc.). When reheating is required by the process
The issue arises when we start asking or for existing plants where MIDA and
where the energy needed to produce H2 QSP-DUE cannot be applied, we have de-
(or electricity for EV) is coming from; fossil veloped burners that minimize NOX emis-
fuel is clearly not the answer, since it will sions and increase efficiency to reduce their
maintain the level of CO2 unchanged, but consumption, thanks to a L2 developed for
would just move them away from the user. the purpose.
Then, the next step forward is the creation Minimized scale formation is another target
of green energy from renewable sources, we developed, to be able to increase the
and Danieli is supporting this transition yield to reduce the OpEx.
with hybrid plant solutions. We are ready Compressed air can be produced with an
to supply the H-MIDA, an evolution of the exclusive process directly using the exhaust
well-known MIDA concept for continuous fumes of the RHF.
casting and rolling of long products, able to Relevant details are available in a dedicated
self-produce up to 25% of required energy section of the magazine.
from renewable sources.
We must take advantage of renewable en-
This technology is possible thanks to a dif- ergy that is available, therefore equipment
ferent application Danieli offers, on top of electrification is a step forward for the tran-

5
DANEWS 184

6
 EDITORIAL

DEVELOPING
TECHNOLOGIES Steelmaking routes
TO SUPPORT Fine ore
Recycled
SUSTAINABLE steel
STEELMAKING Lump ore Natural
gas

Fine ore

Lump ore

Coal
Coal
Natural gas,
Blast oil
O2
O2
Natural gas,
oil or coal

Recycled
steel
3. Each of the routes for crude Air
steel production generates a
vastly different amount of CO2
emissions based on both raw
material and process adopted.

4. With Energiron, it'll be possible MIDA Hybrid H2 ready

to make huge strides in green
– 80%
steelmaking: by generating H2 vs BF/BOF
from renewable sources, steel
production emissions will be – 60%
drastically reduced. H-MIDA
vs DRI NG
of CO2 emissions
O2 per ton of l.s.

FastArc
Q-ONE
+ –

Water
electrolisys

Energy
H 2 DRI
Scrap

Energiron
Renewable (H2 – ready)
sources

Left: by working in close contact sition to CO2-free emissions. process) but they also represent the only
with the workshop team, Danieli
R&D engineers adopt On the other hand, the “H2 ready” approach way to significantly reduce the greenhouse
a hands-on approach with their will give the final user the possibility to eas- gases.
projects, while continuously
monitoring every phase in ily convert this gas to hydrogen when it is
the development and testing available in large volumes, securing today’s The pandemic breakout has become an
process.
investments. opportunity to bolster investments, as coun-
tries decide to face the potential recession
In conclusion we can say that most of with huge financial resources. The steel
the technologies needed for a clean “steel industry must take this chance and use the
industry” are already available, and some available resources to establish a low-car-
more will be added soon. bon future and climate-resilient society. |
Sometimes the investments are relevant
(mainly, in the iron-ore-to-liquid-steel

7
DANEWS 184

8
 EDITORIAL

Danieli Research
Center / Activities
Danieli welder after final testing
in our R&D center. Developed
in–house, it is a key tool in the
production of higher quality
bars wirerod products and
especially for the spooler. Now
on its fifth generation, and
able to process 180 mm square
billets, the Danieli welder is a
true testament to our research
center's continuous innovation.

9
DANEWS 184

Danieli Research
Center / Activities
Thanks to the creation of an
in–house 1:1 model, our R&D
center can accurately study
improvements to the stability
of steel casting inside the key
equipment of the production
line. By reducing turbulences
and optimizing component
design, a higher throughput is
reached, with QSP and DUE
being the pinnacle of HRC
production.

10
EDITORIAL

11
DANEWS 184

12
 EDITORIAL

Danieli Research
Center / Activities
HRC quality is ensured
thanks to the control of
thermomechanical production
process. This means excellent
cooling capacity is fundamental:
Danieli R&D developed for
internal–use, a 1:1 model of a
laminar cooling unit to study
the most suitable cooling–rate
approach, based on different
production requirements.

13
DANEWS 184

— IRON AND
STEELMAKING

FastArc® is widely recognized as a pillar technology for scrap

melting process. Outstanding results from its adoption
are confirmation of Danieli's market leadership

FROM EAF TO DIGIMELTER

FOR A SUSTAINABLE STEELMAKING

GHG Emissions
CO² reduction by production of EAF with ECS alternative to BF/BOF
120

100

80

60
Mio tons/year (of steel and CO²)

40

20
0

-20
Compensating total CO² yearly
PA O L O B U R I N emission by private cars in Italy
-40
Vice President
Danieli Centro Met -60

-80

-100
CO² equal to 15 million
anieli Centro Met has been Rainforest trees

D active in the EAF market

since the 1970s and now has
-120
2005 2007 2009 2011 2013 2015 2017 2019 2021

tallied up to 275 EAF installations and

more than 20 sets of ECS systems in-
stalled worldwide.
Danieli has consolidated and enhanced — FastArc Zero-Bucket with ECS new Danieli DigiMelter.
its strong leadership in the EAF steel- Endless Charging System with scrap As a direct consequence of the applica-
making market with a remarkable preheater; tion of state-of-the-art technologies for
number of innovations for equipment, — Q-Melt Automatic EAF process a relatively mature product, the new
process automation control and new optimizer; Danieli FastArc EAF also provides sig-
power technologies, all converging into — Q-One innovative powering system. nificant benefits in terms of OpEx and
more environmentally friendly and less final product competitiveness, resulting
resource–demanding steel making, All these technologies contribute to in a remarkable number of new proj-
such as: advance the conventional EAF into the ects awarded in recent years.

14
 IRON AND STEELMAKING

– 84%
in CO2 emissions
for steel production
with FastArc+ECS®
compared
to BF/BOF

the advantages of the electric steel melt

The global steelmaking scenario is now
facing a metamorphosis driven by dif- shops, in terms of flexibility in adapting 27
ferent powerful levers: environmental to strong market fluctuations as well Danieli FastArc EAF
issues/CO2 footprint and flexibility to as to stop-and-go operating conditions, in 24 months:
rapid market changes. compared to the integrated steel route: more than 1 EAF per month!
The new, recently released, European Many BFs have been shut down due
Green Deal will significantly influ- to the dramatic market decline (in par-
ence the renovation of the steelmaking ticular automotive steel) and there is 15
Q-MELT Automatic
plants towards technologies with highly no restart date planned. It is also ques-
reduced CO2 footprint; many major tionable if the greenhouse gas certifi- EAF process control in 2 years!
integrated steel producers now are cates may be re–issued after these long
exploring the possibility of substituting shutdowns. Most BF users now are in-
the BOF with efficient, cost-effective terested in increasing their capacity for 23
and environmentally friendly EAF's, for EAF melting, but also in introducing Danieli ECS
both long and flat products. flexibility with higher DRI % charges. Endless Charging Systems
In parallel, the dramatic effects of An incremental use of DRI in an EAF with scrap preheating
the global lockdown measures, due to may result in a permanent effect of this worldwide!
COVID-19, have once more revealed situation, toward a final BF shutdown
(at least at some locations.)
The integration of the latest Danieli production purpose. In terms of pro-
Yearly reduction of CO2 technologies into reliable and consis- ductivity, the new Danieli EAF's have
million tons (ECF vs BOF) tent equipment characterized by a high reached impressive levels. EAF Zero
Million tons by ECS, operational flexibility has enhanced the bucket with ECS charging supported
cumulative potentiality of the EAF, to the point by Q-MELT automatic process control
CO2 million tons reduction, that now it is a very attractive alterna- can surpass 40 heats/day on constant
cumulative tive to the BOF route for any final basis, pointing toward 15,000 heats

15
DANEWS 184

SELECTING Jinshenglan orders four sets of Zero-Bucket EAF's with Endless

EAF TECHNOLOGIES Charging System for scrap. This is the most cost-effective,
FOR SUSTAINABLE environmentally friendly and forward-looking approach to steelmaking.
STEELMAKING
FOUR DANIELI FASTARC® EAFs
WITH ECS® SYSTEM IN A SINGLE ORDER!
per year, thanks also to high utilization
factors.
The Chinese market can be seen as
precursor in this respect. There, the
evolution started two years in advance
and now all major Chinese players are
looking to innovative EAF technologies
with high productivity and low OpEx,
as substitutes for older BF/BOF routes.
The impressive record for Danieli in
China, with more than 10 installations
in the last 24 months, is a confirma-
tion of technological leadership of the
FastArc Zero-bucket technology. The GUANGDONG JINSHENGLAN Steel Industry, the group has a total of
low maintenance and the easy and METALLURGICAL TECHNOLOGY, 18 independent accounting compa-
repeatable operation also lead to a very located in Guangdong Province, China, nies, including 13 I&S companies; its
fast learning curve. is a short-process I&S company estab- headquarters are located in Changle
lished in February 2019. Being part of City, Fujian Province, and its subsidiar-
The first EAF+ECS of this type was Fujian Jinshenglan Group Co., Ltd., ies cover Fujian, Jiangsu, Guangdong,
ordered by Guihang Metal Products with a registered capital of 2 billion Hubei, Shandong and other key loca-
Co., Ltd. This furnace is a global RMB Yuan, this new plant will produce tions.
benchmark for its fast-learning curve wirerod, coiled reinforced bar, high-
and high productivity. The plant started quality special steel and high–strength CUSTOMIZED TECHNICAL SOLUTION
up in May 2019, and immediately hot–rolled ribbed steel bar, among
provided some impressive results. The other products. The key factor of this new plant is
achieved milestones are self-evident: Fujian Jinshenglan Group Co., Ltd. the choice of high–productivity core
was established in March 2008, being technologies, which make it possible
— Hot start-up: 5 May 2019; a large-scale diversified steel enter- to reach extremely efficient operat-
— First week: 8 heats in 8 hours; prise group and a national key steel ing results with optimized manpower
—30 heats per day after 26 days; private enterprise, with investments and low specific-energy consumption,
— 35 heats per day after 44 days; in the steel industry, mining, real es- a combination that renders the plant
— Industrial production after 2 weeks; tate, textile industry and import and highly competitive.
— Average 24 heats/day in the second export trade business. Playing a very The EAF’s design was selected accord-
month of production; strategic and important role in China’s ing to the targets set by Guangdong
— Average 30 heats/day in the third
month of production;
— 39 heats per day in the latest pro-
duction!

The meltshop is consistently running

39–40 heats per day now, thus provid-
ing the customer with a very quick
return on investment and high market
competitiveness. An outstanding confir-
mation of the above tendency is repre-
sented by the latest order received from
Guangdong Jinshenglan Metallurgical
Technology. |

16
 IRON AND STEELMAKING

Souvenir picture during contract signing ceremonies throughout the EAF operation. dynamically regulates cooling water
at Guangdong Jinshenglan: A correct configuration of the chemi- flow considering the specific electrode
Chen Jiawu, Vice GM of Guangdong JSL (seventh
from left); Wang Jinxin, Vice GM of Guangdong cal package is essential for faster steel cooling requirements per EAF step and
JSL (fifth from left); and other participants from decarburization rates and minimized electrode, based on the EAF working
Guangdong JSL: Ma Rong, Wei Weike, Chen
Xiangbin, Li Gongjun, Ye Hongjia. steel-bath over-oxidation during refining. points.
On behalf of Danieli: Loris Coianiz, EVP of Danieli Danieli selected a set of high-efficiency Furnace operation and control are pro-
(sixth from left); Paolo Burin, VP of Danieli Centro
Met (fourth from right); Zhang Chang, EVP of Danieli injectors to address the process require- vided by Danieli’s automation systems,
China (fifth from right); other members of Danieli ments regarding chemistry and energy which support the EAF operators to
team: Tao Lin, and Qiu Liqun.
transfer, which are further potentiated manage the furnace operation. From
by the Palmur telescopic wall lance. electrode regulation to the online scrap
Jinshenglan as a critical path of this proj- The Palmur telescopic wall lance recipes and furnace profiles, the EAF
ect. From the scrap charging to melting is particularly suitable for EAF's operators have at their disposal a wide
and tapping, the new EAF's are equipped equipped with continuous scrap charg- range of support tools and embedded
with the latest technologies available. ing because it allows the oxygen nozzle metallurgical models that permit easier
An upgraded design of Danieli’s to be positioned closer to the steel bath and more accurate decisions to reduce
Endless Charging System (ECS®) from the early melting stage, when the process variability. The plant start-up is
feeds pre-heated scrap to each EAF. bath level is low, and when the sidewall expected at the beginning of 2021.
This latest version of the ECS con- injectors are less efficient. Along with
veyor provides the highest flexibility the increase of the steel level inside CONCLUSION
for productivity and preheating effi- the EAF shell, the telescopic lance is
ciency, for a wide range of scrap types. automatically retracted to maintain Following a strategy of constant im-
Chemical exchanges inside the EAF an adequate distance and angle to liq- provements, Danieli’s EAF's are contin-
are promoted by both the “diving pool” uid steel. The combination of the DP uously updated, profiting from the latest
design of the bottom shell (DP Shell) design, chemical package, telescopic available developments: they’re able to
and the high-performance chemical lance and dynamic electrodes regulator produce more than 10,000 casts/year,
package. The asymmetric design of the (Q-REG) is a key factor rendering op- thus reducing electrical consumption
DP Shell works as a thermal energy timal foaming slag practice conditions and electrodes usage. Recent years of
reservoir, promoting the energy transfer that maximize Active Power from the steelmaking development have demon-
between the molten bath and the scrap beginning of the heat, thus optimizing strated this is an industry eager for tech-
arriving from the ECS. Together, DP operating costs. nological improvements and solutions:
Design and supersonic injectors permit Optimizing operating costs also means thanks to Digital Melter, Danieli’s goal
slag foaminess from the early stages of minimizing the electrode consump- is to exceed 15,000 casts/year, with a
melting, enhancing faster and more ho- tion. In this regard, all four EAF's are 10-15% further reduction in energy con-
mogeneous conditions from melting to equipped with the Q-SmarTEC dy- sumption and 15-20% less electrodes
tapping phases. The result is the practi- namic electrode cooling system, which wear. |
cally constant flat-bath operation with
the arcs covered by foaming slag

17
DANEWS 184

Dynamic flux control promotes extended shell life and chemistry

control during melting process to increase steel quality

LATEST Q-MELT UPDATE FOR SLAG

MANAGEMENT DURING REFINING

of refining to determine the recipes trol parameters and the target IB3,
for slag-builders for successive heats. impacting the slag-builders static set-
This is done within the same produc- points (static recipe). Q-MELT will
tion campaign, where it is foreseen that override the static set-points upon the
the charge-mix has limited and gradual information coming from the preced-
variations. ing heat slag analysis and the process
The slag-builder recipe calculation requirements of the running heat to
is done during the heat preparation achieve the target IB.
step, taking into consideration the slag
analysis of the previous heat, and recal- During the tests in the pilot plant, the
culated for all melting steps in order to slag composition was analyzed compar-
PA U L O D A C O S TA absorb eventual variations of the scrap ing the standard percentage deviation
Manager, Technical Sales mix weight and composition. of Fe2O3, MgO, CaO and IB2 during
Danieli Centro Met
The slag management page makes it three different periods.
possible to set the Basicity index con- The results in the diagram show that

n innovative technology that

A already counts 17 references
worldwide since the first
Pilot plant - Percentage standard deviation
during different periods of production.

commissioning in 2015, the Q-MELT

automatic control for electric arc fur-
nace melting has been demonstrated to
be a strong ally for a stable EAF opera-
Fe2O3
tion and optimization of transformation
costs
MgO
Danieli promotes continuous improve-
ment of Q-MELT to bring our custom-
ers an up-to-date system capable of CaO
facing the diverse challenges of EAF
operation. In this sense, Danieli has
made available a new feature that IB2
makes it possible to optimize slag
chemistry and flux utilization during 0 10 20 30 40 50 60 70 80
refining.
After 1 year After 2 months Before Q–melt
To further improve the slag chemistry,
reducing its variability from heat to
heat, the Q-MELT provided with slag
management control makes use of the
slag samples taken during last stages

18
 IRON AND STEELMAKING

+17%
extension for shell
campaign duration compared
to previous campaigns

the standard percentage deviation of significantly related to the opening FeO

Fe2O3 was reduced by 26%, that of content. The fact that the measured
MgO by 69%, CaO by 32% and IB2 by FeO remained practically unchanged
7%. After comparing the analyses car- reinforces the fact the automatic con-
ried out on heats before and after slag trol system can change the fluxes and
control, the result is that the standard automatically manage the decarburiza-
deviation of IB3 decreased by 26%. tion process without negative impact
A variation in the slag chemistry im- on the yield.
plies a required capacity to control oxi-
dation during the refining period. The higher consistency and repeat-
Q- MELT SLAG ability of the slag conditions benefited
Reduction This is done by the soft-landing logic the refractory life. The shell campaign
of standard deviation that dynamically adjusts oxygen injec- duration was extended by 17% with
for slag contents: tion to reach the final carbon content respect to the previous campaigns. This
and temperature without over-oxidizing result was achieved in the first three
the heat. months of operations after Q-MELT
-26% Fe2O3 The samples were taken in a 6 to 7 was further consolidated thanks to
-69% MgO minutes timeframe, and it was ob- improved oxidation control (steel and
-32% CaO served that the average result is FeO slag) during the refining stage, and
-7% IB2 reduction by 0.05%: FeO increases thanks to the reduced variability in the
and decreases were observed, being slag basicity. |

19
DANEWS 184

TARGET HIGHER
STEELMAKING EFFICIENCY
AND PRODUCTIVITY
Meltmodel HMI: carbon content
Modernization projects prediction and dynamic adaptation
of oxygen injection profile.
in Korea and Bangladesh

over the preceding years in relation

DANIELI Q-MELT to the special charge mix in use. Wall
FOR SEAH BESTEEL, KOREA injectors are employed together with a
door lance, with the latter being pre-
— Revamping project ferred in the first part of the process
SeAH Besteel is the largest special to enhance the melting of the heavy
steel producer in Korea. This project blocks, which is not possible to achieve
aimed to increase process efficiency for by a proper burner phase (use of fuel
EAF #3—a 100-ton electric furnace is avoided due to its cost). In this con-
installed at the Gunsan meltshop. The text, the high oxygen intensity needed
steel quality targets indicated for this to melt the heavy charge frequently
furnace require use of low-residual resulted in variable and unpredictable Q-MELT technological
scrap, which results in very dense carbon contents at the end of refin- package results
charge mixes. The need to avoid over- ing stage. Moreover, it was clear that at SeAH Besteel
oxidation—thus, to maximize process there wouldn’t have been any margin
repeatability and steel quality—togeth- for further increasing chemical oxida- +2%
er with the target of maximizing arc sta- tion energy, so that the only margin for average active power
bility and active power in presence of productivity increase was to maximize -2 %
high-density scrap, were the major rea- active power. energy consumption
sons for the selection of the Q-MELT The following capabilities of Q-MELT -15 %
technological package. perfectly matched the targets: deviation of steel oxygen
— Q-REG electrode control regulator; content
— Achievements — LINDARC real-time gas analysis,
For the revamping project, no modifica- laser based, with closed-loop control of
tion of the injection system was imple- soft-blown oxygen during scrap melt-
mented, since it had been optimized ing; and,
— MeltModel for dynamic adaptation
of oxygen flowrate setpoints during
refining, according to bath oxidation
levels.
The results can be summarized as a
2% increase in average active power, a
2% reduction of electrical energy con-
sumption, and a 15% standard devia-
tion decrease of oxygen content in the
steel before tapping.
The achieved results and the strong
collaboration established between
SeAH Besteel and Danieli technologi-
cal and research teams paved the way
for further improvement of dynamic
control logics for the refining stage,
which has been developed recently
due to the unique features of EAF #3
process. Early oxygen utilization to

20
 IRON AND STEELMAKING

melt scrap together with late carbon Since the necessary use of clean scrap — Electrode consumption < 10 g/KWh;
injection during flat bath operation also limits sulfur at tapping, desulfur- — Delivery time (time elapsed be-
make the last refining phase much like ization is carried out in the LF during tween 2 consecutive LF treatments)
a slag reduction stage. For this purpose, commissioning heats has been in the < 40 min.
additional controls on dynamic carbon order of 15%, adequate to ensure the Thanks to the well-proven design, to
injection flowrates, as well as electrical final product chemical analysis and the process flexibility provided by the
power and oxygen turn-off timing, were mechanical properties according to two ladle cars, and to the strong col-
implemented. specifications. laboration between BSRM and Danieli
Gas pickup was limited thanks to the teams, all the performance guarantees
roof design, together with adequate arc have already been reached before
covering, resulting in a low number of normal operation soon after commis-
DANIELI LADLE FURNACE pinholes/blowholes in the cast product. sioning, not even requiring any official
STARTUP AT MIRSARAI MELTSHOP, dedicated PGT test period.
BANGLADESH — Achievements The LF station at the BSRM Mirsarai
All LF performance guarantees have steel plant is able to deliver steel to the
been achieved: CCM with correct timing and steel
— Heating rate > 4.5 °C/min; temperature and composition, ensuring
— Specific energy consumption < 0,52 high quality to the final product as well
KWh/°C/t; as high productivity to the meltshop. |

— The Project
The Danieli single-roof, 55-t LF station
supplied to Mirsarai plant (Bangladesh)
is equipped with two, 90-degrees-ori-
ented ladle cars and acts as a secondary
metallurgy unit between two induction
furnaces and a Danieli 3-strand billet
caster producing 160×160 mm sec-
tions. The IF-LF-CCM line supplies
approximately 480,000 tons per year of
additional billets to the BSRM opera-
ton.
The LF power system consists of a 10
MVA +20% transformer, bus-bar arms,
and 14-in. electrodes.
The LF roof is inert type to minimize
O, N, H pickup in the steel. Its aux-
iliaries are a 2-strand wire-feeder and
+ 480,000
a raw-material handling system. The
tpy billet production capacity
station is configured to produce re- for BSRM meltshop
bar grades according to ASTM A706/ after plant upgrading
A706M, BS4449, ISO 6935-2, as well
as low- and medium-carbon for general
application.
The novelty of this LF station is its
operation downstream of an IF battery.
It is understood that this type of melt-
ing unit cannot ensure any consistent
phosphorous removal, therefore scrap
quality is critically important to final
product composition.

21
DANEWS 184

Minimizing operating risks under all process conditions.

EXPERT ASSISTANCE AND PROCESS

KNOW-HOW FOR BLAST FURNACE OPERATION
IN TIMES OF CRISIS

R O B VA N O P B E R G E N
Manager Operational Assistance
Danieli Corus

RESPONDING TO A CRISIS Still, past crises have consistently dem- and secure commissioning. Taking into
onstrated that the quickest possible account aspects such as heat-source
hile the DRI and Electric response to faltering demand or uncer- availability and slag chemistry, a post-
W Arc Furnace production
routes account for a sub-
tainty is vital for a steel plant’s viability.
During the present crisis, the industry’s
shutdown burden is designed and
made available and a shutdown plan
stantial share of global steel produc- response has been unprecedented and for replacing the existing burden (and a
tion, the blast furnace has remained blast furnaces around the world have number of other preparation measures)
at the heart of most large-scale steel been shut down or adjusted to lower is drafted. Ideally, the furnace is even
plants. Modern blast furnace ironmak- productivity exceptionally quickly. blown down to tuyere level and the
ing operations have pushed the limits That same nature that makes the blast liquid salamander tapped. Any (rela-
of the process, in terms of efficiency, furnace unsuited for quick response at tively) unprepared shutdown will lead
and increased levels of instrumenta- the same time implies that restarting to increased risk of process instability,
tion, automation and know-how have or ramping up the process after such tapping problems or lack of thermal
greatly improved the operator’s grip on a quick response may be difficult, or reserves during restart.
the process. even risky. Mitigating these risks requires very
However, the majority of blast furnace specific expertise with respect to out-
process parameters are measured and of-normal blast furnace operations,
monitored indirectly and control mea- OPERATING RISKS preferably supported by a controllable
sures have a delayed response of up to external heat source, such as oxy-fuel
six hours. Therefore, the blast furnace Shutting down a blast furnace for a lance equipment.
is—by nature—not ideally suited for quick and especially secure restart re- Any substantial downward adjustment
quick response to changing circum- quires appropriate preparation because of productivity introduces a similar risk.
stances and fluctuating demand, and the optimal burden composition for The furnace is operated far outside its
every operator is aware that a hearth efficient and stable operations greatly design operating window, putting effi-
chill may only be one shift away. differs from that required for smooth ciency as well as operating stability un-

22
 IRON AND STEELMAKING

Danieli Corus
Blast Furnace technology
is the only one
whose capability of achieving

lifetimes beyond
30 years
is beyond debate—also at coal
injection levels up to 250 kg/tHM
and under out–of–normal
and irregular process conditions

der pressure. As an example, adjusted In addition to strictly process-related problem-free operation resulting from
burden composition and charging strat- issues, operators are managing the pro- improved process know-how, better
egy, combined with existing or adjusted cess based on very different operating instrumentation and increased automa-
coal injection and hot blast enrichment rules and procedures than those they tion.
practices, may have consequences for have been accustomed to in the past.
furnace permeability—and as such for These out-of-normal conditions stretch
heat transport/transfer and metallurgi- know-how to its limits, requiring re- PROCESS UPSETS
cal activity. These consequences, such sourcefulness and a wide experience.
as sudden increases in direct reduction, This may seem a stretch for operators The ability to steer the process away
may be difficult to oversee and predict. accustomed to continuous, relatively from escalating upsets and their conse-

23
DANEWS 184

EXPERT ASSISTANCE plants around the world can be sup-

AND PROCESS KNOW-HOW ported simultaneously, and with much
FOR BLAST FURNACE shorter lead times. Also, a wider range
OPERATION IN TIMES of expertise than ever before can be
OF CRISIS available to each of these teams during
a specific support project—allowing
for more comprehensive analyses and
optimized project scopes, to name but
a few advantages.
Danieli Corus experienced technicians During a remote support project, a
operating remotely and on-site for baseline is first established by means
customer support. Above: Rob van of process analysis, with or without
Opbergen, Manager Operational
Assistance. Below: Geerard Acda, remote access to a furnace’s Level 2
Services Department. system or process instrumentation.
During an accelerated desk study and
quences during restarts and ramp-ups conference sessions with the plant’s
also relies on the ability to spot early operational stakeholders, the process
signs. As expert systems so far have is assessed, targets are defined, and
no proven capability to predict and roadmaps are prepared. This approach
mitigate all such events and cannot be applies for process restarts, stabiliza-
relied on entirely in this respect, steel tion and optimization. In connection to
producers are running an increased these roadmaps, key indicators for criti-
risk of process upsets remaining unno- cal areas and parameters, such as raw
ticed. Similarly, steel producers are not materials, burdening, thermal state,
always aware of the potential impact, slag chemistry and tapping practice are
costs and consequences of escalating established and monitored on a highly
upsets. Some examples are: frequent basis.
— Gas explosions caused by gas mix- EXPERTISE AND KNOW-HOW The client’s operational staff can be
tures in the furnace or the release offered remote training courses or sup-
of hot top gas, such as in the case of Bringing in outside experts gives an ported for improved casthouse manage-
furnace slips, damaging furnace equip- organization access to vast experience ment—an important area for stable op-
ment or the surrounding area; in a multitude of operational circum- erations, and absolutely vital for health
— Unexpected hot liquid flows: stances, opening the door for different and safety. Following an initial period
— Burn-out of tuyeres; perspectives and benchmarking against of highly intensive remote monitoring
— Taphole or hearth breakout; practices employed elsewhere. The and support, working towards secure
— Runner overflow; added value is demonstrated by the operations that meet the established
— Bad separation of hot metal and fact that, over the past 10-15 years, KPIs, remote support continues during
slag; the industry has had an increasingly an extended stabilization period—en-
— Gas/liquid blow-out from the frequent need for external operational suring that the on-site operators are
taphole; support during blast furnace blow- fully familiarized with the operating
— Liquid splashes. downs, restarts and stabilizing or opti- setpoints and procedures, and develop
Anomalous process events are, by their mizing ironmaking operations. the use of process instrumentation and
nature, unpredictable and two such automation systems to their fullest po-
events are hardly ever the same. How tential.
these events play out will depend to DANIELI CORUS SUPPORT
some extent on local and furnace-spe- This approach has a proven track
cific conditions, so there is no funda- For decades, teams of Danieli Corus record not only for achieving higher
mental substitute for having specialized experts have supported steel producers productivity, increased coal injection
know-how and experience with these in out-of-normal ironmaking opera- levels and reduced coke consumption,
upsets available, combined with hands- tions and stabilizing or optimizing the but also for eliminating bottlenecks or
on experience of the operations of the blast furnace process. Today this ability other process anomalies identified by
specific blast furnace concerned. Given remains available regardless of travel the client. We embrace steel producers’
the erosion of this specific expertise restrictions and despite the continu- challenges as our own and we continue
due to the retirement of senior experts ously increasing requirement for expert to offer our unique support programs
for whom these events have been rela- support. Remote support services have during these times of crisis. Together,
tively regular practice, it is unlikely for been developed such that operating we will weather this storm and prepare
a steel producer to have it available. departments at multiple blast furnace for better times. |

24
 IRON AND STEELMAKING

Improved burner design for fast-track erection confirms

Danieli Corus leadership in hot blast stove technology

NEW HOT BLAST STOVE 47:

A SUCCESSFUL COMMISSIONING
At SSAB Oxelösund, Sweden

— E D I T E D B Y A L A I N W O L T H E U S / Project Manager, Danieli Corus

One-piece vessel shell

installation strategy
is a joint success for SSAB
and Danieli Corus

he new Hot Blast Stove 47 for

T Blast Furnace No. 4 at SSAB
Oxelösund, for which the ves-
sel shell was erected as a single piece
in an industry-first during Summer
2019, was commissioned successfully.
After a joint investment of time and
effort by SSAB and Danieli Corus into
the preparation of the vessel erection,
the consequential faster and safer
execution of both on-site and off-site
activities have greatly contributed to
the success of the stove’s mechanical
completion, refractory installation and
tie-in into the existing hot blast system.
In addition to the construction method,
the improved burner design is a key
feature of this hot blast stove. With
comprehensive benchmarking on key
performance indicators against current
and alternative new designs, this burn-
er type is an entirely new development.
The final design was selected for its
reduced emissions and excellent mixing
of combustion gas.
The new hot blast stove has been
operating for several weeks now, suc-
cessfully passing the performance
acceptance test that was stipulated in
early June. |

The quick, safe and successful

completion of the new Stove 47 is
the result of a fruitful collaboration
between SSAB and Danieli Corus.

25
DANEWS 184

— FLAT
PRODUCTS

DEEP INTO THE DUE®

Evraz’s QSP Danieli Universal Endless plant:
a winning solution to jump-start the market

vraz ZSMK is a major steel- steel currently destined for slabs to foreign markets. In order to meet to-
E maker in Russia with approxi-
mately 5.5 million tons of pig
high-value added hot rolled coils.
In addition to the QSP-DUE line,
day’s and future market requirements,
Evraz ZSMK has chosen a highly flex-
iron and 7 million tons of steel pro- Danieli also will supply a twin-station ible and robust thin-slab casting and
duced per year, mainly long products, ladle furnace (310 t) and twin-tank rolling mill layout, which can fulfill all
structural steel products and slabs. Its vacuum degasser (310 t) and associated requirements for flat products in terms
ZSMK subsidiary is one of the largest auxiliary equipment, including a fume- of steel grades, geometrical tolerances
steel producers in the Siberian region. treatment plant and water-treatment and surface quality.
In February 2020, Evraz signed a con- plant for the whole facility. The new DUE plant will have a total
tract for a QSP-DUE thin-slab casting The new plant will be located in capacity of 2.5 million tons per year
and rolling line to convert the liquid Novokuznetsk, to serve domestic and of hot-rolled coils, with strip dimen-
sions from 0.8 to 16.0 mm and widths
ranging from 950 to 1,700 mm. The
product mix will include low–carbon,
medium–carbon, high–carbon, LC
HSLA, MC HSLA, weather-resistant,
API and Dual Phase steel grades (see
Figure 4).

STEEL REFINING

Liquid steel for the QSP-DUE plant

will be provided by the existing BOF
melt shop #2, located at Novokuznetsk.
After tapping, the 310–t ladles will
be transferred to a twin-station ladle
furnace, which will be dedicated to the
treatment of liquid steel for the thin-
slab caster. The twin LF is equipped
with a 60-MVA transformer and ca-
pable of reheating the liquid steel at a
rate of 5 °C/min. The typical ladle-to-

26
 FLAT PRODUCTS

Danieli
QSP / DUE
widest range
of HRC steels
and quality
in endless
plants

ladle process time will be 45 minutes. equipped for successive compression of

The Danieli twin LF is equipped with process gas and steam, with intermedi-
an “inert roof”: this concept is based on ate steam condensation (inter-condens-
a pressure balance between the inter- er). The five-stage system will have a
nal suction and the secondary suction, suction capacity of 800 kg/h.
provided by an outer “ring chamber”. A vacuum batch hopper will be in-
The target is to limit the internal suc- stalled on the tank cover to allow the
tion, keeping a small positive pressure addition of Fe alloys under vacuum.
(or neutral) inside the furnace roof, The hopper will be connected to the
thereby making the atmosphere inert materials handling system that will pro-
by stirring argon with the benefit of vide materials for both LF and VD.
minimized side oxidation of the elec- The twin-tank VD station will ensure
trodes, and thus minimized electrode hydrogen content in the liquid steel
consumption; reduced slag oxidation, prior to casting < 1.5 ppm and sulphur
and thus reduced FeO content and content < 0.005%, both preconditions
consequently the oxygen content in to produce high-quality API pipeline
steel, as well as reduced hydrogen and steels, as well as other grades. The
nitrogen pick-up from the furnace at- plant unit also will ensure the control
mosphere. of nitrogen and oxygen content in the
liquid steel, as well as the removal of
Downstream of the twin LF station, tramp elements.
Contract signing at the presence
of Evraz Alexey Soldatenkov Danieli will supply a twin-tank, single-
(Vice President, Head of Siberia cover vacuum degassing unit. For future expansion the VD station
division) and Mike Knights
(Executive Vice President, Danieli
Due to the large heat size, the vacuum will be designed ready for the upgrade
Centro Met). system will be designed with a pow- into a VD-OB station capable to pro-
erful steam ejector vacuum pump duce ULC/IF steel grades.

27
DANEWS 184

Danieli–manufactured ladle turret assembled and tested

in–house, with customer remote supervision. It provides
fully operational reliability for the 3-Msht/y QSP slab
caster; it will handle 200–sht–capacity ladles from
loading to casting position. It features a slew–bearing
vibration monitoring system to constantly check wear for
predictive maintenance, and a Q-Box system for intelligent
management of the on board sensors signals.

28
FLAT PRODUCTS

29
DANEWS 184

DEEP INTO THE DUE® 110–mm thick slab after dynamic soft With throughput rates of the sub-
reduction (132.5 mm at mould exit), merged entry–nozzle (SEN) up to
with a casting speed up to 6 m/min, 7.5 t/min., control of fluid dynam-
depending on the steel grade. ics in the mould is essential. To en-
sure optimal SEN design, powerful
The unprecedented combination of computer-based fluid–element and
large slab thickness and high casting water modelling techniques will be
THIN SLAB-CASTING AND ROLLING speed makes it possible to easily reach applied. Additionally, the TSC will be
the high mass-flow required for full equipped with Danieli’s Multi-Mode
The QSP-DUE line is based on state- endless production mode, necessary for Electromagnetic brake (MM-EMB®)
of-the-art equipment and includes effective production of ultra-thin gauge for precise control of fluid dynamics in
new, innovative features that allow for products. the casting mould, and to address the
maximum process control and excellent specific unwanted flow patterns associ-
product quality, with special consider- Additionally, the ability to feed the roll- ated with thin-slab casters (see Figure 1).
ation given to the endless rolling pro- ing mill with a large slab (as compared
cess and to great flexibility for serving to the conventional thin-slab approach) The new TSC will benefit from
both the mass–production commodi- leads to a considerable increase in the Danieli’s fifth-generation vertical-
ties segment and niche markets. A ref- reduction ratio from slab to strip. In curved roll geometry, which has been
erence for this concept is Danieli’s first turn, this allows the production of a continuously and systematically im-
QSP-DUE plant at SGJT in China, wider mix of steel products. proved since the late 1980s, based
which has been operating successfully upon practical in-field experience and
since April 2019. To achieve both targets of high pro- advancements in roll/bearing design.
ductivity and high quality, the new, Small roll diameters and small rollers
/ The unique Danieli TSC single–strand thin–slab caster will be pitches will contribute to minimize the
and 3Q technologies equipped with a suite of “3Q” tech- bulging, working in conjunction with
nological packages, which reflect the Q-LEVEL+, the accurate mould level
The unique DUE®, vertical-curved know-how gathered by Danieli over 30 control system specifically developed
caster features a 5.5–m main radius years of fieldwork experience in thin- to counteract any mould–level distur-
and will be designed to produce a slab casting. bances.

