Newsletter 19

Russula Newsletter No. 19 November 2019

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RUSSULA IS A GLOBAL ENGINEERING

COMPANY THAT DEVELOPS SOLUTIONS

EXCLUSIVELY FOR THE STEEL INDUSTRY.

WE ARE SPECIALISTS IN THE LONG

PRODUCT ROLLING PROCESS.

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TABLE OF CONTENTS | Russula Newsletter No. 19 | November 2019

Table of Contents by Page #

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ROLLING MILLS

Greenfield bar, wire

rod and section mills

From new plants to modernizations,

Russula designs

rolling mills that are

reliable, easy to maintain

and efficient.

Recent Greenfield Projects:

- Celsa France

- Dojran Steel

- Silat

ROLLING MILLS

Mechanical revamps

Streamline your rolling mill

with custom, mechanical

solutions that lower energy

and water consumption

and optimize spare parts

inventory.

Recent Projects:

- Celsa Atlantic

- Nucor Steel Jackson

- Gerdau Whitby

ROLLING MILLS

Automation/electrical

equipment revamps

Automation solutions for

meltshops, long rolling and

flat processing lines: slitting,

coating, pickling and galvanizing

line applications.

Recent Projects:

- Novelis

- Nucor Steel Utah

- Laminoirs des Landes

- Sidenor Thessaloniki

- CSN

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TABLE OF CONTENTS | Russula Newsletter No. 19 | November 2019

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WATER SOLUTIONS

Meltshops, long mills

and flat mills

Russula develops water

treatment solutions exclusively

for the steel industry.

Recent Projects:

- Galvanizing line in USA

- Laminoirs des Landes

- Gusa Nordeste

WATER SOLUTIONS

Environmental care

Energy efficiency, water

preservation, and environmental

stewardship are at

the forefront of every water

treatment design basis.

Recent Projects:

- Big River Steel Phase II

DIGITALIZATION

Industry 4.0

Russula has made significant

advancements in developing

technologies for

Digitalization and Industry

4.0.

Recent projects:

- Machine vision

- Mill Pulse

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Rolling Mills

Bar mills | Wire rod mills | Section mills

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ROLLING MILLS | Russula Newsletter No. 19 | November 2019

We build

rolling mills

Bar mills

With over thirty-one years experience in

the steel industry, Russula combines its

long product process, automation and

mechanical design expertise to create

bar mills, wire rod mills and section mills

that are reliable, easy to maintain and

efficient. We design new plants and modernizations,

all custom made solutions to

fit the way you roll today.

Wire rod mills

Section mills

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New rolling mill for Celsa Group in

France

Celsa Group has selected Russula to supply a new

rolling mill that will be installed in its Celsa France

Boucau- Tarnos steelworks near the Bayona are in

Southern France. The new rolling mill will feature

Russula’s latest technological developments in mechanical

equipment design, automation and process

digitalization.

The rolling mill has a design capacity of 600,000

tpy, and will serve to vertically integrate the existing

meltshop production at the Celsa France steelworks.

The mill will produce different steel grades

according to European standards.

The new mill will be fed with hot billets directly from

the casting, which will optimize the energy costs

of transformation. It will be outfitted with a walking

beam reheat furnace, RCS Housingless stands

in the continuous roughing and intermediate mills,

and a pre-finishing mill with 3 mini-blocks. The finishing

mill will be equipped with a 10 pass compact

block, water-controlled cooling, a new generation

laying head to form the coils onto a cooling conveyor.

Once the coil is formed, it will be further

cooled and transported by a system of vertical pallets

and horizontal hooks to the compactor and

tying area, where it will be ready for storage and

shipment.

Russula is responsible for the design and the complete

execution of the project under a turn-key contract.

The commissioning of the new mill will take

place within a 20 month time frame. Within the

Russula scope of supply is the general design of the

plant, warehouses, main and auxiliary technological

equipment, civil construction, assembly and commissioning

support.

