• Annual production capacity to increase to four million metric tons of slabs
• Project includes 2 strand slab Caster, Twin position ladle furnace, alloying station and dedusting system
• Expanded product portfolio
• Cross-section heat-pacing solution to coordinate steel production with casting operation
• Reduction of dust content in cleaned gas

Primetals Technologies has received an order from Ukrainian steel producer PJSC “Ilyich Iron and Steel Works of Mariupol” to supply a two-strand continuous slab caster, a twin ladle furnace with an alloying station, and the associated dedusting system. The previous orders for the basic and detail engineering, received in 2014 and 2015, have already been successfully executed by Primetals Technologies.The two-strand caster CC4 is designed to produce 2.5 million metric tons of slabs per annum. This will increase MMKI’s annual production capacity to around four million metric tons, as well as enhancing and expanding its product portfolio to include, for example, HC, UHC and ULC steels. A level 3 heat-pacing solution will coordinate the steel production with the casting operation.

MMKI produces steel with three LD (BOF) converters. A new 150 metric ton twin ladle furnace from Primetals Technologies and the associated alloying station will be used to help set the desired steel grades and the correct casting temperature. A transformer with a rated power of 28 MVA will provide the electrical energy for the ladle furnace, enabling a heating rate of 4.5 °C per minute. Primetals Technologies designed a dedusting system to clean the off gases from the ladle metallurgy facility. When implemented, the project will allow to improve the environmental situation in the city of Mariupol, where MMKI is located. After the commissioning of the new equipment, the ingot casting area will be taken out of operation and the blooming will be shut down. The dedusting system will reduce the dust content in the off gases to a level of 12 mg/m³ (maximum), whereas the Ukrainian standards require up to 50 mg/m³ and the European standards up to 30 mg/m³.

The equipment order for the continuous slab caster covers all the installations from the ladle turret and the tundish car through to the exit zone with its weighing, torch cutting, marking and deburring machines. The caster from Primetals Technologies will have a machine radius of nine meters and a metallurgical length of 29.8 meters. It will cast slabs with thicknesses of 170 and 250 millimeters in widths ranging from 900 to 1,550 millimeters. The maximum casting speed will be 2.2 meters per minute. It will process peritectic and peritectic alloyed steels, low, medium, high and ultra-high carbon grades, as well as medium-carbon alloyed steel. The caster will be equipped with automatic LevCon mold level control, a straight, cassette-type Smart Mold with the DynaWidth technology package to automatically adjust the width of the slab online, and the DynaFlex mold oscillator. The strand guide will be equipped with Smart Segments and I-Star rollers. DynaGap Soft Reduction, the Dynacs 3D secondary cooling model, and DynaJet nozzles will also be installed, making it possible for MMKI to produce a wide variety of high-quality grades with improved interior quality of the slabs.

MMKI is one of the largest iron and steel works in Ukraine. The company produces a wide range of flat products made of carbon, low-alloyed and alloyed steel grades for various applications. These include heavy plates for pipelines, shipbuilding, pressure vessels and the construction industry, as well as hot and cold rolled plates and coils. Primetals Technologies previously installed and started up the 1-strand slab caster CCM#3 at Mariupol, where it has been in operation since 2006.

Source: Primetals Technologies

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In order to increase the productivity on its Taoyuan bar mill, Tung Ho will install a new K-WELDING line to perform endless welding rolling.
The order for the new line was awarded in August 2016, with startup expected to take place in autumn 2017. With this plant upgrade Tung Ho will be the “first in the country” to operate in endless rolling mode on Rolling Mill #1, which has an average capacity of approximately 600,000 tpy in rebar products starting from 150-mm-square, 12-m-long billets.

Installed at the delivery side of the re-heating furnace, the K-WELDING is an in-line automatic continuous welding system for billets ensuring uninterrupted production of long products.

The process substantially increases productivity, material yield and plant efficiency, while reducing production costs and maintaining homogeneous material quality throughout the whole endlessly-rolled stock.
Danieli’s Endless Rolling of billets features advanced Danieli Automation Level 2 controls, models and setup. The EWR process also constitutes the necessary upgrade to shift production of rebar primarily toward compact coils that – especially in tonnages from 3.5 to 5 t – are recording consistent increases in market demand. In this regard, Danieli offers an unparalleled experience by combining the EWR process with the K-SPOOL, Danieli’s compact coil spooling technology.

The K-WELDINGsystem to be supplied at Taoyuan is the fourth generation of Danieli welding machines since 1997. It will be the first to operate along with an induction furnace.

Tung Ho Steel is one of the most important structural steel producers in Taiwan. Originally known as “Tung Ho Hardware” it began with ship dismantling and selling steel, and in early 1962 it became the first H-beam producer in Taiwan.