An air-mist secondary cooling system is

provided with control of the water dis-
tribution across the entire slab width,
1. Schematic of the multi-mode electromagnet independently controlling different
break (MM-EMB)
spray sections by means of dedicated
control loops with separate valves.
Strand temperature control is granted
sticking freezing
by the Q–COOL package that main-
inclusions sticking tains the strand temperature at the
cracks target profile to guarantee the surface
quality, even during transient condi-
tions, such as change of casting speed
and/or superheat variation.

Excellent internal slab quality will

be guaranteed by employing a com-
bination of liquid core reduction and
dynamic soft reduction, using Danieli
DAMPING Q-CORE technology.
BRAKING The solidification profile is evaluated
by a 3D mathematical model and the
BRAKING proper thickness reduction is applied
according to the position of the liquid
STABILIZING pool. The model architecture will be
completed by Q-PULSE, the diagnos-
tic tool to measure the exact point of
slab solidification.

30
 FLAT PRODUCTS

2. HAGC cylinder / 3D sketch. 3. Shifting and bending block / 3D sketch.

/ The hot–strip mill: fundamental buffer time that increases rolling. The mill stands, which will
Danieli Universal Endless plant flexibility (for both scheduled and be designed to guarantee superb geo-
unscheduled stoppages) and provides metrical properties in the final product,
Downstream of the TSC pendulum the possibility of making work-roll are equipped with all state–of–the–art
shear will be located an 80-m tunnel changes as a background task, without features for maximum strip crown and
furnace (TF) designed and supplied by affecting the operation of caster and profile control, bearing in mind that
Danieli Centro Combustion. The TF upstream melt shop. these control functions also have to be
must be considered not just as simple operational under load conditions as re-
connecting equipment between caster The QSP-DUE mill will utilize the quired by the endless rolling process.
and mill, but as a fundamental tool already successfully proven configura- The main characteristics and state-
of an integrated process, capable of tion with separation of the mill stands of-the-art actuators, especially for
granting high operational flexibility to into high-reduction units and finish- fast-response finishing mill stands, are
the whole DUE plant by providing the ing units, in order to perform two-step described here:

3D view of Evraz’s
meltshop preceding the MELTSHOP
QSP. QSP-DUE
1 310-t twin ladle furnace
1 2
station;
2 310-t twin-tank, single-
cover vacuum degassing
station.

31
 DANEWS 184

DEEP INTO THE DUE® — Better thickness tolerances; the WR thermal expansion during roll-
— Reliable and maintenance-friendly ing by using segmented WR cooling
design; headers (see Figure 5-6).
— Flying gauge control. The roll thermal-crown control system
is conceived to:
Beside the HAGC, one of the most — Keep work-roll thermal crown under
critical factors for quality are the pro- control, thereby reducing the need to
file, contour and flatness controls. To offset this effect by using work–roll
4. Quality pyramid structure. ensure the quality of flatness, contour bending.
and profile within tight tolerances, the —To extend the capabilities of primary
mill stand needs powerful tools that crown and flatness control systems and
which can be mainly classified in two to have a wider control range, leading
different categories, i.e., primary and to optimal results (see Figure 7).
secondary.
s
de

The primary tools are those that con- In order to fulfil these targets, RTC
gra

trol the strip shape by specific active (3 zones and 2 circuits) and RTC Plus
ed
ue

nc

mechanisms like work–roll bending (5 zones and 3 circuits) cooling systems

val

va

60%
ad
ce

and shifting, also using shaped rolls. are foreseen. Through independent
de
pri

re

gra
Mo

Especially the new requirements of proportional valves, water distribution

ct

ed
du

s
de

endless rolling also make it necessary along the barrel length can be modi-
nc
pro

gra
va

to apply shifting under load during fied. In this way, it is possible to guar-
Ad

ial

20%
erc

rolling. Danieli’s design uses one mono- antee a customized work-roll cooling
mm

lithic block for shifting and a single effect according to the specific thermal
Co

20% bending cylinder module. The bending loads of the rolls.

system is able to change the deflection With Danieli’s automation system the
of the work rolls in a highly dynamic primary and secondary strip shape–
manner. In this way it is possible to control features are in a closed loop
Hydraulic Automatic Gauge Control have high-speed control and to reach a with the measuring systems, to achieve
HAGC is adopted for on-line regula- wide range of target crown for different excellent strip quality.
tion of the mill equipment to ensure strip formats during different rolling
product thickness within the tightest phases, and with optimal flatness. In
target tolerances, in the range of mi- case of shifting under load, lateral forc- / OSR - Optimized Shaped Rolls
crons (see Figure 2). es resulting from roll movement will be
absorbed by the guiding element inside WR shifting systems can be used, ap-
Main benefits: the block (see Figure 3). plying two different strategies:
— Fast-response thickness control; Secondary tools are those where strip first, to distribute the WR wear dur-
— High-accuracy gap positioning; shape is influenced by the control of ing rolling by moving in axial direction

QSP-DUE

3 4

MELTSHOP

32
 FLAT PRODUCTS

along all the work–roll barrel length; with so-called “gap killing cylinders”, — Optional roll-bite lubrication head-
and second, to increase the strip pro- that act on back-up roll chocks, push- ers mounted in a double wiper configu-
file and flatness control using shaped ing them into the rolling position. ration at the entry side of the stand,
(OSR) rolls. which spray a mixture of lube oil and
In the latter case the work-roll shifting A sophisticated shape-control model is water into the work-roll bite, in order
system is no longer used to control only used to adapt all mentioned actuators to reduce friction coefficients between
the WR wear distribution, but is mainly to achieve the necessary strip flatness work rolls and rolling material, and
devoted to the strip profile and flatness for each product while maintaining therefore reduce separating force, limit
control. Here, the top and bottom work optimal work-roll wear conditions. The roll wear, and reduce energy consump-
rolls are shaped for a special function. system integrates set-up functions with tion;
The profile of the work roll is a curve on-line control, based on mathemati- — Anti-peeling system, consisting of a
consisting of an anti-symmetric sine cal models and being auto-adapted by header that sprays water on the strip to
function and a third-order multinomial using the plant measurement gauges decrease the strip surface temperature.
function. (in particular, from the profilometer In this way, the lower strip temperature
and the x-ray flatness gauge) it acts on helps to preserve the roll surface from
To stabilize the roll stack during the the dedicated actuators (mainly work- peeling phenomena resulting in lower
initial transitory time (the time needed roll bending and selective cooling). OpEx;
by the material to move the undis- The set-up calculation provides refer- — Skin cooling is installed on the entry
turbed rolls from central position to ence values for bending, shifting and side of the first mill stands to reduce
rolling position against the exit side of cooling, based on input data (rolling the surface temperature of the bar.
the stand) the rolling stand is equipped schedule by mill set-up model, tun- If the traveling time between these
nel furnace entry geometry, etc.) Over stands is quite long, this also makes
time, this data is validated and adapted it possible to reduce scale growth, in-
by a self-learning mechanism, which creasing surface quality;
3D view of Evraz’s QSP-DUE following
the line meltshop. provides automatic updating of the set- — Cross sprays are installed in order to
up model parameters. sweep water from strip surface and pre-
3 Vertical–curved TSC to produce vent it from flowing in a longitudinal
110÷123–mm–thick slabs;
4 Pendulum shear; Especially in the case of endless roll- direction, thus making further systems
5 80–m–long Danieli Centro Com- ing, advanced control of the strip (skin cooling and anti-peeling) more
bustion tunnel furnace;
6 DUE’s 3–stands high-reduction guidance together with optimized strip effective;
mill; cooling are essential. — Oxide blowing system, with proper
7 Transfer bar area with crop shear,
Q-Heat induction heater and HP sucking system, consists of a header
descaler; Danieli’s inter-stand guides are installed on the rear mill stands that
8 DUE’s 5–stands finishing mill;
9 Laminar cooling system;
equipped with the latest features, in- spray water as close as possible to the
10 Downcoilers. cluding: roll bite in order to avoid mill scale
— Inter-stand cooling to control strip powder formation, and consequently
temperature; scale fume emissions. (see Figure 8).

6 7 8 9 10

33
DANEWS 184

DEEP INTO THE DUE® 5

The line is completed with a laminar

cooling system, including power and
normal units, and a coiling area made
up of a high-speed shear to cut the
coil to length when working in end-
less mode, pinch rolls, and two down-
coilers.

/ A unique switchable
layout modes of operation

A DUE plant can be operated in vari-

ous production modes:

— The coil-to-coil production mode

is characterized by non-continuous
rolling. Casting and rolling processes 6
are decoupled. The slabs are generated
by cuts by the pendulum shear (PS) in
front of the tunnel furnace. The slab
weights are calculated by the L3 pro-
duction planning system, which then
are rolled to a single coil.
— The semi-endless production mode
is characterized by a ~80-m mother
slab generated by the PS in front of
the tunnel furnace, rolled and then cut
with the high-speed shear located in
front of the 2 down-coilers into sepa-
rate strip lengths. In the case of Evraz,
up to three or four coils may be rolled
from a single semi-endless slab. The
rolling speed is independent from cast-
ing speed. Therefore, it is not strictly
necessary to use the induction-heating
system, however, the induction heater
also can be used beneficially to further
reduce the rolling mill load and the 7
strip thickness. Compared to endless
production, the IH energy consump-
tion can be reduced significantly, due
to higher rolling speeds.
— The endless operation mode
is characterized by an interlinked cast-
ing and rolling process with a constant
mass-flow throughout the whole plant,
defined by the casting machine, result-
ing in a continuous endless casting
and rolling operation. There is a direct

34
 FLAT PRODUCTS

Roll thermal crown RTC Anti–peeling Roll–bite lubrication Oxide blowing

Work roll cooling Cross spray Roll thermal

crown plus
Interstand cooling

Left page, from top: enhanced strip dimensional and flat- coil, semi-endless and endless mode,
Schematic of roll thermal expansion;
RTC plus work–roll cooling header; ness tolerances. enabling:
Flatness control system. The Level 1 automation system will be — Thermomechanical and multi-phase
This page, top: based on the latest generation of indus- rolling;
3D sketch of inter-stand area. trial controllers and Ethernet-based, — Production of ultra-thin and thick
high-speed fieldbus. Control pulpits strips;
will be equipped with a new generation — Green technology, a step ahead in
of operator interface, fully based on OpEx and energy savings;
touchscreens. — High–quality products;
relation between the casting and rolling Danieli Automation Q3-Intelligence, — High-value-added products for the-
speeds, with the casting speed acting which is a core part of the DIGI&MET mass production commodities segment
as master for the line. Main advantages platform for “Danieli Intelligent and niche markets.
of the endless production mode are: System” solutions, will coordinate pro- The partnership between Evraz and
— Rolling stability for ultra-thin gauge cess quality control along the whole Danieli will set a new benchmark for
production (no threading and tailing production chain, from liquid steel the thin-slab casting and rolling tech-
out); down to finished products. nology in terms of competitiveness and
high-quality production. |
— Further reduction of the minimum The DIGI&MET platform will allow a
achievable strip thickness to 0.8 mm; further step ahead in Big Data collec-
—Tighter geometrical tolerances for tion, ready for Industry 4.0 applications
ultra-thin gauge production. for the use of the new DUE® line it-
self, as well as integrated with all other
plant expansion projects.
/ User-friendly
and intelligent automation In conclusion, we can state that the
QSP-DUE concept provides full flex-
The plant will be equipped with state- ibility combined in a single production
of-the-art automation systems based on line, with the below main advantages:
the Danieli 3Q automation concept.
At Level 2, powerful and fast-learning — High productivity based on Danieli’s M AT H I A S K N I G G E
process models will provide accurate proven, vertical–curved casting tech- Senior Technologist, Sales Manager
set-ups for the equipment in all pos- nology; Danieli Wean United
sible operational conditions, achieving — Production flexibility using coil-to-

35
DANEWS 184

36
 FLAT PRODUCTS

Danieli mould equipped with the advanced online

electromechanical mould–width adjustment and
online thermal mapping, ready for Danieli multi–mode
electromagnetic stirring MM-EMS® installation.
Solid and simple design to ensure reliability in production
and simplicity in maintenance operations.

37
DANEWS 184

Two-stage strand-stirring system for consistent

slab internal quality and improved final strip quality

QUALITY SLAB CASTING RESULTS

AFTER 2 YEARS OF OPERATION
at ThyssenKrupp AST, Italy

— E D I T E D B Y P A O L O G A S P A R I N I / Vice President, Sales Slab Casters, Danieli Davy Distington

hyssenKrupp Acciai Speciali

T Terni (AST), the leading pro-
ducer of stainless steel flat
products in Italy and one of the major
suppliers in the European market, con-
tracted Danieli in 2017 to supply a new
strand-stirring system to be installed
on its existing single-strand slab caster
(CC03), originally supplied by former
VAI in the 1988.
The customer recognized Danieli
Rotelec as the partner capable to sup-
ply the unique, patented and most
advanced system currently available on
the market. The installation consists of
two pairs of In-Roll EMS systems posi-
tioned face-to-face. The first pair of IR-
EMS has been installed on segments
0 and the second pair on segment 1.
The combination of two stirring sys-
tems made a significant increase in the
stirring area possible, compared to the
commonly used, box-type single-stage
system.
Thanks to the thermal effects on the
liquid steel by virtue of the stirring
combination between both IR-EMS
pairs, a greater equiaxed zone as well as
consistent quality have been achieved.
Specifically, the equiaxed zone has
been improved by 5/4 times compared
to before the system upgrade, for the
ferritic and ferritic stabilized grades,
respectively. The roping index has been
improved by 3.75 times for the ferritic
grades and 2 times for the stabilized
ones.
A significant reduction in transversal Souvenir picture of the teams after conclusion of the revamping project.
cracks on the slabs during the process From right to left: I. Bosnjak (Key Account Manager, Danieli), S. Turiani (Project Manager,
before hot rolling has been recognized AST), M. G. Ricci (Manager Plant Development and Maintenance Engineering, AST),
L. Perelli (Production Quality Manager for Hot Area, AST), and P. Gasparini (VP Sales,
thanks to the improved homogeneity Danieli Centro Met Slab Casters).

38
 FLAT PRODUCTS

up to
5 times
improved
equiaxed zone

up to
3.75 times
improved roping index

50%
reduction
in power consumption
vs a box–type
EMS
Shorter Longer
mixing zone mixing zone

Single–stage In-Roll EMS Double–stage In-Roll EMS

for slabs’ internal structures. Other

achievements include a dramatic power
consumption reduction of at least 50%
compared to a box–type stirring system,
minimized conversion cost and im-
proved plant yield.
Design, manufacturing and installa-
tion were done by Danieli with a Plug
& Play approach, using only monthly
planned maintenance shutdowns (1 to
2 days each) was possible, without any
production loss thanks to:
25 °C
Macro-etches of cast slabs,
— A simpler design compared to box- Single–stage lower from top:
Equiaxed zone width (arbitrary unit)

type systems, not requiring any hydrau- equiaxed zone 409LI Ferritic Stainless Steel
lic manipulator; Titanium stabilized,
100% Equiaxed Zone;
— The installation of rolls on existing 441LI Ferritic Stainless Steel
segment structures, with minor modifi- Titanium and Niobium stabilized,
100% Equiaxed Zone.
cations made off-line;
Double–stage greater
— The installation of auxiliary systems, equiaxed zone
piping, cables and electrical equipment
while the caster was in operation.
A final acceptance certificate has been
signed by the parties, confirming AST’s
satisfaction and the solidity of this
proven Danieli Rotelec technology. | 0 10 20 30 40
Superheat (°C)

39
 DANEWS 184

A Step Ahead Technology TO HIT RECORDS

Interview with voestalpine stahl Linz

CC8 slab caster operators

review performance
results and records
in ULC and IF productivity
following two years
of successful operation

Mr. Peter Hodnik Mr. Herbert Moser Mr. Roland Fluch

Casting Process Head of Caster Caster Maintenance
Supervisor Operations Manager

oestalpine is a leading steel and on five shifts, and during the first 13 weeks
V technology group with a unique
combination of materials and
it covered almost all the contractual steel
products. Quick ramp-up, excellent product
processing expertise operating globally with quality and excellent caster reliability were
around 500 locations in more than 50 coun- confirmed in mid-May 2018, when the cast-
tries and about 49,000 employees. voestal- er processed a sequence of 29 heats.
pine products are recognized worldwide as
a benchmark for quality, and it is a leading Now, after two years of operation, the voes-
partner to automotive, consumer goods, talpine CC8 slab-caster team—the Head
aerospace, and oil-and-gas industries, as well of Caster Operations, Mr. Herbert Moser,
as the world’s leading producer of railway the Casting Process Supervisor, Mr. Peter
systems, tool steel, and special sections. Hodnik; and the Caster Maintenance
The voestalpine’s steel mill in Linz/Austria Manager, Mr. Roland Fluch—offered a sum-
FROM THE is one of the world’s most modern flat-rolled mary of the operation.
FIRST PAGE steel plants. In January 2015 Danieli was as-
signed the order for the new CC8 slab cast-
Right: Continuous casting machine No. 8
er. Five weeks after the new caster started at voestalpine Stahl overview: from the casting
up in January 2018 it already was producing platform down to the marking machine.

40
FLAT PRODUCTS

41
DANEWS 184

THE PERFORMANCE RESULTS

CONSIDERATIONS ON DANIELI CASTER on CC8 and this choice is primarily due to

OF SUCCESSFUL OPERATION
the advantages given by the Multi-Mode

FOLLOWING TWO YEARS

The slab caster started up in January 2018: up Electro Magnetic Stirrer (MM-EMS®) and
to now, it's been operating for more than two the box-type stirrer supplied by Danieli
years. What is the present situation with your Rotelec and installed in the mould and in the
plant and specifically with Danieli equipment? bender, respectively. The rest of the produc-
tion is covered by all other types of grades.
Presently we have two slab casters running
100% of the time including CC8, focusing
on plate grades and strip grades respectively, PRESENT DESIGN AND
the remaining part of the production is then POSSIBLE IMPROVEMENTS
mainly shared among two slab casters and
a fifth caster is operating with a marginal We know that it’s always difficult to define the
amount of production. requirements for a new production unit, choic-
Two years since the plant start-up, we es range between high specialization and high
are fully satisfied with the performances flexibility, trying to find the best compromise
achieved by the Danieli slab caster. Because for future scenarios that are quite uncertain.
of its high reliability, slab format and Mould After these two years of operation, if you could
EMS equipment, the Danieli CC8 slab go back to the beginning of the project, is there
caster is the priority caster for the hot-strip any different or additional requirement you
mill production. would consider?
In the last business year we’ve cast about
1,000,000 tons of steel on CC8, for a total At the very beginning of the project, having in
amount slightly exceeding 5,000,000 tons, mind what we did for the previous new caster,
and 70% of operating time it had steel in our goal was to focus the machine on specific
the mould. The Danieli slab caster is very targets and to avoid defining a too wide range
reliable, generally with fewer stoppages com- of operations. But in the end, we chose a
pared to other casters. solution capable of casting everything, so, for
On CC8 caster we cast all the grades in our instance, we asked to design a machine that is
portfolio, and the slab quality we achieve is able to cast both slowly and very fast.
very good and fully in line with our expecta- Actually, due to the logistics in our melt
tions. shop area related to the vacuum treatment
Presently, production is focused on ultra–low time, our target casting speeds are around
carbon (ULC) and interstitial–free (IF) steel 1.4 m/min and we never need to run at the
grades, used mainly for exposed automotive maximum design speed of 1.8 m/min. For
Max of monthly
applications, and on all families of silicon this reason, the cooling nozzles have to work slab production (ton)
grades up to more than 3% of silicon. This mostly towards the end of the control range
covers approximately 85% of the production Max of cumulated
and that could have been avoided. slab production (ton)

120,000 2,500,000

100,000
2,000,000
Accumulated slab production (t)
Monthly slab production (t)

80,000
1,500,000

60,000

1,000,000
40,000

500,000
20,000

30 months of reliable
0 0 production: exceeding
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun
2 million tons of prime
2018 2019 2020 quality slabs.

42
 FLAT PRODUCTS

Stirrer (MM-EMS®), we use it for nearly

all the steel we cast on CC8. Of course,
the main benefit we have when casting slab
surface-sensitive grades, like ultra-low car-
bon grades with niobium or interstitial-free
grades used for exposed automotive parts.
We do use all its functions and specifically,
for the stirring function, we started some
testing with peritectic grades, aiming to re-
duce corner cracks and improve shell growth
stability.
In contrast to other steel producers we do
not want to have a storage area for separating
slabs according to prime or secondary qual-
ity. We aim to have all prime-quality slabs,
scarfing when and where necessary. The
MM-EMS® is helpful in keeping the casting
process in the mould under control, correct-
ing any possible deviation from the optimal
conditions, for instance a higher temperature
of the steel due to melt shop logistics.
Souvenir picture of the We can say the same about the capability of It is difficult to quantify the improvements,
voestalpine CC8 slab-caster
team. In the center, from left: the machine to cast the additional thickness as we have a tight control of the melting
Peter Hodnik, Casting Process of 285 mm; at the moment we do not use it. and casting process, running at optimized
Supervisor; Herbert Moser,
Head of Caster Operations; In general, we are satisfied with the design conditions for 90% of the time. MM-EMS®
and Roland Fluch, Caster solutions we have defined and implemented. allows us to consistently control the casting
Maintenance Manager.
For instance, the dummy–bar car system is a process within the mould also in the remain-
really good solution, both in terms of opera- ing 10% of the cases. Nevertheless, we are
tion and maintenance: engineering and fabri- thinking of buying a new mould with this
cation have been extremely fast, and the sys- equipment.
tem worked from day one without problems
and with very little maintenance demand. — Box stirrer
In the end, basically, we would change noth- Regarding the box stirrer on the bender, we
ing at all, although there is always space for find it very useful for the slab internal qual-
improvement. For instance, the stainless- ity. On the final strip quality we found rele-
steel rollers of the box-type stirrer: we are vant benefits in removing the roping defects,
currently working together to extend their and 100% of the steel grades where this de-
lifetime, to minimize the operational ex- fect is likely to appear are cast on CC8.
penses.
— Mould–width adjustment
Mould–width adjustment we operate a lot.
DETAILS ON EQUIPMENT AND During the last business year, for CC8 only,
TECHNOLOGICAL PACKAGES we applied 8,700 width adjustments. This
means more than one change per hour, on
Danieli CC8 caster was designed together with average, with a maximum individual width
voestalpine Stahl Linz to implement all the adjustment of 600 mm. We are absolutely
latest available solutions, to establish the abili- flexible in applying width changes during
ty to cast the widest product mix. Among many production, both increasing and decreasing,
details we can mention the electromagnetic and this capability is very important for us
devices in both mould and bender segments, to follow the required production schedule
and the on-line mould–width adjustment. Do based on the order requirements.
you use these features regularly? Are you satis-
fied with their performance? Do you see any Are there any other specific solutions you find
possible improvements? useful for the casting process? Do you have in
mind possible enhancements like, for instance,
— MM-EMS® mould stirrer moving to optical fiber installations for the
Regarding the Multi-Mode Electromagnetic mould thermal mapping?

43
DANEWS 184

SLAB QUALITY
EXPECTATIONS
FULLY ACHIEVED 1
WITH DANIELI
SOLUTIONS

2
3
4

— Online mould–oscillation monitor need resources and experience without clear 1. Q-ROBOT.
2. Multi-Mode EMS
We find the online monitoring of the mould evidence of the benefit. installed in mould for
oscillation very useful and important for braking, accelerating
and stirring functions.
controlling the actual behavior of the oscil- 3. Q-WIDTH in line mould
lating table. Understanding that in operating SLAB QUALITY AND YIELD width adjustment.
4. Q-MOD online mould–
conditions the moving tolerances are good is oscillation monitor.
a great advantage because, even if during the In terms of overall slab quality and yield, does 5. Box-type strand stirrer
offline test we are not within the required the CC8 meet your expectations? for electrical steel grades.
6. PDR Roll cooling design
tolerance, we know that during casting for longer equipment life
things will stabilize, so we can run safely. We are satisfied with the results we obtain. and dry casting practice.
Having an online monitor gives us confi- Slab internal quality is very important to us,
dence during casting. and the results are in line with our present
expectations. If in future there would be the
— Dry casting need to change the operating conditions, for
During the design stage we also required instance to increase the casting speed, we
the ability for dry casting, but actually, when don’t think there would be any limitations.
casting 225-mm thick slabs, we rarely need Of course, we will have to update the casting
it. On CC8 we very seldom require dry cast- practices, but we don’t see any issue in those
ing, only for one or two steel grades, because terms. Regarding yield, our production phi-
with secondary cooling we are able to ap- losophy is to optimize the production sched-
ply very low amounts of water, as required. ule; long sequences are not our target, so the
Anyway, we made tests for this functionality yield value cannot be compared to other situ-
and we were satisfied because the results ations. For one month, the average sequence
met our expectations perfectly. length on CC8 was 18 heats, but normally
our average sequence length is about 12
— Mould thermal map heats. To date, the longest sequence we have
About thermal mapping, the current thermo- cast on CC8 is about 101 heats. We can do
couple installation is very reliable. So far, we long sequences, but our mix and philosophy
had only one breakout on the CC8, so there are not in that direction. In the end, for the
is not so much to be improved in this regard. CC8, we have the same conditions as we
An optical fiber system could provide much have for the other casters: we have the same
more information, but to use it we would tundish, and we have the same practice

44
 FLAT PRODUCTS

concerning the scrapping, but a little bit less The operators enjoy working on the CC8 so
THE PERFORMANCE RESULTS

OF SUCCESSFUL OPERATION
scarfing considering the mould. much that it’s the favorite caster for many of
FOLLOWING TWO YEARS

them. In this, the design of CC8 helps a lot:

the safety system is reliable and easy to use,
OPERATIONAL CONSUMPTION so operations are smooth and safe. The op-
erators were involved in the design phase, so
Are you satisfied with the present consumption it’s their machine, every solution is accepted,
levels on the CC8? Are they as expected? and the feeling is positive.

Electrical power consumption for the elec-

tromagnetic devices is not as high as ex- CONSIDERATIONS ON DANIELI TEAM
pected during the design phase, so we were
positively surprised. In general, for other Danieli found in voestalpine Stahl a demand-
consumptions we think we are quite on a ing and motivating customer. How would you
very good level; machine cooling and second- summarize the experience with Danieli during
ary cooling air-consumption were optimized these two years of collaboration?
significantly during the design phase, and What is your opinion and comments on the
we found a good compromise between air-oil project execution and follow up by Danieli?
and grease lubrication systems.
One strong point we found in Danieli as
a partner is the availability to develop and
MAINTENANCE AND RELIABILITY adopt new solutions by adapting the design
to specific requirements arising during proj-
In terms of overall maintenance and reliability, ect execution, and at the same time respond-
how would you judge the Danieli design for ing quickly to the consequent engineering
the CC8 equipment? and manufacturing program. For instance,
the dummy-bar car engineering and fabrica-
We have a very good and stable roller gap. tion have been extremely fast. It is not easy
Roll conditions are very good in terms of to find a supplier that always is available and
wearing, and so far we have not noticed any willing to discuss new ideas or requests and
damage from sticking in the rolls. At the be- to apply improvements.
ginning of the project we had some doubts We are satisfied by the quick and flexible
about the roll design, but Danieli did every- support we have received from Danieli con-
thing very well. In terms of roll life we are tinuously during this period, especially re-
in line with the expected values. After two garding the mould and segment workshops,
years of operation we are in the middle of an and even if two years have passed from the
optimization of these figures, there are things start-up we still have a close contact and
to be finalized and we think we can improve good cooperation. We have found a good,
these values. Segment lubrication and hy- common understanding between our people.
draulic systems are working well. Despite the
wide regulation range we required, the spray
nozzles have been properly designed, and so CONCLUSIONS
we have very few cases of clogged nozzles.
Thanks to the synergy between quality and
reliability of the Danieli technology and the
SAFETY experience and knowledge of voestalpine
Stahl, the new CC8 has exceeded all expec-
EDITED BY
There was a lot of attention to safety measures tations for both productivity and product
and solutions during the design of the quality. These results are only possible due to
G A B R I E L E PA U L O N CC8 caster. Did you find them useful and the extremely strong teamwork between the
Product Manager, Slab Casters properly implemented? voestalpine and Danieli, and are a testament
Danieli Centro Met
to the hard work and commitment undertak-
The safety features designed for CC8 are en by all. We are satisfied by this experience
MASSIMO MAURIZIO
Vice President, Engineering
radically different from other casters. The and by the choice made in January 2015.
Danieli Centro Met solutions implemented are very good, and The cooperation will remain, for continuous
from the operator side we have a very good improvement as per voestalpine Stahl DNA,
understanding and usage of the system. and in order to be always “one step ahead”. |

45
DANEWS 184

Successful commissioning for

multi-cassette, hot- and cold-levelling technology
ensures consistent flatness
at relocated Chinese steelmaker

DANIELI EVO/5
LEVELLING PROGRESS
at Shandong Rizhao I&S

— EVO / 5 ensures enough steel plasticization to

eliminate original waves, while a subse-
Levelling is a mechanical process quent set of “soft” bending cycles guar-
involving a series of bending cycles antee achieving a flat plate free from
applied to the material, with the main residual stresses.
purpose of stretching it over its plastic A correct cassette geometry definition
limit, eliminating undesired material in terms of roll quantity, diameter and
waves, relaxing stresses and mechani- pitch, sets the flatness performance
cal tensions introduced by upstream and machine capability. However, in
operations, such as rolling and cooling many practical cases this is not an easy
processes. task, and basically a trade-off. Thin
ENRICO ZAMBON A high material overstretch (OS), plates require small roll-diameter cas-
Project Manager, Rolling Technologies typically between 3.3 and 5, (corre- settes to ensure high Plastic Ratio,
Danieli Wean United
sponding to a Plastic Ratio (PR) range while thick plates require larger roll-
70-80%) in the first bending cycles diameter cassettes to withstand the

handong Rizhao Iron & Steel,

S a major producer of steel
flat and long products in 1 Typical leveling capability diagram.
Shandong province (P.R. China), con-
tracted Danieli in early 2017 for a new
hot leveller and a new cold leveller, as Motor power
Roll diameter Torque of roll
part of its plan to relocate steel produc- Roll pitch
tion from Jinan to Rizhao. The scope adjustment
of work included the most critical me-
Yield stress

chanical components, the automation smaller roll Maximum leveling force of machine
package (including L1 and L2) sup- diameter Hertzian surface stress between levelling
plied by Danieli Automation, as well as roll and back-up roll
bigger roll
the most critical electrical components. diameter
limit of operation
Danieli provided the updated leveller
generation EVO/5 featuring multi- area of operation

cassette technology to boost capability Plate thickness

range as well as flatness performances.

46
 FLAT PRODUCTS

required torque/load. The concept is — HOT LEVELLER alloyed grades cooled at low tempera-
summarized by the machine capability ture.
diagram (see Figure 1). The hot plate leveller installed in The production ramp-up graph record-
When the product mix required is sig- Rizhao is operating with a cassette of ed (see Figure 2) shows a steep climb
nificantly wide in terms of thickness 11 small-diameter rolls, suitable for to a stable production of over 100,000
(from 4–mm thin plates to 50–mm thin plates down to a 4 mm as mini- tons/month in the January—April 2020
thicknesses, and more) as well as mum designed thickness; and a second period. Most products levelled were in
grades to be processed with one level- cassette of 9 rolls featuring a larger the thickness range between 15 and 40
ling pass, a single cassette geometry diameter, for medium-thick plates up mm, and in the width range between
becomes insufficient for the overall to a 50-mm maximum thickness and a 2,150 and 2,700 mm. (see Figures 3, 4).
production. 3,250-mm maximum width. The cas-
Danieli levelling technology EVO/5 is settes are interchangeable by means of Over 875,000 tons (87.5% of the total
answering this specific need, utilizing quick cassette changing using a shift- production) have been processed using
a multi-cassette configuration with a ing platform. The drive system for each the 9–roll large–diameter cassette, par-
small roll-diameter cassette for thin– cassette is accommodated in a shifting ticularly efficient when material thick-
plate levelling and an additional, larger platform as well (see picture above). ness exceeds 15 mm. Since August
roll-diameter cassette. This arrange- Since the hot start-up occurred on 1st 2019, progressively thinner gauges have
ment boosts the extension of the capa- April 2019, the hot leveller already has been introduced, with 20% of the mix
bility diagram by 20% to 50%, depend- processed nearly 1,000,000 tons of stably below 15 mm. Such products
ing on the mix processed. plates, including high-strength micro- were mainly processed using the 11-roll

47
DANEWS 184

2. Production learning curve (ramp up).

DANIELI EVO/5
LEVELLING PROGRESS
at Shandong
Rizhao I&S 120,000

100,000

80,000

Tons
60,000
small cassette (for the remaining 12.5%
40,000
of the total production).
The quick cassette changing proce- 20,000
dure, nearly fully automatic, can be
completed in less than 45 minutes. 0
A M J J A S O N D J F M A

The multi-cassette technology, as high- light 118422 heavy 880993

lighted above, permits efficient and
flexible levelling for the entire range
of thickness and grades. As a result,
the measurement executed showed a
3. Thickness mix.
general achievement of plate flatness
within 6 mm over a 2 meters length,
with a single levelling pass.
120,000

100,000
— COLD LEVELLER
80,000
The cold plate leveller also belongs to
Tons

the EVO/5 multi-cassette technology 60,000

and now is operating with a cassette 40,000

made of 13 small–diameter rolls (for
thin plates down to 4 mm) and have 20,000
provisions for a future installation of an 0
additional cassette made of 9 larger–di- A M J J A S O N D J F M A
ameter rolls (for medium-thick plates 40≤T≤50 25≤T<40 15≤T<40 8≤T<15 T>8
up to 50 mm).

The MULTIMOTOR drive concept

was chosen as well as other modern
features typical of the latest-generation
levelling technology provided by 4. Width mix.
Danieli, such as hydraulic gap control
and multipoint bending to process cold
plate processed upstream, but also
suitable for the high-strength, post-
120,000
treated plates, with a yield strength up
to 1,500 MPa. 100,000
The machine installation was com-
80,000
pleted recently and the leveller already
Tons

successfully its first plate processed. 60,000

40,000

— AUTOMATION 20,000

The core of the leveller technological 0

A M J J A S O N D J F M A
package is the advanced and field-prov-
en process control and automation sys- <2150 ≥2150 <2700 ≥2700

48
 FLAT PRODUCTS

tem, developed by Danieli Automation.

The set-ups of both hot and cold level-
lers are automatically generated by pre-
dictive and self-adaptive mathematical
models, which accurately calculate the
plate material behavior in the plastic
deformation region and the deforma-
tion of the levelling machine frame
under the levelling forces, considering
the selected process rules and the type
and severity of the flatness defects of
the incoming plate.

The steel grade–dependent proper-

ties, along with plate geometry and
incoming temperature, are stored in a
technological database, to be retrieved
when such data is required, on-line or
off-line. The levellers’ Level 2 process
control system also includes flexible
process control functions which can
be accessed through the user-friendly
process workstation interface (PWS) to
supervise the levelling operations.
Production and quality reporting func-
tions also are included in the supplied
system, which allows a post-processing
analysis of product flatness and ma-
chine performances.
A fast-acting and integrated Level 1
equipment control system promptly im-
plements the set-up values sent by the
Level 2 system, delivering consistent
target flatness on the outgoing plates.