With the addition of the new wire rod mill, the

Boucau-Tarnos steelworks will become a fully

integrated steel complex, the largest of its kind in

Southern France. Once the mill is fully operational,

Celsa Group will be able to offer a full range of

finished steel products to customers in the France

and Benelux markets.

About Celsa Group

Celsa Group is the leading Spanish and second

largest long steel producer in Europe. Currently,

the Group recycles eight million tons of ferrous

scrap per year. The company employees more than

9,400 employees worldwide in industrial facilities in

Denmark, Spain, Finland, France, Norway, Poland,

Sweden and the United Kingdom.

Russula will apply all of its experience and technology

to provide Celsa with a wire rod mill that is

at the forefront of process digitalization, automation,

production management and the standards

and tools of Industry 4.0. The new rolling mill will

have all the latest advances developed by Russula

focused on maximizing production and reducing

processing costs.

A rendering of the new rolling mill at Celsa France

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Dojran Steel

Russula supplied 350 Kt/yr

merchant bar and section

mill in 15 months

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Merchant bar and section in full

operation at Dojran Steel

Dojran Steel, part of the Sidenor Group (Steel

Industry of Northern Greece), contracted Russula

to supply a new 350 kt/yr merchant bar and section

mill to be built on an existing installation. The site is

located in Nikolic, North Macedonia, on the coast

of the Dojran lake, almost 80 km from Thessaloniki,

Greece.

Russula designed the mill to roll bars and sections

with tight dimensional tolerances and a good surface

finish. The overall scope of supply included

civil works, rolling mill layout, roll pass design, new

mechanical equipment, automation and on-site

services such as supervision installation and commissioning.

The mechanical equipment supply included 18 new

housingless stands in an H/V arrangement ranging

in 3 different stand sizes, seven vertical loopers,

three start-stop shears, a dividing shear, bypass

roller tables and conveying channels. The finishing

area featured a 42 m x 12 m rake type cooling bed.

There were three major constraints during the

course of this project; budget, space and time. In

order to keep the project costs within the budget,

a lot of the existing equipment was reused. Space

became an issue because the new mill layout had

to be designed to fit within the current installations.

Gearbox, spindles and motors were configured to

avoid the building columns and foundations and

vertical stands were modified to fit into the height

of the building. Driven by market demand, time was

the most critical constraint during the project execution,

the mill had to completed in fifteen months.

In a joint collaboration between Dojran Steel and

Russula, the mill started up as scheduled fifteen

months after the contract award date. The outcome

of the project was a resounding success. The

modern merchant bar and section mill has enabled

Dojran Steel to extend its market into rolling small

and medium-sized merchant bars.

Fifteen months from the contract

award date Dojran Steel’s

new merchant bar and section

mill was commissioned. The

new mill has expanded Dojran

Steel’s (Sidenor) production

capacities for structural steels,

designed to produce a wide

range of end products, including

small and medium-sized

merchant bars, flats, small

equal angles, square bars,

UPN channels, IPE and T sections.

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We build

greenfield mills

Russula supplied a 600,000 tpy greenfield

bar and wire rod mill to Silat, (Siderúrgica

Latino-americana). It was build on 148

hectares of land in the Pecém industrial

port complex (CIPP), 50 km from Fortaleza,

Brazil. The mill produces 8-32 mm

bars, 5.5-16 mm wire rod in coil weighing

up to 2.4 t.

The mill was installed on a mezzanine 6 meters

above the floor for easy access to lubrication and

hydraulic units and removal of crops

20 stand continuous mill feeds both outlets

The rod mill outlet features Russula’s patented

laying head design

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Russula supplied greenfield bar and

wire rod mill to Silat in Brazil

The main objective was to build a mill that has low

yield losses, high asset utilization and low conversion

costs. As a result, the mill layout, mechanical

and electrical equipment supply was based on

proven design concepts. The Silat and Russula

teams collaborated very closely on every phase of

the project, from the feasibility study to the equipment

design to the commissioning, leveraging joint

experience to construct a mill that is easy to operate

and maintain and minimizes spare parts.

