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Danieli GFG Alliance signing ceremony

Danieli Technology Partner for GFG Alliance

New structural and rail mill project in Australia

Danieli has struck a new partnership with GFG Alliance for the design and construction of a new high-tech rail and section mill at the Whyalla Steelworks.

The new 750,000-tpy structural and rail heavy section mill will be an environmentally friendly facility that will increase the Steelworks production capacity, reduce waste and enable GFG ’s Liberty Primary Steel to lift product capability and improve its competitive advantage.

The mill will be equipped with the RH2 system, the Danieli patented process for rail hardening that enhances mechanical properties of high-speed rails through multi-immersion steps into a quenchant.

The project will be executed in two phases. The first phase foresees Danieli to work in combination with AAR TEE Ferretti International for turnkey construction and auxiliaries, and the Liberty team to develop the engineering stage.

The second phase will consist of equipment design, manufacturing, supplying and commissioning to reach the goal of hot commissioning in the following 18 months.

The Australian government paid much attention to the project. The Prime Minister of Australia Scott Morrison, the Federal Leader of the Opposition Bill Shorten, the South Australian Premier Steven Marshall, and the Mayor of Whyalla City Clare McLaughlin attended the signing ceremony.

Source: Danieli


AST Terni, Thyssenkrupp Group, Chooses Danieli EAF Technological Packages

Aiming to lower electrodes consumption, AST Terni, part of ThyssenKrupp Group, recently awarded Danieli Centro Met with the order for two Q-Smartec dynamic EAF electrode cooling systems.

Q-Smartec is a proven technology installed on almost 30 plants worldwide, that applies dynamic and independent control of the cooling water flow during the EAF operating phase to achieve the most efficient electrode cooling. This allows a drastic reduction of electrodes consumption related to air oxidation, up to 15% compared to conventional electrode cooling systems.

Considering the actual cost of electrodes a typical ROI is between two and six months, depending on production capacities.

With a production capacity of 1 Mtpy, Italian steelmaker AST Terni is a world leader in the production of stainless steel flat products in all sizes and finishes for a wide variety of applications.

Source: Danieli


Nucor & Danieli

Danieli QSP® – Quality Strip Production to Upgrade Nucor Steel Gallatin

The partnership of Nucor and Danieli teams will bring the Gallatin casting and rolling plant to the next level of high-quality production and competitiveness. This is the first time that a classical compact thin slab casting and rolling plant is fully reconfigured into an ultra-modern QSP® (Quality Strip Production) plant.

Both Nucor and Danieli teams are committed to set a new benchmark in Casting and Rolling Technology. Formerly known as the Gallatin Steel Company, the thin slab rolling plant located in Ghent, KY has a name plate capacity of 1.6 million shTPY of hot rolled coils having a thickness range from 1.4 to 12.7 mm, widths up to 1,625 mm and maximum coil weight of 35 shTon.

The existing plant operates a 185 t twin shell DC EAF, a single LMF, a vertical caster, 206 m tunnel furnace, a six-stand close-coupled rolling mill, traditional laminar cooling and one down coiler. The current capabilities of the steel plant are mostly structural steel, micro-alloyed grades and thin line pipe grades. Like similar compact plants, Gallatin was originally designed for doubling the annual capacity by means of a second meltshop, second vertical caster and tunnel furnace connected by a swivel ferry system to the in-line HSM.

The new equipment was originally meant to be a copy of the existing one. In October 2014, Nucor became the owner of the Gallatin Steel Company and has recently approved an investment to advance the technological capabilities and competitiveness of the Nucor Steel Gallatin Sheet Mill. Danieli is the selected technology supplier for the complete equipment and automation system, from raw materials to hot rolled coil.

In full partnership spirit, the Nucor and Danieli team of specialists agreed to re-engineer the plant by changing the original concept into an advanced QSP® plant having improved thermomechanical rolling capabilities thereby expanding production of AHSS grades, API line pipe steel grades and a number of other value added grades.

The revamped plant includes a high performance DC EAF and Twin LMF, and future provision for vacuum degassing. Being equipped with state of the art technology, the new meltshop will make use of the most recent process management tools, including Q-MELT, which is a key aspect to optimizing the transformation costs. After the upgrade, the complete production will be delivered by a single strand vertical curved caster having a total capacity of up to 3.0 million shTPY. The new caster represents the 5th generation of Danieli high production slab casting machines.

The slab will be delivered to the rolling mill by a new tunnel furnace via a swivel-type ferry system. The layout allows for the installation of the new caster and first portion of the tunnel furnace and swivel system without affecting the mill’s production. Furthermore, two new roughing mills will be added to expand rolling capabilities. The six-stands finishing mill will be retained but will be widened and upgraded with new interstand guides, loopers and new bending and shifting system. This will enable rolling strips as wide as 1,870 mm.