— CONCLUSIONS

Shandong Rizhao levelers are a step

forward in levelling technology thanks
to the multi-cassette concept, with
two times better flatness results for
a wider thickness range compared to
a standard machine.Danieli put four
multi-cassette EVO/5 systems into
operation in China, consolidating its
position as a technology market leader
and unique supplier with experience in
multi-cassette levelling technology for
WPM’s above 4,000 mm.
Cooperating with Shandong Rizhao
ensured excellent plate quality, smooth
operations and a fast learning curve
during commissioning. |

From top: Shandong cold leveler and

L1 HMI – Hot leveler overview.

49
 DANEWS 184

A Step Ahead Technology TO HIT RECORDS

Hoa Phat 6.0 Mtpy

integrated complex adds
a new flagship to its portfolio
Danieli 3.5 Mtpy QSP® flat products
installation is up and running in Vietnam

to be implemented in two main phases, to

achieve an initial hot–rolled coils production
capacity of 3.0 Mtpy, with possible expan-
sion up to 4.0 Mtpy in the future, and strip
thickness ranging from 1.5 (provision for
1.2) to 12.0 mm and widths ranging from
900 to 1,500 mm. The product mix is widely
diversified, including low–carbon, medium–
carbon, LC HSLA and MC HSLA families.
Produced hot–rolled coils will be used either
to feed the existing cold mill complex already
FRANCESCO STELLA supplied by Danieli to Hoa Phat and operat-
Vice President, Project Director ing in Hanoi premises, or to supply the local
Danieli Wean Unitedt
market.

From a technological point of view, the plant

oa Phat is among the most im- consists of two thin-slab casters connected
H portant private enterprises in
Vietnam, leading in different busi-
to the high–technology hot-strip mill via tun-
nel furnaces.
ness sectors such as agriculture, commodi- Due to the extreme competition in this kind
ties and especially steelmaking. of highly demanding market, Hoa Phat se-
In Autumn 2017 Hoa Phat Group awarded a lected the best technology for production of
contract to Danieli for a complete new QSP high-level product mix, covering the most
complex to be installed at Dung Quat, in demanding steel grades to ensure of the ef-
Vietnam. fectiveness of such an investment, and to be
It’s a strategic project for a strategic mar- a front–runner in the Southeast Asian flat
ket, and represents Hoa Phat’s first step product market.
into hot-rolled coil production, therefore a
fundamental milestone for the future of the Danieli’s scope of work included the com-
company. plete supply of technological equipment,
The QSP plant is part of a new integrated from the caster turrets down to the mill’s
complex for which Danieli group was pre- coil handling area, including mechanical,
viously awarded the orders for four blast hydraulic and electric equipment, as well as
FROM THE furnaces and two billet casting lines coupled relevant L1/L2 automation system.
FIRST PAGE with a rolling mill, already commissioned, to In addition, Danieli also was awarded the
further strengthen Hoa Phat’s leadership for contract for erection activities.
wirerod production in Vietnam. The QSP production line consists mainly of
The QSP project execution was conceived the following units:

50
 FLAT PRODUCTS

Souvenir pictures
from first caster start-up
at Hoa Phat plant.

— THIN-SLAB CASTERS tromagnetic flow control system;

— Latest-generation electromagnetic stir-
To maximize plant productivity both QSP’s rer supplied by Danieli Rotelec (for future
vertical–curved thin–slab caster strands installation);
feature a 5.0–m main radius, designed to — Mould breakout-prevention system with
operate with a slab thickness of 70–85 mm thermocouples and complete thermal map-
after dynamic soft reduction (100 mm at ping;
mould exit), with a casting speed up to 6.0 — New roll diagram with optimized roll
m/min, depending on the steel grade. diameter and pitch, for casting up to 6.0 m/
Machine containment length is 13.9 m, with min;
segments 0–9 installed and provision for — Patented Dynamic Soft Reduction with
additional segments 10–11 for future plant Liquid Pool Control System;
productivity increase. — Air-mist secondary cooling with dynamic
DANIELI
QSP

control and high-efficiency spray nozzles (on

Each casting strand is comprised of the lat- Seg 0).
est technological solutions, such as:
— Butterfly ladle turret for 120–ton ladles; The Hoa Phat plant represents a further step
— Patented, long, funnel–shaped mould in thin–slab casting and rolling technology
(H2 mould) designed for installation of elec- for high productivity. In fact, based on Hoa

51
DANEWS 184

Phat’s requirements for utmost production the most advanced system to control the Hoa Phat 6.0 Mtpy
flexibility, the QSP complex is designed with temperature inside the furnace itself, integrated complex
a casting capacity up to about 2.0 Mtpy per and consequently to guarantee the slab adds a new flagship
strand, which makes Hoa Phat’s QSP the temperature uniformity at the entry of the to its portfolio
most productive thin–slab based plant world- hot strip mill.
wide. Total length of the furnace area is 210 me-
The machine’s roll–diagram design takes ters, of which 40 meters are dedicated to
into full consideration, new developments in the shuttle area and 40 meters dedicated to
“ultra-high-speed casting” of Danieli’s latest common section.
generation thin–slab caster, in terms of short
roll pitches in the containment area to pre- The tunnel furnace was conceived to:
vent dynamic bulging. — guarantee correct slab reheating, to
A dedicated descaler is foreseen at the caster achieve the proper rolling temperature;
exit, for removal of the primary scale from — ensure suitable slab temperature homoge-
slab surface before the entrance on the tun- neity along the length, width and thickness;
nel furnace, for a substantial improvement in — manage thin slabs with different lengths;
slab surface for high-quality grades. — minimize the slab residence time inside
At the exit of each caster a pendulum shear the furnace, so that both scale formation
is installed to cut-to-length the produced and decarburization depth are reduced to a
slabs. minimum.

Temperature uniformity of the slabs is en-

— TUNNEL FURNACES sured by an optimized furnace length that
permits their fast transfer to the mill.
The Furnace area it is comprised of a The total length of the tunnel, including the
two–strand tunnel furnace equipped with shuttle, comes from a dedicated study and
DANIELI
QSP

52
 FLAT PRODUCTS

simulation taking into account the whole — HOT ROLLING MILL

product mix and a suitable buffer capacity.
The presence of two shuttle furnaces guar- The QSP mill will use the already
antees even more flexibility, each shuttle successfully proven configuration that
to be used as a buffer according to the mill separates the mill stands into high reduction
requirements. units and finishing units, in order to perform
Total installed power is sized to ensure flex- two-step rolling. The transfer bar area,
ibility over the neat heat requirements, con- between the roughing and finishing mills,
sidering the whole range of casting speeds accommodates a second high-pressure 380-
and different production according to slab bar water descaler, in addition to the one
widths. installed at the high-reduction unit entry, to
The combustion system is designed to work eliminate imprinting scale phenomena on
properly with a mixture of propane gas and the final strip, thus significantly improving
air, including the predisposition for natural the relevant surface quality.
gas as a secondary fuel. Additionally, in this area a transfer-bar cool-
Water–cooled rolls are designed with tires ing system is installed, incorporated into the
realized in heat-resisting alloy, which allows descaler box at finishing mill entry, to guar-
a high tire surface temperature to avoid any antee the correct bar temperature profile and
risk of pick-up or marks on the slabs, and proper control of grain growth, which are
ensures perfect tracking through the fur- essential features of the thermomechanical
nace. rolling process.
Use of TFB SIK burners guarantees high cir-
culation of waste gases, avoiding the direct The mill includes two high-reduction units
contact between the flame and the slabs, and four finishing units (with the provision
Below: 3D rendering of Hoa and producing an advantage in terms of fuel
Phat’s 3.5 Mtpy QSP for the fifth) and the stands are designed to
production complex. gas consumption and temperature unifor- guarantee superb geometrical properties of
mity along the stock width. the final product; they are equipped with
Removable roof and scale clean-out hoppers state-of-the-art features for utmost strip
for easy maintenance are located alongside crown and profile control, such as:
the tunnel furnace. — long stroke hydraulic cylinders and hy-
The Level 1 automation system provides draulic automatic gauge control (HAGC);
basic control functions for both lines, while — positive heavy-bending system;
Level 2 automation is implemented in order — long-stroke work-roll shifting, with
to achieve the target temperature for the Optimized Shaped Roll technology
slab, considering the process variables. — work-roll thermal crown cooling;

53
3
DANEWS 184

DANIELI TSC TWO–STRAND ROUGHING MILL

TWO VERTICAL-CURVED TUNNEL FURNACE
THIN-SLAB CASTERS

Last–generation, 2X single strands high–speed Tunnel Furnace and related Shuttles connect The QSP mill applies the successfully
caster with Dynamic Soft reduction for high the two casters to the QSP mill for utmost proven configuration with separation of
productivity and a superior slab internal quality. operational flexibility. TF are equipped with the mill stands into high reduction and
high–efficiency burners for optimized fuel finishing units to perform dual–step rolling.
consumption and slab temperature uniformity. Two–stand roughing mill with 380–bar
high–pressure descaler is employed for
steel grain refinement and best surface
quality.

Hoa Phat 6.0 Mtpy — roll-bite lubrication system; technologies for Level 1 and Level 2 con-
integrated complex — skin cooling system; trols, as well as a Danieli Automation Q3
adds a new flagship — hydraulic interstand tension control; and platform for data-driven process analysis and
to its portfolio — fully automatic work-roll changing sys- optimization.
tem. Powerful and fast-learning process models
designed to provide accurate set-ups for
The line is completed with the laminar the equipment in every possible operational
cooling system, consisting of a combination condition, along with the integrated tracking
of power and normal units for outstanding system, achieving enhanced strip dimension-
strip-cooling strategies. This is followed by al and flatness tolerances, as well as deliver-
the coiling area, made of two pinch rolls ing the required mechanical properties.
and downcoilers (provision only for the third
one), fully automated with hydraulic entry The entire QSP is controlled from just two
side guides, designed for low coiling tem- control pulpits, the first one installed in the
perature and high-tension control. caster area; the second located within the
The coil handling facility will be equipped mill area, allows mill operators to oversee op-
with circumferential and radial strapping eration of the tunnel furnace, hot-strip mill,
machines, robot marking machine and coil strip cooling, downcoiler and coil handling
inspection station. A fully advanced auto- process areas. Pulpits are equipped with a
mated pallet conveyor system is used to newly designed operator interface based on
transfer coils to the storage area. touch screens, which implement Danieli
Automation’s Operator Assistant (OA), a
knowledge-based approach to process and
— PLANT ELECTRICAL AND AUTOMATION equipment control, which presents to the
operator only relevant and useful informa-
Danieli Automation designed and supplied tion for each process step, thus improving
the complete electrical and automation sys- overall work efficiency and, ultimately, prod-
tem for all QSP process areas, from Level 0 uct quality.
to large drive system for HSM stands. The Area Performance Indicator (API) and Plant
automation system features state-of-the-art Performance Indicator (PPI) provide real-

54
 FLAT PRODUCTS

FINISHING MILL LAMINAR TWO SETS OF PINCH ROLLS

COOLING SYSTEM AND DOWNCOILERS

Four–stands finishing mill equipped with the Laminar Cooling is a combination of power and Two down coilers with gearbox and related pinch
most modern devices (fast cooling system, normal units for outstanding strip cooling strategies. rolls for improved tension and centering control.
HAGC, heavy bending, shifting, etc.) with
380–bar high–pressure descaler for strip
quality control.

Above: Showcase of the time monitoring tools through specific KPIs control for the metals industry.
main areas making up the
plant line. for individual process areas (API) or for the In fact, besides powering L1 technological
integrated QSP process (PPI). controls, HiPAC is deployed as drive con-
troller in Q-Drives, thus providing a common
The mill main synchronous motors are driv- platform for all the critical control tasks.
en by Q-Drives, Danieli Automation 3Level- Main features of DA HiPAC include:
NPC IGCT MV drives, specifically designed — Industrial PC controller;
for metals application and featuring: — EtherCAT-based high-speed I/O bus;
— Synchronous motor control (induction — Open connectivity through integration
motor also available); of multiple standard I/O buses and SCADA
— Active Front End; systems;
— Single unit arrangement for H1 (1x15M- — Industry 4.0 ready via OPC UA and
VA AFE + 1x15 MVA inverter); double unit Apache Kafka.
arrangement for H2, F1, F2, F3 and F4
(2x11MVA AFE + 2x11MVA inverter); The data-driven approach is pushed further
— Mill drive-related control functions by Q3-Intelligence, Danieli Automation’s
(backlash compensation, shaped frequency proven, state-of-the-art Business Intelligence
response, improved dynamics); solution dedicated to the metals industry,
— Water cooling; which allows users to collect and merge mul-
— Rugged construction; tiple and heterogeneous data sources into a
— Maintenance friendly with easy trouble- unique, centralized repository, providing KPI
shooting. libraries and advanced statistical analysis
Q-Drives represent a well-established tech- tools to support decision making and process
nology for Hoa Phat, as the newly commis- optimization.
DANIELI

sioned HSM drives join the systems already

QSP

in operation for wirerod mills at other sites.

The core component of the system is rep- — EXECUTION
resented by the latest generation of DA
HiPAC, the integrated automation platform The supply chain has been quite complex
specifically designed to apply high-speed and diversified, however entirely handled

55
DANEWS 184

Above: Different moments

from June 23rd second caster
start-up and its first coil
produced.

and managed by Danieli. All noble equip- tion of specialists of different nationalities Hoa Phat 6.0 Mtpy
ment has been directly manufactured with high experience in the field of steelmak- integrated complex
in Danieli’s factories in Italy, China and ing equipment erection. Working with mul- adds a new flagship
Thailand, while the balance of the equip- ticultural teams is another important plus of to its portfolio
ment has been sub-supplied globally in order Danieli’s work worldwide, which guarantees
to match a tight project schedule. high flexibility in the management and pur-
By the strength of Danieli’s expediting and suit of the project objectives.
logistic organization, it was possible to de- Flexibility has been the key feature shared
liver goods in time, quantity and quality. since commencement of erection activi-
ties with site team, which have been able
The plant erection started in April 2019 and to reach the target of the 11 contractual
has been completed in March 2020. months for entire plant erection. In terms of
Assembly activities started in May 2019 with time, the scale of this effort is further high-
the first pre-assembly phases of the tunnel lighted by the completion of civil works in
furnaces outside the plant area and piping November 2019, while from the beginning
prefabrication. These activities ensured a of March to the end of April 2020 we suf-
high degree of pre-assembly, which led to fered the uneven Covid-19 emergency.
the maximum reduction in the use of the
bridge cranes that were currently occupied Thanks to the strategy implemented in this
for civil works activities, at that time 55% project, the years of Danieli’s experience
complete, which resulted in a consistent and background in the erection field as well
overlapping between mechanical, piping, as the flexibility to offer changes on work
electrical and civil disciplines. fronts, Danieli was able to guarantee to Hoa
A peak of 800 people on-site was reached for Phat the achievement of the contractual ob-
DANIELI

the assembly activities—mainly Vietnamese jectives with full customer satisfaction.

QSP

contractors—while Danieli workers from the The cold test started in January 2020 and
subsidiaries’ workshops were involved for was completed in April 2020 with the pro-
critical equipment assembly. duction of the first hot–rolled coil, bringing
The Vietnamese contractors worked together the new Hoa Phat’s QSP complex into the
with Danieli teams and under the coordina- hot commissioning stage. |

56
 ANIEL

I
TA L
GRE
EN E
M

Danieli
News
for
the True
Green
Metal

/1
 150
kWh/t DRI
saved through EAF installation
and continuously feeding it
with hot DRI

/2
 DANIELI for the True GREEN METAL

DIRECT REDUCTION ANIEL

I
TA L
GRE
EN E

with ENERGIRON
M

Low-carbon emission steelmaking

is already possible

DRI production with H2 as a reducing agent

is a technologically proven solution for “green” steelmaking,
with potential for optimized electricity costs

2000
worldsteel.org
Millions tonnes finished steel products

Developed regions
Developing regions excluding China
1500
China

1000

500
Alessandro Martinis
Vice president Ironmaking DRI
Danieli Centro Metallics 0
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017

1. World apparent steel use per region

Steel is everywhere in our lives, and A sustainable world needs steel, and grees Celsius above pre-industrial
central to making modern society sus- lots of it. Because a developed econ- levels, and to make a further step
tainable. The steel industry is integral omy needs so much steel, and about towards CO2 emissions reduction, a
to the global circular economy, and three-quarters of the world is still drastic change of paradigm is required
thus to the successful delivery and developing, the demand forecast sug- in primary steelmaking.
maintenance of a sustainable future. gests that annual steel consumption
will be in the range of 2.6 billion t by European Commission’s Roadmap pos-
Steel is truly a “green” material be- 2050. Despite recycling or reusing ex- tulates a CO2 emissions reduction of
cause it is infinitely recyclable, and isting stock the environmental impact 80 to 95 per cent by 2050 compared
its by-products and waste energies are must be addressed (figure 1). to 1990 for European industry, and
valuable resources. at present in Europe the emissions of
Yet, today steelmaking contributes Today’s technology offers plants with CO2 are taxed at levels of 25 €/t CO2,
7% of the world’s carbon-dioxide very high energy efficiency, so that to with provision of a steady increase in
emissions and on average for the last be aligned with the objective of the the coming years, affecting the over-
decade 1.83 t of CO2 were emitted for Paris Agreement to limit the global all OpEx and competitiveness of all
every ton of steel produced. temperature rise to well below 2 de- plants.

/3
 by-product of the iron oxide reduction
DIRECT REDUCTION will be water: Fe2O3 + 3H2 —> 2Fe +
WITH ENERGIRON 3H2O !
Low-carbon emission steelmaking
is already possible Hydrogen will eliminate the carbon
footprint for iron and steel produc-
tion - making Carbon Direct Avoidance
(CDA) a reality. (see Figure 3)

It becomes evident that the only way

to produce carbon-free H2 is based on
water electrolysis by using renewable
energy to provide the required power.
One of the possible abatement scenar- as coke-oven gas (COG), blast furnace (see Figure 4)
ios, theoretically resulting in 60 per- gas, hydrogen, or syngas from coal
cent emissions reductions per ton of gasification or produced in external For carbon-free H2 generation, there
steel between 2010 and 2050, relies reformers. are different available electrolyzer
on retrofitting existing blast furnaces So, Energiron stands as the perfect technologies, such as Proton Exchange
with top-gas recycling technology and technology to satisfy the need for a Membranes (PEM); Atmospheric
full deployment of Carbon Capture and progressive transition from BF / BOF to Alkaline Electrolyzers (AAE), with units
Storage (CCS) in Europe. However, DRP / EAF (Figure 3) route. For exam- already in operation for high–purity H2
this technology has yet to be proven ple, in a first step it could allow for the and power consumption ranging from
as technically feasible at industrial use of the COG or NG as a reducing 3.8 to 4.6 kW/Nm3 of H2; and High
scale. Moreover, to date the economic gas and use the resulting product, DRI Temperature Electrolyzers (HTE), cur-
viability and the general applicability in the BF. In that way it is possible to rently at smaller scale, using steam
of CCS in Europe appear questionable. maintain all the downstream configu- with related power consumption of
Public resistance to CCS in a growing ration of the already existing BF/BOF about 3.6 kW/Nm3 of H2. Larger PEM
number of member states, as well as plant and so decrease the and AAE modules are now in the
the lack of a business case for such a CO2 emissions. range of 4,000 Nm3/h of H2, enough
technology, make it doubtful that the In a second step it is possible to in- to operate a DR module of about
technology will be applied throughout stall an EAF and to consider the pos- 40,000-50,000 t/a DRI, depending
Europe in the foreseeable future. sibility of continuously feeding it with on the availability of alternate fuel.
Hot DRI (at more than 600 °C), with Replication of available modules will
Not withstanding all this, there is one savings of about 150 KWh/tDRI , thus be proportionally required for larger
mature and industrially proven solu- maximizing efficiency and reducing DR plant sizes.
tion which can achieve an immediate emissions.
reduction of 50% of the CO2 emissions Finally, in a third step the complete In Europe, projects aiming to utilize
in the primary ironmaking production: transition can be completed by dis- hydrogen are starting to appear: in
gas-based Direct Reduction. mantling the BF/BOF and increasing general, Europe is leading the trend
the capacity of the DRP/EAF installa- toward the intensive use of H2 for
Danieli is actively promoting the tions. steelmaking. Some projects directed
transition from the traditional Blast This is only an example of pos- at this target are:
Furnace (BF) – Basic Oxygen Furnace sible transition scenarios, where the
(BOF) to the more flexible and envi- Energiron technology can be used – ThyssenKrupp Steel with the
ronmentally friendly Direct Reduction (Figure 2). Carbon2Chem® Project, aiming to use
(DR) – Electric Arc Furnace (EAF) CO2 emissions from steelworks and
route, proposing to the market the surplus energy from renewable sources
Energiron technology, jointly devel- Hydrogen: the solution for for chemical production, is currently
oped by Tenova and Danieli. the Carbon Direct Avoidance shifting to the CDA approach.

Thanks to its advanced design, The Energiron process scheme, origi- – Voestalpine, Siemens and Verbund
Energiron is the only technology able nally designed to accept hydrogen, is a for the H2 Future Project are building
to maintain its standard process step ahead toward a green and circular a pilot facility for green H2 at Linz.
configuration for every type of gas economy. Thus, it is perfectly suited to
make-up, thus guaranteeing operators producing steel in a sustainable way. – SSAB, LKAB and Vattenfall with the
complete versatility. In fact, Energiron The use of H2 is the ultimate response HYBRIT initiative based on H2 for steel
is designed to use not only natural gas to the necessity of reducing green- production. Energiron is supporting
but any gaseous reducing agent, such house gases emissions since the only this with equipment and technology.

/4
 DANIELI for the True GREEN METAL

2. Schematic transition
DRI in BF Partial transition Full transition
from BF/BOF to DRP/EAF.

DRI
Energiron Energiron EAF Energiron EAF
reactor reactor reactor

Liquid steel

Pellet
DRI/HBI
sinter
pellet sinter
cokes
cokes BF BF BOF BF BOF

Coke rate Coke rate -40÷60% CO2

More flexibility
CO2 emissions CO2 emissions

Productivity Flexibility

Iron Ore 3. Selective CO2 removal

From total carbon input in Energiron ZR process.
CO2 removal H2 O
CO2
(+H2S)

NG, Hydrogen
62% as selective CO2 Syngas, COG
others O2
Approx. 256 KgCO2/tDRI
Fuel
can be sequestrated
and/or sold as by-product

Hot DRI and cold

high-carbon DRI HBI

Carbon–free power H2 ENERGIRON 4. Carbon-free steelmaking

DR plant route based on Energiron
ZR process.

Liquid
Renewable High–efficiency DRI EAF steel
energy sources electrolyser

O2

/5
 Energiron Zero-Reformer plant for
delivering Hot/Cold DRI using the
HYTEMP system, to feed the
EAF of a Danieli MIDA minimill,
in order to integrate the iron
and steel production and reduce
environment impact.

Cold DRI production via the hydrogen

route by means renewable
energy sources for 100% breakdown
CO2 emissions.

/6
 DANIELI for the True GREEN METAL

DIRECT REDUCTION
WITH ENERGIRON
Low-carbon emission steelmaking
is already possible

– Salzgitter, with its SALCOS study Renewable Energy Agency), electricity Table1– Natural gas equivalent cost compared
to Hydrogen production cost.
for high-C DRI as feed to BF and from renewables will soon be consis-
EAF (replacing finally BF/BOF) and tently cheaper than from fossil fuels.
the GrInHy project to generate H2 By 2020, all the power generation
via reversible, high-temperature technologies that are now in commer- El. En. El. En. OPEX Equivalent
Electrolyzers making use of renew- cial use will fall within the fossil Cost for DRI production NG cost
(H2 prod only)
able energy. Salzgitter has se- fuel-fired cost range, with most at the
lected Energiron as a Best Available lower end or even undercutting fossil [€/kWh] [€/tDRI] [€/GJ]
Technology (BAT) for the green steel fuels.
0.01 25 2.5
transition. Record-low auction prices for solar
photovoltaic (PV) energy in 2016 and 0.02 50 5.0
– In The Netherlands there are serious 2017 in Dubai, Mexico, Peru, Chile,
0.03 76 7.5
projects to make a stream of hydrogen Abu Dhabi and Saudi Arabia have
available also for the local metallurgi- shown that an LCOE (Levelized Cost of 0.04 101 10.0
cal industry. Electricity) of $0.03/ kWh is possible,
0.05 126 12.5
with the right conditions. According to
IRENA, the weighted average electric- 0.06 151 15.0
Economics ity cost of a new onshore wind farm
for H2-based ironmaking can be as low as 0.03 USD/KWh.

In terms of OpEx, producing hydrogen To be competitive in the green H2- While the technology to significantly
by water electrolysis implies a direct based DRI production scenario, as per lower the carbon footprint of steel
cost of the connection to the power current electrolyzers efficiency and production is ready, enabling a shift on
grid. Considering ~4.5 kWh/Nm3 H2, without CO2 credits, the electricity the scale and speed required to match
the energy consumption for DRI based from renewable sources should be the Paris Agreement depends upon
on the Energiron ZR technology will be < $0.02 /kWh. CapEx also has to be significant long-term investment and
~2,5 MWh/t DRI. Since green H2 will significantly reduced. This may be- collaboration between industry and
be produced from renewable energy, come possible within the coming institutions.
the analysis shall be made on that years (Table 1). Because approximately 30% of steel
power cost. The point is that due to is traded internationally, policies also
the high-power consumption for H2 Therefore, it is easy to understand how must promote a level playing field to
generation, the energy costs are of a it becomes essential to have a plant ensure that steel companies in one re-
high level as well. that has the highest energy efficiency gion are not put at a disadvantage with
and flexibility in usage of reducing steelmakers from other regions or in
Currently , for example, in Germany gases make-up. Energiron plants, by relation to competing materials.
the power from renewable sources has using a make-up of 100% H2, can Meanwhile, there is a technically well
dropped to below €0.05/kW, which reach consumption values as low as proven answer for the low-carbon
would mean an equivalent Natural Gas 2.0 Gcal/tDRI, an extraordinary result footprint, green steel production: the
cost of about € 13/GJ for DRI pro- which makes it the technology of the Energiron ZR process with the usage
duction, which is still high. However, future. of up to100% H2.
costs related to water make-up, CapEx “Green” H2 from high–efficiency elec-
of electrolysis modules, H2 storage and trolyzers, powered by electricity from
transport (when applicable), and CO2 Conclusion renewable sources is the approach for
emissions targets, with corresponding free-carbon steelmaking, with the pro-
credits, also shall be accounted for in Major investment in new technology is vision that optimization of electricity
the cost equation. needed even during challenging finan- cost and investment will be reached in
According to IRENA (International cial times like, the present. the future. |

/7
 1.95 Mtpy capacity plant for hot and cold DRI production via Energiron
ZR technology. The HYTEMP system directly feeds the EAF with hot DRI.
A CO2 removal unit allows the selective removal of the CO2 produced
by the reduction of iron ores. This is a unique feature of the Energiron
process that allows an efficient absorption of the CO2 contained in the
process gas stream, with no need for additional expenses for unnecessary
equipment and/or for further compression of the process gas, as may
happen for other DR processes.

/8
DANIELI for the True GREEN METAL

/9
 Danieli Centro Combustion furnace for wirerod mill cuts
scale losses and recovers thermal energy for local houses
Energy-saving WB Furnace
improves yield, carbon footprint
for Acciaierie di Verona ANIEL

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E D I T E D B Y A N D R E A B I L I O T T I / Engineer, Project, Danieli Centro Combustion

29.4
Waste Gas 1.2 Recuperator
Losses
84 Losses 3.4 Heat to stack
12.2
AdV Heat to Steel Economizer
Recuperator
Furnace
59.2
29.4 8.8
Heat recovery
16 4.6 Cooling Water
W Losses 16 by Econmizer

Fuel Input 7.3

Adsorber 2.7
2.7 Heat recovery
3.7 Refractory losses by Absorber
Preheated
Air Input 0.4 Opening losses

29.4
Waste Gas
Losses 1.2 Recuperator
84
59.2 Losses
12.2
Conventional Heat to Steel Heat
Furnace Recuperator to stack
29.4
16 7.3
Cooling Water Losses 16
3.7
Refractory Losses
Fuel Input
0.4 Opening Losses

Preheated
Air Input Sankey diagrams of energy balance
for the ADV walking–beam furnace
(top) and for the conventional one
(bottom).

The new Wirerod Mill for the Pittini Danieli Centro Combustion success- productivity. The highly flexible com-
Group includes a high-performance fully started up a 120-t/h walking- bustion system responds promptly to
walking-beam furnace that achieves beam furnace for Acciaierie di Verona, the sudden production changes that
very low levels of scale loss and is running at the highest rate since occur when switching from one to two
equipped with an energy-recovery September 2018. rolling lines, and vice versa ,thanks
system for the HVAC system, feeding From the first hot billet the furnace to the heating practices implemented
thermal energy for hot-water genera- completed a quick ramp-up phase that and the L2 thermal model, which
tion in the city of Verona, Italy. after a few days led to performance easily support every steel grade and

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 DANIELI for the True GREEN METAL

production-rate changes required

(low-, medium- and high-carbon
steels) in a fully automatic mode.
22%
better DCC WB
DCC supplied the furnace together
with a handling/feeding system and a
dedicated water–treatment plant char-
furnace efficiency acterized by four levels of emergency,
compared and an energy-recovery system that
to same-type, uses hot water coming from the fur-
traditional furnace nace in a water-water heat exchange to
produce the necessary energy for the
HVAC system, to cool down the electri-
cal cabin.

Moreover, an economizer is installed

in the waste-gas duct in order to
recover the fumes’ thermal energy
by generating hot water: it makes it
possible to deliver 3.5 MW to the
city of Verona, for distribution to heat
homes.

The described energy-saving systems

coexist with a furnace able to keep
its average emission level under the
value of 40 ppm of NOX thanks to the
Danieli Centro Combustion proprietary
burners, which can operate in flame-
less mode and with the PHL firing
logic that optimizes burner perfor-
mances in terms of both efficiency and
emissions.

The above improvements, positioned

to minimize environmental impact,
do not affect the productivity and
yield performance of the furnace, and
significantly enhance yield by achiev-
ing the challenging value of 0.40%
of scale loss. This is possible thanks
to three main factors: the high avail-
ability of the whole plant, because it
avoids long residence times for billets
in furnaces; the accurate control of
the combustion ratio; and the heating
curves selected to reduce the exposure
time of steel surface to high tempera-
ture.

A traditional walking-beam furnace

with comparable productivity presents
an efficiency of approximately 70%.
The energy-recovery systems adopted
at Acciaierie di Verona allow the fur-
nace to increase system efficiency up
to 84%, leading to decisive improve-
ment in terms of OpEx and the carbon
footprint. |

/ 11
/ 12
 DANIELI for the True GREEN METAL

Digital controls for EAF melting and casting

bring together efficiency, power, and flexibility
for a new steelmaking scenario
MIDA Hybrid: a new milestone
solar-powered by Danieli ANIEL

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Up to
330 kWh/ton
savings
with MIDA ECR
Andrea De Luca
Vice President, MIDA Danieli Additional
90kWh/ton
savings
— Energy saving and efficiency in
with Hybrid
metal production is the driving force of
the Danieli history, and it always has
been since Danieli pioneered the min-
imill concept in the 1960s.

Danieli, in the early 2000s, under-

stood and accepted this emerging
challenge, with the MIDA concept,
standing for Micromill Danieli, an ex- four configurations—Nano, Standard, The Digimelter
tremely compact minimill where the Jumbo and Twin—MIDA ECR plants and Q-One technology
caster is directly connected to the roll- can produce straight, coiled and
ing mill—from liquid steel to finished spooled bars, as well as light sections, While MIDA layouts have been imple-
products in 12 minutes or less. with capacities ranging from 100,000 mented by Danieli to achieve major
Scorecards for this technology are to 2,000,000 tpy. Each configuration energy-saving benefits, from high-
established all around the world: offers the most competitive CapEx and speed continuous casting, at the
the unique ability to cast billets at OpEx, giving tangible advantages over same time reducing CapEx and OpEx,
speeds above 8 m/min for quality re- traditional minimills. steel melting technology has seen
bar production, with 99% plant yield Since the first complete MIDA ECR much progress, mostly based on
achieved at a MIDA industrial installa- minimill supplied at CMC Steel in the improving process control, on using
tion, allows energy savings up to 330 USA in 2009, Danieli now counts 16 chemical energy to enhance perfor-
kWh/ton and zero NOX, SOX, and CO2 reference plants worldwide, including mances, and on optimizing charging
during casting-rolling. Available in three repeat orders. processes.

/ 13
 MIDA Hybrid

Taking advantage of the experience

in controlling power electronics on
high-power inverter drives (Danieli
Q-Drives), in 2015 Danieli Automation
explored the idea of improving the arc
current and voltage during melting
and refining processes. The Q-ONE
DigiMelter technology thus was born,
and the electric arc started to be con-
trolled digitally, just like the speed and
torque of stand motors are regulated.
The testing of the first prototype in
2016 immediately proved and sur-
passed the best design estimates,
and thanks to a very low flickering
and voltage unbalance, Q-ONE proved
to be capable of operating with total
harmonic distortion within the limits
and a power factor constantly above
0.96-0.97.
There is no more need for compensa-
tion. We also saw that such digital
control was improving arc stability with
very positive effects on electrode con-
sumption and refractory consumption.
Paired with the Danieli Q-MELT, which
optimizes process performance thanks
to artificial intelligence, the Q-ONE
provides full digital control of the arc:
that's why Danieli DIGIMELTER.