Russula developed the original concept for the

Greenfield steel plant. The scope of supply included

basic and detailed engineering for civil works mechanical,

electrical and auxiliary installation, specification

development, electrical and mechanical

equipment supply, construction supervision, and

start-up support. In addition, Russula also provided

the water treatment plant. The steel plant complies

with all local environmental standards in Brazil

as well as in Europe.

Fed by a 90 ton/hr (cold charge) walking hearth

reheat furnace, the rolling mill includes a 20 stand

continuous mill with two outlets, one for the 8-32

mm straight reinforcing bar and the other for 5.5-

16 mm the wire rod. The smaller bar sizes are

produced in a four strand slitting scheme at high

speeds. The rod outlet includes a one 10-stand,

high-speed twist free finishing block fed from the

bar mill finishing stands.

The wire rod outlet features the latest of Russula’s

innovations for long product rolling technology.

The patented laying head design allows for more

consistent coil formation and rolling stability. With

this innovative technology Silat will be able to roll

at 110 m/s sustained speeds. Russula’s compacting

and handling system is completely automatic, designed

for a fast, sophisticated process. Integrated

encoders, sensors and advanced automation make

for reliable operation, easy trouble-shooting and

maintenance.

All rolling mill equipment was

produced in Europe to better

control the equipment assembly

from the headquarters office.

The Russula mechanical

team went through a strict selection

process to ensure that

experienced craftsmen with

rolling mill process know-how

guaranteed the equipment will

have longer service life and reduced

downtime.

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Made to last

Mechanical equipment

designed by humans

crafted by machines

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Celsa Atlantic chose Russula to upgrade

bar mill

Celsa Atlantic chose Russula to perform a mechanical

upgrade that allows the plant to roll 180 mm

size billets on both the bar and wire rod mills. The

objective of the upgrade was to achieve greater

flexibility and a higher tonnage output per billet. Included

within the mechanical scope of supply were

two roughing mill RCS stands, by-pass roller tables,

pinch rolls, toggle shear and looper.

The two RCS stands were installed after the reheat

furnace of the bar mill along with a bypass roller

table to replace the stands when they are not required

by the production schedule. High rigidity,

simplicity and reliability are the features of Russula’s

housingless mill stands. Once a stand is installed,

the only connection required is the air-oil connection;

operations and maintenance procedures have

been simplified to the fullest.

Russula is supplying an interconnecting trough to

connect the two mills. The trough is movable and is

designed to reduce the switching time. Two guiding

pinch rolls, a horizontal looper table, toggle shear,

electrical and pneumatic systems are all included

within the trough scope of supply. The ability to roll

180 mm square billets on both mills provides Celsa

Atlantic not only with higher flexibility but also cost

savings.

The equipment was installed during planned shutdowns

in September and October, 2018. The commissioning

occurred as scheduled on November

18, 2018.

As Russula celebrated its 30th anniversary this year,

it is time to reflect on how it all began. Twenty-nine

years ago, Celsa was Russula’s very first customer,

a long-lasting partnership that has spanned many

projects and many countries. With gratitude and

appreciation, Russula would like to thank Celsa for

their continued trust and confidence to undertake

this mechanical revamp.

CELSA Group is the second largest manufacturer

of long steel products in Europe, being the most

diversified and vertically integrated. With industrial

operations in Denmark, Finland, France, Ireland,

Norway, Poland, Spain, Sweden and United Kingdom,

CELSA Group produces steel exclusively in

electric arc furnaces, using recycled metal scrap as

raw material, contributing significantly to the preservation

of the environment.

The rolling mill stands and accompanying equipment

for the interconnection were manufactured

and assembled in reputable workshops throughout

Europe. Close proximity to the Russula headquarters

allowed the engineers to perform frequent

quality checks. Strict controls in the manufacturing

process together with premium materials is why

Russula rolling stands are built to last.