Source: Danieli Group

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After having doubled their overall rolling, tempering and pickling capacity since 2011, Tat Metal, one of Turkey’s leading flat steel producers, has chosen CMI, with headquarters in Belgium, to supply their new, state-of-the-art hot-dip galvanizing line. The new line will allow the customer to increase its galvanizing capacity, in order to cater for a growing domestic steel market, but also to allow for increased exports to neighboring countries and Europe. The produced hot-dip galvanized steel is destined to be used to manufacture roll-formed shapes, steel structures for construction and components for automotive and “white goods”.

In order to support Tat Metal in its capacity expansion plans, CMI will supply a line, designed to galvanize 400,000 tons per year of steel strip, that will be installed in the customer’s steel works in Ere?li, Turkey. CMI will be in charge of the complete design of the line, the manufacture of some of the core machines, the supervision during erection and commissioning, as well as the coordination of all key subcontractors. Additionally the scope of supply includes some of the major components of the electrical and automation systems.

The line, aiming at a high level of operating efficiency and eco-friendliness, features all essential, high-quality core process technologies designed by CMI: Cleaning section, Vertical annealing furnace (incl. CMI’s L-Top math model and Blowstab®  jet cooling system), Air-Knife system and Zinc bath equipment, APC Blowstab® low vibration cooling system, Inline skin pass mill and Tension leveler, Chemical roll-coat post treatment, Exit shear.

But it also incorporates a number of innovative features. As such CMI’s vertical annealing furnace provides recuperative low NOx burners, and the patented Blowstab® jet cooling system. Furthermore, CMI’s high-quality air-knife system will provide next to the patented Blowstab® low vibration cooling system, modern features such as a closed loop pressure system, an automatic lip cleaner and no-touch edge baffles. All of these features will allow the CMI air knife to achieve high-quality surfaces, while keeping zinc consumption low, and have convinced the customer to additionally order the upgrade of its existing Galvanizing line number 1 with the CMI air-knife system and zinc bath equipment.

The line will be designed for strips in thicknesses ranging between 0.25 and 3.00 millimeters and widths of up to 1,300 millimeters. The strip will be galvanized at a process speed of 200 m/min, while in the entry and exit sections speeds of up to 270 m/min will be attained.

The project is scheduled to be completed in a record-breaking time frame by the end of 2017.

Source: cmi Group

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• Welded billets permit endless rolling with high product quality
• 3-6% boost in plant output and utilization levels
• First use of ERT-EBROS in China
• System will pay for itself within 18 months

Chinese steel producer Shandong Laigang Yongfeng Steel Corp. (Yongfeng Steel) has placed an order with Primetals Technologies to supply ERT-EBROS endless rolling technology for the company’s existing bar rolling mill in Qihe, Shandong province. The aim is to boost plant output and utilization levels by three to six percent. The system welds together billets intended for rolling, thus enabling a continuous rolling process with a consistently high product quality. The new ERT-EBROS plant is scheduled to commence operation in the second quarter of 2017 and will pay for itself within 18 months. It is the first system of its kind in China.

Yongfeng Steel is a subsidiary of Yongfeng Group Co., Ltd. and is one of the most important steel producers in Shandong province. Its principal products are ribbed steel and wire rod. In 2015, the company produced around four million metric tons of crude iron and steel products. Yongfeng Steel’s bar rolling mill has an annual production capacity of 1.2 million metric tons of steel rods. It processes billets with a square cross-section of 150×150 millimeters and produces reinforcement steel with diameters between 12 and 50 millimeters from low carbon and low alloy steel grades.

Primetals Technologies is responsible for project engineering and also assembly and commissioning supervision of the new equipment, and will be supplying the ERT-EBROS billet welding system, including a deburring station and equipment such as a roller table and a shear. The scope of supply also includes the fluid systems, the electrical equipment and automation system and also technology packages for control of welding.

The ERT-EBROS system welds consecutive billets together so that, once joined in this way, they can be processed in an endless rolling process. This increases output, cutting the time otherwise taken by two billets between rolling. Utilization of cooling bed capacity can be enhanced and production of customized coil weights is also possible. ERT-EBROS is installed between the reheating furnace and the first roll stand and uses a flash welding process with fast and intensive heating. This results in solid-state joining of the billets without the need for additional filler metal. A dynamic flash control system helps to control all the process parameters in real time and thus ensures high joint quality as well as reduced energy consumption and material loss.

After welding and head upsetting, joints are deburred on a self-cleaning deburring station. The deburring machine operates independently of the welding unit and so the cycle time is not increased. Active spatter protection protects the mechanical and electrical equipment from steel spatters. This is crucial for process quality, extends components’ useful lives and facilitates maintenance. The core of the electrical system is the integrated high-frequency transformers. These compact components are extremely reliable and can perform an indefinite number of welding operations without maintenance. Each transformer is equipped with diodes that convert the high-frequency square-wave voltage into a stable, extremely flat DC voltage. The square-wave voltage is generated by converters with which the current can be controlled ten times faster than with thyristor circuits. A stable voltage and short control times are essential for a stable and repeatable process flow.

EBROS is a registered trademark of Steel Plantech Co.

ERT-EBROS is a registered trademark of Primetals Technologies in some countries.

Source: Primetals Technologies

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