MIDA Hybrid,
the revolution

While exploring future additional po-

tential for this new technology, and
having the flexibility given by digital
controls, as well as the full power ca-
pacity of the traditional transformer
solution, Danieli immediately under-
stood that efficiency, power and flex-
ibility together opened a new scenario
for steelmaking: the MIDA Hybrid
technology.
Like the vehicles, H-MIDA uses two
or more distinct types of power to feed
the plant: solar and conventional

/ 14
 DANIELI for the True GREEN METAL

100
90
Energy saving (kWh/ton)*

80
70
60
50
40
30
20
10
0
0 4 8 12 16 20 24 28 32
Installed power (MW)
*compared to a conventional MIDA

From top. coming years. Solar feeding can be Depending on weather and time of
Aerial view of a MIDA ECR plant.
Saving simulation diagram thanks to applied thanks to the Danieli Q-ONE the day, the system automatically
the installation of a photovoltaic park of DigiMelter technology. controls a plants production and sets
various sizes to feed 350,000 t/y MIDA
plant (based on south US location).
Q-ONE is the only patented technology up the correct energy source (grid,
Worlwide locations of 16 MIDA-ECR that can feed an electric arc furnace solar panels, batteries, or other). The
reference plants. using solar, wind or other alterna- energy produced in excess thanks to
Left page. View of the MIDA meltshop, tive–energy power sources, since it’s the furnace cycles then can be stored
and Endless Casting-Rolling section. inherently suitable for connection to in batteries and reused later. The area
such sources, which can be seamlessly required for installing solar panels
energy. The basic principle is to use connected to the Q-ONE DC Link, al- depends on installed power, which can
solar energy during the day and the lowing for an increase in total power partially or totally cover the plant's
conventional network energy during available for melting or refining. actual requirements. As a result, OpEx
the night. An innovative energy-management savings can be estimated as a function
H-MIDA is setting new rules for steel system will control the availability of the installed power (see chart).
production and will represent the of alternative electric power and the Thanks to the high efficiency, high
new benchmark for rebar and wire process-required loads, to direct the yield of the plant, the absence of NOX,
production. Furthermore, H-MIDA excess energy where needed (not only CO2 and SOX production during cast-
looks to the future thanks to an en- toward the furnaces but also other DC ing and rolling, as well as the usage of
vironmentally sustainable production Link-based drives, such as induction renewable sources, Danieli H-MIDA is
concept, aiming to become the new heaters or inverters for stands or other the perfect solution for the green steel
standard for steel production in the variable speed loads). industry of the future. |

/ 15
 Danieli Environment technology offers environmental
and economic advantages
Comparing water-cooling options
for Fume Treatment Plants
ANIEL

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In fact, reduced consumption of electri- but by small pipes welded one next
cal energy and water are not only ben- to each other. The heat of the primary
eficial for the planet, but at the same fumes is removed by water that flows
time it means reduced Operating Costs inside these pipes (cooling is not done
(OpEx) during the plant lifetime. This by direct contact of the water with the
concept can be applied to several parts fumes): the water is warmed
of a steel plant, for example the Fume and returned to the Water Treatment
Treatment Plant (FTP). Plant.
In the Fume Treatment Plant there are The pipe diameter typically may vary
Alberto Feruglio different parts that can be carefully between 2 ½ and 4 inches, and differ-
Proposal Engineer conceived and designed in order to fol- ent schedules can be used.
Danieli Environment and Systems
low this philosophy, and one of these This pipe-to-pipe design also is ap-
is the water-cooled part of the primary plied to water-cooled EAF panels.
fume-suction line: the direct extraction
system for Electric Arc Furnace prima- — Spray configuration
In a world that is growing more aware ry fumes involves water-cooled parts The pipe-to-pipe configuration is not
of the importance of the environment, (ducts and post-combustion chamber) the only one now available: there is in
and that is trying to take the necessary that are necessary because of the high fact another one that is quite common,
steps to preserve it, the steel industry temperature of the fumes. especially in the United States, and
is adapting to this vision by reducing There are different standards and that is the spray-cooled design.
the emissions and becoming as “envi- designs that can be applied to these As in the “pipe-to-pipe” design, the
ronmentally friendly” as possible. parts, but a careful design is essential cooling of fumes is not done by direct
for reduced water consumption and, contact of the water with the fumes:
But what is the meaning of “environ- as a consequence, reduced electrical the spray-cooled design has a “sand-
mentally friendly”? That is tough to energy consumption. wich” configuration consisting of two
answer in a few words, but what is steel panels with an empty space in
important to understand is that this between, where water spray nozzles
expression relates not only to the intui- Design types of are installed. These nozzles create a
tive concept of “emissions reduction” water-cooled parts constant water spray against the steel
but also to a careful and reduced walls, allowing the heat removal from
consumption of primary goods, for ex- — Pipe-to-pipe configuration the primary fumes.
ample water, electrical energy, etc. The water-cooled parts proposed by An objective benefit of this solution
The interesting part of this wider point Danieli are assembled in a “pipe-to- is that, in case of damage to the steel
is that there is actually a double ben- pipe” (tubular) configuration where part, the water leak is reduced com-
efit: one for the environment and one the walls of water-cooled components pared to the tubular design because
for the plant owners. are not made by simple steel sheets, in the pipe-to-pipe design the water is

/ 16
 DANIELI for the True GREEN METAL

pressurized, while in the spray solution

the water works at atmospheric pres-
sure.
This safety benefit could make sense
for the EAF, even though the safety
features of the EAF tubular water-
cooled panels are now highly efficient
(by significantly reducing the risk of
explosions due to water leaks), but it
does not make much sense for primary
fumes water-cooled parts: in fact,
there is basically no risk of explosion
in case of water leakage, as it could be
in the furnace instead.
In addition, the water spray-cooled
design usually is more expensive than
the tubular one, but what is more
important is that it requires much
more cooling water to obtain the same
cooling performances. As a direct
consequence, the electrical energy
consumption is higher compared to
the tubular design: the tubular design
has less water, which means smaller
pumps in the Water Treatment Plant
(WTP).

193
Danieli
Advantages of the Danieli
tubular-design
Fume-Treatment for water-cooled parts
Plants
Since 1980 The best way to understand the ad-
vantages of the tubular design is to
analyze a real case.
In a recent project in the United
States, Danieli implemented its design
for the water-cooled parts of the FTP,
while the first choice of the customer
was the water spray-cooled design.
Table 1 presents the main data of the
plant.
With the mentioned input data, water
consumption with the two designs was
significantly different: with the spray-
cooled configuration, the design water
consumption was 4,950 m3/h, while
with the tubular Danieli design the
water consumption was 2,900 m3/h.
Top: primary fumes water-cooled duct with the “pipe-to-pipe”
(tubular) configuration that allows significant savings in cooling water
This means that with the pipe-to-pipe
consumption and related added saving due to a smaller WTP and design there is a savings of more than
auxiliaries dimensioning. 40% in water consumption.
Bottom: water-cooled duct internal view during quality inspection This saving is clearly reflected in
at Danieli workshops. the Water Treatment Plant as well,
because the total circulating water
is less: this means that not only the
entire WTP is smaller, but more spe-
cifically that the pumps related to the

/ 17
 Pictures below:

Comparing Completely water-cooled

water-cooling options drop-out box.
Thermal flow simulation in
for Fume Treatment the water-cooled downcomer
Plants duct.

FTP water-cooled parts are smaller, Electric Arc Furnace (EAF) size (approx.) 170 tons Table 1
with reduced motor size.
Table 2 shows the main differences Minimum Tap-to-Tap time 41 min
expressed as kW saved, with Danieli Primary Fumes Heat at the Water-Cooled Duct inlet 134 MW
tubular design compared to spray- (after the EAF fourth hole elbow and the gap) (approx.)
cooled design. Primary Fumes temperature at the Water-Cooled Duct inlet 1400°C
These numbers are quite significant, (after the EAF fourth hole elbow and the gap) (approx.)
but they become even more impres-
Requested Primary Fumes temperature 850°C
sive if they are “translated” into cost at the Water-Cooled Duct outlet (approx.)
savings. Considering the fact that this
project was in the United States, and
that the cost of electrical energy tb is
Total difference of installed power 1126 kW Table 2
0.045 USD/kWh approx., while con-
sidering 8,322 working hours per year Total difference of average absorbed power 848 kWh
too, the total savings in the OpEx is
approximately 315,000 USD/year.

Finally, an additional benefit of the

tubular solution is the optimized
layout: the water–cooled parts with
tubular design are more compact than
for the water spray-cooled design, and
also the water collection tank (which
is usually placed right outside the
meltshop) can be completely avoided
(if the EAF has a tubular design too)
or at least reduced (if EAF has a
spray-cooled design). This is reflected
also in a reduction of the civil works,
with additional savings on the Total
Investment Costs.

Considering all the above-mentioned

topics, the objective conclusion is that
the tubular design proposed by Danieli
for the FTP water-cooled parts is a bet-
ter choice than the water spray-cooled
design, because there are benefits for
both the environment and the plant
owners.
This is a clear proof that an environ-
mentally friendly solution also can
be economically convenient, and this
should encourage steel plant owners
to carefully analyze the different solu-
tions now available. |

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 DANIELI for the True GREEN METAL

Brownfield WTP installation will guarantee contractual

performance with 40% footprint savings
Customized and integrated design
for cooling-water treatment
at Nucor Steel Gallatin, USA ANIEL

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New WTP will satisfy the water requirements

of the recent HSM upgrade to a 3.0 Msht/y QSP®
thin-slab casting and rolling plant

202
Danieli
Water
Treatment
Plants

Marco Flumignan
Vice President,
Danieli Environment and Systems

Nucor Steel Gallatin is raising the pro-

duction capacity of its hot-strip mill
from 1.8 to 3.0 Mtpy, installing a new
Danieli meltshop and thin-slab caster
and modifying the existing hot-strip
mill. To reach the new production to-
tal, the water treatment plant also will
be updated to satisfy the new water
requirements.

Introduction

Due to the above increase in produc-

tion, cooling water has to be supplied
to the new equipment, for both con-
tact and no-contact circuits.
In a “brownfield” project many con-
straints must be considered: available
space, existing equipment reutiliza-

/ 19
 Customized and
integrated design
for cooling-water
treatment

tion, possible interference, and

mechanical-electrical-automation inte-
gration. The challenge is to apply the
right treatment technology while mini-
mizing civil construction and erection
time, while respecting all the existing
constraints. This is the case of the
WTP for Nucor Steel Gallatin awarded
to the Danieli Environment Team.

Design integration

During the bidding phase, working to-

gether with the technological team and
Nucor specialist, Danieli proposed a
general layout fully integrated with the
existing equipment, electrical cabin, Design Integration. Space availability, equipment
and piping routing, while applying the reutilization, mechanical-electrical-automation integration
same standard for the mechanical and up to 40% footprint reduction
electrical/instrumental design used in
technological area.
At the end of the project there will be
only one WTP with a single control
Brownfield WTP
pulpit for the whole steel complex. installation: laser
scanner captures a 3D
site map for a smooth
implementation of new
Direct Cooling circuits: equipment. General
building view (top)
DanFilters® and details (right)
of adopted solutions
The most challenging step of the proj- such as DanFilter
technology and skid,
ect was defining the treatment process equipped with filters
for direct cooling circuits of the HSM valves and piping, for
time-saving installation
and casting machine. and connection.
The Danieli solution was to reuse the
existing scale pit entirely, with the fol-
lowing objectives:
— to create a new, “small-scale pit”
for the roughing mill water (same de-
sign as per new TSC scale pit) allow-
ing the water to flow into the existing
scale pit;
— to send water coming from new TSC
scale pit directly to the sand filters

/ 20
 DANIELI for the True GREEN METAL

battery, avoiding increasing the hy- Danieli Environment

and Systems is
draulic load of the existing scale pit; specialized in design,
— to provide a new common pump- manufacturing and
erection of WTP
ing station for both new and old HSM solutions, offering a
equipment, to send the water from range of proprietary
the existing scale pit to the revamped technology for water
treatment, water
sand-filter battery. saving, water recycling,
— to use DanFilters® instead of stan- and energy saving.
dard filters, to reduce the footprint.
Thanks to DanFilters®, Nucor is install-
ing only 8 filters of 5 mt. with 40%
footprint reduction compared to the
16 standard filters, to fit the available
area for the implementation of WTP.

Smart construction solution

Nucor technicians considered creat-

ing an underground pump room for
the new scale-pit horizontal pumps,
as they had a bad experience with
submerged pumps. Due to the pumps
size and the bottom level of the basin,
this would have meant a costly civil
construction program. Instead, Danieli
suggested applying vertical pumps
and using the existing basin where the
submerged pumps were installed. tion by customers, especially where —a cohesive team working together
Vertical pumps maintenance is easier the labor cost is high. All piping, during commissioning phase for all
than that for submerged ones, and the instruments and cables are mounted products.
customer appreciated the Danieli ap- on board and tested in the Danieli Danieli Automation will integrate the
proach and solution. This is another workshop. hardware and software of the existing
example of cooperation between sup- operation and the new aspects of the
plier and customer: we are not only an Skid-assembled equipment reduces WTP. After the revamping there will be
equipment supplier but a multidisci- the erection and commissioning ac- only one water-treatment plant with
plinary consultant for our customers. tivities considerably and represents a just one control pulpit.
cost saving for the customer. Nucor
Gallatin endorsed the skid-mounted
Easy erection design, which will be implemented Conclusions
in the new WTP.
To speed up the erection and reduce Nucor Gallatin was seeking a reliable
the cost for Nucor, Danieli suggested partner to enhance the performance of
package cooling towers instead of the Automation integration its existing WTP, one capable of car-
field-erected type. Filling material is rying out a full integration with smart
already installed within these tow- Danieli Automation is the link between and time/cost–effective solutions.
ers and does not need to be glued in all the Danieli product lines regarding Danieli accepted the challenge and
place. Erection is very fast, requiring power supply and advanced automa- designed tailor-made solutions that
only fixing the block in place on top of tion. This is an important advantage deliver true value to the customer.
new concrete basin and connecting it for our customer, ensuring:
to the existing one to create a common —consistent design that conforms to The Nucor Gallatin team appreciated
basin for cold water. the functions of the other technologi- the design and valued the proposed
cal lines; technology, engineering, organiza-
—a unified brand for supplied compo- tion, collaboration and technical sup-
Skid-mounted approach nents, with matching spares; port through the proposal phase, and
—software tested before the commis- awarded this project to Danieli.
The skid-mounted approach to system sioning, together with the other tech- Commissioning of the WTP is expected
installation is gaining more apprecia- nological lines; during Q3 2020. |

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 Proven and profitable solution for energy recovery
Absorption chiller
meets steelmaking goals
and green targets ANIEL

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Analysis of performance at Acciaierie di Verona (Pittini Group)

demonstrates efficiency, ROI, and electrical energy savings

The ongoing search for green solutions – The rated power of the absorber is
and the contemporary need to opti- much lower than chiller’s;
mize plant costs has revived interest in – Water is the fluid used inside the
absorption chillers systems (“absorb- absorbers, not HFCs (like R134a) of
ers”), that have been available since traditional chillers.
1859 but little used in industry today.
Following the absorption chiller refrig-
Unlike chillers, which are activated by erant cycle, after evaporation water is
electric power, the absorber is driven by mixed with lithium bromide (LiBr) at
Daniele Zorzi thermal power. Figure 1 illustrates and high concentration, coming from the
Senior Manager compares the two processes. Through generator.
Danieli Environment and Systems
this comparison it’s possible to note:
– The absorber requires a heat source The characteristic of LiBr is its high
to trigger its internal process; hygroscopicity; as a result, after mix-

1. Schematic comparison between absorber chiller (left) and traditional one (right).
Thermal
waste
recovery Condenser
Condenser water
water

High pressure High pressure

vapor R134a
Generator Condenser Condenser
Water + LIBR

R134a
Liquid
Liquid
water

Compressors
LIBR

Absorption Traditional
chiller chiller

Electricity

Low pressure Low pressure

vapor R134a
Generator Evaporator Evaporator

Chilled
water Chilled
water

/ 22
 DANIELI for the True GREEN METAL

ing with water at low-pressure vapor — Cooling capacity supplied by the — The process of separating water
state, the resulting blend is in liquid absorption chiller, making it possible from lithium bromide is more effec-
state. to analyze the system from thermal, tive;
The liquid can now be pumped (instead electrical and Return on Investment — Water (i.e., the refrigerant fluid of
of compressed) to the generator, at a (ROI) perspectives. the cycle) streams with higher flow;
very low electrical cost. — The efficiency of the heat exchang-
Here—through thermal waste—heating ers (the evaporator, in particular) in-
water and LiBr are separated again, and Thermal analysis creases;
water can close the remaining standard of the absorber — The overall cooling capacity im-
refrigeration cycle going by condenser, proves, not only in terms of power
throttling valve and evaporator. By re-processing the data it was pos- (kW), but also as power per water flow
sible to note that the best performance (i.e., refrigerant flow) (kJ/kg).
One of the waste media that can be of the machine occurs at the maxi- See Figure 3.
used in the steel making plants is the mum demand for chilled water, which
one coming from the cooling circuit coincides with the maximum produc-
of the furnace, as happened at the tion peak. Comparison of electricity
Acciaierie di Verona (ADV), part of the The above also can be easily deduced consumption between
Pittini Group, where a 1500-kWf ab- from the following formula: absorber and chiller
sorber had been installed by Danieli to
serve the new, 750,000-ton/year wir- Absorption Considering the nominal data valid,
Cooling capacity
erod rolling mill and future extensions. chiller’s ≈ the following is obtained:
Generator’s heating – Internal absorber pump:
efficiency
During the first year of operation of power PaN = 3 kW;
the system, the following data were – Electric chiller compressors:
recorded (see Figure 2): Note: The low-rated power of the ab- PcN = 305 kW;
— Heat recovery coming from the roll- sorber internal pump has been consid- – Plant operations:
ing mill plant; ered negligible. L = 6,443 h/year;
— Rated power of the pumps for cool- – The annual power saved is:
ing water, of furnace water and of Following the reason why is that in ES = Energy Savings = (PaN-PcN)*L
cooling tower water; these conditions: = 1,950 MWh/year.

/ 23
 sorption and traditional chillers has – Cooling towers’ fans.
Absorption chiller been done based on collected data (to-
meets steelmaking goals gether with some technical literature Overall first-year data coming from the
and green targets about chiller): rolling mill indicate that the return on
investment is on average 40%, which
[CrP – Ar] * [Cost of EE] coincides with a payback of 2.5 years.
ROI = This result depends on cost of energy
Cost AC – Cost C and on production mix (as mentioned
in the thermal analysis).
AC = Absorption Chiller
C = Chiller At the absorption chiller nominal work-
This value equals the yearly energy re- ing conditions, this value could be
quirements of more than 500 houses, CrP = Chiller rated Power even two years, thanks to the Italian
i.e. a city of 1,500 inhabitants. Ar = Absorption’s rated environmental fiscal benefits, similar
As carbon dioxides avoid pollution, it EE = Electic Energy to the ones available in many other
corresponds to about 900 t CO2/year. countries.
For thoroughness, the following (mi-
nor) management costs also have been To conclude the analysis above, it is
Return on investment (ROI) considered: confirmed that the absorption chiller
– Water pumps to absorption chiller’s is an investment that fits steel making
In terms of return on investment, a generator; plants and the environment protection
CapEx/OpEx comparison between ab- – Water pumps to cooling towers; philosophy. |

Heat recovery, kW
A/C water temperature, °C
Cooling capacity, kW
Thermal power, kW

Temperature, °C

2. Diagram of the direct

correlation among measured
parameters: heat recovery, cooling
capacity, A/C water temperature.

1 4 7 10 13 16 19 22 25 28

120 350 3. The recorded data of heat

recovery vs. cooling capacity
100 300 shows that the best performance
Cooling capacity (%)

of the machine occurs at the

250
80 maximum demand for chilled
200 water.
60
150 4. Required electric power
40 comparison between systems.
100
20
50
0 0
0 20 40 60 80 100% Required electric Required electric
Heat Recovery (%) power traditional power absorption
chiller (kW) (kW)

/ 24
 DANIELI for the True GREEN METAL

Save
yearly
electric energy of

500
families’
houses

and avoid
about

900
tpy of CO2
emissions

3
years ROI

/ 25
 Smart and flexible compressors configuration
ensures OpEx reduction, leading to energy savings

Sustainable Compressed
Air Production: a new approach
that achieves fast ROI ANIEL

I
TA L
GRE
EN E
M

E D I T E D B Y E N R I C O N O R O / Senior Engineer, Process & Plant, Danieli Engineering

— The core equipment of a com- A compressor should have a flexible 1 Advanced control system -
maximum operating economy
pressed-air plant (CAP) are the com- design that meets the users’ needs, and efficiency.
pressors, which are flanked by a set with maximum operating economy and 2 Plant operating data –
monitoring and control.
of air-treatment units designed to give efficiency: this can be achieved by 3 Dew point – process
compressed air the required quality, using a combination of compressors control.
see Figure 1. with different capacities and speed- 4 Zero-air purge adsorption
system – energy saving.
Electricity is the standard energy controlled motors that, combined with 5 Variable capacity
source for such installations and a modern CAP control system, can compressors - flexibility
to suit different operating
represents approximately 80% of the lead to substantial energy savings. conditions and energy saving
overall cost during the life of the com- Analysis of compressed-air consump- 6 Low DP filters – energy
saving.
pressors: any reduction in energy con- tion, by collecting plant operating data, 7 Generous pipe sizing –
sumption can bring sensible savings. forms the basis for assessing the load- energy savings and reduced
ing factor of the installation, identify- pressure drop.

Greater concern for environmental ing wrong set-up or leakages, finding 8 Pressure – process control.
issues and efforts to reduce carbon potential energy savings and tuning the 9 Flowrate – process control,
data recording and process
dioxide emissions raise the need for configuration of future CAPs. analysis.
a critical review of the solutions used Over 90 % of the power supplied to the
to minimize the environmental impact compressor can be recovered in the form
of CAPs by reducing energy consump- of highly valuable heat that can be trans-
tions and introducing more sustainable ferred by a suitable medium (e.g. water)
processes. to where it can be utilized (see Figure 2).

4 3 6 5 8 9

7 1 2

/ 26
 DANIELI for the True GREEN METAL

1. Typical arrangement of a compressed-air production plant.

Process air to users

Compressed air to users

Air receiver
Pre-filters
Refrigerant dryers
Instrument air
to users

Air compressors
Adsorption dryers

2. Total recoverable energy under ideal circumstances can rise to 94%.

Total electrical
energy consumption
100%

Up to 6%
energy
savings
Heat radiated
from the drive motor
and dissipated
3.5 years
into the cooling air
9%
Heat radiated
from the compressor
return of
Heat recoverable
2%
investment
Heat remaining
from the compressed in the compressed air
air aftercooler 4%
13%
Heat recoverable
from the oil cooler
72%

With more than 40 compressed-air and increase of environmental sustain- considering to run the plant for 8,000
plant installations in the last 15 years, ability. hours per year, ROI is achieved in less
Danieli Environment and Systems Just to mention an example, the use of than three years.
(DESY) has developed and consolidat- a 950 m3/h-capacity heat-regenerated DESY is focusing now on this new ap-
ed the necessary know-how to apply adsorption dryer, in place of a heatless proach in designing compressed-air
the most up-to-date technology and to type, implies an additional investment processes and installations, and the
pursue customers satisfaction through cost of 20,000 €, but the electri- activity is on the way.
achievement of plant performances, cal energy saving during operation A campaign for measuring com-
reduction of operating costs, fast ROI amounts to approximately 18 kW: pressed-air consumption has been

/ 27
 Sustainable Compressed
Air Production: a new approach
that achieves fast ROI

carried out at Egyptian Steel and AQS, the new rolling mill was optimized to sors in place of fixed-speed compres-
to create the basis for evaluating the provide the maximum flexibility and to sors working in load/unload mode, is
actual loading condition of these in- follow the different working configura- almost 5.5 % and the forecast for re-
stallations: from a first estimation, the tions of the mill, at the same time turn of additional investment is around
installation of a variable-capacity com- minimizing energy consumption. This 3.5 years.
pressor in place of the fixed-capacity will be possible thanks to the com-
one would entail a consumption sav- bination of fixed- and variable-speed The future needs sustainability:
ings up to 4 %. compressors, duly sized, together with Energy-saving and environmentally
an advanced control and monitor- friendly practices must inspire indus-
The innovative approach has been ing system capable of controlling key trial projects, and Danieli is already
applied since the design stage working parameters of the CAP. The proceeding in this way, seeking to
in the ABS QWR 4.0 project: the expected savings on energy consump- make this approach a competitive ad-
compressed-air plant that will serve tion, given by variable-speed compres- vantage that benefits customers. |

Danieli
Engineering
Systems

More than

40Danieli
compressed-air
plant
installations
in the last
15 years

/ 28
 DANIELI for the True GREEN METAL

The world's first for commercial operation to apply linear

Fresnel collector technology with molten salt
Ready to shine
Concentrating Solar Power plant
under completion ANIEL

I
TA L
GRE
EN E
M

E D I T E D B Y S E R G I O P A G A N I / Chief Operating Officer, Fata EPC

— Despite all the difficulties gener- since the annual saving on emissions tries, as soon as the performance in
ated by the Covid-19 outbreak, Fata compared to an equivalent gas turbine Partanna will be demonstrated.
is close to completing the erection of plant will be close to 8 million tons
a 4.26–MW solar plant in Partanna of carbon dioxide. Around 8 thou- This first industrial plant in Partanna,
(Sicily) and it is planning to achieve sand households will benefit from the although of a size necessarily limited
its full commissioning by the end of power generated by the sun shining on by compliance with the authorization
the summer. Partanna site. constraints, responds already to a
fundamental request: to guarantee the
A crew exceeding a hundred people is As announced in a recent ENEA ability to supply the grid with electri-
presently on site in accordance with article, on the Partanna engineer- cal power according to real demand:
Fata's commitment to generate power ing phase, with which FATA ac- a fundamental requirement for the
from the sun within few weeks. By tively collaborated it has been stated: further development of renewable en-
exploiting, around the clock, the heat “Partanna CSP plant provides a ergies.
of 18 hundred tons of molten salt, the concrete response to the mechanisms
Partanna plant can collect and store and feeding tariff incentive available Plants like Partanna, but with capaci-
the sun's energy to provide stable and for CSP—as foreseen in Ministerial ties between 50 and 100 MW.e, are
on-demand supply of electricity. Decree DM of 23 June 2016 - which also particularly competitive both in
will support a reliable and sustainable terms of CapEx and "time to market".
The thermal energy storage has an transition to larger plants”. In fact, a
average capacity of 15 hours operation second solar installation, almost equal In view of the development of CSP
and the annual energy production will to the Partanna plant, is going to be technology, its ability to supply me-
be around 19 GWh. This plant will be built by Fata in the area, while a group dium– and high–temperature thermal
the first in the world in commercial of CSP plants for a further total capac- energy makes CSP the preferred solu-
operations to apply linear Fresnel col- ity of 25 MW are expected to follow tion for industrial processes in general:
lector technology with molten salt. soon, as per the Italian plan. one example for all in the jointly pro-
The Partanna plant also will contrib- Furthermore, plants of larger size are duction of electricity and desalinated
ute to the decarbonization process, going to be marketed in sun-rich coun- water or steam. |

/ 29
Bird view of erection phase of the 4.26 MW solar plant in Partanna (Sicily).
The thermal energy storage capacity has an average of 15 hours operation
and the annual energy production will be around 19 GWh.
This plant is the first in the world in commercial operations applying linear
Fresnel collector technology with molten salt.

/ 30
 DANIELI for the True GREEN METAL

19 GWh
annual energy
production

/ 31
 ANIEL

I
TA L
GRE
EN E
M

Danieli innovations for

True Green Metal are
steadily evolving,
ushering the company
and customers into
a new era: breakthrough
technologies and
processes to preserve the
environment. Renewable
sources, Energiron,
H-MIDA, QSP-DUE,
are just some of the
concepts behind
Danieli’s push to be
a step ahead in a greener
future.
 LONG PRODUCTS

— LONG
PRODUCTS

Consolidated results for quality and OpEx optimization

MIDA ECR® KNOW-HOW IS A GUIDE

TO EVER–IMPROVING EFFICIENCY
AND ENERGY SAVINGS
Feng Hsin takes full advantage
of Danieli direct casting and rolling technologies

CCM installation, followed by sev-

eral other plants in subsequent years.
The most important of these was the
425,000-tpy, Super Flexible Rolling
Mill for bars and sections installed in
1993. Other projects there included
new roughing stands, a rolling mill for
small profiles, LF, VD and CCM for
meltshop n°1. Surface layer of ultra-fine grain ferritic-pearlitic
structure, hardness: 210 – 230 HV.

Confirming the successful decades

ANDREA DE LUCA of solid partnership, Feng Hsin’s lat-
Vice President est contract with Danieli involves the
MIDA Micromills Technology
supply of a new, high-speed bar mill.
It produces 745,000 tpy of deformed
stablished in 1969, Feng bars, from D10 up to D36, applying
E Hsin Iron & Steel in Taiwan
today produces over 1.8 mil-
two–strand slitting for D10-D19 at a
maximum finishing speed of 40 m/s
lion tpy of commercial steel grades in for construction grades CNS 560,
bars, wirerod, large rounds in coils, and A2006,and Grade SD280(W) up to Core zone of fine-grain ferritic-pearlitic
structure, hardness 190 – 210 HV.
sections. Having expanded its market SD420(W).
position over the years, Feng Hsin now
50 μm
competes successfully with the major The main production route feeds the
steel suppliers in the region. rolling mill using the roller table con-
Danieli Group’s cooperation with Feng nected with the four-strand caster.
Hsin started in 1983 with the first Then, the billets (165 mm2) pass

57
DANEWS 184

Distance – Temperature curves along the T (°C)

RM Endless Rolling – Rebar 2X16 mm from 1300
SQ190
1200
Core temperature
1100
Surface temperature
1000
Average temperature
900

800

700

600

500

Continuous Induction Roughing & Pre-cooling Finishing Final cooling stage Cooling bed
casting machine heaters intermediate stage mill
mill

MIDA ECR KNOW-HOW resulting from poor chemistry are bal-

IS A GUIDE TO EVER– anced by the microstructure obtained
IMPROVING EFFICIENCY via the UFG process, which promotes a
AND ENERGY SAVINGS very fine microstructure and enhanced
final mechanical properties, minimizing
or even avoiding the need for alloying
elements.
With the UFG process, a grain-size
through an 8–MW induction heater definition from 5 to 1 μm is obtained,
with a rated power of 140 t/h, to equal- resulting in higher ductility because the
ize/increase billet temperatures before smaller grain-size prevents any poten-
rolling (temperature range from 800 °C tial cracks from propagating.
to 1050 °C) is applied for fine control
of temperature, since the power is set of rolling operations by direct charging. CONCLUSIONS
according to the actual thermal load of With a 98% yield, today this rebar mill
the single billet. is a highly competitive, energy-saving With zero emissions for billet reheat-
The mill is comprised of 18 housing- and high-quality operation. ing through gas furnaces, the Danieli
less stands, with four, two-pass modu- Endless/Direct Casting and Rolling
lar Fast Finishing blocks fitted with M2 Another important factor contributing technologies are now solidified to fulfill
Multiple Drive system; a 102-m cooling to energy and cost savings is the roll- the demands for high efficiency and
bed and associated entry/exit facilities; ing of low-alloy rebar thanks to the in- energy savings in production of rebar
a cold shear for final cutting to length; line UFG (Ultra-Fine-Grain) process, bundles, spooled coils and wirerod . In
and a 28-m–wide counting/sub-bun- which allows a significant reduction in addition, with patented Danieli UFG
dling/master bundling station. Danieli the expense of the alloy elements, such technology the average transformation–
Automation provides the Q-LONG as niobium (Nb) or vanadium (V). cost savings resulting from the absence
Level 2 automation and all the electric of vanadium micro-alloy addition have
systems for the whole plant. With a dedicated and optimized chem- been evaluated at approximately 17
istry, the use of alloying elements USD/ton savings.
Danieli introduced Feng Hsin to the starting from low-carbon and low- Using these technologies, the Feng
MIDA DCR direct casting-rolling rebar manganese steel is minimized and even Hsin mill has become a very competi-
mill concept, and now the operating avoided thanks to low-surface tempera- tive benchmark operation, not just in
practice is to process more than 99% ture rolling. Low mechanical properties Taiwan but around the world. |

58
 LONG PRODUCTS

98%
yield for
high competitiveness

17 USD/ton
of savings
thanks to the absence
of vanadium
microalloying

59
DANEWS 184

A Step Ahead Technology TO HIT RECORDS

Record-breaking trust
World’s largest
beam-blank ever cast
at Maanshan MaSteel

PIERLUIGI ARMENANTE The BB5 etched sample,

Process Technology Engineer Steel grade A992H1 microalloyed, shows very high quality.
Continuous Casters
Danieli Centro Met

n March 2018, China’s Maanshan to support the huge oscillating mass.

I Iron & Steel (MaSteel) placed a
contract with Danieli for a new beam-
The automation system includes the Danieli
Liquid Pool Control System, which oversees
blank CCM. The new, 12–m radius, 2–strand the air-mist cooling to ensure accurate and
CCM was designed to cast three beam-blank balanced secondary cooling.
sections and a small slab in twin mould con- A plate mould, comprised of copper plates
figuration, or to cast four slabs on two strands. fixed to support plates, allows for an opti-
The CCM is fed by a 120–ton BOF of 180 mized cooling configuration using a combina-
t/h (future 195 t/h) productivity. To match tion of gun-drilled holes for web and fillet
the melt shop productivity, the CCM can zones, and slots for flanges.
reach productivity of 97 ton/h per strand. For The plate mould also allows optimization of
energy savings, all beam-blanks should be hot taper in various areas. The bi–dimensional,
charged into a section rolling mill. thermomechanical approach was chosen to
The largest among the three beam-blank sec- study the taper of a BB mold; the model uses
tions measures 1,300×510×140 mm and with a so–called “travelling slice”, where a layer of
a linear weight of almost 2.7 ton/m, making it the transversal section is subjected to differ-
the largest beam-blank section in the world ent thermal boundary conditions (i.e., thermal
flux) during its movement from meniscus to
The new MaSteel continuous caster is mould exit.
FROM THE equipped with advanced Danieli technologi- Due to the complexity of the mould
FIRST PAGE cal packages, such as the Q-INMO oscilla- geometry, uniform liquid metal delivery
tor that guarantees excellent mould guidance is a challenge and the Submerged Entry
thanks to bearing- or springs-free design, Nozzle (SEN) design plays a key role in
using a “rolling element”, with twin cylinders supplying liquid steel flow without

60
 LONG PRODUCTS

New Danieli
Combicaster
produces a
2.7-ton/m BB7
measuring
1,300x510x140
mm

Produced sections summary. Sections [mm] BB5 BB6 BB7 SLAB

Overall dimensions [mm] 900×510×130 1,030×440×130 1,300×510×140 280×550

Width [mm] 900 1,030 1,300 550

Height [mm] 510 440 510 280

Flange Thickness [mm] 165.0 112.5 215.0

Web Thickness [mm] 130 130 140

Web / Flange Rad [mm] 130 130 130

Metric Weight [kg/m] 1,922 1,624 2,687 1,194

excessive turbulence, to prevent mould flux FIRST HEAT

entrainment and to promote uniform heat
transfer and steady flow conditions. The first heat was produced on 20.12.2019,
Danieli worked closely with the refractory casting ”BB5” section. Four more sequences
supplier Flow Simulation Team, which first of “BB5” section were cast before the com-
conducted several numerical simulations to missioning was interrupted due to the
determine the flow performance of different Covid-19 pandemic, though the early results
pouring nozzles based on previous experi- were encouraging. The achieved casting
ence and considering the different phases speed was 0.74 m/min, resulting in produc-
of the plant commissioning, with two nozzle tivity of 85 ton/h per strand with very good
designs being considered as final options. surface and internal quality for the beam-
The W&S group was designed to unbend blank produced.
the largest section BB7 and the steel grade
families with highest hot-strength to be pro- SURFACE QUALITY
duced. Both steady-state casting and non-
steady state conditions, such as head and tail Good surface quality has been found with
unbending or flying-tundish operation, have regular oscillation marks, smooth surfaces,
been thoroughly analyzed. and absence of surface defects.

61
DANEWS 184

World’s largest
beam-blank
ever cast

Beam-blanks production
under way at MaSteel
Maanshan plant.

INTERNAL QUALITY AND SHAPE web, weighing almost 2.7 tons/m and the
maximum productivity of 97 ton/h per strand
The internal soundness of BB5 was found was achieved during the first cast.
to be very good. Overall shape of the BB5 is The BB7 production was made possible
excellent also, fulfilling the tight tolerances thanks to very close cooperation between
required for the product. MaSteel and Danieli. Personnel located
on-site in China, limited due to travel re-
On April 21, 2020, after a two-month break strictions, were extensively supported by col-
due to the Covid-19 pandemic, the new leagues located in various Danieli offices us-
Danieli two–strand, 12–m radius, continu- ing remote connections and advanced tools,
ous casting machine successfully cast the such as Q-SPACE.
largest beam-blank section in the world. This Several steel grades already have been pro-
goal is another step reconfirming the sound- duced, including micro-alloyed and fine-
ness of Danieli design and innovation. grain steels, obtaining good product quality
The new section BB7 is 1300-mm wide, and meeting the strict dimensional design
with 510-mm tall flanges and a 140-mm tolerances from the first heat. |

62
 LONG PRODUCTS

High-quality blooms thanks to MSR,

stirring and cooling technologies

Maanshan Masteel
five-strand bloom caster
exceeds global standards

— The 5–strand, 14–m radi-

us continuous casting ma-
chine supplied by Danieli
was successfully commis-
sioned at Maanshan Iron &
Steel in Maanshan, Anhui
province, China, on 15
April, with a casting sec-
tion of 250x250 mm.