Russula supplied two roughing mill RCS stands

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Mechanical

equipment

revamps:

New water boxes improve bar homogeneity and

reduce water consumption at Isdemir

Russula is revolutionizing the rolling mill process

by questioning the accepted market

standard and taking every piece of rolling mill

equipment back to the drawing table. Our

idea is to make what currently exists, better.

Higher efficiency, lower energy and water

consumption and fewer spare parts are the

results. Here are a few recent mechanical revamp

projects that have improved rolling as

we know it.

New uplooper table at Gerdau Midlothian

Russula supplies new guides to Cascade Steel

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Russula supplies crank shear and

automation upgrade to Nucor’s bar

mill in Jackson, Mississippi

Nucor Steel Jackson, Inc., located in Jackson, Mississippi,

USA, has contracted Russula to supply a crank

shear and control software and drives upgrade for

the merchant bar mill. This upgrade counts as the

fourth project that Russula has collaborated on with

Nucor Steel Jackson over the past thirteen years.

Russula was responsible for the complete mechanical

and electrical supply of the new crank-type crop

and cobble shear, installed between stands 7 and

8 of the roughing mill’s exit. The 40-ton force shear

is designed for head and tail cutting of rounds, rebar,

angles and flats, as well as cobble cutting at

speeds between 1-4 m/s. An AC motor drives the

crankshafts of the upper and lower knife holders

at the same angular velocity, but in opposite directions.

Key features are a detachable flywheel to cut

large sections, entry and exit guides for all products

and an air operated trough to facilitate scrap

collection. The shear was provided complete with

onboard lubrication, pneumatic and air piping and

safety covers.

The new crank shear was delivered to the plant in

the third quarter of 2018. Commissioning of the

shear and automation upgrade occurred in late

February and early March of 2019 during a maintenance

shutdown.

The cooperation between Russula and the Nucor

Steel Jackson mill began in 2006 with the upgrade

of the AC and DC drives. Since then multiple projects

in software and data acquisition improvements

were implemented. Russula would like to

thank Nucor Steel Jackson for their continued trust

and confidence.

A software upgrade for the furnace and mill and

seventeen DCS800 upgrade kits for the mill stands

and dividing shear were included within the scope

of supply. Russula provided a new control application

for the furnace material handling, which is the

system responsible for controlling the billet movements

from the charging table to the discharging

side. In addition, the existing mill control application

that controls the roughing, intermediate and

finishing mill areas, as well as the cooling bed was

replaced with a Russula Mill Control package. The

implementation of the Russula Control Framework

in conjunction with the new crank shear will ensure

reliable cutting at close tolerances.

Crank shear installed and operating at Nucor in Jackson,

Mississippi, USA. Russula designed and supplied

the crank shear and a control software and drives

upgrade to the merchant bar mill.

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Gerdau Whitby orders new combined

dividing shear from Russula

Gerdau Long Steel North America, located in Whitby,

Ontario, Canada has placed an order for a new

combined dividing shear. The Gerdau Whitby mill

produces angles, channels, rounds, square reinforcing

and flat bars.

Within the project scope, Russula will supply a new

pinch roll, a divide shear, servo actuated diverter

and a chopping shear. The mechanical and electrical

equipment including the motion controller,

drives, servos and new motors is also included

within the scope of supply. Russula is responsible

for the engineering, installation supervision, commissioning

and production support.

The new 40-ton combined shear is multi-functional

with both crank and flying modes. The shear is

movable. In order to switch between the crank

and flying mode the complete shear assembly can

be moved hydraulically. This feature reduces the

switching time to a few seconds and avoids the laborious

task of coupling and uncoupling the shear

cutting arms.

The new combined dividing shear is scheduled to

be in full operation by the summer of 2019. Taking

advantage of our extensive knowledge of the steel

process and experience in mill revamping, Russula

specialists are equipped to develop equipment that

will improve productivity and mill performance.

Russula has a long-standing relationship with the

Gerdau Whitby plant over the past thirteen years. In

2004, Russula upgraded the bar mill. The upgraded

resulted in an 8% production output increase.

Recently, Russula supplied all the electrical equipment

and control software necessary to upgrade

the 120 tons/hr reheat furnace, such that the mill

complied with international safety standards and

improved plant safety and reliability.

