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Brazil’s Aço Cearense Group’s Siderúrgica Norte Brasil (Sinobras) has officially produced the first steel coil at its rolling mill #2 in Marabá, Pará state, Brazil.

A press release said that Sinobras invested in the new mill from Italy’s Danieli to increase its annual production capacity from 380,000 tons to 850,000 tons per year of wire rod and spooled rebar in coils. The mill features an innovative, full cantilever stand configuration with a total of 26 passes. It has 10 cantilever stands arranged in H/V configuration, followed by a series of Delta-type, fast-finishing blocks, with a 45° design, for the remaining 16 passes of the reduction sequence.

The new mill will produce wire rod from 5.5 to 16 mm, and rebar from 6.3 to 16 mm, at a maximum finishing speed of 110 m/s. The project includes a new substation and 230kV transmission line to meet the new electrical load needs of the steel producer and facilitate the use of energy from the Belo Monte Hydroelectric Plant, of which it is a partner as a self-producer.

Sinobras Industrial Director Milton Lima described the expansion as a transformative moment for the Group. “This achievement represents a significant milestone ... taking us to an even higher level. By doubling the size of Sinobras, we are not only expanding our operations, but we are also transforming our company into a powerhouse, generating new opportunities.

Italy’s Acciaierie Venete has chosen Danieli to supply a new wire rod production line to expand capacity at its plant in Sarezzo (Brescia).

A press release said that, fed by the existing Danieli rolling mill that produces straight and coiled quality bars, the new wire rod line will produce special steel smooth rounds from 5.5 to 25 mm, at speeds up to 110 m/s, expanding the company product portfolio.

The mill will start operation in early 2025. It will have three fast-finishing blocks to perform a total of 18 passes. It will include a TMB Twin-Module Block that will guarantee holding a ± 0.1 mm tolerance and 50% ovality to the whole range of products. Danieli Automation’s Hi-Profile Lite gauge measurement system will provide real-time feedback on the rolling operations and certify the quality of the final product, while motorized remote control of the rings will allow prompt adjustments during rolling. A Danieli-patented, high-speed shear will ensure accurate, consistent head-and-tail in-line trimming.

Italy’s Danieli has received an order from Russian steelmaker AO Severstal for a new rolling mill for special steels to be installed at its plant in Cerepovec.

A press release said the new plant will produce 5.5 to 32-mm wire rod and coiled bars for engineering and automotive industries, and 8 to 16-mm quenched rebar for construction purposes. Danieli will provide all the technological equipment, automation and advisory services. A Danieli Centro Combustion walking beam reheating furnace will bring to rolling temperature 12-m-long, 150-mm square-billets, at a pace of 170 tph. A single-strand high-speed roughing mill made of horizontal and vertical housingless stands will feed two independent wire rod lines and a garret coiler to produce the bigger diameters. Startup is planned for by the end of 2022.

Italy’s Danieli announced winning two orders for wire rod mills from two separate companies in Turkey.

A press release said that one of the orders is from İÇDAŞ ÇELİK Enerji Tersane ve Ulaşım Sana (İÇDAŞ) for its plant in Biga, Turkey. İÇDAŞ has two other Danieli wire rod lines at the site that have been in operation since 2005. The manufacturer is investing to increase its market share of wire rod coils, and to add more advanced steel grades to its product portfolio. It is designed to produce a wide range of steel grades, inclusive of welding wire, high carbon, cold heading, bearing steel, spring steel, free cutting and alloyed steels, at rolling speeds up to 110 m/sec. Line startup is scheduled for the second quarter of 2021.

The new line includes a ten-pass fast finishing block with the latest technology Multidrives (M2®) configuration; Danieli Structure Control (DSC®) water cooling line; and four-pass reducing and sizing Twin Module Block (TMB®) equipped with an individual drive control system. The vertical coil-compactor will be supplied by specialist Swedish Sund-Birsta, part of Danieli Group.

The second order is from Habaş Sınai ve Tibbi Gazlar İstihsal Endüstrisi, which ordered a new Danieli wire rod line, slab caster electrical and automation system, along with technological packages to be installed in the company’s Aliaga steelmaking plant. The wire rod line will produce a wide range of steel grades/products—and medium-carbon steel, welding wire, high-carbon and PC wire and reinforcement steel—at a maximum rolling speed of 110 m/sec. Startup is scheduled for the third quarter of 2021.

Italy’s Danieli reports that it has received orders for two high-productivity and H3 rolling mills to be installed and put into operation in Russia during 2020.

A press release said that AEMZ (Abinsk Electric Steel Works Ltd.) ordered a new 600,000-tpy H3 wire rod line to be installed at Abinsk, in the Krasnodar region. The new mill will produce wire rod coils, 5.5- to 16-mm, smooth rounds, and 6- to 12-mm, quenched and microalloyed rebar, for construction, welding wire and CHQ grades.

The second order is from NPZ (Novorossiysk Rolling Plant LLC), which ordered a new 500,000-tpy H3 wire rod mill to be installed at Novorossiysk, also in the Krasnodar region. The mill will roll 150 x 150 billets into 5.5- to 16-mm wire rod and deformed wire rod in coils weighing up to 2.1 metric tons.

Depending on customer requirements, Danieli notes that its H3 mills operate at over 100 m/sec. They consist of an ESS (Energy Saving System) cantilever-type and SHS housingless stands and fast-finishing blocks; a water-cooling line suitable for wire-rod quenching and controlled cooling, and a loop-laying head, rotary reforming tube and easy-down system for a perfect coil pattern.

Danieli’s H3 mills are typically supplied along with Danieli Centro Combustion reheating furnaces equipped with the latest-generation, ultra-low NOx emission, flat MAB flameless burners. Danieli Automation provides process control, power and instrumentation—like medium-voltage Q-DRIVE, HiPROFILE LITE and HiSECTION measuring devices—for in-line tracking and product monitoring, and optical system for rolling guides set-up, and for rolls and guides alignment for the finishing block.

Italy’s Danieli Group reports that production has begun for the new high-speed wire rod mill it supplied to Acciaierie di Verona (the Pittini Group) that represents the 500th rolling mill the company has now supplied.

A press release at the Danieli website reports that the first coil was recently produced, some 19 months after the contract signature. “The timely start-up and the following hot-test period of seven weeks, during which 25.000 tons of finished wire rod in quality have been produced, reflects the long-term cooperation between the Pittini Group and Danieli,” it said.

Regarding the rolling mill, it was designed to hold strict end-product size tolerances, employing the most advanced wire-rod technology and in full compliance with Industry 4.0 requirements, the release said. It noted that the plant is capable of annually producing 750,000 metric tons (mt) of plain wire rod from 5.5 to 25 mm and rebar from 6 to 18 mm at rolling speed of 100 m/sec, and further outlined the capabilities as follows.

The mill has a high-speed rougher feeding two independent rolling lines that consist of cantilever roll stands, featuring quick roll changes and temperature control along the mill and downstream. High-speed shears, installed downstream the multi-drive, high-speed, twin-module sizing blocks, perform wire-rod head and tail cropping. The fourth-generation loop layers guarantee extended pipe life, quick rotor changes, and no vibration during rolling, resulting perfect loops from heads to tails.  The variable-pitch cooling conveyor features modular slow-to-ultrafast cooling.

 The Danieli Automation Q3 Intelligence system is used for integrated data collection of the whole plant, analysis, and web reporting with Key Performance Indicators and powerful statistical tools to support decision making. The new plant automation ensures consistent product quality consistency, high utilization factor and yield, and workshop coordination, and establishes a link to “Big Data” and plant digitalization practices.

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