The CCM is designed to

achieve the highest qual-
ity blooms and initially will
produce 250×250-mm and
380×450-mm sections. The
caster is equipped with a
Mechanical Soft Reduction
system, combining three ing other aspects of internal Maanshan CC5 represents to the long and profitable
twin-modules and three quality. the new frontier in high-qual- collaboration with Danieli,
single modules designed to In addition to the advanced ity bloom production through Maanshan is proud to be the
apply soft and hard reduc- MSR system the new caster the exceptional integration of frontrunner for heavy bloom
tion on a wide range of steel also is equipped with mould electromagnetic stirring and production and the sup-
grades produced by Masteel, stirrer, final stirrer and air- soft reduction process to ex- plier of the most advanced,
including 100Cr6, P91 or mist cooling. Excellent qual- ceed the current, global qual- soft-reduction Continuous
H13. ity has been achieved from ity benchmark for special Casting Machine in the
the first heat. bar quality products. Thanks world. |
Dynamic soft reduction has
proved to be a state–of–the– Left: souvenir picture
art technology for improving of the team working at
the Maanshan Masteel
centerline porosity and car- plant.
bon segregation, which can
Above: 250x250 bloom
be applied successfully on caster production exceeds
wide range of steels. quality standards.
The soft/hard reduc-
tion is driven by Danieli
Automation Liquid Pool
Control Model “Q-SOFT”
paired with L1 and L2
systems. Precise control of
MSR process allows for the
improvement of centerline
quality without compromis-

63
DANEWS 184

New actuator and oscillating unit maximize

billet casting performance

HY-POWER® technology improves process

control and surface quality
at Acindar, Argentina

— In April 2019, AM
Acindar awarded Danieli
a contract to supply the Up to
new billet caster oscil-
lating bench during the 33%
plant’s next summer shut- casting speed
down. increase
for 1010 to 1020
In 1998 Danieli supplied
two 6-strand CCM’s with low–carbon
7-m radius, one for com- steel grades
mercial steels and the other
for specialty steel and small
slabs with EMS. At that
time, due to production and in a wide range of casting are clearly visible: steel grades like 1070. The
productivity reasons, both speeds. The choice of each — the need to manually results of first tests showed
CCM’s were supplied with a parameter depends on the adjust stroke is eliminated, not only surface-quality
trolley oscillating bench de- steel grade produced, and facilitating section change; improvement for all grades
vice for quick mould chang- for optimal result it should — surface quality improve- (low and high carbon) but
es. After more than 20 years be kept within a narrow ment was observed already also a casting speed increase
and thanks to the continu- band to ensure optimal after the initial heats; up to 33% for low-carbon
ous improvement in casting lubrication and shell com- — in case of some steel steel grades 1010 to 1020.
technologies, AM Acindar pression for different casting grades, productivity can be
selected Danieli to sup- speeds. increased without risk of The HY-POWER® actuator
ply, in a challenging time, Incorrect oscillation param- breakout; and new oscillating unit rep-
6 HY-POWER® oscillating eters may not only affect — increased reliability of resent a solution for maxi-
benches, to be installed at surface quality, but in some the machine thanks to closer mizing process control,
Villa Constitución meltshop cases lead to breakouts. process control. plant productivity and im-
during the summer plant proved surface quality for all
shutdown. Acindar produces two During the commission- grades.
square sections, 120×120 ing phase, the primary With reduced plant stop-
The copper mould and the mm and 160×160 mm, in a focus was on two groups of pages to implement the new
oscillator putting it in mo- wide range of steel grades, steel grades, which before equipment, the hydraulic
tion are the heart of the including low-carbon steel revamping caused more actuator is the right solution
continuous casting machine. grades such as 1004B, free- surface quality issues and for enhanced plant monitor-
The flexibility provided by cutting steel grades such as breakouts, namely: very low ing, to avoid human set-up
hydraulic drive allowing ad- 1112, peritectic grades, and carbon-steel grades with errors and maintenance is-
justment to both stroke and high-carbon grades up 1085. boron 1004B, which is par- sues due to heavy-duty com-
oscillation helps to ensure This is a scenario in which ticularly susceptible to sur- ponents replacement, with
optimal negative strip-time benefits coming from an up- face-defect formation and a direct effect on product
and negative strip time ratio grade to the oscillation drive breakouts; and high-carbon quality reliability. |

64
 LONG PRODUCTS

Fast commissioning for JSW Monnet

billet caster revamping

Broadened engineering steel

production achieved thanks
to key upgrades to technological
packages

— JSW Monnet contracted The main equipment up-

Danieli to revamp the ex- grade included mould as-
isting 6–strand billet cast- semblies, oscillating tables
er at Raigarh, India, which with new hydraulic drive
was supplied by Danieli in units, air-mist secondary
2012. cooling, radioactive mould
level control system, as well
The revamping target was to as new transport and dis-
expand the product mix with charge roller tables and new
three new sections, from run-out area, to accommo-
structural and API steels to date the new sections and
engineering steel, to solidify 14 m–long billets.
JSW’s standing as a high- The equipment installation
quality steel producer in the was planned to take advan-
more demanding Indian and tage of annual maintenance
international markets. schedules, to minimize

downtime and production the local and overseas mar-

losses. kets. Tailor-made solutions
Seven days after hot com- designed and supplied by
Caster ramp–up missioning the caster Danieli allowed the original
16 reached its new target billet caster to be upgraded
14
productivity. Now, with the into a flexible combi-caster
new equipment installed, equipped with all the latest
12 JSW Monnet will produce a casting technologies, satisfy-
10 wider range of steel grades, ing all the requirements in
8
including ball bearing, cold- terms of productivity, quality
heading, free-cutting and and readiness which are the
6
high-carbon grades. most demanding charac-
4 teristics for supplying the
2 The Monnet Continuous dynamic global market for
Casting Machine revamp- steel long products. |
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
ing allows JSW to expand its
market share thanks to its
Days from start–up
capacity for producing dif-
ferent formats and a wider View of the 6–strand billet caster
range of steel grades for after revamping

65
DANEWS 184

A Step Ahead Technology TO HIT RECORDS

Continuous improvements
make the difference for WRMs
119.6 m/s stable rolling speed
for 6-mm rebar sets
a new world record
at Ferriere Nord, Italy

— E D I T E D B Y S I M O N E C O N C I N A / Area Manager, Sales, Danieli Morgårdshammar

he Pittini Group, whose headquar- 1. K-SPOOL AND BAR LINE

T ters are in Osoppo (Udine, Italy), is
a leading manufacturer of low-car-
equipped with the Danieli K-Welder to pro-
duce in endless mode:
bon steel long products for building and in- — deformed bars from 8 to 40 mm dia.
dustrial applications. Every year, more than — spooled bar-in-coil from 10 to 25 mm dia.
3 million tons of steel are produced by 17
manufacturing facilities in three European 2. TWO-STRAND WIREROD MILL
countries. to produce:
The facilities of the Pittini Group cover — Smooth wirerod from 5.5 to 20 mm dia.
the entire manufacturing cycle, from scrap — Deformed wirerod from 6.0 to 18 mm dia.
to finished products, an essential require-
FROM THE ment to ensure high quality standards The two-strand wirerod mill has been in op-
FIRST PAGE
for customers. eration since the end of the 1970s and today
In the Osoppo plant there are two rolling is one of the most efficient and productive
mills: plants in Europe. These performances have

66
 LONG PRODUCTS

and machines, both Danieli experts and ex-

ternal tutors are involved for training of new
hires.
Also, “true” training sessions have been or-
ganized for the maintenance and overhaul of
the machines, together with Danieli Team,
to elevate both the skills and autonomy of
Pittini operators. Today, Pittini teams are
selected according to the individuals’ affinity
(age or interests) to enhance their cohesion
and to ensure constant reliability on main-
tenance operations, which are mandatory to
guarantee safety and proper plant restart.

— Why is maintenance operation

so important?

been reached thanks to the collaboration LDP: Correct and constant maintenance of
with the Danieli Group through several ex- the plant allows us to reduce changing times
pansion phases. as well as to reach stable rolling production,
reducing down times almost to zero.
Luciano Del Pin, Mr. Luciano Del Pin recently marked 40 At Pittini we appreciate the benefits of pro-
head of years of service in the steel business, start- grammed daily maintenance, from 9 AM for
rolling mills for ing as electrical maintenance operator, then 2-2.5 hours (3 hours the longest) to ensure
moving to technical office of Pittini group. stability of the rolling process.
Ferriere Nord, Since 2005, he has worked as Wirerod Mill At the same time, we set a daily morning
Pittini Group, manager and since 2008 also as K-Spool & meeting with the maintenance team and
credits Bar Rolling Mill manager. shift foremen, so that everyone is aligned
Danieli solutions As the project leader he recently supervised about performances reached during the
for making the installation of the 500th Danieli wirerod previous day, and areas for possible improve-
mill, a mill that represents a step ahead in ment and incoming daily activity: Everyone
the difference. wirerod technology while being fully en- knows his own duties and he is responsible
hanced by the latest Industry 4.0 standards. to complete the assigned job.
Installed in Verona for the Pittini Group,
after 19 months from contract signing it has — How do you reach rolling stability?
already surpassed the required performanc-
es, ready to look for new ambitious goals. LDP: Tension regulation between rolling
stands along the rolling mill is essential, so
— What is the secret of this success? that a quality product can be constantly pro-
duced at high speeds. In this regard, devices
LDP: The team. Thanks to the skills and to like the Hi-Section, which gives real-time
the great synergy of Pittini’s teams it was cross-sectional values of the product, and
possible to achieve these records and, most the Hi-Profile, which allows control of the
important, to maintain them steadily during dimensional tolerances, are essential in our
daily production. mill. Now, without such devices we would
Specifically, all the equipment in the high- not be able to roll at all. I especially consider
speed area is duly maintained, taking special the Hi-Section to be an historic break-
care of the alignments of the in-line heat- through in rolling mills.
treatment equipment and ensuring constan- A perfect and consistent automation system
cy and stability of the power line. is fundamental to our work, as demonstrated
by the recent start-up in Verona, where I
— How do you keep the team have to emphasize the excellent performanc-
prepared and motivated? es reached.

LDP: Training is essential. It is mainly ar- — What are the main revamping
ranged within the Pittini plant by our “OPF” projects completed over the years
Academy. For key technology components on this line?

67
DANEWS 184

New world record

for wirerod rolling
speed:
6-mm REBAR
AT 119.6 m/sec

LDP: I can mention only the main ones. For I want to highlight the efficiency and qual-
the full picture, you can see the picture be- ity of the equipment supplied: As a matter
hind me: of example, you can see our stand cartridges
— 2006 relocation of the cooling conveyor, provided in 2005, where the original bear-
laying head and coil-finishing; ings are still in operation.
— 2011 installation of the 3–pass CSB In general, every revamping had the specific
Compact Sizing Block; target to realize a benefit for Pittini’s final
— 2012 installation of the 4–pass pre-finish- customer, as well as for the plant manage-
ing block; ment. In recent years, indeed, the increased
— 2015 replacement of high-speed, in-line demand for final product quality pushed us
heat-treatment equipment. to look for the most efficient and advanced
technologies; thanks to Danieli’s solutions,
Have you achieved good performances on it was possible to achieve tight tolerances,
other products as well? granting full satisfaction of our customers.

LDP: We were able to increase the rolling

speed for 5.5–mm smooth rounds, stabiliz- — Why do you describe the several revamp-
ing production around 118 m/sec with an ing as “innovative”?
average ovality on all product ranges around
0.04-0.06mm, while the 6–mm rebar mm LDP: Because most of the projects repre-
speed increased by more than 10% com- sented a milestone in rolling production.
pared to previous production values. Especially for the CSB block project, Pittini
was the first low-carbon steel plant to have
— Why did Pittini choose Danieli sizing equipment and, due to space con-
for these revamping projects? straints, we have been forced to realize it in
the most compact way possible. Thanks to
LDP: It’s because of the effectiveness of the the commitment of the respective teams,
Danieli team, commitment and competence today the constancy of extremely tight oval-
demonstrated, as well the professional deter- ity is very much appreciated by final users of
mination to pursue the target at any cost by our coiled products.
ensuring the necessary assistance until the Moreover, I must mention the other rolling
target is achieved, especially in our projects blocks as well, the PFB Pre-Finishing Block
with a high level of innovative content. The and the FFB Fast Finishing Block, because I
contract targets always have been exceeded, think these are the best equipment supplied
to achieve higher goals set by both teams, to by Danieli, since they are never a source of
aim for excellence. downtimes or problems for our operators.

68
 LONG PRODUCTS

Left: screenshot reporting

achieved wirerod rolling speed
record.

Right: Pittini two-strand wirerod

mill. It’s been in operation since
the 1970s, and its efficiency is a
benchmark in Europe.

— Are you finally satisfied after improvement, to meet and exceed

all of these revamping stages started customers’ needs.
15 years ago?
— How do you evaluate after-sales
LDP: No! Never satisfied! services?

— So, what are the future plans? LDP: I consider it excellent for managing
spare parts and consumables. As a matter
LDP: It think it should be important to real- of fact, for important equipment Pittini is
ize some projects to improve the mechani- ordering only original spare parts. Moreover
cal properties of final products, being able during specific emergency episodes, the
to take the advantage reached during the Danieli Workshop always supports Pittini
recent experience at the Verona plant, with with immediate action.
the aim always to give our customers a better
and better product. — If you could make a step-back, is there
something that you would like to change?
— How do you compare Danieli
with other suppliers? LDP: I don’t think so. All the projects re-
alized during this long relationship with
LDP: Pittini rolling mills are 100% Danieli exceed the expectations by far, al-
Danieli equipment, demonstrating how lowing Pittini to continuously increase the
our long-lasting relationship is the result of quality of final products, and making our
the common attitude for continuous customers more satisfied. |

69
DANEWS 184

K-SPOOL EVOLUTION: ANTICIPATING

AND ANSWERING MARKET TRENDS
Flexible machine allows twist-free winding of rebar
into high-quality, ultra-compact heavy coils

C L AU D I O FA B B RO
Executive Vice President
Danieli Long Products

oday the term “spooler” is

T synonymous with “Danieli
Technology” thanks to the
unbeatable performances proven by
an impressive list of installations dem-
onstrating Danieli’s leadership in this
technology, born from an innovation
developed at the end of the 1990s.

The K-Spool solution answers market

demand, supporting the local cut-and-
bend industry with top-quality prod-
ucts. The latest developments already
have extended the limits of the process
up to 32-mm diameters for coiled bar.
The automatized bar temperature
control system ensures homogeneous
and consistent product quality, fully
complying with the standards for high
ductility, elongation and weldability.
According to specific standard require-
ments, different cooling processes can
be applied to guarantee the best perfor-
mances, in terms of mechanical prop-
erties and overall transformation cost.

70
 LONG PRODUCTS

Thermal profile of bar section while From left to right: coil wraps
coiling on Danieli K-Spool: unbeatable temperature evolution during
quality performances of horizontal different coiling stages with perfectly
spooling technology. symmetrical thermal profile.

Evolution of K-Spool
technology from 12÷20mm 1,5t 8÷20mm 3,5t 8÷32mm 5t 8÷32mm 8t
2000 to 2020.

1st K-Spool 1st K-Spool 1st K-Spool 1st 5t K-Spool 1st 8t

Ferriere with K-Weld with MIDA Ferriere K-Spool
Nord Pittini Alfa Acciai Nord Pittini

80
2nd K-Spool 66
K-Spool supplied

60 Alfa Acciai
45 Dongkuk Pohang
41 38 m/s
40 39
4 K-Spool
20 machine
13 Megasa Seixal
5
0
2000 2002 2005 2006 2007 2010 2011 2015 2016 2017 2018 2020 202...

1st K-Spool Celsa largest K-Spool 1st K-Spool in Japan

in China producer 2 Mtpy Topy Industries

1st K-Spool in USA

Commercial Metals Co.

Thanks to the horizontal spooling winding and during the crucial layer — Q-VID® SPOOL, a groundbreak-
technology, Danieli K-Spool delivers step formation. ing vision system to ensure the perfect
unbeatable performances for uniform Automation systems include: angle of distribution on the drum;
technological properties, due to the — Automatic vibration monitoring
symmetrical thermal profile maintained — HiSection eddy-current mass flow system, to control the most sensitive
while winding (when metallurgical meters, providing indications of mate- equipment, such as the gearbox and
transformations are completed). Such rial section and rolls wear during pro- spooler drum.
conditions are impossible to obtain with duction; The latest generation of Danieli
other technologies. K-Spool can produce coils from 2.0 to
— Hi-Profile, laser-based measurement 8.0 tons, making it a truly flexible ma-
An improved automation control sys- instrument providing non-contact, chine, capable of covering the complete
tem, developed by Danieli Automation on-line profile shape inspection and di- range of coil sizes and weights required
guarantees perfect formation through mension of rolled products; by the market. With this machine, a
the double pivoted distributor, main- — Automatic weighing while winding new milestone in rolling mill history
taining the correct wire tension while and automatic labelling; will be reached. |

71
DANEWS 184

Third long-product mill to be supplied

for Dung Quat complex

NEW, 1-MTPY WIREROD MILL ORDER

FORTIFIES HOA PHAT LEADERSHIP
IN LONG PRODUCTS

— E D I T E D B Y F E D E R I C O R O C C H E T T I / Vice President, Danieli Morgårdshammar

oa Phat, the largest steel pro-

H ducer in Vietnam, renewed
its confidence in Danieli
with the order for a new, 1-Mtpy wir-
erod rolling mill, to be installed at the
Dung Quat complex.
This will be the third long-product
rolling mill at Dung Quat—all of them
supplied by Danieli.
Fed by 12–m–long, 150–mm–square-
billets produced upstream by Danieli
continuous casting machines, the new
mill will produce 5.5– to 16–mm dia
plain wirerod and D8– to D16– ribbed
wirerod, in low–, medium– and high–
carbon grades. Moreover, it also will
produce PC strand in the range of 8–
to 13–mm dia plain wirerod.
The rolling line is comprised of a high-
speed, free-rougher followed by an in- Contract signing ceremony souvenir picture. From left: Nguyen Vu Tin (Sales Manager,
termediate mill rolling on two strands. Danieli Vietnam), Stefano Marinig (Sales Manager, Danieli Automation), Federico
Rocchetti (VP Danieli Morgårdshammar); and on behalf of Hoa Phat, Mai Van Ha
Rougher and intermediate stands are (Director), Vuong Ngoc Linh (Vice Director), and Ta Tuan Duong (Purchasing Manager).

New 1–Mtpy Wirerod Mill for Hoa Phat, Vietnam

2 3 4 5 6 7
1

72
 LONG PRODUCTS

View of the Hoa Phat Dung Quat RM #2 recently started up. The plant has a nominal capacity
of 1,400,000-tpy, producing deformed bars down to 10-mm-dia in 2-strands slitting at a rolling
speed of 47 m/s consistently, through a double twin-channel system.

the latest-generation Housingless all the most modern requirements in mill setup production parameters and
Stands SHS+. After that, bars continue terms of safety for operators and high accuracy under continuous control.
on two independent rolling lines com- automation levels. As a matter of fact, The complete electrical and automa-
prised of pre-finishing cantilever stands the installation on both lines of Hi- tion system for the entire line will
followed by 10–pass wirerod blocks, Section devices for on-line measure- be supplied by Danieli Automation
adopting semi-multidrive technology ment of the cross section and weight to achieve a wirerod mill of the lat-
for improved management of rolling per meter of hot-rolled bars, will make est generation, incorporating the best
rings and reduced spares inventory. it much easier for the operators to combination of mechanical design and
Finished product quality is monitored track the material data directly from advanced controls, to reach maximum
in real time by Hi-PROFILE measur- the main pulpit. Both lines will be competitiveness in a challenging and
ing devices, while water-cooling lines equipped with Hi-Profile Lite, a laser– crowded market. |
installed before and after (across) the based 3D measurement instrument
fast finishing blocks, together with the for a non-contact on-line profile shape
95–m–long cooling conveyors, provide inspection and dimension. Thanks to a
1 Induction Heater
the desired final mechanical charac- superior blur-free fast acquisition time 2 Four SHS Stand roughing mill
teristics to the finished products, ac- of less than 20 μs for a true full bar 3 Four SHS Stand intermediate mill
4 Four SHS Stand (Two future stands),
cording to the different sizes and steel contour , Hi-Profile Lite will provide Pre-finishing mill
grades. benefits in terms of product quality 5 Four ESS Stand pre-finishing mill
6 Ten-pass finishing blocks
Pinch rolls and oil-film bearing lay- assessment while increasing rolling 7 Water Cooling/QTR lines
ing heads will guarantee the best coil tolerances. Wirerod dimensional data 8 Twin Module Block (Future)
shape and surface quality. can be used for the product quality 9 Laying head & controlled
cooling conveyor
The mill is designed to comply with certification and are required to keep 10 Wirerod finishing services

10
8 9

73
DANEWS 184

Expanding rolling mill 6-pass block will optimize

the roll-pass design and expand range
capacity and of finished product sizes
product quality
at Aceros Guatemala New fast-finishing block
for Pittini Group bar mill

> Pittini Group recently mm–dia. bars, with a strict

chose Danieli to revamp end-product size tolerance
the bar and spooler plant and ovality. Furthermore,
in Osoppo, Italy, which will this project will ensure that
involve replacing the exist- the products achieve a roll-
ing 8–pass block with a new ing temperature of 850°C at
6–pass block comprised of the entry of the new 6–pass
2×250 mm dia. rolling rings, block, conserving energy
M2 Multiple and AC drive thanks to lower rolling tem-
technologies, and 4×200– peratures while applying
mm dia. rolling rings, Semi- Soft Quenching Process
Multi and AC drive tech- for the best bar mechanical
Bar slitting and four-strand QTB system nologies. properties.
The spooler line will pro-
highlight improvement project The new Fast Finishing duce coils from 2.4 t up to 5
Block will optimize the t, with bar products ranging
roll-pass design upstream from 10 mm dia. up to 25
on the mill, increasing the mm dia. The new block will
> A comprehensive upgrade — Installing two bar-count-
production range up to 25– start-up in Summer 2021. |
project for the bar mill at ing and -bundling stations,
Escuintla, Guatemala, will equipped with four counting
include improvements to systems, to produce sub-
the existing rolling mill to bundles and master bundles
increase finished-product from 6 to 15 m long and
quality and line productivity, weighing 800 to 2,000 kg; New installation for WRM will ensure
from the 350,000 to 500,000 best set-up for in-line water treatment
tpy. These goals will be — Installing Danieli Sund
achieved by: Birsta automatic tying ma-
— Modifying the hot mill
section to include bar slit-
chines for wirerod coils.
Danieli Automation
Pre-Box unit will optimize
ting for rolling up to four
strands;
will supply the complete
Level 1 and Level 2 automa-
rolling temperatures
tion systems for both the bar at ESF, Germany
— Installing a new 4–strand, line and the existing wirerod
23–m long QTB (quench- line.
ing and tempering system) > Following the recent in- treatment, in accordance
to obtain the required me- This project, besides in- stallation of a Hi-Profile siz- with the latest Danieli tech-
chanical characteristics and creasing mill productivity ing unit for the wirerod mill nology.
minimize the high cost of and product quality also will at Elbe Stahlwerke Feralpi in The ESF plant rolls 5.5– to
alloy addition in the steel allow a consistent decrease Riesa, Germany, a new proj- 20–mm dia. plain and de-
melting phase; in the manual activities in ect calls for Danieli to sup- formed wirerod into 2,400
the finishing area and con- ply a new Pre-Box thermal kg coils at speeds of up to
— Installing a new dividing sequently a reduction in treatment unit on the same 115 m/s.
shear at the cooling bed en- manpower and an increase line, to ensure best tempera- The new Pre-Box will start-
try side; in work safety. | ture set-up for in-line water up in January 2021. |

74
 LONG PRODUCTS

Twin high–speed shears

to update Yongfeng WRM’s

Automatic head and tail cropping will improve

coiled product quality and reduce operating costs
> Shandong Laigang
Yongfeng Steel Corp. will
be relocating two Danieli
wirerod lines to a new plant
site at Lingang by the end of
2021 and Danieli has been
awarded a contract to supply
two new High Speed Shears
(HSS), for automatic head
and tail cropping of 5.0 to
20-mm bar and rod products
prior to the laying head, and
at speeds up to 120 mps.

HSS makes it possible to

improve the quality of fin-
ished coils thanks to both
uncooled and out-of-toler-
ance head and tail trimming,
Left: latest-generation of Danieli as well as operating cost re-
Morgårdshammar high-speed shear duction that will result from
manufactured, assembled and tested
at Danieli high-tech workshops. avoiding manual tasks on
the final coil. Together with
Above: Yongfeng Steel Corp. plant
the guaranteed cut repeat-
ability, these improvements
will increase the existing

34
HSS UNITS
plant yield.

The supplied package will

include the related pinch
SUPPLIED rolls with the best technol-
WORLDWIDE ogy available for superior
coil quality, thanks to its
operational stability, and a
dedicated scrap conveyor
to properly collect cropped
pieces in a scrap box.

Danieli Automation will

provide the complete auto-
mation and sensors package
in order to provide a system
with benefits in constant
speed and better accuracy
for finished product sizes. |

75
DANEWS 184

Danieli workshops proceed past challenges

to complete the 500,000-tpy installation,
based on the new FQT® process technology
for exceptional product tolerances

OMK’S SEAMLESS-PIPE
COMPLEX IS ON TRACK AND ON TARGET

seamless pipe plants, it was decided to

assign production of the main techno-
logical machines to our Italian center
of excellence.

The first billet cutting saws, part of

the hot-rolling mill, have been tested
and shipment is in progress, while pipe
layer cutting saws are at the advanced
stage of preparation. The core of the
hot-rolling line is the new FQT® (Fine
ANDREA BAGLIO Quality Train) mill being manufactured
Director, Projects Extrusion & Forging, now. This new technology, providing
Tube & Pipe Plants
excellent performance in terms of qual-
ity (geometrical tolerances) and pro-
ductivity, calls for the latest–technology
MK Group, one of Russia’s Danieli to start all manufacturing ac- CNC machine tools and advanced
O largest producers of pipes,
railway wheels and other
tivities.
When planning manufacturing activi-
measuring systems to guarantee the
strict manufacturing requirements.
steel products for energy, transport ties, Danieli relies on its own work- The FQT® is comprised of two main
and industrial sectors, selected Danieli shops, especially for the main tech- machines:
as a partner to supply a steelmaking nological machines. This choice guar-
complex for producing seamless casing, antees the most qualified and experi- — The already known FQM® (the
tubing, line pipe and industrial pipes enced technicians are involved in each six-stand LCO EsrSmart (Easy Sticker
with an OD (Outside Diameter) range project, while taking best advantage of Removal) for which the machining
of 2-7/8 to 10-3/4”, and a capacity of the latest–technology CNC machine activities are completed, and assem-
up to 500,000 tpy of finished pipes. tools and advanced measuring systems, bly is on schedule for a summer 2020
including laser trackers and Coordinate completion target;
It will be the first seamless pipe facility Measuring Machines (CMM).
for OMK Group. The above criteria has ensured that — The completely new, 16–stand,
The contract includes a hot-rolling Danieli has made significant progress three-roll ESM, is scheduled to be
mill equipped with the new FQT® in its manufacturing activities, notwith- completed in the fourth quarter of
Technology and a finishing floor, able to standing the highly disruptive effect of 2020.
deliver pipes according with GOST and the Covid-19 pandemic.
API standards.
The contract entered into force in the DANIELI HQ WORKSHOP
fourth quarter of 2018 with the engi-
neering phase (Phase 1), while in 2019 Based on the experience developed at
Right page:
OMK started the Phase 2 (Purchasing our HQ workshop over several years Piercing mill exit under assembly
and Manufacturing phase), allowing manufacturing similar machines for at Danieli Changsu workshop.

76
 LONG PRODUCTS

DANIELI CHANGSU WORKSHOP Danieli Automation, based on Danieli

process knowledge.
The remaining main technological Process controls are carried out
machine is the piercing mill, being through Levels 1 and 2.
planned in Danieli’s Chinese work- All the equipment is presently in manu-
shop, equipped with cone–type rolls facturing: Level 1 equipment is ready to
and guiding disks, and relevant exit be inspected (pre-shipment). Shipment
sections. is foreseen in early summer 2020.
The assembly activities are almost
completed, and the pre-shipment tests CONCLUSIONS
are planned to start before summer
“Herewith, please accept 2020. The project is moving forward ac-
our gratitude for the high
cording to the contractual schedule.
degree of cooperation being DANIELI CO, LTD. WORKSHOP Notwithstanding the impact of the
demonstrated in the per-
present situation, Danieli is guaran-
formance of Contracts The Danieli Co Ltd. workshop was teeing proper progress, allowing the
20-18-2726 and 20-18-2727 chosen thanks to its highly specialized project to proceed without significant
in the current difficult Covid-19 know-how and experience in hydraulic impact.
environment” noted by OMK technology. Every machine is ready for This result has been possible thanks to
Chief Investment preshipment inspection, with dispatch the full commitment and high profes-
and Asset Development Officer expected in early summer 2020. sionality of the Danieli team and, last
Dmitry Chernyshev.
but not least, to the significant col-
ELECTRICAL & AUTOMATION laboration offered by OMK. As always,
teamwork achieves results that are not
The electrical and automation systems feasible with the effort of just
are developed in-house and supplied by one party. |

77
DANEWS 184

Danieli FQT® / Fine Quality Train in Danieli workshops

during assembling of the LCO EsrSmart stands (Easy
Sticker Removal). It will be the core technology for quality
seamless pipe production at the 500,000–tpy OMK
Vyksa complex.

78
LONG PRODUCTS

79
DANEWS 184

Commissioning programs are proceeding

for the welded-pipe finishing complex, covering
heat-treating, threading, QA and finishing

THREE PIPE-FINISHING LINES

FOR OCTG
at OMK Vyksa, Russia

The plant layout was developed in or-

der to perform both quenching/temper-
ing (Q&T) and normalization treatment
cycles.
The line is equipped with: hardening
and tempering walking–beam furnaces,
with fully automatic combustion sys-
tem managed by level 2; a quenching
unit (sprayer); a straightener machine;
a cooling bed; two cutting saws (one in-
line); a marking machine (in line); and
M AT T E O Z U C C H I the pipe–handling system.
Project Manager,
Danieli Centro Tube
The hot tests were completed success-
fully, leaving the line ready for commer-
cial operations.
anieli Group was chosen by In April 2020 all performance tests
D OMK as main supplier and
integrator of production ma-
were completed and successfully con-
firmed the line capabilities to reach
chines for three separate process lines required quality targets for pipes, in
in the plant finishing section: a heat- terms of both mechanical and chemical
treatment furnace, supplied by Danieli characteristics, and with the complete
Centro Combustion; a threading line; range of piece rates, including the chal-
and a Quality Assurance and finishing lenging target rate of 180 pieces per
line. OMK’s new finishing operation hour. pipe ends. The line was designed with
will produce API and GOST OCTG two parallel twin branches, to achieve
welded pipes in the range from 60 to THREADING LINE the highest production rate.
177.8 mm diameter. FOR TUBING AND CASING PIPES Hot tests were completed successfully
and demonstrated the line’s readiness
HEAT-TREATMENT LINE Designed to process approximately for commercial operations in the first
FOR TUBING AND CASING PIPES 135,000 tons per year, this line is half of 2020 Performance tests and all
equipped with a double set of thread- necessary preparations are ongoing,
The heat–treatment line has been de- ing machines, two coupling screw–on led by Danieli specialists who also are
signed to achieve a nominal production machines, pipe connection hydrotest- progressively transferring the opera-
of 36 tons per hour, meaning up to 180 ing machines, and the necessary equip- tion and automation knowledge to the
pieces/hour for pipes of specific OD. ment for NDT inspection of threaded OMK operators.

80
 LONG PRODUCTS

The line is being optimized to reach a hydrotester machine equipped with Danieli threading line team is follow-
the target production rates, meanwhile three working positions, and straight- ing commissioning works, passing
the technological machines are being ness control with a drifter machine. through the hot and performance tests
prepared to execute the required opera- Moreover, there’s the possibility to stages. Also, Danieli is working to sup-
tions on the pipes, to achieve the pro- produce line pipes with beveled ends port OMK Vyksa in the first phases of
ductivity and quality requirements. thanks to a pair of bevelling machines commercial production, while the line
installed before the hydrotester. is being adjusted and properly set to
QUALITY ASSURANCE The second section is dedicated to match the contracted requirements.
AND FINISHING LINE FOR TUBING, finishing, which includes coating (UV Each of the three lines is equipped
CASING AND LINE PIPE paint type, complete with upstream with in-house electrical and automa-
cleaning and drying sections), weigh- tion systems supplied by Danieli
Partially connected to the tubing ing, marking and automatic bundle Automation (DA). Process controls as
and casing threading line, this line forming and collecting. well as material tracking and techno-
is designed to handle approximately The two parts of the line are connected logical machines integration are guar-
165,000 tons per year. It is arranged by an intermediate warehouse. anteed through the installation of L1
as two separate, independent sections: The second part of the line can be load- and L2, interfaced through a common
the first one is dedicated to full ultra- ed directly from the threading line when communication network for an inte-
sonic testing of pipe bodies and ends, tubing or casing pipes are produced. grated and effective plant supervisory
pressure testing of all the pipes through In the first half of 2020, the same control system. |

81
DANEWS 184

— DANIELI
AUTOMATION

Digitalization and data management for enhanced productivity

INTELLIGENT PLANT DEVELOPMENT

FOR FULL PROCESS CONTROL
AND INCREASED EFFICIENCY
— E D I T E D B Y M A R C O O M E T T O / EVP Digi&Met and R&D Dept. Danieli Automation

teelmaking is an extremely Example of productivity improvement due to automation systems

S energy-intensive process. To
sustain their competitiveness
16:48:00
on a global scale even when confronted Delay per turn
with high energy costs, steelmaking 14:24:00
companies always need to be one step
ahead in terms of innovation, energy 12:00:00
efficiency and product quality. Indeed,
09:36:00
slight efficiency increases can show sig-
nificant impact on the bottom line. 07:12:00
In reality, the efficiency of a process
is directly proportional to its ability to 04:48:00
control the process itself, and for this 3Q Automation effect on stoppages
02:24:00
reason Danieli Automation’s greatest
effort over recent years has been the 00:00:00
realization of a control room that can
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truly help operators in the daily chal-

lenge that is developing the Intelligent
Plant. Danieli Automation’s current Example of delay management improvement due to automation systems
activities over the development of the (September-December production)
Intelligent Plant break down into four
tracks. 16
14
12
Track 1 focuses on plant oversight 10
and it is the development of the new, 8
innovative and proactive pulpit. The 6
Linear (heats)
4
idea behind the project is to enrich and 2
simplify the operators’ experience, mak- Heats
0
ing the system capable of providing the
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right information at the right time. This

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 DIGI&MET AUTOMATION

is done by collecting Big Data directly The centerpiece of this track is the breaches in the patterns.
from the plant and monitoring the area creation of a single and centralized da- AI-driven algorithms enhance the ac-
with 360° video cameras, so the opera- tabase management of what has been curacy of anomaly detection, avoid
tor can navigate dangerous or inacces- defined as Points of Interest (POI), the nuisance alerts and false positives/
sible areas safely. highlights of the plant life to which ac- negatives triggered by static thresholds,
tions and interactions with the systems and constitute the core of self-learning
The system is able to detect specific and automations of the plant itself can systems that are able to learn from data
events, called Points of Interest (POI) correspond. Predefined in the master patterns and deliver predictions or an-
triggered by values and states reported data, next to the automatic POI’s, will swers as required.
by the plant automation and its tech- be the possibility for operators to report
nological packages. Events that require manual POI’s, which will represent Track 4 is the development of a “plant
user interaction will be proposed reports of significant behavior or phe- image” that includes augmented reality
as questions on the OA (Operator nomena observed by them (similar to to navigate upstream and downstream
Assistant), to which the operator can what happens with modern car GPS of the plant.
respond without having to search systems, re-porting accidents or points The next step toward the Intelligent
for commands between the various of interest). Occurred POI recordings Plant is the substitution of the clas-
screens. POIs also can define the mod- therefore will represent the system sic HMI, in which the operators must
ification of either information sources knowledge, expressed as a series of pin- know where to find specific data. This
or the highlight of specific content. pointed events that have occurred over feature will allow an operator to look
This works via dynamic management time. Both track 1 and 2 are ongoing over the entire plant, thanks to a group
of content displayed on maxi-screens for the new QWR 4.0 plant. of mobile cameras, and to “enter” sen-
and service screens, such as camera sitive information of that prefixed plant
streams and HMI, to focus attention Track 3 is the development of a library key point through augmented reality.
on machine events: what this means is of POI’s that will be used to power AI– It’ll be possible to highlight process da-
information gets surfaced and brought driven algorithms. ta, sensors data, maintenance data, etc.
to the operator’s attention instead of By creating a big database of revised In this way, time-to-information is
him having to search for such data. POIs it will be possible to increase reduced for both operators and tech-
This contextualized approach allows detection of anomalies. Anomaly detec- nologists, a more complete data set is
the machine to receive a series of tion refers to identification of items available, in real-time, when needed
feedbacks aimed at reducing the band- or events that do not conform to an and both the plant machines and the
width of information that is proposed expected pattern, or to other items in product status can be controlled during
to the operator, condensing the data a dataset that usually are undetectable operating condition.
into process summary information. The by a human expert. These anomalies From there, the road from Smart
actions to be performed can be pre- usually can be translated into problems Factory to Intelligent Plant is really
programmed or learned right from past such as steel defects, loans, etc. short; with information at your finger-
decisions. This application approach AI-driven anomaly detection algorithms tips. The pulpit will definitely be the
predicts events rather than reacting to can automatically analyze the POI li- core of the production control, with
them. brary, dynamically fine-tune the param- operators located there and confirming
In this way the new pulpit helps to en- eters of normal behavior and identify the “no man on the floor” approach. |
rich a company’s know-how repository
by developing the AI learning from the
most qualified technicians’ decisions.