Gerdau orders combined dividing shear

New pinch roll & chopping shear included in design

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Automation

Solutions

For bar, wire rod, section

mills and processing lines

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Nucor Steel – Utah upgrades finishing

end of bar mill #1

Nucor Corporation contracted Russula to upgrade

the drives and automation of the finishing end of its

bar mill #1 in Plymouth, Utah. Russula successfully

completed a similar upgrade for bar mill #2 in September

2016.

The main objective of the upgrade was to replace

the obsolete automation and AC/DC drive equipment

with a new modern first line control and HMI

system. The new, modern drives, control and HMI

helped Nucor Utah improve operational performance,

failure troubleshooting, spare parts availability

as well as facilitate training.

The scope of this upgrade included all the equipment

from the aligning rollers at the cooling bed to

the removal rolls, including layer forming, straightening

and cold shear cutting, layer forming, bundle

forming, tying stations and bundle exit. The existing

AC and DC drives were part of the Reliance Electric

drive series, which had become antiquated and had

limited replacement parts and support. All of the

AC and DC drives were replaced with ABB ACS880

and ABB DCS880 drives respectively. The drives

were supplied pre-installed in a new lineup up of

cabinets to match the existing power distribution

and to reuse the existing power cables whenever

possible. The existing Automax automation system

and Reliance RIO hardware were replaced with new

hardware based on Allen Bradley ControlLogix and

Point IO series and Factory Talk HMI.

Russula was also responsible for the installation

advisement, commissioning and training. The electrical

and automation equipment was assembled in

the Russula workshop at the end of last year and

underwent a factory acceptance test in January

2019. Technical specialists from Nucor Steel – Utah

and Russula were present during the test to ensure

that the new automation and drives functioned

correctly and according to specification. Commissioning

occurred in March, 2019. The switchover

was implemented in a fast and sequenced manner

in order to least disturb production.

The cooperation between Russula and the Nucor

Steel – Utah mill began in 2014 with the upgrade

of mill #2 stacker. This is the fourth consecutive revamp

project that has occurred over that time.

Nucor Corporation is the largest steel producer in

the United States, and is North America’s largest recycler.

Nucor Steel – Utah is one of Nucor’s 13 bar

mills strategically located across the United States,

which produce a wide usage of bar product for

the agricultural, automotive, construction, energy,

furniture, machinery, metal building, railroad, recreational

equipment, shipbuilding, heavy truck and

trailer market segments. The capacity of Nucor’s

bar mills is approximately 8,830,000 tons per year.

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Novelis contracts Russula for

automation upgrade of cold mill

Following the successful electrical and automation

modernization of slitter no. 2, Novelis contracted

Russula to modernize its cold rolling mill in Pindamonhangaba,

São Paulo, Brazil. Russula won the

automation project in October, 2018.

The purpose of the upgrade is to replace the antiquated

ABB AC450 process controller with first line

Siemens S7-400. After the upgrade, the cold mill

will have a single supplier controller platform, which

will make spare part management easier.

The drives will remain intact as they are. Although

the complete automation systems comprise Level

1 and Level 2 system in accordance with standard

industry practices, the revamp will only affect Level

1 automation. Russula will also reconfigure the interface

with the existing Siemens TDC that controls

Level 2 and the HMI WinCC interface.

The commissioning tasks will be carried out during

the plant scheduled annual maintenance in 2019

and 2020. During these periods, the level one automation

system will be replaced and the cold mill

will undergo intensive cold and hot testing with the

new level 1 automation system. After the switchover,

the cold mill is expected to return to full operation

in 12 days.

Novelis is the number one recycler of aluminum in

the world and a leading producer of flat-rolled aluminum

products. The cooperation between Russula

and Novelis began in 2017 with the modernization

of slitter no. 2. This project marks an important

milestone for Russula in the supply of electrical and

automation solutions for flat processing lines and

cold rolling mills in both the aluminum and steel

sectors.