Source: Danieli

MEPS Expects Global Steel Production to Increase by 4.6 Percent in 2018


Danieli Steelmaking

Chinese Steelmakers Prefer Danieli Casting Technology for Quality and Productivity

Two more orders from Valin Xiangtan and Hengyang Valin Steel Tube

Following recent orders from Maanshan Iron & Steel for a new bloom caster and Huaigang Special Steel for a caster upgrade with the Q-SOFT technological package, another two Chinese top steel producers, Valin Xiangtan and Hengyang Valin Steel Tube, chose Danieli casting technology to improve their steelmaking plants.

Valin Xiangtan awarded Danieli with the order for a new bloom caster to be installed in their Hunan steelmaking facility. It will be a 14-m radius, 5-strand machine for 280×280-mm and 350×430-mm blooms in a variety of special carbon steel grades, from low carbon up to high carbon, such as bearing steel. The caster will be equipped with two electro-magnetic stirring systems, soft and hard reduction packages, and run by Danieli Automation L1 and L2 systems. The Liquid Pool Control (LPC) system will provide accurate and balanced secondary cooling, with controlled stirring and reduction processes for each type of steel produced.

Hengyang Valin Steel Tube ordered “Eco Power Moulds” to increase caster productivity.

Eco Power Mould is the latest evolution of Danieli Power Mould technology which allows fast casting thanks a highly efficient thermal exchange.

The installation of this revolutionary mould will allow Hengyang Valin to enlarge the casting section and increase productivity without adding an additional strand.

Further, this solution will allow Hengyang Valin to incur lower CapEx and a short shutdown.

The revamping project also will include the supply of spiral-design, secondary cooling system for more uniform and gentle heat removal, and the Danieli Automation Q-Mould package to monitor the status of the mould and oscillation to continue guaranteeing top-quality cast blooms.

Source: Danieli

MEPS Expects Global Steel Production to Increase by 4.6 Percent in 2018


Acciaierie Venete relies on Danieli for its new ultra-modern SBQ mill

Acciaierie Venete has chosen Danieli technology again for its new mill located in Padua, Italy to produce SBQ round bars from 18 to 82.5 mm, and in the future flats and hexagons from 30 to 60 mm.

The rolling mill, made of heavy-duty horizontal/vertical stands, is characterized by a drawing/rolling block to produce bars with high dimensional tolerances of 1/8 EN 10060:2003. Featuring four-roll technology, The Drawer allows great production flexibility thanks to free-size rolling up to 4 mm and quick production changeover in less than 4 min.

Danieli Automation 4.0 system will provide Acciaierie Venete the total production control from liquid steel up to the finished product, facilitating the production of small steel lots and frequent size changes to quickly satisfy the requests of the customers.

Automatic process repeatability, LTR-thermomechanical processing of bars, and the preparation of the rolling mill in the workshop, together with the rolling guides under the “ready-to-roll” concept will be performed.

The plant features an in-line control of the process, as well as of surface and dimensional defects.

A new 80 t/h reheating furnace will bring to rolling temperature round blooms from 200, 220 and 240 mm.

Thanks to its rolling-drawing capability, The Drawer will lead to ready-to-use hot rolled bars without downstream peeling operations.

Source: Danieli

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Silva Mash orders welded tube mill from Danieli

The new high-productivity ERW line will produce niche tubular products mainly for high-end automotive and furniture applications
Silva Mash orders welded tube mill from Danieli.

The new high-productivity ERW line will produce niche tubular products mainly for high-end automotive and furniture applications
With an actual capacity of 60,000 tpy of high-quality tubes delivered to the main European automotive and furniture manufacturers, Silva Mash is one of the largest welded tube producers in Bulgaria.

The new Danieli W+K “ERW 45/2.5-150” mill is designed to produce round, rectangular, square, semi-oval and elliptical high-quality and high-strength tubes with superior surface finishing, ODs ranging from 10 to 45 mm and WTs from 0.5 to 2.5 mm.

With a velocity reaching 150 m/min, the new line is able to offer superior diameter/wall thickness ratio capability which along with quick product change-over time (less than 60 min) results in great product flexibility.

In order to achieve the high level of productivity requested, the line is composed of an entry line with a double decoiler, strip joiner, horizontal accumulator, heavy duty forming section with break-down, fin pass, welding and sizing stands, a cut-off and evacuation system including a packaging machine.

Simplified, cost effective ERW mill configurations are also available for commodity tube producers.

Source: Danieli Group

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