Track 2 is the “plant time machine”

development. By interconnecting
information coming from L1, L2,
CMS, CCTV, IBA, MES, Energy
Management System, WMS, MMS,
technology packages etc., it will be pos-
sible to historicize the most important
elements in the plant record on an
IIOT platform, making sure that non-
homogeneous data are aligned with
each other on a timely basis and can be
searched later, with different criteria
(e.g. production order, customer, anom-
aly, steel grade, period, etc.)

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DANEWS 184

Danieli Automation’s partnership with the Japanese

company confirms DA’s abilities in quick order fulfilment
with breakthrough products and technologies

TOKYO STEEL AND DANIELI AUTOMATION:

A NEW CHAPTER IN A LONG–STANDING
PARTNERSHIP

Q-ONE Power Optimization

Installation for Tokyo Steel LF.
New furnace transformer and
new electrical distribution
system will control flicker
limits and harmonic distortion
without additional filters.

okyo Steel will install Danieli’s

T innovative Q-ONE technol-
ogy at the Kyushu plant, with
plant start-up scheduled for summer
2021. The LF has a 100-t capacity,
with arc currents up to 20 kA and 205- Souvenir picture with friendly handshaking, from left: Hirotsugu Katayama, Manager of Purchasing Department,
V arc voltages, now fed through an Soichiro Tsuda, Manager of Purchasing Department, Toshikazu Nishimoto, President (Tokyo Steel), and for
Danieli, Antonello Mordeglia, President Danieli Automation; Daniele Martire, Manager, Projects; and Mattia
18-MVA transformer that will be sub- Pellizzari, Project Manager.
stituted by Q-ONE.

Project description mize performances for the Tokyo Steel

ladle furnace. The converter will work
The patented Q-ONE technology is al- with an up to 25–kA current, therefore
ready in use by three plants in Europe, the single Q-ONE module will have
and this will be the first installation in enough power to feed this ladle fur-
Japan. The complete electrical package nace, meaning higher power density
for furnace feeding will be supplied by and less space required in the furnace
Danieli, replacing the furnace trans- cabin.
former now in operation.
The scope of work also includes a new With the purpose of minimizing losses
electrical distribution system and re- and making maintenance and as-
MANUEL BIANCO quired modifications to the plant’s civil sembly easier, the connection from
Manager, Direct Sales works. the Q-ONE to the existing secondary
Danieli Automation
This Q-ONE has been designed with a furnace was redesigned, based on high-
single, high-current module, born from current conductors with limited length.
past experiences and aiming to opti- The complete water-cooling system,

84
 DIGI&MET AUTOMATION

required to cool power units and con- tune and monitor system performances system is working as expected. The
ductors, will be supplied and fully from anywhere at any time. purpose of this integrated test also is
managed by Danieli. to check and optimize installation pro-
The existing Level 1 automation sys- Targets cedures, which then will be replicated
tem will be kept and interfaced to the by the same personnel on-site in a very
Q-ONE control system. The existing Tokyo Steel, through the Q-ONE adop- short time.
actuators for electrode movement tion, will have the latest and most in- Danieli Automation engineers will train
will also be kept and interfaced with novative technology for arc furnaces. TSK personnel on the equipment and
the new electrode control, part of the Thanks to this solution, the flicker maintenance strategies. TSK person-
Digital Melter, a new control system limits and the harmonic distortion nel also will have the chance to see
based on Danieli HiPAC units to maxi- thresholds imposed by the grid supplier Q-ONE system in operation and expe-
mize plant performances, controlling will be respected, without installing ad- rience the control interfaces and opera-
power converter and electrodes move- ditional costly and bulky filters. tion of the equipment.
ment together and therefore reducing The full system will be installed in just
electrodes consumption. The adoption 20 days during the summer stoppage, Conclusion
of HiPAC units increases plant reli- working on three shifts to reach the
ability and reduces the maintenance challenging target. Danieli Automation will engineer, sup-
needs. An integrated FAT test at our ply and integrate this innovative and
headquarters in Buttrio, Italy, will be breakthrough technology with the exist-
Remote monitoring of voltage and cur- required to make sure that individual ing system, to be installed during a very
rent gives us the possibility to analyze components are responding to the re- limited time schedule in full compli-
waveforms in real time and to check, quirements and that the fully installed ance with network requirements.

85
DANEWS 184

Tokyo Steel: an exemplary case MV/MV transformer, induction motors

of operational revamping and ancillary devices. Tokyo Steel revamping
The drive cabinet layout was specifi- performance results
Danieli Automation proven cally designed to be installed quickly
know-how for a very short and and interfaced to the existing control
effective commissioning time. system, while the induction motors
New MV Q-DRIVEs lead with “tailor-made” frames helped to
a full power-system minimize the need for any structural
changes. Thanks to the flexibility of the
Zero
modernization for a high- unwanted production stoppage
Q-DRIVE Platform and our engineers’
time, continuous production
speed, cold-reversing mill skill in customizing every technical
started with the first coil
solution to satisfy customer require-
ments, the production shutdown was
A revamping program generally impacts condensed to 10 days, during which
process production capacity, an inevita- the whole power driveline system was 100%
ble consequence of both the shutdown replaced. Pre–commissioned in the quality achieved on first coils
needed to accomplish renovations and Factory Test Area, the drive cabinet
the learning curve typical of new tech- minimized the commissioning stage,
nologies introduced in a consolidated and once it had been energized, the 100%
process. equipment was quickly ready to run. production capacity
Revamping poses the challenge of The revamping strategy established in achieved in one shift
minimizing the production impact, advance with Tokyo Steel and in com-
implementing technical solutions and bination with a dedicated team skilled
strategies focused on quickly restoring
full production capacity.
in revamping projects, contributed
to obtaining a great result, as can be
18 months
of production without fault
This is significant in the case of a seen in the highlight beside. Another or warning cases,
complete power system modernization, distinguishing feature of the Q-DRIVE absolute reliability
such as the power driveline of a rolling 3L-NPC is an easy-maintenance de-
mill for flat or long products. sign, allowing Tokyo Steel to be imme-
Danieli Automation met and overcame diately independent with confidence in
this challenge at Tokyo Steel by provid- terms of maintenance activities. Zero impact
ing a revamping strategy and solution Another key factor that convinced on network thanks
aimed at shortening the shutdown Tokyo Steel to choose the Q-DRIVE to the ultra-low harmonic
period and erasing the impact of the Platform is the Remote Teleservice modulation algorithm
technological learning curve. assistance for immediate system inter-
The revamping solution for a high- rogation or tuning on the request of the
speed cold reversing mill involved
replacing the cyclo-converters with the
customer.
The Tokyo Steel revamping is yet
50%
reduction in commissioning
MV Q-DRIVE 3L NPC in a multiple- another confirmation of Danieli and plant shutdown time
inverter configuration, with high over- Automation’s fast revamping
load capability and common 3L DC capabilities, delivering full customer
Bus. The revamping also affected the satisfaction. |

86
 DIGI&MET AUTOMATION

Quality verification for bar grades and bundle formation,

with no human involvement

Q-ROBOT FOR QUALITY INSPECTION

AND VALIDATION AT ABS
— EDITED BY DAVIDE SENESI / Manager, Direct Sales, Danieli Automation

Thanks to Q-ROBOT ROLL ANTIMIX,

ABS is taking another step forward in
the process of robot migration, and
achieving the final phase of "no men
around” operation.

he Q-ROBOT system provides

T inspection and validation
activities on bar bundles, in
order to properly identify the chemical
composition and relevant steel grade
for each bar composing the bundle.
Especially on the production line
where existing automation could lead
to mistakes due to an obsolete tracking
system, manned intervention on the
finishing line is necessary to verify the
congruence of steel grades for bars in a
bundle, to ensure proper delivery of the
product to the customer.
Q-ROBOT ROLL ANTIMIX includes
a multi-function end-effector: as soon
as the bundle reaches the inspection
area, Q-ROBOT laser-scans the bundle
end to identify the x, y, and z positions
of each visible bar-end. Following such
operation, the control system knows the product to be analyzed, possible line working on three shifts/day, three
the position of each bars then, analyz- oxidation phenomena on the bars sur- operators can be reassigned to safer
ing cycle can start. face (i.e., due to long periods of bundle and healthier tasks and environment,
storage in the bundle yard) could com- limiting the human exposure to a haz-
A spectrometer probe installed on the promise the result of the analysis due ardous area.
multi-function end effector is handled to missing or improper spark. By means The collateral benefit of this reloca-
by t he robot in full contact for each of a grinding wheel device installed on tion is a faster start for the Return
bar – one by one – providing chemical the multi functions end-effector, oxide- on Investment that – even if strictly
analysis; the operation is repeated for removal operation is provided to ensure depending on the specific regional
all bars that comprise the bundle. the full contact of the probe to the man-power rates – can be estimated in
In case the result of the analysis is not steel surface, avoiding any possibility 2.5 years. Indirect cost saving has to be
in line with the theoretically expected of mistakes due to unreadable bar. Bars considered as well, in the production–
composition, a new verification cycle is that still do not conform to the test are quality level improvement, ensuring a
provided. Because the spectrometer’s marked by means of a paint marking reliable product ID to the final custom-
working principle is based on an elec- nozzle to simplify their identification er and avoiding any potential mistakes
trical-arc between probe-electrode and by operators. Considering a production in the product delivery. |

87
DANEWS 184

Patented TFH technology reduces

heat losses and scale formation

Q-HEAT WINS TRANSFER BAR HEATING

CHALLENGE FOR QSP-DUE® at Shougang

Q-HEAT transverse-flux technology has several advantages compared

to standard longitudinal flux inductors. For example, higher efficiency,
higher power density, and lower power supply frequency.

ALESSANDRO COTTICA
Design Engineer B.U. power systems,
Danieli Automation

n 2019 Danieli installed and

I commissioned a new Q-HEAT
system based on a patented,
TFH (Transverse flux heating) technol-
ogy for Shougang Jingtang United Iron Each induction-heating module transfers a symmetric power-density
distribution along the width of the bar. The relative shift of the two
& Steel Co. Ltd. Working between 200 inductors makes it possible to control the heating of the edges of the
and 500 Hz, the induction heating pro- bar and to adapt to all the slab widths to be processed.
cess is suitable for a transfer bar thick-
ness ranging from 8 to 25 mm, and
from 900 to 1600 mm widths.
In the DUE™ process a slab must be
re-heated rapidly up to a temperature
of about 1150°C after a roughing mill
section, before entering the finishing
mill section.
Each TFH inductor unit, supplied by
a Q-HEAT voltage-source frequency
converter based on IGBT technology,
has a rated power of 4.3 MW. The
overall, 39–MW installed power cor-
responds to nine Q-HEAT modules
that occupy less than 8 meters on the
production line. It is crucial to limit
the installation space for the induction
heating station to reduce the thermal

88
 DIGI&MET AUTOMATION

The main issue for TFH technology along the width of the transfer bar. The
is the edge effect, characterized by magnetic concentrators, arranged along
overheating of the transfer bar edge fol- the straight sides of the copper coils,
lowed by a lack of power density in the are primarily used to increase the elec-
vicinity. trical efficiency of the system. A spe-
This problem was successfully solved, cific magnetic core, whose configura-
even considering the operability con- tion is patented, is installed at the coil
straints of the line. Each induction edges and is used to compensate the
heating module forms a C-shape struc- lack of power density, helping to flatten
ture, opened toward the operator side, the transversal temperature profile of
made of an upper and a lower inductor. the transfer bar. |
losses of the transfer bar and scale for- The supporting frame is designed to
mation. ensure the necessary degrees of free-
The inductors, based on the transverse dom for both the upper and lower in-
flux technology, are best suited for this ductors, in order to adapt to all the slab
application, which makes possible a widths to be processed and to preserve
power density of 5.3 MW/m, with an the integrity of the system during the
electrical efficiency around 80% for transitory phases (i.e., deformed head/ 80%
larger slabs (1,600–mm wide slab) and tail of the transfer bar), while managing electrical efficiency
an overall efficiency greater than 62%. all the emergencies of the line. for larger slabs
In the so-called “transfer bar” area, the In fact, the vertical gap between the
slab temperature is above the Curie two inductors of each module can be
point and undergoes intermediate
reheating in the Q-HEAT induction-
adjusted, even when the device is en-
ergized.
> 62%
overall efficiency
heating process. The system is de- The inductors are made of water-
signed for consistent production of thin cooled, copper-tube windings and
and ultra-thin gauges in endless mode, magnetic concentrators. The electro-
and can be moved off-line when not magnetic design of the two inductors
in use (i.e. in coil-to-coil production of each module is oriented to obtain a
mode). symmetric power density distribution,

89
DANEWS 184

Successful revamping project

to lay the basis for future cooperation

A WINNING PARTNERSHIP
BETWEEN LIBERTY MAGONA
AND DANIELI AUTOMATION

— E D I T E D B Y G I A C O M O B A C C A R O / Sales, Flat Products, Danieli Automation

uring a briefing review

D meeting with Emanuele
Gentili (Plant Maintenance
Manager & Real Estate) and Giuseppe
Ferrelli (Engineering Department
Manager), Liberty Magona and Danieli
Automation discussed the positive
experience, six months after the final
acceptance, for the CPL revamping
project and how to continue the part-
nership established just one year ago
for future cooperation.

What was the key factor

influencing your decision in favor
of Danieli Automation? Review meeting: Giuseppe Ferrelli and Emanuele Gentili from Magona Liberty
on the left, and Giacomo Baccaro from Danieli Automation on the right.
We were looking for a reliable partner
who was able to support us during this
challenging revamping, where short de- I can say now, without any problem, focused on the same target. Migration
livery and fast ramp-up were a crucial that we made the right choice! of existing line functionalties into new
issue in our roadmap since we needed application software was not easy, but
the pickling line to feed our plant fa- due to their competence in process-
cilities as soon as possible. Describe briefly the job execution with ing lines they were able to complete
In the past (we did our latest main the crucial site activities during the in a very short time all the engineering
revamping fifteen years ago), we never commissioning period. activities related to the PLC software
had the opportunity to cooperate with without any problem. Another success-
Danieli Automation but we found many It was not an easy job, since the line ful key point of this task was of course
positive references in revamping proj- was stopped for many years and a lot of the integrated test of the application,
ects and new installation performed in information was missing from the origi- where also our experienced mainte-
cooperation with Danieli Wean United, nal design documentation. nance engineers attended to factory
so we decided to select a qualified The project team of Danieli acceptance test held at their headquar-
partner with consolidated background Automation worked side-by-side with ters.
in continuous pickling in order to have our maintenance team in order to com- Moreover, their skills and experience
the guarantee to complete in time and plete the reverse engineering of the ac- in commissioning activities gave a plus
in quality our line restart. tual plant, working as a common team to the site activities, speeding up the

90
 DIGI&MET AUTOMATION

line restart in shadow with the major

mechanical refurbishment performed
at same time. They also were fully
available to support us, providing some
improvements and optimizing the exist-
ing functionalities during the commis-
sioning stage, adapting details related
to practical operativity without any
problem. The line was running without
acid three weeks in advance compared
to the contractual milestone, while we
were still working on the acid pump
station beside!

What is the feedback from your en-

gineers and operators about the new
automation system?

Very positive. Consider that the new

HMI is well oriented to the line opera-
tors, since it is very detailed and com-
plete with all the information required
for the line operation.
It is not a simple tool only for a synop-
tic purpose, but we use it for detailed
diagnostics that help to trace the
reason of mechanical and electrical Plant restart ceremony of modernized CPL
problems through a linked events/per- at Liberty Magona
missives chain.
The new system is a powerful tool
which will allow us to integrate future After 8 years of inactivity due to plant Liberty Magona during all the revamping
stoppage, and with over 10 million euro phases, playing a major role in the effective
potential plant upgradation, since its in investment, Liberty Magona Continuous plant restart.
extendable architecture and used com- Pickling Line at Piombino (Italy) was In the souvenir picture, from right:
ponents are based on the latest tech- introduced. The plant is now more versatile, G. Mareschi, CEO Danieli; S. Gupta,
more competitive and characterized by better Executive Chairman & CEO Liberty Steel;
nology available in the market. performance, thanks to a successful A. Mordeglia, CEO Danieli Automation;
revamping program concluded ahead I. Bosnjak, Key Account Manager Danieli;
of schedule. Danieli Automation supported G. Carpino, Managing Director Liberty Magona.

Did you have the chance to cooperate

with them after the final acceptance of
pickling line?

Of course, having a complete new pro-

duction and maintenance team on the knowledge required to operate inde- antee our business.
line after the long shutdown, we need a pendently. In recent days, we signed also a new or-
technical support in order to assist our Also during the Covid-19 period, they der for their technological “Q-CMC2”
engineers during the critical activities, guaranteed the availability of remote package (coating mass control for air
like restart after ordinary maintenance assistance (also in smart working) to knives installed on galvanizing line) to
stoppage. We setup a small assistance our maintenance engineers. be installed on our Z4, which will al-
contract where Danieli Automation low us to improve the performance of
engineers, in remote mode from their our products and optimize the OpEx
office, can provide us all the necessary In conclusion, are you satisfied of the in zinc bath area. It is our intention to
support when required. job performed by Danieli Automation? involve Danieli Automation for future
Moreover, their competence and expe- projects, including them in our list of
rience are key factor in order to train Yes, absolutely. We are now happy to qualified and preferred suppliers for
and improve the skills of our young consider Danieli Automation not only a automation solutions and plant im-
team, transferring to them the proper good supplier, but as a partner to guar- provements. |

91
DANEWS 184

— EXTRUSION
AND FORGING

Danieli Breda

LATEST TECHNOLOGICAL PACKAGES

DEVELOPED FOR ALIGNMENT CONTROL
ON EXTRUSION AND FORGING PRESSES

Hydraulic jack
to lower
the die cassette.

GABRIELE MACEDONIO
Vice President, Sales
Danieli Breda

DAS die-alignment system

for extrusion presses
Mechanical
stop blocks
Patented technology maintains embedded in the
die cassette guides.
die centering for consistent
quality production and reduces
system maintenance
— The correct positioning of the die
inside an extrusion press is extremely
important for product quality, influenc-
ing the aluminum flow into the die.
The vertical/horizontal centering of the
stem and container over the extrusion

92
 CROSS PRODUCTS / EXTRUSION AND FORGING

axis can be easily adjusted to regulate — When the die holder is in the center The die cassette includes a locking
the screws outside of the machine, but of the press, the sliding plates are auto- system during the butt shearing. The
vertical die alignment has always been matically lowered and the die cassette whole system has been designed to
difficult and involves long machine sits on four mechanically hardened guarantee easy maintenance of the
stops. thrust blocks. These blocks, not affect- moving parts.
The die centering, due to wearing of ed by friction and wear, keep the die al- The sliding plates in the upper position
the bronze pads on which the die cas- ways centered without adjustment op- are five millimeters higher than the
sette slides, is inconstant over time and erations needed. The sliding surfaces, mechanical stop blocks: considering an
periodic adjustment is needed. made with graphite–filled bronze, don't average wear for the bronze of 1 mm
The die cassette slides on bronze guides need any greasing and help to reduce per year, the patented system doesn’t
into the extrusion axis and is horizon- maintenance. require any vertical adjustment of the
tally aligned by a mechanical stop. die for almost five years, and after this
The die vertical alignment, due to the time it is only necessary to replace the
wearing of the bronze guiding is more bronze without making any adjustment
complicated: to regulate the height of
both the die and die cassette, shims are 60,000 with shims. With traditional systems,
the height adjustment must be done at
inserted or removed under the bronze EUROS/YEAR* least five to six times per year.
sliding surfaces. This operation takes a Reducing
long time and qualified people. the press downtime With the Die Alignment System it
The newly patented system saves over and increasing is possible to save over two hundred
40 hours of maintenance, and was en- hours of maintenance in over five years
gineered with a liftable bronze sliding the plant reliability while keeping a constant and reliable
surface: quality for extruded products, reduc-
* depending on operating conditions
— When the die cassette moves in and ing the need for quality checks. This
out of the press, the bronze plates are means up to 240 tpy of gross produc-
lifted; tion increase for a 12" press. |

93
DANEWS 184

LATEST TECHNOLOGICAL 1 Automatic gap control system (top face).

2 Mechanical stop.
PACKAGES DEVELOPED 3 Automatic gap control system (bottom face).
FOR ALIGNMENT CONTROL
ON EXTRUSION
AND FORGING PRESSES

SAAP system for aligning

forging press shoes and 2
1
guide plates

The Semi-Automatic
Alignment Package
automatically closes/opens
the gap, for product accuracy
and OpEx improvement
— A forging press working with the
right alignment between the movable
crosshead shoes and guiding plates will
reach the best performance in terms of
product accuracy and OpEx.
3
Due to the heat transfer from the hot
ingot to the press, the gap tolerance
between the crosshead shoes and the
guide plates can change during forging
operations.
If the gap is set too loose at the begin-
ning of the forging process, the result
will be a poor alignment up to the point
that the press reaches steady hot con-
ditions. By contrast, if the gap is too
tight, there is the risk of blocking the
shoes against the guiding plates when
the crosshead reaches its maximum
thermal expansion.
To ensure uniform behavior during
non–constant operating conditions,
Danieli Breda patented the new semi-
automatic alignment package (SAAP).
This system makes it possible to
automatically close or open the gap
between the guiding shoes of movable
crosshead and hardened steel plates on
the casing from the operator pulpit.
A typical operation that needs gap ad-
justment is the forging of a large ingot
to be upset until it is forged to small
or medium size products, with subse-
quent finishing steps.
Maintenance costs savings are in the 7-10% range
The SAAP can adjust the gap of the thanks to reduced wearing of the sliding parts,
crosshead/guiding plates horizontally, as well as reduced stress on the guiding, resulting
keeping the alignment stable and con- in minor production stops due to unforeseeable
stant. | maintenance.

94
 CROSS PRODUCTS / EXTRUSION AND FORGING

Danieli Breda line

will be converted and its press
force increased
for Trafilerie Carlo Gnutti

Extrusion press
upgrade to profit
From 60 MN to 70 MN
aluminum alloys
market
— E D I T E D B Y G A B R I E L E M A C E D O N I O / Vice President, Sales, Danieli Breda

Assembly of a 60-MN double

action direct/indirect press
for brass tubes with 8–MN
piercer at Danieli workshops
in 2003. The press will
be revamped to operate as
indirect with piercer and with
an increased force of 70 MN
to extrude aluminum alloys.

— Trafilerie Carlo Gnutti The new, Danieli Breda bars and pipes with the round and hexagonal bars
selected Danieli Breda to special oil-hydraulic sys- same excellent quality it has and profiles will be produced
carry out an overall revamp- tems, along with BreDanExt demonstrated for copper and in the 2000, 6000, and 7000
ing of a 60–MN, direct-type automation and smart engi- brass products. series aluminum alloys.
extrusion press with piercer neering solutions, will allow The extrusion press will Trafilerie Carlo Gnutti and
at its plant in Chiari, Italy, Trafilerie Carlo Gnutti to be relocated to the Urago Danieli have maintained
supplied by Danieli Breda in produce a wide product mix d’Oglio plant, and by the a long-lasting partnership
2003 to extrude brass prod- in a highly flexible way. The second quarter of 2021 it since 1987 when the first
ucts. rebuilt press will offer an im- will produce semi–finished Danieli Breda giant, direct-
The upgraded press will op- portant step forward in indi- aluminum products for type, extrusion press with
erate with an increased force rect piercer extrusion cycles. mechanical processing and piercer for brass profiles,
of 70 MN to extrude alumi- The transformation will give molding for the automotive, was ordered, and this press
num alloys in indirect mode, Trafilerie Carlo Gnutti the aircraft, pneumatics, oil- is still in operation at the
with the piercer. chance to extrude aluminum and-gas sectors. Specifically, Chiari location. |

95
DANEWS 184

Danieli Breda installation includes open–die press,

with manipulators and DanForge® automation system

INTEGRATED FORGING LINE

COMMISSIONED for ZMZ, Russia

— E D I T E D B Y G A B R I E L E M A C E D O N I O / Vice President, Sales, Danieli Breda

new, integrated for-

A ing complex supplied
by Danieli Breda was
commissioned successfully at the
Zlatoust Metallurgical Plant (ZMZ),
Chelyabinsk, Russia.
The plant consists of a 25–MN open–
die forging press and two integrated
manipulators, AMF and RMF type,
operating through the DanForge auto-
mation system.

The open–die press has a frequency of

80 spm, with approximately 3,500 mm
daylight, automatic top-die clamping
and an automatic tool-changing device.
The manipulators are available to lift
20–tons ingots with a 60 t/m load mo-
ment.

DanForge automation provides com-

plete coordination between press and
manipulators, allowing fully integrated plant. DanForge also includes remote Technological packages like the au-
controls for the highest productivity diagnostic features to support the tomatic tool change, pop–up table,
and repeatability of the forging cycles. ZMZ maintenance team in predictive accurate manipulators positioning,
Because activities for movement, man- maintenance operations. With the new DanForge automation and energy-
agement, and control are accessible plant, ZMZ is able to produce high– saving hydraulics will allow ZMZ to
from the main desk, only one person is quality forged parts with diameters of solidify and improve its position in the
needed to operate the complete forging 100–800 mm and lengths of 10 m. special forged steels market. |

96
 CROSS PRODUCTS / EXTRUSION AND FORGING

New Danieli Breda press starting

for ProfilGruppen
28–MN, front-loading mm billet length;
press offers process — 30–sec. die change;
speed and energy — Variable frequency drive
savings to optimize energy savings;
— Sophisticated hydraulics
— ProfilGruppen is a and automation, including
Swedish specialist for cus- Predictive Maintenance;
tomized aluminum extru- — User–friendly interface
sions and components. for HMI;
The group has approximately Having worked with DBE
450 employees, and head- since 1991, HAX (Sweden)
quarters are in Åseda. special and close coopera-
loading press. Its primary pressure in the main cylin- tion allowed all targets to
In 2018 Danieli Breda was features include: der; be reached successfully and
awarded an order for an — 10.5 sec. from the extru- — 12 sec., including burp timely, with full customer
“ultrafast”, 28–MN front- sion end to reaching 100–bar cycle at 100 bar, with 1,350- satisfaction. |

Danieli Breda advanced press at Poongsan

Latest–generation consisting of coiler lines and
indirect extrusion line a walking-beam cooling bed
with downstream for extruded bars. Danieli
processing delivered a special coiler
is now in Final system comprised of three
Acceptance Testing automatic, self–centering
coilers to avoid any squash-
— Danieli Breda, along ing effect, while granting the
with its team of supervisors, highest quality on extruded
has started the Acceptance products.
Tests on the new indirect The cooling bed is divided
extrusion press for brass into four sections to handle the brass and copper indus- lutionary, single–stem con-
and copper-alloy products several lengths and to allow try, maintaining a high level cept, allows for consistent
at the Poongsan Ulsan plant either picking up or pushing of product-quality control energy savings and notably
in South Korea. The latest of the extruded bars, provid- starting from the press up enhances press performance
technology supplied to the ing a high degree of flexibil- to the extrusion line output. in terms of Dead Cycle
client had already earned ity to the operators. This approach differentiates Time reduction, leading to a
the PAC and it is now being In line with its vision, Danieli Breda from standard productivity increase.
commissioned to extrude Danieli Breda also integrat- and old–fashioned solutions The Danieli team is now
high–quality brass and cop- ed a free-graphite concept in available for this type of performing the Final
per wire and rod products. the cooling bed, pursuing an plant. Acceptance Testing, to start
The line includes the lat- eco–friendly and 100% safe The 36–MN indirect extru- up one of the most advanced
est–generation indirect approach. sion press, equipped with and state–of–the–art plants
extrusion press and a com- Such an integrated plant is the ESED 4.0 energy–saving for brass and copper extru-
plete downstream operation a revolutionary concept in drive package and the revo- sion. |

97
DANEWS 184

— CRANES

Three teeming cranes fully tested and demonstrated off-site

to be employed in extreme environmental conditions

FULLY REMOTE-CONTROLLED HD
CRANES FOR HOT COPPER HANDLING
at Codelco
copper and its commercialization. shop led to full customer satisfaction.
El Teniente ("The Lieutenant") is In order to achieve the highest levels
an underground copper mine in the of safety and reliability for production
Chilean Andes, 2,300 m above mean continuity and operators’ health, cranes
sea level. With over 3,000 kilometers have been equipped with automatic op-
of underground drifts, El Teniente is eration functions and remote control,
reportedly "the world's biggest under- to cope with the necessity to operate in
ground copper mine" and is the largest a highly aggressive environment.
of Codelco's operations. In fact, one byproduct of the cop-
per smelting process is sulfur dioxide
Danieli was chosen by Codelco to sup- (SO2), a toxic gas that can be used for
DANIELE STELLUTO ply three teeming cranes with capaci- the production of sulfuric acid.
Project Manager, ties of 100/30(45)/30(45) ton F (D) As well as many components of the
Advisory & Commissioning
class (CMAA) and 18 m span, repre- cranes, the electrical cabin and operator
senting critical equipment for produc- cabin have been specifically designed
ing copper. and equipped for being sealed and pro-
odelco chose Danieli cranes Several technical solutions were imple- tected from the sulfur dioxide gas.
C to handle a crucial part of
its copper production pro-
mented to obtain the highest level of
safety and reliability for production
With the implementation of the cranes
engineered and supplied by Danieli
cess, with a fleet of three completely continuity via remote control and auto- and operated from the remote pulpit,
unmanned teeming cranes handling matic operation. the operators are finally safely away
liquid copper. The cranes were designed by Danieli from the high–risk areas.
Corporación Nacional del Cobre de and completely built in its workshop, The remote pulpit is conceived for au-
Chile (Codelco) is one of the world's where they have been fully tested to tomatic and manual operation and op-
three largest producers of copper. The simplify the erection and commission- erators are supported by several screens
company is owned by the State of ing operations at the customer's prem- showing cameras on the crane and
Chile and its main business is copper ises. During the project, a top–notch crane statuses and the same controls
exploration, development and exploita- collaboration between Codelco and configuration is installed in the pulpit
tion—mining resources and byprod- Danieli by means of meetings, site for an effective working experience.
ucts—and processing it into refined visits, inspections and tests in work- While the crane is still equipped with

98
 CROSS PRODUCTS / CRANES

2,300m
above mean sea level
El Teniente underground
copper mine

a crane operator cabin, the overall au-

tomation architecture is conceived to
provide normal cruising operations in
assisted automatic mode.
To guarantee remote operation, the
cranes are equipped with an advanced
vision system that supports the opera-
tor, and assisted automatic missions
can be achieved through crane HMI/
PC. The system automatically selects
and shows on screens the areas of in-
terest to the operation, and one camera
continuously and automatically follows
the hook.
An integrated automation system as-
sists the operator with automatic crane
positioning along the building bay,
easing the operation and leading to a
higher efficiency.
All missions are provided with track
routings for the crane movements
made in automatic mode, leaving the
operator the option to pause actual
mission during movement, and return-
ing to manual crane operation using
the full–size crane pulpit chair and
HMI.
Additional lifting equipment has been
supplied for lifting the entire teeming
crane, for maintenance.
For a smooth transition, the erection of
the cranes was performed in an exten-
sion structure out of the main foundry
building. After the cranes' erection was
completed the new structure was used
as a maintenance area for cranes. This
allowed the customer to have no im-
pact on production during erection and
commissioning phases. In November
2019 the last crane was accepted by
the customer as a result of the tests
performed, and the whole fleet is now
in production.
A new, successful achievement for
Danieli Centro Cranes in a highly de-
manding project with Codelco in its
critical El Teniente plant. |

99
DANEWS 184

Remote connection to the Danieli workshop

for customer feedback and updates

CRANES OPERATIONAL TRANSPARENCY

DIGITAL WINDOW
INTO MANUFACTURING TASKS

PA O L O T O G N I
Project Engineer,
Danieli Centro Cranes

he more strategic the crane On the other hand, providing a con- Danieli inspectors, located in different
T is to the metals process for
which it is destined, the more
tinuous feedback alongside the full
supply process has been a time– and
places the same real–time digital tools
to control together details and quality
important and enhanced are all its cost–consuming activity often impact- of the objectives.
customized details. ing the project schedule, without being Through a remote visualization soft-
In addition to the engineering design, feasible from a project management ware, customers can decide what to
co–developed with the client—a cru- point of view. see, whether it’s focusing on special
cial aspect of every Danieli techno- This is the reason we decided to do equipment aspects or feeling as if
logical crane project—we also believe it differently: we created “digital win- physically participating in the inspec-
our product quality can be recognized dows” into the Danieli cranes manufac- tion. The display window is interactive,
through the details of its manufactur- turing process, adopting a digital tool— so people involved can exchange draw-
ing. the Q-SPACE 1—to let clients interact ings, highlight parts, display images
with us remotely. and take snapshots in real time.

Technological integration We recently used this tool to connect

How does it work? our American client and the Danieli
With these premises of deep custom- inspector in the Danieli Thailand work-
ization and technological integration, The IT system (DIGI&MET Q-SPACE shop for a final inspection of a techno-
customers assume a central role in 1 technology) works with interactive logical charging and teeming crane.
terms of feedback and experiences dur- glass, smartphone or tablet by connect- This experience proved to be success-
ing the engineering check points and ing people physically far from each oth- ful for both parties, allowing them to:
manufacturing inspections in Danieli er. Through the Q-SPACE 1 applica- witness the latest phases of equipment
Cranes' supply chain. tion we provide to both the client and assembly thoroughly and remotely;

100
 CROSS PRODUCTS / CRANES

execute together the functional tests of

the equipment; recording the full test;
taking snapshots of crucial aspects and
videos of the activity; while defining
modifications and improvements to be
performed before delivery takes place
in real time.

We believe the client is an essential

part of successful project execution.
The benefits of the proposed system
are many and important: from the abil-
ity to inspect every key productive step
without being physically present at the
workshop, to the minimization of logis-
The IT system (DIGI&MET Q-SPACE 1 technology) works tics and transportation costs during the
by connecting people physically far from each other with manufacturing phases.
interactive glass, smartphone or tablet. In this Covid-19 era, with all the limi-
tations imposed nowadays by default,
the operational transparency is an
added value to keep a constant connec-
tion with our clients, thriving and even
stronger than it was in the past. |

101
DANEWS 184

The US company reconfirmed its technological

partnership with Danieli awarding them
an order for four high-technological process cranes

FULL LADLE-HANDLING
CRANES PACKAGE 20
at Nucor Brandenburg, USA CRANES
IN TWO
YEARS

the vacuum degassing station, and from

the VD to the CCM ladle turret. Based
on the strategic missions to be ex-
ecuted on a continuous basis at a high
performing pace, this handling system
is fundamental to the productivity tar-
gets of the entire steel complex. It has
been designed and tailored to apply the
maximum reliability concept, in terms
of safety and operating functions in the
heavy-duty environment of the steel
IVO BUDIGNA making plant.
Senior Manager, Sales
Danieli Centro Cranes
The horizontal movements for bridge
travelling and trolley traversing cranes
n February 2020, Nucor are designed with a four-motor arrange-
I Steel (USA) reconfirmed its
technological partnership
ment in order to operate in nominal
conditions at all times, even in case of
with Danieli with the order for four failure of one or two motors, or in case
high-technology process cranes, to be of failure of their related control.
installed in the meltshop of the new The hoisting mechanism has a double
Nucor steel complex, in Brandenburg, hoisting speed through two indepen-
Ken. The supply package will include dent motors connected by planetary
one 290(400)/75/25–shton charging gears that allow full-load lifting and
crane, two 290/75/25–shton teem- lowering, even with a single motor at
ing cranes, and one 220/45–shton 50% of the nominal speed, to prevent
caster crane, all designed according to crane stoppage in case one motor or
CMAA highest duty class F. the related controls fail.