Novelis has placed a second

order with Russula to upgrade

the automation of the cold

rolling mill in São Paulo, Brazil.

This upgrade will replace obsolete

control equipment and

simplify the configuration to

one platform.

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Next

Generation

High performance drive

and motor upgrades

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Successful startup of straightener at

Laminoirs des Landes

Following the successful installation and startup of

the 500,000 tpy heavy plate mill in Tarnos, France,

Laminoirs des Landes (LDL) contracted Russula to

integrate a 1600 ton-force straightener machine

into its production line. The mill currently produces

a wide variety of heavy plate steel grades for shipbuilding,

pressure vessels and wind energy.

The straightener is located upstream of the heavy

plate rolling stand. Russula supplied the complete

electrical and automation solution as well as the

structural engineering and on-site services that

allowed LDL to replace, commission and fully integrate

the straightener into its operations, distributing

the production schedule as little as possible.

In order to install the straightener, the existing

foundation had to be modified. Russula provided

the foundation design, reinforcement specifications

and bill of materials. Russula supplied the drives for

the drive and control of the main straightener motors.

The two motors drive a single gearbox, as a

result, speed control is very important, therefore

the drives of each motor are configured as master-follower.

”It is always more challenging to integrate and commission

mechanical equipment that we haven’t

supplied. In this case, the straightener was supplied

by a 3rd party company. But all the automation was

carried out successfully and to the full satisfaction

of our client, Laminoirs des Landes.” said José

Manuel García, the Russula Project Manager.

The straightener is highly automated allowing LDL

to measure and control the hot plate leveler, pressure

drop, side roll device, spindle bracket lifting,

changing roll and continually monitor the hydraulic,

grease lubrication and oil lubrication systems. All

functionality was integrated into the existing ControlLogix

PLC.

The new straightener was successfully commissioned

in late February, 2019 in only 4 days. The

Russula team was on-site to ensure a smooth return

to production.

Laminoirs des Landes contracted

Russula to integrate

a straightener into its heavy

plate mill operations. Main

690 VAC motors were replaced

with 400 VAC motors

due to limited voltage supply.

The 500,000 tpy heavy plate

mill successfully returned to

operations in February, 2019.

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Sidenor Thessaloniki choses Russula to

upgrade 800,000 tpy merchant bar and

wire rod mill

Sidenor Group (Steel Industry of Northern Greece)

has contracted Russula for a complete electrical

and automation revamp of its merchant bar and

two-strand wire rod mill located in Thessaloniki,

Greece. The hot rolling mill has an annual production

capacity of 800,000 tpy and produces reinforcing

bars, squares, rounds, equal angles, beams,

UPN channels and wire rod.

The steel mill in Thessaloniki began operations in

1962. It is Sidenor Group’s first production facility.

As such, the current mill control layout is a combination

of different hardware platforms and software

generations from many automation suppliers.

As a result, the main goal of the electrical and automation

upgrade is to replace obsolete equipment

and simplify the control platform, which will improve

maintenance and troubleshooting.

The scope of supply for the 15-stand mill includes

all equipment from the roller table after the reheating

furnace to the bar outlet dividing shear and the

reforming tubes of the wire rod mill outlet. The existing

Toshiba PLCs will be replaced by new Siemens

S7-1500 PLCs for the continuous mill and wire rod

outlet. Other PLCS will be converted into new remote

IOs. Russula will equip the mill with new Delta

loop scanners, DC Sinamic drives for the stands, a

new main pulpit desk for the control room, iba data

acquisition system, HMI WinCC interface specifically

tailored for the rolling mill process.

A full factory test of the HMI, PLC and I/O will be

performed in October in the Russula workshop, prior

to shipment to Thessaloniki. Start-up of the upgraded

mill is scheduled for mid-December 2019.

Sidenor Group grants Russula

a contract to up-grade

the automation of its 800,000

tpy merchant bar and twostrand

wire mill. The upgrade

will simplify the current control

platform and replace obsolete

control equipment.

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Russula upgrades two-strand slab

casting machine at CSN

Following the successful productivity improvement

project of the bar and rod mill in Volta Redonda,

Rio de Janeiro, Companhia Siderúrgica Nacional

(CSN) has contracted Russula to perform a control

system upgrade on its two-strand slab casting machine.

CSN is the largest integrated steel producer

in Brazil with a crude steel capacity of 5.6 million

tons. Russula won the contract in August, 2019.

The goal of the upgrade is to replace legacy automation

equipment, primarily the ABB PLCs and ABB

APC boards that are installed in the ABB drives and

communicate with the AC450, with first line control.

This will improve the safety and reliability of

the casting process, as well as improve spare parts

availability.

The existing main ABB AC450 PLC processors will

be replaced with new Siemens S7 400 and New

ABB DCS880 drives will replace the existing drives.

The existing HMI ABB 800xA equipment and application

will be reused, keeping all existing servers

and operator stations. The new control system is

scheduled to be commissioned in June 2020.

In 2016, CSN contracted Russula to re-engineer

the bar and rod mill at its same production facility.

Russula engineers provided an on-site process

evaluation and plan forward to remove the electrical

and mechanical bottlenecks. Subsequently,

when the brake slide and straightening grids were

replaced with a new mechanical design and the existing

electrical and control system was upgraded,

the productivity of the bar and rod mill increased

significantly. Russula is very pleased to be selected

by CSN again for this important project.

Since 1991, Russula has performed many electrical

upgrades for the melt shop area of integrated steel

mills. Blast Furnaces, EAFs, ladle furnaces and continuous

casters are all part of the Russula portfolio

of electrical and automation solutions, offered by

its local Brazilian structure, located in São Paulo.

Russula is pleased to be selected

by CSN for the control

upgrade of its two-strand slab

casting machine, located in

Volta Redonda, Rio de Janeiro.

Photo view is from the slab

exit area.

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Water Solutions

Meltshops | Flat mills | Long mills

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WATER SOLUTIONS | Russula Newsletter No. 19 | November 2019

We build

water treatment

plants

Founded on years of experience from working

in the steel industry, Russula develops

water treatment plants for meltshops, flat

mills, long mills and processing lines. Engineering

designs are made according to the

requirements of your steel plant. Complying

with local legislation and your environmental

protection plan is first and foremost. There

are currently 22 Russula water treatment

plants in 9 countries operating in the world

today.

Water treatment equipment for a galvanizing line in

the USA

Water treatment plant for heavy plate mill at Laminoirs

des Landes in France

Water treatment plant for meltshop, combined bar

and rod mill at Gusa Nordeste in Brazil

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ENGINEERING SOLUTIONS WITH ENVIRONMENTAL CARE

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WATER PLANTS BUILT

16

YEARS

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WATER SOLUTIONS | Russula Newsletter No. 19 | November

Big River Steel

doubles capacity

Russula has begun the

engineering for the water

treatment complex expansion

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Big River Steel awards Russula water

treatment complex for Flex Mill

expansion

In January 2019, Big River Steel awarded Russula a

contract to supply the water treatment solution for

Big River Steel’s Flex Mill expansion that will double

the hot-rolled steel production capacity to 3.3

million tons annually. Russula designed and supplied

the 154,000 gpm water treatment complex

for the first phase of Big River Steel, delivered in 14

months from the contract award date.

This expansion was contemplated in the original

layout of the water treatment complex which is divided

into four areas to treat water from the meltshop,

continuous caster, hot strip mill, and cold

mill. Part of the existing installations will be expanded

and other areas entirely built from scratch. In

order to double capacity, BRS will be adding a new

meltshop and continuous caster, which will require

three new water treatment areas, for the meltshop,

continuous caster and waste water. The existing

make up water and HSM areas will be expanded.

In total, the new expansion will treat an additional

92,000 gpm of water critical to the steel process.

Energy efficiency, water preservation, and environmental

stewardship are the considerations at the

forefront of the expansion design basis.