This fleet of EOT cranes will handle The same redundancy concept ap-
the full meltshop steel flow, delivering plied to the mechanisms has been
the scrap from buckets to the EAF, the replicated for the main components
liquid steel from the ladle furnace to of the air-conditioned electrical and

102
 CROSS PRODUCTS / CRANES

MIDA cranes package start-up was completed 3D rendering of Nucor Steel charging crane:
in 2019: these cranes can operate semi-automatic it'll be able to assist in the entire meltshop
movements, for better crane driver assistance. steel flow.

automation room, where the systems safely lowering it to the ground. The component status and faults, and other
are equipped with the latest-generation emergency brakes act on the drum data useful for preventive maintenance
frequency converters fed by a regen- flange with hydraulic device control, planning, component troubleshooting,
erative unit, itself redundant too. The automatically activated in case of over and for optimizing maintenance opera-
most advanced technologies in term speed. Overload protection by electron- tor intervention time.
of “green” features have been applied ic load cells will be provided as well for
to guarantee significant energy savings all the hoist units. To optimize on-site installation ac-
during the braking phases of vertical tivities and minimize commissioning
and horizontal movements, with the Adopting some of the key technologies schedule, all the cranes will be com-
collateral benefit of having optimized of an autonomous crane, the teem- pletely preassembled in the specialized
the configuration of the area made free ing and charging cranes can perform Danieli workshop in Thailand, as well
from braking resistors. semi-automatic movements along their as tested for all movements and func-
respective bays in order to assist the tions.
Extending the concept of safe rope crane driver during the standard opera- High reliability, optimization of op-
reeving to the charging crane—a con- tions; the crane driver executes the erating costs with defined common
cept always applied by Danieli for operations of ladle/bucket pick-up and components, and full 3D-design co-
liquid steel applications—we imple- deposit under his control instead. development with customer operational
mented the safe reeving configuration. Moreover, the cranes are designed to teams are some of the key factors that
This means that, in case of the main include an advance monitoring system Danieli and Nucor, front runners of
hoist rope failure, the crane is able to to record the main standard param- the steel industry, have chosen to be "a
keep the load stable and suspended, eters, such as crane working cycles, step ahead." |

103
DANEWS 184

— HEATING
SYSTEM

New concept roller-hearth design improves bar steel properties

at Çemtas, Turkey

MULTILINE ROLLER-HEARTH FURNACE

FOR ALLOYED STEEL BARS H&T

CARMELO VENTURA
Senior Manager, Tech Team
Danieli Centro Combustion

anieli Olivotto Ferrè sup- bars during handling inside the aus- The layout of the line allows maximum
D plied a new heat-treatment
line for automotive bars to
tenitizing furnace and the quenching
system. The new solution improves bar
flexibility. In addition to the quench-
ing and tempering thermal cycle it is
Çemtas, in Turkey. The latest trends quality in terms of mechanical/metal- possible to perform normalizing and
in the premium automotive-steel bar lurgical properties and straightness. soft annealing in parallel on the two
market are to comply with the highest furnaces.
quality standards requested by end us- The design of the roller system keeps
ers. Meeting those quality standards, the bars spaced and treated with all the The line can treat the main automo-
which are directly related to the prod- advantages of a single-bar solution tive steel grades: Q&T (42CrMo4,
ucts' metallurgical and mechanical As a result of the roller design and the 41Cr4, 30CrNiMo8, 34CrNiMo6,
performances, involves heat-treating combustion system arrangement, the 34Cr4, C45E, 51CrV4, 55Cr3,
technologies. bars reach temperature uniformity of 52CrMoV4C40, C35); Normalizing
±5°C at the end of the heating process (C45, S355J2, 16MnCr5).
The heat-treating equipment is de-
signed with a new concept of multiline, The bars' temperature uniformity, to- The quenching segment is able to work
inclined and shaped rolls. This patent- gether with the quenching machine with water and water-plus-polymer, due
pending solution is based on the con- design, are the key factors for reaching to the wide range of the steel grades
cept of continuous rotation of selected “top quality” heat treatment . to be treated. The bars OD range is

104
 CROSS PRODUCTS / HEATING SYSTEMS

Layout of the heat-treatment line Danieli Austenitizing Reduction

Olivotto Ferrè supplied Çemtas with. chimney tempering
tempering austenitizing
station
Charging
table
Transfer table Roller Quench
(normalizing) table 2 system

Furnace

Roller
table 1

Roller
table 5

Roller table 4/
soft annealing Tempering
charging table furnace

Normalizing
Roller table and
table 3 cradle

Left: Hardness variation in surface of bars Right: Hardness variation from surface to center of bars upper and lower variation limits.

Hardness value (HRc) along the length of bars Hardness value (HRc) from surface to center of bars
after quenching and tempering (± 1 var.) after quenching and tempering (± 2 var.)
38 38

37 37

36 36
+2
35 35
+1
HRc

HRc

34 34

33 33
-1
32 32
-2
31 31

30 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Number of samples Number of samples

15÷100 mm and length from 3 meters — Hardness variation, surface to core Results for metallurgical properties:
up to 8 meters. < ±2 Delta HRc (center–right chart); — Martensite percentage along bar sur-
The productivity of the line is: — YTS: 850÷906 N/mm2 (Standard face (water quench) > 90%
— Quenched and tempered: 10,000 EN 10083: min. 600 N/mm2); — Martensite percentage on bar core
tons/year; — UTS: 976÷1023 N/mm2 (Standard (water quench) > 85%;
— Normalized: 10,000 tons/year; EN 10083: range. 900÷1100 N/mm2). — Decarburization (mm) < 0.003 x OD.
— Soft annealing and stress-relieving in — Elongation: 15.6÷16.7 % (Standard
tempering furnace: 10,000 tons/year. EN 10083: min. 12%); The results from the hardening and
— RA: 60÷61% (Standard EN 10083: tempering line performance tests fully
Results for mechanical properties: min. 50%); comply with and exceed the most re-
— Hardness variation, surface < ±1 — Straightness of bars after heat treat- strictive standards requested by the
Delta HRc (center–left chart); ment < 1 mm/m. automotive market. |

105
DANEWS 184

State-of-the-art Danieli Centro Combustion:

excellent performances reached

TURNKEY WB FURNACE FOR SLABS

at AM Krakow, Poland

DCC design guarantees quality heating

and low NOx emissions,with optimal control
thanks to Danieli Automation

The walking-beam furnace has sidewall — Two combustion air fans;

burners on top and bottom preheating,
heating, presoaking, and bottom soak- — Two booster fans to raise the COG
ing zones, and radiant roof burners on pressure for appropriate use in the
the top soaking zone. walking-beam furnace;

The combustion system and burners — One centralized heat exchanger

have been designed to use natural gas, (metallic, suspended convection-type
coke-oven gas (COG) or a mixture of recuperator) designed to preheat com-
both of these. bustion air to 550 °C using waste-gas
The combustion system consists of: heat recovery;
ELISA SALAMONE
Professional Sales Engineer,
Danieli Centro Combustion

anieli Centro Combustion

D supplied a new, 450 tph-
walking-beam furnace for
slabs to Arcelor Mittal in Krakow,
Poland. The top– and bottom–fired,
61-m long furnace is designed to re-
heat 220 x 1.350 x 11.000-mm slabs
up to a temperature of 1.250 °C, in
advance of rolling.
In order to guarantee excellent heat-
ing quality and low NOX emissions,
Danieli Centro Combustion’s MAB
Flameless™ Technology and PHL con-
trol were implemented.

Danieli Centro Combustion also car-

ried out erection of the furncace on a
turnkey basis (picture on the right).

106
 CROSS PRODUCTS / HEATING SYSTEMS

Furnace characteristics

Roll to roll external length 68,300 mm

Wall to wall inside length 61,440 mm

Wall to wall inside width 12,200 mm

Charging method Frontal, on external roller way and charging machine

Flameless Mode
Discharging method Frontal, on external roller way and discharging machine

Thermal Power & MAB Technology configuration

Combustion Preheating Heating 1 Heating 2 Heating 3 Presoaking Soaking

zone

Burner type MAB MAB MAB MAB MAB Radiant

Flameless™ Flameless™ Flameless™ Flameless™ Flameless™ and MAB
Flameless™

Flame Mode Total Burner 12 sidewall 12 sidewall 12 sidewall 12 sidewall 12 sidewall 40 rad
for zone 8 sidewall

— Thermal power distribution across

several control zones (eight, in total);

— Combustion control by soft- Furnace performances

ware running on dedicated PLCs
(redundant) representing Human
Machine Interface for operators in Description M.U. Values achieved in Remarks Variations
performance test
the main control room. The com-
bustion control software oversees Slab thickness mm 220 - -
all combustion loops and is user-
Slab width mm 1,350 - -
friendly, allowing the operator to
select: Slab length mm 11,000 - -
> Manual mode (output selected via
Weight kg 25,645 - -
HMI);
> Automated mode (set-point se- Fuel used - Natural Gas - -
lected via HMI); Steel grades - Low Carbon - -

— Sidewall burner management Charging temperature °C 20 - -

(Multi Air Burner type, or MAB) us- Rows in furnace - 1 - -
ing dedicated software (once again,
running in PLC mode) permitting Productivity t/h 457 450 (contract value) + 1.7%
the operator to select manually (for Discharging temp. (T) °C 1,250 -
each corresponding combustion zone
available): Specific consumption GJ/t 1.06 1.15 (contract value) -9%
> Modulated mode; Temperature uniformity °C +/- 12 < 20 (contract value) Better temp. uniformity
> PHL mode (on/off mode with
round-robin management); Thermal NOX emission mg/Nm3 89.5 with 3% O2 < 150 mg/Nm3 -67%
in waste gas (contract value)
> Flameless mode;
> PHL flameless mode (on/off
flameless mode with round-robin
management);

— Roof burner management

(radiant–type) using the modulated

107
DANEWS 184

TURNKEY WB FURNACE 1. Furnace 3D overview. 4. Furnace Level 2 overview: the

calculated slab temperatures (green,
FOR SLABS 2. An instrumented slab red and yellow lines) are made
at AM Krakow, Poland for model calibration. to follow their heating practice
(black line).
3. Comparing target temperature
at furnace exit (L3 plan), model 5. Remote pulpit.
temperature and measured one
at roughing mill.

Strength
and effectiveness
in reheating systems
design and
construction

Thermal NOX
emission
-67%*
Specific
consumption
-9%* 2

Productivity
+ 1.7%*
Better
temperature
uniformity

(*) compared to contract value

mode, allows effective control of the infiltrating into the actual furnace in
slab head or tail temperatures. MECHANICAL EQUIPMENT the vicinity of the vertical posts of the
movable beams, thus an ideal atmo-
— Additional control loops (furnace Furnace walking-beam mechanism sphere is maintained inside the furnace.
pressure loop; recuperator protection and door movements are powered by a Scale hoppers are provided for dry scale
loops, including waste-gas dilution and hydraulic package devoted to furnace collection, both in the charging and
hot-air bleeding; automated, preheating and charging/discharging machines, discharging areas where slabs are ma-
top and bottom combustion zone short- including lifting cylinders (2), travelling nipulated during operations by the two
ening etc.) cylinders (2), charging door lifting (1) machines.
and discharging door lifting (1). Slab movement inside the furnace is
— Level 1 – Level 2 System intercon- Water seals along the entire length performed by movable and fixed beams.
nections. of the furnace prevent cold air from These beams are fixed either to the

108
 CROSS PRODUCTS / HEATING SYSTEMS

movable frame or to the fixed hearth. 3

The system is sized not only to mechan- Carbon Steel
ically withstand vibrations from slab 1270
movement inside the furnace but also 1250
1230
to ensure minimal skid marks on the 1210
slab's lower surface during slab heating. 1190
Horizontal beams are equipped with 1170
suitably dimensioned riders that limit 1150
1130
the cooling effect over the lower surface 1110
brought about by cooled beams found 1090
below the slab. Movable and fixed skid 1070
frames are split in several sections, 1050
1030
the last of which is staggered just in 1010
correspondence to the last 25% of the T_Disch T_Target RM last pass
furnace length.

4
OPTIMIZATION MODEL

The supply included Danieli

Automation Furnace Level 2, the on-
line package meant to optimize the
reheating process.
It is based on a Model Predictive
Control (MPC) system, using a feed-
forward algorithm to estimate the fur-
nace behavior from the actual condition
and to evaluate the proper actions to
get the desired product output, while
fulfilling constraints and optimizing per-
formances of the furnace.
This approach, fully in line with the
Industry 4.0 paradigm, contributes to
maximize the furnace efficiency. 5
The primary aim of Furnace Level 2 is
to automatically manage the furnace
temperatures in order to minimize the
difference between the mean product
temperature and their heating practice.

Heating practices are open to plant

engineers, who can manage them to get
the desired results, like favoring fuel
consumption saving or following special
heating strategies (low decarburization,
alloyed steels, etc.).

A dedicated reporting system provides

all the essential data for quality auditing
(fuel specific consumption, tempera-
tures, ratios, chemical analysis, etc.).
The installation achieved a full integra-
tion with existing plant automation as
well as the replacement of the Level 2
of the other parallel reheating furnace
on the existing Level 1 automation
(Figures 3–5). |

109
DANEWS 184

The project will enhance automation systems and reduce emissions

DCC turnkey plate furnace revamp

for Marcegaglia
— The aim of the project production boost.
is to increase the furnace The improvement in the au-
throughput and replace the tomation system with mod-
current automation system ern application software to
with a new, integrated level be installed on the furnace
1 and level 2 system. will reduce maintenance
This also will help to reduce costs and considerably im-
polluting emissions (NOx) prove the management of
and specific fuel consump- the material flow.
tion, while improving ther- Emissions will be reduced
mal efficiency under differ- thanks to new technologies
ent operating conditions. applied to the combustion
The result of the revamping system, resulting in a green-
Souvenir picture of the companies' teams at Marcegaglia offices in San Giorgio
will allow the plate mill to di Nogaro. From left: Ugo De Siervo, Danieli Automation; Giovanni Battista
er and cleaner system.
increase its market com- Vallarino, Danieli Automation; Giancarlo De Lucchi, DCC Sales Manager; Marco The contract is a turnkey
petitiveness due to better Ferrone, Marcegaglia Plant Manager; Franco Leorati, Marcegaglia Corporate project with delivery in
Purchasing Dept. Director; Alessandro Venanzini, DCC VP Sales; Stefano Martinis,
quality products, as well as a Danieli Automation December 2020. |

Start-up of flexible aluminum homogenizing furnace

to treat slabs or billets of all aluminum alloys

Olivotto Ferrè’s furnace: a winning choice

for Rusal Research Center
— In July 2017 JSC Rusal tioned on the furnace roof E norms) are achieved by
Krasnoyarsk Aluminium when not in operation. This means of an electrical resis-
Smelter selected Danieli furnace is designed for tor-type heating system; air-
Olivotto Ferrè to supply a homogenizing annealing of recirculation system, with
new homogenizing furnace slabs and billets of the entire axial fans installed in each
for billets and slabs, as aluminum series (1–9), in zone; and a movable cooling
part of a new Research & square or round sections system, equipped with axial
Development facility. from 300×700 mm up to fans.
800×3200 mm, in lengths
The installation consists of a from 1,000 to 6,800 mm. The plant was installed and
movable, electrical homog- Billet cooling is provided by successfully achieved the
enizing furnace, attached forced air flow. Final Acceptance from the
to a wheeled mechanism Top performances in tem- customer in a timely fash-
with two fixed bases and perature uniformity (in ion, right after the smooth
a movable cooling system, Class 1, i.e. ±3°C, in com- commissioning and start-up
the latter of which is posi- pliance with AMS 2750 rev. sequences. |

110
— HOT AND COLD
PROCESSING

Fire-Refined, High-Conductivity copper rod

NEW COMPLETE PLANT FOR

FRHC COPPER ROD PRODUCTION

< 60%
rod ovality
excellency

The new order — Rain Floods Trading ity, consolidated through the process variables will be
awarded an order, to the many years of copper prod- pre–set and adjusted sim-
is aimed to establish consortium of Danieli ucts yields; Danieli Centro ply using the Technological
the most advanced Centro Maskin and La Farga Maskin will take care of the Work Station (TWS), which
technology from Yourcoppersolutions, for de- wheel continuous casting is located in the main con-
sign, supply and commission- machine, the rolling mill, trol room. The rolling mill
scrap to compact ing of a complete plant for and the coiler at the end of technology stands, based on
coils for FRHC 25,000 tpy of FRHC Fire- the line. Danieli’s 100 years’ experi-
copper rod plant Refined, High-Conductivity ence in long-products rolling
in Iraq and will be copper rod. The finished Danieli Automation will and the specific experience
product will be 8–mm rod provide the electrical and au- gained by Danieli Centro
installed at Erbil. produced at up to 15 tph. tomation systems. The auto- Maskin in the area of non-
The plant configura mation will make it possible ferrous materials, will make
tion consists of an 80–t ca- to operate the plant minimiz- it possible to reach consis-
pacity furnace, a continuous ing the manual intervention, tency in mechanical proper-
casting machine, a two-stand while maximizing safety and ties, accurate tolerances on
rolling mill, and a coiler to ensuring maximum produc- diameters ≤ (± 2%), and ex-
collect the final product. tivity, and even more impor- cellent rod ovality < (60%).
La Farga Yourcoppersolution tant—maximum repeatability The new plant is scheduled
Rain Floods Trading, Danieli
and La Farga delegations after
will supply the furnace for and quality for the whole to start production by end of
contract signing in Buttrio unparalleled process qual- process. The set-points for 2020. |

111
DANEWS 184

Danieli Centro Maskin has the know-how to do it best

GRINDING IS AN ART
TO GET TOP QUALITY IN SLABS
AND BILLETS PROCESSING
— E D I T E D B Y S A N D R O O R L A N D O / Vice President, Danieli Centro Maskin

CastGrind technology and updated HGS300 slab grinder consists of the

automation platform improve stainless shift from spindle lubrication with
steel slab surface treatment an air/oil system to an oil-only sys-
tem, ensuring improved stability and
SLAB GRINDER IN OPERATION control of the lubrication flow, and
FOR POSCO POHANG, KOREA maximum reliability for more than one
year before workshop check and re-
— Danieli Centro Maskin success- vamping. In the past two years a grow-
fully commissioned the new HGS300 ing number of customers followed
slab-grinding unit at STS1 Plant. the Danieli Spindle Service Program,
Equipped with a 250–kW motor on a package designed to keep Centro
the main unit, the new grinder will Maskin in optimal operational con-
work on 140– to 220–mm thick stain-
less steel slabs, up to 1.65 m wide 1,090 ditions under a full guarantee, with
recognizable advantages to customers
and 10.5m long, to ensure an output HOT for overall operation and maintenance
of approximately 200,000 tpy in full costs.
skin-grinding mode at an average re-
AND COLD
moval depth of 2 mm per slab face. GRINDING Variable-angle HiGrind unit plus
The plant is equipped with CastGrind Danieli Automation package ensures
technology for processing mate-
MACHINES accurate removal for multiple steel
rial with surface temperature up to grades and billet sizes
700°C, in addition to Hi-Grind, the
E-Cube set-up for stepless–angle NEW SYSTEM FOR SURFACE-
grinding from 45 to 90 degrees. applications, for long and flat prod- GRINDING 50,000 TPY OF BILLETS
An updated automation platform was ucts, and for stainless steel as well as AT MASTEEL, CHINA
developed by Danieli Automation. for low- and medium-carbon grades.
This is a very important milestone in Today, Danieli Centro Maskin ac-
the collaboration between Danieli counts a total of 30 grinders in opera-
Centro Maskin and Posco, a rela- tion with Posco, of which 18 HGS300
tion started in 1979 and developed units are for slab grinding.
through various areas of conditioning Since its market launch in 1995, the
HGS300—throughout its design evo-
lution path—has established itself as
the leading edge for slab conditioning,
especially of stainless steel slabs,
and the top-selling grinding unit in
this field: a total of 35 units have —Danieli Centro Maskin supplied
been installed worldwide, from South and started up the new billet grinder
Korea to China, and from Europe successfully at Masteel, a 250–kW
to United States. HGS200 unit equipped with a
The main, new development for the variable-angle system to grind from

112
 CROSS PRODUCTS / HOT AND COLD PROCESSING

main motors to ensure 70,000 to

90,000 tpy of output. As usual the
Danieli Hi-Grind system will control
the grinding process to ensure tight
tolerance on the removal depth and
provide all safety functions required
for this type of installation.
Danieli Automation will supply the
electrical and automation systems,
including all the latest features de-
veloped for equipment operations
and process data management. Both
NGS16 units will be operated and
controlled from a single, remote pul-
pit room, in that way improving plant
safety and operational costs.
45 to 90 deg; an Hi-Grind system to
ensure accurate removal control in the Two more orders for special A new system will be installed to re-
range of ±10% of the nominal grind- steel billet grinders duce the wheel-changing time up to
ing depth; and a Danieli Automation 30% versus the previous process.
electrical and automation platform for HENAN JIYUAN RELIES AGAIN Manufacturing for the mechanical
full process control that allows flexible ON DANIELI CENTRO MASKIN equipment will be done at Danieli
and fast operation whenever operating GRINDING TECHNOLOGY China in Changsu where, aside from
in spot-grinding mode. the high specialization developed for
The plant, complete with loading and — Danieli Centro Maskin have re- building Centro Maskin grinders, the
unloading benches, is now processing newed the collaboration begun in Service Hub provides the full techni-
billets in grades ranging from alloy to 2014 with the supply of two NGS16 cal support for commissioning and
bearing and free-cutting grades, from billet grinding units, and now will be consulting for operations ramp-up,
140– to 280–mm square as well as strengthened with a new order signed with the most qualified local person-
rectangles, at maximum length of 12 in December for two more grinders of nel.
m. The upgrade to the oil-type spindle the same model. Planned to be in full These will be the 504th and 505th
lubrication system, from the old operation by early 2021, the new units billet grinders installed by Danieli
air-oil hybrid system, is also applied will process 150–mm square specialty Centro Maskin since 1967. This very
on the HGS200 series, and leads to steel billets up to 12 m long, in full important contract further solidifies
improved stability and control of the skin mode or spot/pattern grinding. Danieli Centro Maskin’s presence in
lubrication flow, and thereby ensures The new grinders will be equipped the Chinese market where 12 billet
fully safe spindle operations for more with the highly reliable, NGS16 belt- grinders are already at work in nine
than one year. driven spindle, powered by 160–kW plants across the country. |

3D rendering of one of the two

grinders that will be supplied
to Henan Jiyuan.

113
DANEWS 184

— SERVICE

Danieli China Service

A GLOBAL PROVIDER FOR OFF-LINE

SLAB-CASTER MAINTENANCE
A roadmap for improved slab CCM
equipment service life and optimized maintenance costs

— E D I T E D B Y C H E N X I N G J I Sales Director, DCM&DCM Slab,Danieli Service China

A N D P A O L O S A C C A V I N I Senior Manager, Refurbishment Projects, Danieli Service

he DCS caster-roll workshop between Danieli and NISCO, DCS in-

T has the ideal configuration, troduced the overall outsourcing idea,
up to 50%
proven standard refurbish- to be executed by “cost per ton” overall higher service life, for CCM
ment process and quality manage- outsourcing model (contract price=cost equipment, compared to nor-
ment, and sufficient capacity. With price per ton X actual output). mal domestic maintenance
extensive experience in the slab caster Since 2010, Danieli has three times supplier
field, Danieli constantly applies new signed and renewed the contract with
technology to improve the service life NISCO for slab-caster roll global
of equipment. Curiosity drives us to service; contracted with Rizhao Steel
explore and commit to continuous in- ESP for two years of caster-roll refur- ROI
novation, thereby achieving qualitative bishment technology export service; less than 2 years
improvement over time. contracted with Shandong I&S Rizhao with 3–year–long global ser-
DCS has an advanced supply-chain for CCM 1 and 2 off–line global main- vice contract
network and supplier management tenance service; and contracted with
mechanism, which ensure timely and Hanye Special Steel for CCM 3 off–
qualified procurement for roll com- line global maintenance service.
ponents, keeping track of each roll’s At present, there are a total of six
manufacturing parameters and analyz- stands and eight strands slab-caster
ing and summarizing the statistical data offline maintenance projects under tic carbon steel. The scope of service
collected in the maintenance process, execution. The annual output of these includes roll refurbishment; segment
to achieve continuous, multi-dimen- lines is over 10 million tpy, and the mechanical and electrical mainte-
sional optimization. steel grades include low-carbon steel, nance, and spare parts supplement;
In 2010, at the beginning of a caster- medium-carbon steel, high-carbon banana–frame alignment, online main-
roll maintenance service negotiation steel, alloyed carbon steel, and peritec- tenance support; and so on.

114
 CROSS PRODUCTS / SERVICE

Mould and segment Mould and segment

workshop maintenance
Transport, Disassembly
checks, of rolls,
cleaning nozzles and
and tests components
from
Take over segments

Off-line final New fabrication and

alignments, reconditioning workshop
final water, Maximize
oil, grease Roll assembly /
tests the life cycle disassembly
welding

>
machining
heat treatment
Disassembly consignment
of fixed Hand over spares, stock
and loose
sides Plate assembly/
disassembly
nickel plating
machining
of the plates
Consignment
stock

DMCC Danieli Maintenance

Competence Center

Along with signing the three-year off– line re-grading rate of 0.27% fully com- aligned successfully all in one year.
line global maintenance service contact plied with the Shandong I&S Rizhao Working in close cooperation, the
with Shandong I&S Rizhao for CCM company target. high-quality spare parts provided by
5 on March 19, 2019, Danieli offered Danieli guarantee alignment accuracy.
slab caster off–line global maintenance With periodic realignment, the slab The simultaneous alignment for two
service for over ten years. caster will maintain good alignment strands improved the service efficiency,
Danieli has a team with nearly 100 for condition to serve the caster produc- ensuring the customer resumed the
on-site services. In the process of off- tion, bringing good product quality and production on-time. Compared to the
line maintenance, DCS site–service productivity, and avoid major problems prior conditions, the equipment instal-
teams apply the “6S” management ac- associated with cracks and other slab lation accuracy and slab quality showed
tivity, strictly implementing the request defects. significant performance improvement.
of Management System Documents From 2015 to now, the DCS team Shagang expressed its satisfaction with
established by the client and Danieli for has completed nearly 30 strands/set the DCS service and indicated its
quality management and environmental slab-caster banana-frame and off–line willingness to choose DCS for regular
and occupational health and safety. stands alignment projects, including maintenance service.
For example, for the Shandong I&S global maintenance service customer
Rizhao job DCS team actively cooper- Shandong I&S Rizhao and Hanye Global maintenance service from DCS
ated with the client to improve the Special Steel. provides higher segment maintenance
quality of service: roller-gap accuracy quality, stable production rate and
has been improved from ±0.15 to ±0.1 Shagang, China’s largest private iron value-added services, such as banana-
mm; segment roller alignment toler- and steel company, selected the DCS frame and stand inspection and align-
ance has been controlled to within ±0.1 team as exclusive supplier to carry out ment, and caster process technical sup-
mm; the rate of qualified slabs reached a slab caster alignment and adjustment: port. All of this makes Danieli a reliable
99.57%; and the hot–mill production 12 caster strands were inspected and partner to the metal industry. |

115
DANEWS 184

A GLOBAL PROVIDER
FOR OFF-LINE SLAB-CASTER
MAINTENANCE

Shandong Steel awards

Danieli another 3-year
Global Service contract
for its slab casting plant
Danieli Service competence gains
unanimous approval from Shandong
Steel. Excellent maintenance
strengthens further cooperation. WORDS FROM OUR CUSTOMER with Shandong Steel and Laiwu Steel
in the past several years. 70% of SDRZ
Shandong I&S Rizhao placed another < I visited Danieli HQ 15 years ago, employees came from Laiwu Steel
order with Danieli for off–line main- and I was really impressed. Danieli and Jinan Steel, so most of them are
tenance of its #5 single-strand slab are developing very rapidly, especially impressed and familiar with Danieli.
caster, supplied by Danieli. This order in the fast-growing Chinese markets. The customers of CCM 1 and 2 are
follows the successful performance Danieli had a very close relationship very satisfied with the off–line main-
of slab caster maintenance for SDRZ tenance, not only maintenance and
casters #1 and #2, which have been personal quality but also site 6S man-
running for one year and six months, agement. That is why SDRZ selected
respectively. The contract is based Danieli, although the bidding price
on a €/ton concept, and provides for of Danieli exceeded our expectation.
complete maintenance of the entire Thus, we hope Danieli may continue to
strand-guidance system, including re- provide excellent services and develop
furbishing of segment rolls, all off–line more cooperation in the upcoming
maintenance activities for the bender SDRZ project phase II >
segment, bow segments, straightener
MR. CHEN XIANGYANG,
segment and horizontal segments, to
ensure smooth and productive equip- Party Secretary
ment performance. of Shandong Steel Rizhao Base
The “Ultra High Performance” (UHP)
overlay technology and roll-cladding
materials developed by Danieli, focus-
ing on pitting-corrosion resistance and
thermal fatigue-cracking resistance
while ensuring best weldability, will be
applied to achieve high performances
and balance cost with production per-
formance. The contract will run for
three years and start after the reloca-
tion project.

Shandong Rizhao and Danieli teams after successful

conclusion of the meeting headed by Mr. Chen
Xiangyang (Shandong Rizhao Chairman), Mr. Brusini
Emanuele (Danieli Service EVP).

116
 CROSS PRODUCTS / SERVICE

Souvenir picture of the ceremony for CCM #1 off-line global

NISCO selected Danieli maintenance services new order. In the foreground the two
again for CCM #1 off- companies' top officers during the contract signing: Mr. Zhu
Ruirong, NISCO President (left side) and Mr. Brusini, Danieli
line Global Maintenance Service EVP (right side), are signing the contract.

Service
Slab caster off-line maintenance man-
agement and innovation.

Established in 1958, Nanjing Iron and

Steel Co. produces 10 Mtpy of flat and
long products.
NISCO and Danieli signed a new,
three–year contract for slab CCM #1
segment off-line global maintenance
service. This order means Danieli will
have provided constant global service
for more than 10 years.
Compared with before, the scope of
supply for the new order for CCM #1
is expanded with additional off–line
maintenance labor activity, segment
consumables, and segment frame
overhauling.
Starting in 2010, Danieli has per-
formed a “cost per ton” global supply
and refurbishment service of all caster
rolls in slab CCM #3 of the plate and
coil plant.
This continued in 2013 with the fur-
ther charge to supply and refurbish
all rolls supply and refurbish slab
CCM #1.
Through past years’ cooperation, the
client realized that stable quality/avail-
ability of spare rolls, reduced off–line
maintenance workloads, reduced pur-
chasing cost, higher communication
efficiency, and stronger technical sup-
port are some of the main benefits in
relying on Danieli service. |

117
DANEWS 184

3D drawing of DanOil oil–film bearing. Babbit welding machine installed at

Buttrio HQ, Italy.

118
 CROSS PRODUCTS / SERVICE

New customized solutions: conversions and upgrades

to bearings, seals, and locking configurations,
plus technical assistance

DANOIL® ADDED-VALUE OIL-FILM

BEARINGS FOR ROLLING MILLS

ing body also entails transforming the life (two to three times longer than
sleeve from Full Key (FK) to Semi standard life) thanks to the new materi-
Keyless (SK) design. This increases als used for the contact surfaces.
the load-bearing capacity of the bear- Significant testimonials to the per-
ing while reducing strip defects due formance of the seals have been
to Backup Rolls (BUR) during rolling given by Essar Steel and ArcelorMittal
(-75%) to a minimum, with consequent Termitau, which have declared their
increase in productivity. satisfaction after installing the first
Neither of these modifications require DanOil Seals and subsequently replac-
making changes to the existing equip- ing all the roll-neck seals for their roll-
ment. ing mills.
W I L L I A M TA M I
Product Engineer, Sales
DanOil Bearing Division
Sealing conversions Locking conversions
and upgrades
In the traditional configuration, the
anieli launched its By investing in research, Danieli has backup-roll chock is fastened to the roll
D DanOil products for the
oil-film bearing market
been able to develop a new Seal End
Plate (with all surfaces nitrided), new
body with a threaded locknut assembly.
This threaded assembly requires the
about 20 years ago, after the split roll neck seals (Danieli patent) and a use of an overhead crane, pin and wire
of Morgan Construction Co. into new roll-coolant seal (Danieli patent) rope wound around the circumference
Davy Engineering and MORGOIL to retain the oil within the bearing and of the lock nut for tightening and loos-
Bearings. Today, the oil-film bearing prevent infiltration of the coolant. ening.
technology has made giant steps for- The standard roll-neck seal rotates This method carries the risk of projec-
ward, and the major global players in with the roll and has garter springs and tiles due to pin failure and does not in-
the market still focus on these prod- internal stiffening to prevent it from dicate how much load is present during
ucts, which the experts refer to as “the being deformed by centrifugal forces fastening or loosening.
heart of the rolling stand”. when rotating at high speeds. One of the latest innovations that
For the cold rolling mills, careful selec- Danieli is bringing to the market to
tion of the correct grade of rubber com- solve the above-mentioned problems
Bearing conversions bined with PTFE lips has substantially is the mechanical lock, referred to as
and upgrades reduced heat hardening of conven- T-lock, which provides the same results
tional seals, which leads to premature as the hydraulic lock but is less inva-
It is possible to convert a bushing from failure. sive and costly.
hydrodynamic to hydrostatic while Nitreg hardening ensures a hard-wear- In fact, the T-lock fits the existing
maintaining a constant oil pressure in ing and heat-conducting seal-running backup roll perfectly, ensuring that the
the load area, thus reducing the friction surface that outperforms ceramic coat- sleeves and other components are in
coefficient between bushing and sleeve ings. the proper operating position, with a
(up to 0.001) and increasing the life- This new sealing system, which im- measurable locking pressure that is not
time and efficiency of the bushing. proves rolled product cleanliness due possible with the traditional method.
A complete conversion of the bear- to reduced oil leakage, increases seal At the same time, the use of a cable

119
DANEWS 184

DANOIL® ADDED-VALUE pete with the quality of new mills and

OIL-FILM BEARINGS remain highly cost effective. In recent
FOR ROLLING MILLS cases, mills have recovered the cost of
the upgrade within a year through in-
creased productivity and more efficient
utilization of mill equipment.
With appropriate back-up roll bearing
and crane is eliminated, thus guaran-
upgrades, mills can increase capacity,
teeing operator safety during the as-
allowing them to roll products that had
sembly and disassembly operations in
not been previously considered.
the workshop.
This conversion upgrades all aspects of
This innovative system, installed and
the bearing. However, if it is not fea-
tested at ArcelorMittal Dunkerque and
sible to perform a full upgrade, individ-
Metinvest Valsider, has given excellent
ual areas can be upgraded separately. |
results in terms of HSM performance,
with an investment cost that is 40%
lower than a Hydraulic Locking Unit
(HLU). The T-Lock system installed
at ArcelorMittal Dunkerque
(France).

On-site technical assistance

Danieli Service is able to supply com-

plete assistance service for any plant,
helping the customer to understand
what the problems are and at the same
time propose pinpointed solutions.
A specific procedure also has been DanOil modern sealing
established for DanOil, by which the system respects the existing
sensitive data of the plant is first mea- solution.
sured, and if necessary, a second, spe-
cific laser measurement is performed
by our technicians.
At the end of the procedure, a techni-
cal report is drawn up together with a
specific plan of action intended to limit
costs for the customer, while running
the plant at its maximum capacity.
In recent years, Danieli has obtained
various results with this method,
transferring the assembly/disassembly
procedures and oil-film bearing mainte- Recent advisory services/
nance practices to existing plants, such training on oil-film bearing
as Tata UK, USS Posco in the USA, maintenance practices in
Egypt.
NSC/JFE in Japan, SSAB Hameenlina
in Finland and EZZ Flat Steel in Egypt.

Advantages of bearing
upgrades

Upgrades, strategically planned by the

mill operator and equipment supplier,
can extend the life of a mill far into the
future.
Conversions such as the ones pre-
sented here help older mills to com-

120
 CROSS PRODUCTS / SERVICE

Alfa Acciai and Danieli Service implemented new stands, auxiliaries,

and changing equipment, and improved overall mill performance

REVAMPED ROUGHING MILL

SAVES TIME AND COSTS FOR ADS
— E D I T E D B Y G I O VA N N I D E L O R E N Z O / Consultant, Danieli Service

nother successful revamping

A has been completed by Alfa
Acciai Group and Danieli
Service at Acciaieria di Sicilia (ADS),
after previous ones carried out togeth-
er by the same teams. In this case, the
scope of supply covered six new GCC
5543 roughing mill stands along with
auxiliary structures, a roll–changing
robot, and tilting mechanism.
The first billet was rolled successfully
just 14 months after the contract sign-
ing, while the onsite intervention lasted
only 35 days, two days short of the al-
ready tight schedule.

Key advantages
— Single stand change
is reduced from 4 hours In this short time, thanks to the syner- Souvenir picture of the team involved
to 30 minutes gy established by the teams from ADS, in the successful revamping of six new
Danieli Service and the electrical sub- GCC roughing mill stands.
— Equipment replacement contractor AIC, the existing equipment
reduced from 1 day to 1 hour was dismantled, old foundations from
furnace exit to shear nr.1 were rebuilt, —Staffing for the mill is reduced, from
electro-mechanical assemblies were 4 to 2 operators, as is the time for
— Significantly reduced
completed, the cold / hot start was car- maintenance and consumption of spare
stand changes frequency ried out, and production restarted. parts.
thak to multi-groove rollers —Lower roll wear due to roller–driven
implementation Several advantages have been estab- guides, extended service life, and sig-
lished at ADS by the new roughing mill: nificantly reduced plant shut-downs,
— Mill staffing reduced —Time for a single stand change is re- along with a decreased percentage of
from 4 to 2 operators duced from 4 hours to 30 minutes; and spares in inventory. Conveyor replace-
rollers and equipment replacement are ment needed every 8-10 hours has
— Conveyor replacement reduced from 1 day to 1 hour, thanks been improved to over 2 months fol-
at 2+ months, compared to technologically advanced quick- lowing the revamp.
to previous 8-10 hours changeover systems. —Mill Utilization Factor improved,
—Multi-groove rollers in place of stoppages in the roughing sector break-
— Roughing sector break- mono-groove ones allow a significant downs lowered from 30% to 3% (or,
downs stoppages down reduction in the frequency of stand spanning 3–4 days prior to the interven-
from 30% to 3% changes. tion, but now lasting just few hours). |

121
DANEWS 184

DANIELI Orders
with a 2-week maximum
shutdown period per stage.

ORDERS FLAT

& STARTUPS
PRODUCTS NEW SLAB GRINDER
FOR POSCO, KOREA

NEWS Danieli Centro Maskin com-

missioned the new HGS300
slab grinding unit for Posco in
Korea. With a 250-kW motor,
the machine will output ca.
200,000 tpy in full-skin
DANIELI QSP-DUE grinding mode, with an aver-
FOR EVRAZ age 2 mm removal depth per
slab face. The equipped Cast-
Danieli will deliver Evraz Grind technology will allow
(Russia) a QSP-DUE (Danieli material processing at up to
Universal Endless) plant for 700 °C.
hot rolled coils production,
ranging from 0.80 to 16.0
mm thickness and 950 to NEW TATA STEEL SLAB
1,700 mm width, for a total INSPECTION AND
plus “Palmur” supersonic 2.5 Mtpy. The plant features CONDITIONING PLANT,
sidewall lances together with three rolling modes in one INDIA
ORDERS advanced automation. single line: coil-to-coil, semi-
endless and endless. A 310-t Danieli Centro Maskin was
twin-station LF and twin-tank tasked by Tata Steel with the
COOLING WTP REDESIGN VD will be provided too, along design, supply and commis-
FOR NUCOR GALLATIN with Danieli 3Q-based auto- sioning of a new and com-
mation systems. plete slab inspection and
A new water-treatment plant conditioning plant. It’ll fea-
will meet the requirements ture a 630-kW grinding power
for the expanded, modernized TSC MODERNIZATION and over 400,000 tpy in full
Danieli QSP meltshop and AT OMK, RUSSIA skin-grinding mode. It’ll be
thin-slab casting and rolling supplied in 2020 and start
plant, to produce 3.0 million OMK Vyksa contracted Dan- operations in Spring 2021.
Orders shtpy. In a reduced footprint, ieli to modernize a single-
IRONMAKING the WTP will serve new and strand, thin-slab caster sup-
existing equipment, with one plied by Danieli in 2005. In a STECKEL MILL UPGRADE
AND electrical cabin, and with the two-stage project, the caster AT NISCO
STEELMAKING same standard for mechani- metallurgical length will be
cal and electrical/instrumen- increased from 14.2 m to Nanjing I&S Co, China, se-
tal design. Commissioning is 17.3 m, the two extraction lected Danieli technologically
set for Q3 2020. modules will be replaced, and advanced HAGC Hydraulic
new caster technological Automatic Gauge Controllers
packages will enhance thin- to upgrade its 3,500-mm
FOUR PROCESS CRANES slab quality. Phase 1 will take Steckel mill located in Nan-
FOR NUCOR STEEL, USA place in August 2020, and jing, Jiangsu province. HAGC
FOUR NEW EAFS AT ONCE Phase 2 in August 2021. is a critical component used
BY GUANGDONG In February 2020, Nucor in flat product rolling mills to
JINSHENGLAN Steel awarded Danieli the or- perform on-line regulation of
der for four process cranes: NLMK PLC AND SCADA mill equipment, to achieve
Four 150-t zero-bucket UHP one charging crane, two SYSTEMS UPDATES rolled product thickness with-
EAFs with ECS for continuous teeming ones and a caster in tight target tolerances. It
scrap preheating and charg- crane. They’ll handle the en- NLMK, based in Russia, con- will allow NISCO to produce
ing will be installed in a new tire meltshop steel flow and tracted Danieli Automation to high product quality.
steel complex in Yunfu City, feature a four-motor arrange- upgrade both Level 1 and
Guangdong province, China. ment for horizontal move- Level 2 slab caster CCM-6
They will feature a “Diving ments to operate at nominal control systems, for caster HOT-STRIP MILL
Pool” asymmetric bottom conditions even in case of modernization with state-of- REVAMPING AT
shell, Q-REG+ electrode regu- failure. the-art Danieli solutions. Per- SHOUGANG JINGTANG
lation and a melt chemistry formed in two stages, the
package based on fixed oxy- project will start in October Shougang Jingtang ordered
gen- and carbon-injectors 2020 and end in Q4 2021, the refurbishing of hot-rolling

122
 ORDERS & STARTUPS

line 2250 in operation in HIGH-VOLUME REBAR 6-pass block, ensuring an

Tanghshan since 2008, for MILL AT TIBA STEEL 850 °C rolling temperature at
process and performance im-
Orders the block entry, with the
provements. The quick recon- LONG Tiba Steel, Egypt ordered a spooler line capable of
ditioning of mill stand geom- PRODUCTS Danieli mill to roll 150x150- 2.4-to-5-t coils, and bar
etry was performed by a tech- mm billets into quenched re- products ranging from 10 to
nical Danieli Service team in- bar products, 8- to 32-mm 25 mm dia. Start-up is ex-
volving special laser cladding dia., with Slit Rolling Tech- pected in Summer 2021.
and machining processes. It nology for 8- to 18-mm dia.
was the most efficient and rebar. Supplied equipment
economical solution to save includes a Danieli Centro HIGH-SPEED SHEARS
costs and improve the quality Combustion reheat furnace, FOR YONGFENG GROUP,
of the rolled strip. 18 housingless mill stands in CHINA
HOA PHAT ORDERS H/V configuration, QTB pro-
DANIELI NEW ROLLING cess-water quenching line, Shandong Laigang Yongfeng
FURNACE REVAMPING MILL IN VIETNAM cooling bed, bar counting/ Steel Corp. awarded Danieli
AT MARCEGAGLIA PLATES, bundling facilities and bundle the provision of two new high-
ITALY Danieli was awarded the con- collecting facilities. speed shears for the custom-
struction of a 1 Mtpy wire rod er’s relocation of two existing
Danieli Centro Combustion rolling mill for deployment at Danieli’s wire-rod lines. New
was selected by Marcegaglia Hoa Phat Dung Quat plant. RAIL/SECTION MILL HSS’s will allow for automatic
Plates, based in San Giorgio Fed by 12-m-long, 150-mm2 REVAMP FOR NTMK, head and tail cropping of
di Nogaro, to provide a push- billets, it’ll produce 5.5- to RUSSIA 5.0- to 20-mm bar and rod
er furnace’s revamping, for 16-mm dia plain wire rod, as products, with speeds up to
reduced maintenance costs well as D8- to D16-ribbed Evraz selected Danieli to re- 120 mps. Automation and
and NOX emissions. Danieli wire rods, in low-, medium- vamp the rail and section mill sensors packages will be de-
will provide new and integrat- and high-carbon grades. at NTMK Nizhniy Tagil, to livered too.
ed Level 1 and Level 2 auto- produce 950,000-tpy of rails,
mation systems. Its delivery beams, and other structurals.
is expected in December ACEROS GUATEMALA A new reversing breakdown RIVA CHOOSES
2020. ROLLING MILL UPGRADE mill will be followed by three HIPROFILE FOR
UFR Ultra Flexible Reversing CERVENO SITE
The long-products manufac- pre-finishing stands, and a
PLATE MILL AUTOMATION turer named Danieli to up- finishing universal stand, Riva Cerveno awarded Danieli
UPGRADE FOR grade the mill at Escuintla to working in continuous mode. Automation with another bar
MARCEGAGLIA, ITALY improve final product quality Working with pre-assembled mill HiPROFILE order, which
and increase productivity equipment and prefabricated will be installed after the re-
Danieli Automation will up- from 350,000 to 500,000 foundations, start-up is sizing block to cover both 33-
grade Marcegaglia’s 4-high tpy. Danieli will modify the planned during 2022. to-160 mm rounds and 120-
plate mill in San Giorgio di hot mill with bar slitting for mm squares. Installed in the
Nogaro; it’ll install a custom- rolling up to four strands; and early 2000s, the first HiPRO-
made solution comprised of add QTB quenching and tem- DANIELI TO SUPPLY FILE terminated operations in
both automation updates— pering, a dividing shear, bar PRE-BOX AT ESF, 2019, substituted by another
like new HiPAC, L1, L2 pro- counting and bundling, and GERMANY HiPROFILE to be used in Ri-
cess control systems, for bet- Sund Birsta automatic wire- va Cerveno’s new generation
ter yield—and mechanical tying machines. After installing a Hi-Profile mill.
ones, like new hydraulic cyl- sizing unit at ESF in Riesa,
inders to support screw-down Feralpi Group ordered Danieli
gears, for better speed and REAL STEEL TO OPERATE a new pre-box thermal treat- NEW HIPROFILE LITE
position accuracy. THE FASTEST BAR MILL ment unit for the wire-rod FOR CMC, ARIZONA
IN ASIA mill, modernizing the Group
plant thanks to much better CMC Steel chose Danieli Au-
To be installed in Pampanga, temperature setup for in-line tomation to supply a new
San Simon province, Philip- treatment of water. The new HiPROFILE Lite Laser gauge
pines, the new mill with in- pre-box will start up on Janu- for its Arizona facility. CMC
line quenching and self-tem- ary 2021. Arizona steel complex, the
pering will roll 150-mm first full MIDA plant installed
square billets weighing up to worldwide, produces rebars in
2,000 kg into 10 to 32 mm- BAR AND SPOOLER LINE endless mode. Danieli Auto-
dia deformed bars. UPGRADE FOR PITTINI mation’s laser-based technol-
Thanks to a finishing speed GROUP, ITALY ogy adoption represents the
up to 48 m/s onto the cooling best solution to improve pro-
bed for 10-mm-dia bars, it Danieli will revamp Pittini duction performance and
will be the fastest bar mill in Group’s Osoppo plant bar and quality. Start-up is planned in
Asia. spooler lines with a new February 2021.

123
DANEWS 184

DOUBLE HIPROFILE NEW GRINDERS FOR TRAFILERIE CARLO GNUTTI

SOLUTION FOR HENAN JIYUAN. CHINA Orders EXTRUSION PRESS
ACCIAIERIA VALSABBIA REVAMP, ITALY
Danieli Centro Maskin will NON-FERROUS
A double configuration of supply two NGS16 billet Danieli Breda will provide
HiPROFILE Lite gauges will grinding units to Henan Jiyu- Trafilerie Carlo Gnutti with an
be installed at Acciaierie Val- an, powered by 160-kW mo- overall remodeling of their ex-
sabbia to obtain 100% prod- tors, allowing for a 70- to isting 60 MN direct-type ex-
uct quality monitoring, to- 90,000 tpy output. Danieli trusion press at Chiari plant,
gether with a fast return of Automation will provide both to produce round and hexago-
the investment. electrical and automation nal aluminum bars with an
Valsabbia order is representa- systems; The units, controlled upgraded 70 MN force. Bre-
tive of a real, positive and from a remote pulpit room, DanExt automation and smart
long-lasting collaboration: are planned to be in full oper- 6-HIGH FINISHING MILL engineering solutions will be
this new order came after he ation by early 2021. FOR NORTHERN COPPER provided too. Production is
installation of two billet cast- INDUSTRY, CHINA expected to start in Q2 2021.
ing machines, also installed
by Danieli. EXISTING WTP UPDATE Danieli Fröhling will install a
FOR ACEROS DE new six-high, single-stand re-
GUATEMALA versing mill capable of rolling
TWO HIPROFILE LASER a wide product mix of copper
GAUGES FOR GERDAU Following rolling mill revamp- alloys, from soft, pure copper
MONROE, USA ing order, the customer or- to hard bronze. Plant start-up
dered the implementation of is expected by Q4 2021, and
Gerdau Monroe minimill plant the water treatment plant to it will roll strips starting from
is specialized in the produc- complete the project with one a 3.0 mm thickness, down to
tion of specialty steel grades single point of responsibility. 0.05 mm, with a 670 mm
for automotive and engi- The plant is designed to treat maximum width strip.
neered products. To gain and recycle all the contact
complete control of sizes and water coming from the mill
production tolerances, Danieli and quenching system. It fea- 18-HIGH COPPER COLD
Automation will supply two tures the patented DanFilters, MILL ORDER OVERHAUL
HiPROFILE PR84200/F that will reduce the WTP
gauges, the most reliable so- footprint. Mill upgrade for F-Magnesium
lution for monitoring both the Industry Co. Ltd in Taiwan.
dimensional tolerance and The Z-high mill insert will be
the quality of finished prod- fully refurbished in Danieli
uct. Start-up will happen in Germany workshop, and to-
mid-2021. gether with a product related
re-tuning of the technological
controls, it shall serve the
A NEW HIPROFILE FOR market especially for foil prod-
NUCOR JEWETT, USA ucts down to 0.05 mm with
enhanced thickness and flat-
Nucor Jewett, a structural ness performance.
mill located in Texas, placed
an order to Danieli Automa-
tion for one HiPROFILE Laser ADVANCED PLANT
profile gauge. The system, FOR COPPER-ROD
featuring ultra-high-speed la- COILS
ser heads capable of acquir-
ing several hundred profiles Danieli Centro Maskin has an
per second, allows real-time order from Rain Floods Trad-
3D representation of the bars, ing in Iraq to design, supply
accurate dimensional control and commission a plant to
and integrated surface defect produce 25,000 tpy of Fire-
detection during rolling. Refined, High-Conductivity
Start-up is scheduled for Feb- (FRHC) copper rod in coils, at
ruary 2021. Erbil, Iraq. Partner La Farga
Yourcoppersolutions will pro-
vide an 80-t capacity fur-
nace, while Danieli will sup-
ply a continuous caster, two-
stand rolling mill, and a coiler
for 8-mm rods.

124
 ORDERS & STARTUPS

QUICK STARTUP erage removal depth of 2 mm

STARTUPS OF Q-REG® AT GERDAU,

BRAZIL
Startups per slab face.
FLAT
Two weeks and only one spe- PRODUCTS MULTI-CASSETTE
cialist to achieve the FAC for LEVELING AT SHANDONG
the start-up of new the Q- RIZHAO, CHINA
REG® (Electrodes Regulation
System) for the ladle furnace Shandong Rizhao Iron &
in Divinopolis plant (MG). Co- Steel started up EVO/5 multi-
vid-19 did not slow down the cassette hot and cold levelers
activities, communication after relocating steel produc-
and I/O tests have been exe- tion from Jinan to Rizhao.
cuted using remote connec- THYSSENKRUPP AST Danieli supplied mechanical
Startups tion to safeguard as much as NEW STRAND STIRRING components, Danieli Automa-
IRONMAKING possible everyone’s health SYSTEM, ITALY tion L1 and L2, and major
during the commissioning. electrical devices. From hot
AND Contracted in 2017, Danieli start-up April 1 to early De-
STEELMAKING designed, manufactured and cember 2019, the hot leveler
HOT BLAST STOVE 47 installed a new strand stirring processed nearly 500,000
FOR SSAB OXELOSUND, system at ThyssenKrupp Ac- tons of plates, including high-
SWEDEN ciai Speciali Terni, consisting strength micro-alloyed grades
of two pairs of In-Roll EMS cooled at low temperature.
The new Hot blast stove 47 positioned face to face, in-
for Blast Furnace #4 has creasing the stirring area
passed its performance ac- while reducing transversal FIRST COIL ROLLED
CONCLUDED WTP ceptance test in June 2019. cracks on the slabs. Power ON COLD MILL
COMMISSIONING AT In an industry first, the vessel consumption was reduced by AT WAELZHOLZ NEW
NUCOR SEDALIA, USA shell was erected as a single at least 50% compared to MATERIALS, CHINA
piece. The hot blast stove is box-type stirring systems.
Commissioning for Nucor equipped with an improved Wälzholz relied on Danieli to
Steel Sedalia minimill water burner design for reduced expand production of high-
treatment plant is complete. emissions and improved com- NEW HOA PHAT QSP performance steel strip. The
To expedite construction and bustion gas and air mixing COMPLEX FOR FLAT first coil was rolled on the
installation, WTP components performance. PRODUCTS, VIETNAM new 4-high Danieli Fröhling
were assembled at Danieli mill installed in Taicang, Chi-
workshop, and pack-age-type The Hoa Phat’s Danieli QSP na. The mill can roll a wide
cooling towers were selected. SEVERSTAL SUBLANCE complex started up with the product mix of special steel
Danieli patented DanFilters SYSTEM REMOTE 1st caster line, and the first grades at a maximum strip
were chosen for their high fil- COMMISSIONING, RUSSIA coil was successfully rolled width of 670 mm. It can also
tration speed, while Danieli on May 2. Hot commissioning be operated in skin-pass
Zero-Scale Separator simpli- In 2019, Severstal Chere- will be completed beginning mode.
fied civil works needed. povets awarded Danieli Corus in 2021. Initial hot rolled
a contract for three Sublance coils production target will be
systems for their three 350-t 3.0-Mtpy, with a future up-
LADLE FURNACE STARTUP converters at the Cherepovets grade to 4.0-Mtpy. Strip
AT BSRM, BANGLADESH integrated steel plant. Cold thickness ranges from 1.5 to
and hot commissioning of the 12.0 mm, with widths be-
Danieli supplied Mirsarai first system were executed re- tween 900- and 1,500-mm.
plant with a single-roof, 55 t motely for the first time in
ladle furnace. Thanks to it, the global steel industry and
BSRM billet production ca- the system was recently put CASTGRIND FOR SS SLABS
pacity is extended by into operation. AT POSCO, KOREA
480,000 tpy. Notable
achievements include heating Danieli Centro Maskin com-
rate > 4.5 °C/min, energy missioned a HGS300 unit for
consumption < 0.52 surface-grinding stainless
kWh/°C/t, electrode consump- steel slabs at Pohang Works,
tion < 10 g/kWh, and a < 40 Korea, equipped with a 250-
min. delivery time. kW motor to process 140- to
220-mm thick slabs, up to
1.65 m wide and 10.5m
long. It will process approxi-
mately 200,000 tpy in full
skin-grinding mode at an av-

125
DANEWS 184

JSW MONNET CASTER ser-based bar diameters mea- start-up. Key equipment in-
Startups REVAMPING, INDIA suring, as well as the work-
shop machinery.
cludes #4 SHS housingless
stands, #2 six-passes rolling
LONG Danieli was contracted by blocks and #2 additional
PRODUCTS JSW Monnet to update their SHS stands.
existing 6-strands billet cast- NEW HIPROFILE SIZING Provisional Acceptance was
er in Raigarh (India), original- DEVICE INSTALLED AT ESF, granted, and commissioning
ly supplied by Danieli in GERMANY is proceeding towards plant
2012. The upgrade allowed Final Acceptance.
to accommodate new sections A new HiPROFILE was in-
and 14-m long billets. Target stalled on January 2020 at
productivity was reached sev- ESF, Germany, and final ac- OMK COMMISSIONING
en days after hot commis- ceptance was quickly provid- IN PROGRESS AT VYKSA
REVAMPED BILLET CASTER sioning. ed on April 2020. The plant PLANT, RUSSIA
AT ACINDAR, ARGENTINA can roll 5.5 to 20 mm diame-
ter both plain and deformed Commissioning for the new,
The 6 HY-Power oscillating HIGRIND FOR BILLET wire-rod into 2,400 kg coils, modern, OCTG welded pipes
benches, for AM Acindar bil- SURFACES OPERATING while maintaining rolling finishing complex is in the
let caster revamping, have AT MASTEEL, CHINA speeds of to more than 115 last phase. Its 3 lines are
been installed and the caster m/s. producing pipes with a 60– to
started up successfully. The Danieli Centro Maskin sup- 177.8–mm diameter: the
CCM casts 120x120 and plied and started a new billet heat treatment line produc-
160x160 square sections bil- grinder at Ma’anshan Iron & SHANXI TAIGANG ROD tion rate is up to 180 pieces/
lets. Among the results, sur- Steel, a 250-kW HGS200 MILL MODERNIZATION hour; threading line capacity
face quality improvements for unit with a variable-angle sys- COMPLETED, CHINA is up to 135,000 tpy, while
low- and high grades, were tem to grind from 45 to 90 quality assurance and bevel-
reached, as well as up to deg; an Hi-Grind system to Modernization program for ing line capacity is up to
33% casting speed increase ensure accurate removal con- two-stage, special steel BWR 165,000 tpy.
for low-carbon steel grades. trol in the range of +/-10% of mill at Shanxi Taigang is now
the nominal grinding depth; in full operation, capable of 5-
and a Danieli Automation to 25-mm wire rod and 6- to HIPROFILE INSTALLATION
NEW MASTEEL BEAM electrical and automation 120-mm straight bars on cool- AT ARCELORMITTAL
BLANK CCM, CHINA platform for full process con- ing bed. Rolled stock alloys PLANT, BRAZIL
trol. can now be rolled at up to 75
In March 2018 Danieli was m/s speeds, while overall pro- A 4-laser heads HiPROFILE
awarded by MaSteel, China, duction increased to 200,000 PR84200 gauge, performing
the contract for the new SURFACE-GRINDING AT tpy. accurate profile measurement
beam blank CCM. In order to MASTEEL, CHINA of large beams and channels
match meltshop productivity, up to 155 mm, was recently
CCM can go as high as 97 t/h Danieli Centro Maskin sup- 500-KTPY TUE MINH installed and commissioned
per strand. On April 21st, plied and started up a new, REBAR AND WIRE ROD at Arcelor Mittal Sul Flumi-
2020, it cast the largest 250-kW, HGS200 billet grind- MILL FAC nense plant, Barra Mansa,
beam blank section in the er at Masteel. Equipped with Brazil. Difficulties due to
world, coming at a variable-angle system, it’ll The commissioning for a new, pandemic emergency did not
1300x510x140 mm. produce up to 12-m-long, high-speed bar and wire rod slow down the start-up. Com-
140- to 280 mm billets, for a mill at Tue Minh Steel in munication and full cold tests
total output of more than Vietnam was successfully have been executed in just
MAANSHAN MAGANG 50,000 tpy of billets in full- completed by Danieli. The 8h stoppage
BLOOM CASTER, CHINA skin grinding mode. supply includes a Danieli Au-
tomation induction furnace
On April 15th, 2020, Maan- and a 10-pass Multidrive, ROLLING MILL #2
shan Magang CC5 bloom LESEGNO RIVA ACCIAIO, twist-free finishing block, PROCESS AUTOMATION
caster in China, provided by ITALY: SBQ MILL feeding both the bar and wire UPGRADE FOR GERDAU,
Danieli, was successfully MODERNIZATION rod lines. BRASIL
commissioned. The 5-strand,
14-m radius continuous cast- A bar mill modernization at Danieli Automation recently
ing machine will initially pro- Lesegno Riva Acciaio was YUNNAN QUJING upgraded Gerdau Pindamon-
duce 250x250- and completed at the beginning CHENGGANG HTC LINE hangaba’s rolling mill #2 pro-
380x450-mm sections. Soft/ of 2020. To be fed with 160- STARTUP, CHINA cess control system, that was
Hard reduction is controlled mm, square steel billets, the focused on upgrading the
by Danieli Automation Q- bar mill upgrade includes a Designed to produce 8–to–40 speed control for the existing
SOFT model paired with L1 crank shear and a four-stand mm rebar and 14–to–40 mm rolling mill and improving
and L2 systems finishing mill, together with a plain bar, Yunnan’s new HTC process control for the Garrett
Compact Sizing Unit, plus a line exceeded contractual val- coiling lines. Moreover, for an
Hi-profile unit for in-line, la- ues after two weeks from hot effective traceability of the

126
 ORDERS & STARTUPS

product, the outgoing materi- cooling are performed in con-

als from reheating furnace is
followed by a new precise
Startups tinuous mode, while keeping
fuel and power consumption
tracking system.
NON-FERROUS below the specified limit.

PT TUNGGAL NEW WIRE PROFILGRUPPEN

ROD LINE, INDONESIA EXTRUSION PRESS
STARTUP, SWEDEN
The commissioning for a new
high-speed wire rod line at Based in Åseda, Sweden,
PT Tunggal was successfully ProfilGruppen awarded Dan-
completed by Danieli. The ieli Breda an order for a
450,000 tpy mill is now ca- DANIELI PROVIDED FLEET 28MN front loading press;
pable to produce 4.5- to-22- OF CRANES TO CODELCO, among its features: 10.5 sec-
mm smooth wire and 6-to-13 CHILE onds from extrusion end to
quenched rebar, through a reaching 100 bar pressure in
semi-multi-drive 10-pass fast Codelco awarded Danieli the the main cylinder, 30 sec-
finishing block, and new gen- supply of three teeming onds for die change, variable
eration OFB LLH, at up to cranes. Provided cranes have frequency drive for energy
105 m/s speeds. a 100/30(45)/30(45) ton ca- savings optimization, HMI us-
pacity and span 18 m; they’ll er-friendly user interface.
be controlled from a remote
NEW INTEGRATED pulpit with operators being
FORGING PLANT supported by multiple NEW BRASS EXTRUSION
AT ZMZ, RUSSIA screens and cameras. The LINE FOR POONGSAN,
last crane was accepted by CHINA
A new forging complex, the client on November
equipped with a 25 MN 2019. Acceptance tests took place
open-die forge, two integrated for a new, 36 MN indirect ex-
manipulators and the Dan- trusion press for brass- and
Forge automation system, ALUMINUM copper-alloy products, award-
was supplied by Danieli Bre- LABORATORY MILL ed to Danieli by Poongsan. A
da to Zlatoust. Thanks to the STARTUP AT RUSAL coiler system comprised of
new plant, it’ll be possible to three automatic, self-center-
produce 100-800 mm-diam- Rusal’s technology center be- ing coilers was provided to
eter parts with length up to gan operation with the new avoid squashing effect. A
10 m. Danieli Fröhling combined graphite-free cooling bed and
hot/cold plate mill. The new ESED 4.0 systems ensure
mill will allow researchers to sustainability. Final Accep-
NEW CEMTAS MULTILINE perform and accelerate the tance Test is ongoing.
ROLLER HEARTH development of new alumini-
FURNACE, TURKEY um alloys and processes in
the most comprehensive, effi- FLEXIBLE HOMOGENIZING
Danieli Olivotto Ferrè sup- cient and economical way, FURNACE FOR RUSAL,
plied a new heat-treatment enabling a low-risk imple- RUSSIA
line for automotive bars to mentation of the newly devel-
Çemtas, in Turkey. Based on oped process knowledge. Danieli Olivotto Ferrè sup-
a new concept of multiline, plied JSC Rusal Krasnoyarsk
inclined and shaped rolls, it Aluminum R&D center with
will allow for both hardening ALRO-SLATINA’S an homogenizing system for
and tempering of alloyed ALUMINUM SLAB billets and slabs. A movable,
steel bars with diameters of PRODUCTION, ROMANIA electrical furnace is attached
15-100 mm for an up to to a wheeled mechanism,
30,000 tpy output. After smooth commissioning with two fixed bases and a
and providing Final Accep- movable cooling system. It
tance, with an overall output treats squares or rounds in all
up to 24,000 tons/year, Alro- alloys, 300x700 mm up to
Slatina’s plant has put Dan- 800x3200 mm, from 1,000
ieli Olivotto Ferrè’s homoge- to 6,800 mm long.
nizing furnaces and cooling
chamber into operation, for
treating 500x1,650-mm, up-
to-8-m-long, aluminum alloy
slabs. Heating, soaking and

127
DANEWS 184

DANIELI
THE
RELIABLE
INNOVATIVE
PARTNER
TO BE
FRONT
RUNNERS

Danieli Headquarters Danieli Worldwide

Via Nazionale, 41 info@germany.danieli.com mh@morgardshammar.se info@turkey.danieli.com infodcs@china.danieli.com info@japan.danieli.com

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128
[The new Danieli advertising campaign] [The new Danieli advertising campaign]

TWENTY DANIELI TECHNOLOGY ANSWERS TWENTY DANIELI TECHNOLOGY ANSWERS

TO BE A STEP AHEAD TO BE A STEP AHEAD

Danieli
03 Danieli
10

ANSWER

ANSWER
Answers Answers
to be to be
a step a step
ahead ahead

Danieli DIGI&MET Danieli Turboflo+OSRT

benchmark technology benchmark technology
Efficient, quality pickling
and strip cold–rolling

An Intelligent Plant is a manufacturing organization The coupled Pickling Line and Tandem Mill installed at
strongly supported by digital assets (systems, sensors, Yildiz Demir Çelik, Turkey, is the most advanced PLTCM,
equipment, etc.) which are fully integrated for the best and allowing unmatched ease-of-operation and product quality.
most efficient synergy between humans and machines.
The Turboflo® pickling line with energy-saving patented
Processes are automatically and autonomously improved, technology and preceded by a powerful scale breaker
and decision-making supported by data and statistics. improves efficiency and flexibility.
3QPulpit is Danieli Automation’s innovative and proactive
pulpit for a no-man-on-the-floor approach. The Danieli Wean United 6-high tandem mill features
original Danieli OSRT control for superior strip flatness and
From one 3QPulpit the whole production line or even Danieli Automation mathematical models.
multiple lines can be safely and efficiently controlled by a Final strip thickness of 0.20 mm and widths up to 1,550
few operators. 3QPulpit enriches, simplifies and empowers mm are achieved for DP600, DP1000, IF and HSLA
the operators’ experience, providing the right information at automotive products.
the right time by collecting Big Data directly from the plant,
with 360° video monitoring so operators can safely navigate Ultra-low hysteresis HAGC, X-Dry for 20x greater strip
dangerous or inaccessible areas, even analyzing past drying capacity, and D-Rec automatic eccentricity
events. Events requiring user interaction are conveniently compensation algorithm are featured too.
Twenty 09. Quality slab casters proposed as questions directly on the Operator Assistant. Strip thickness tolerance down to ± 0.6%, head/tail off-
Danieli answers 10. Pickling and cold mills gauge length lower than four meters, and strip flatness less
Twenty 09. Quality slab casters
to be a step ahead 11. Galvanizing / Air knives The result is a sustainable plant where Key Performance Danieli answers 10. Pickling and cold mills than 6IU are achieved.
12. Billet casters Indicators are measured, energy consumption is optimized, to be a step ahead 11. Galvanizing / Air knives
01. Sustainability 13. Billet welders 12. Billet casters One week after commissioning the newly suplied PLTCM
02. CO2 reduction 14. Wirerod mills
and quality is monitored and adjusted in order to produce
more with less. 01. Sustainability 13. Billet welders already was producing at more than 60% nominal capacity,
03. 4.0 intelligent plant 15. Rail and section mills 02. CO2 reduction 14. Wirerod mills
danieli.com 04. MIDA ECR 16. The Drawer sizing block 03. 4.0 intelligent plant 15. Rail and section mills
and after 2 weeks 20,000 tons were produced in first
05. QSP DUE 17. Reheating systems 04. MIDA ECR 16. The Drawer sizing block quality, for almost all contractual steel grades.
06. Digimelter 18. Seamless tubes 05. QSP DUE 17. Reheating systems
07. Energiron DRI 19. Extrusion lines 06. Digimelter 18. Seamless tubes
08. Long-life BF 20. Aluminium mills 07. Energiron DRI 19. Extrusion lines
08. Long-life BF 20. Aluminium mills

danieli.com

You can learn about these winning 01. Sustainability

02. CO2 reduction
11. Galvanizing / Air knives
12. Billet casters You can learn about these winning 01. Sustainability
02. CO2 reduction
11. Galvanizing / Air knives
12. Billet casters
technology solutions from 03. 4.0 intelligent plant
04. MIDA ECR
13. Billet welders
14. Wirerod mills technology solutions from 03. 4.0 intelligent plant
04. MIDA ECR
13. Billet welders
14. Wirerod mills
the advertising pages published 05. QSP DUE
06. Digimelter
15. Rail and section mills
16. The Drawer sizing block the advertising pages published 05. QSP DUE
06. Digimelter
15. Rail and section mills
16. The Drawer sizing block
in the international steel and 07. Energiron DRI
08. Long-life BF
17. Reheating systems
18. Seamless tubes in the international steel and 07. Energiron DRI
08. Long-life BF
17. Reheating systems
18. Seamless tubes
nonferrous metals magazines. 09. Quality slab casters
10. Pickling and cold mills
19. Extrusion lines
20. Aluminium mills nonferrous metals magazines. 09. Quality slab casters
10. Pickling and cold mills
19. Extrusion lines
20. Aluminium mills

DANIELI.COM DANIELI.COM
 IN THIS ISSUE: DANIELI NEWS FOR THE TRUE GREEN METAL INSERT

Danieli is steadily evolving to usher the customers into a new era: breakthrough technologies
to preserve the environment. Renewable sources, H-MIDA, QSP-DUE are just some of the
concepts behind Danieli’s push to be a step ahead in tools for a greener future.

DaNews 184 SEPTEMBER 2020 Danieli Group

DANIELI NEWS
N.184 SEPTEMBER 2020
DANIELI GROUP

DaNews 184

A STEP AHEAD
TECHNOLOGY
TO HIT RECORDS
Jumbo size beam blank cast.
119.6 m/s 6-mm wirerod
average production speed.
Greenlit 3.5-Mtpy QSP
thin slab casting
and rolling commissioning.
Excellence in thick slab caster
to produce ULC
and IT steel grades.
DANIELI A step ahead technology to hit records danieli.com