The basic engineering for the water treatment expansion

began in January of this year. The startup is

estimated for the fourth quarter, 2020.

About Big River Steel

Big River Steel invested $1.3 billion to build and

start up the world’s first Flex Mill. The mill produces

a wide product spectrum of advanced automotive

steels and motor lamination and semi-processed

non-grain oriented electrical steels. Since

operations began in early 2017, Big River Steel has

provided steel products to nearly 200 customers in

the automotive, energy, construction and agricultural

industries. The expansion will permit BRS to

produce higher grades of electrical steels that can

be used to improve energy efficiency in hybrid and

electric vehicles.

Russula will be supplying the

water treatment solution for

the Big River Steel Flex Mill

expansion that will double the

hot-rolled strip production to

3.3 MTpy. The new expansion

will treat an additional 92,000

gpm of water critical to the

steel process.

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Digitalization

The future of rolling is now

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DIGITALIZATION | Russula Newsletter No. 19 | November 2019

Computer Vision

An artificial eye on your

process can provide data

you have never seen before

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Process digitalization and Industry 4.0

Computer Vision

Computer vision adds a new dimension to the rolling

process. Changes in product dimensions, looper

height, rolling speed and cobble detection can

easily be measured by a camera with a precision

unmatched by sensors today.

Building on Russula’s experience in installing cameras

in rolling mills and synchronizing images and

signals with the process control system and data

acquisition systems, the company has launched

developments in the field of computer vision. Currently,

Russula is testing several applications in real

conditions that will allow our customers to improve

the precision of their existing sensors and gather

valuable data about the rolling process that they

never have seen before. The end goal is to replace

existing sensors, such as the HMD and loop scanners

with cameras and computer vision algorithms.

Mill Pulse

As manufacturing becomes smarter, new technologies

are allowing companies to record and retain

more data than ever before. But are you measuring

what you need to measure? Is your data presented

intuitively and in the right context? Now more

than ever it is paramount to identify the key performance

indicators of the rolling process and ensure

the right smart sensors are in place to record the

right data.

Russula’s R & D + i department have developed Mill

Pulse - a new, fully integrated manufacturing execution

system to monitor production progress and

key plant performance indicators. The interface is

intuitive, with clean, uncluttered screens, allowing

users to easily measure and calculate equipment

and mill efficiency. Mill Pulse is configured for regular

computing systems and smart devices, such as

tablets and cell phones.

Process Control

PLC, Drives, Sensors,

Instrumentation

Process Models

AI Algorithms, Digital Twin

(ERP)

Process Direction

Mill Pulse

(MES)

Data Capture

and Analytics

HMI, Recipes, Tracking,

Data Acquisition Systems

Mill Pulse is a Manufacturing

Execution System integrated

with all sensors, instrumentation

and drives on the mill

floor, Level 1 automation

systems in the electrical and

control rooms and Enterprise

Resource Planning systems,

running process and business

models, globally.

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Mill Pulse

Track Key Plant Performance

Indicators with Russula’s

Manufacturing Execution

System

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Global support,

locally

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Headquarters

Electrical Workshop

South America

North America

Galileo Galilei 8, Bajo B

15008 A Coruña Spain

T: +34 981160344

Polígono Bergondo

C/Parroquia Rois D-7 15165

A Coruña Spain

Av. Ibirapuera, 2907

Indianópolis São Paulo

04029-200 Brazil

T: +55 11 5044 8847

559 Main Street, Unit 202

Fiskdale MA 01518 USA

T: +1 774 452-4411

Italy

Viale del Ledra 108

33100 Udine Italy

T: +39 0432 231911

Russia

Nekrasova str. 41A, office 93

Yaroslavl, Russian Federation

150040

India

Plot No: 727 3rd floor

Bivab Gulmohar Nayapalli

Bhubaneswar Odisha

India 751012

T: +91 0674 2420196

Mexico

Ciudad Victoria 1022

Monclova Coahuila Mexico

T: +52 (55) 5564 1419

Russula S.A.U. Certifications

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Newsletter 19

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