STEEL + TECHNOLOGY 01/2020 EXTRACT

STEEL TECHNOLOGY | 37
From left to right, Giacomo Mareschi Danieli / Danieli CEO, Gianpietro Benedetti / Danieli Chairman, John Ferriola / Nucor Chairman
and CEO, Leon Topalian / Nucor President and COO, Paolo Losso / Danieli Corporation President (Picture: Danieli)
Heavy plate
Nucor to build greenfield plate steel mill
complex in Brandenburg, Kentucky, USA
Producing thermo-mechanical rolled plates, supported by advanced automation, it will become a new
benchmark plant. Main production facilities of the new plate steel mill complex will comprise an electric arc
furnace (EAF) melt shop, a single-strand caster for ultra-wide and thick slabs and a plate-/Steckel-mill.
Nucor Corporation, America’s largest
steel and steel products producer, has
selected plant suppliers to provide main
equipment for its new greenfield plate steel
mill complex in Brandenburg, Kentucky, USA.
Danieli will supply the new Electric Arc Furnace
(EAF) melt shop and plate/Steckel mill,
as well as an electrical and automation package
provided by Danieli Automation.
Nucor will invest approximately $1.35 billion
USD to build the mill, which will be capable
of producing 1.2 million net (US) tons per
year of steel plate products. The value of Danieli
supply is approx. $330 million USD.
The selected location on the Ohio River
will give Nucor logistical advantages in the
heart of the largest steel plate consuming
region in the United States. Nucor currently
operates plate mills in North Carolina, Alabama
and Texas.
“We are proud to be able to continue our
long-time, successful relationship with Danieli.”
said Johnny Jacobs, vice president and
general manager of Nucor Steel Brandenburg.
“Our new plate mill will serve as a
benchmark for our industry and will make
Nucor the market leader right in the center of
America’s largest plate consuming region.”
The EAF will be a full platform design with
an eccentric bottom tapping system (EBT),
equipped with all modern mechatronic devices
to improve the performance and the safety
of the EAF, such as: Q-Melt and Zero Man
Turn Around.
Danieli will also supply secondary metallurgy
equipment, including a twin station ladle
metallurgical furnace (LMF) and a twin station
vacuum tank degasser (VTD) equipped with
mechanical pumps. Both units will be
equipped with the latest automation and process
models to ensure precise chemistry and
temperature control, whilst minimizing transformation
costs.
The plate/Steckel mill will be equipped
with two stands: a roughing mill and a Steckel
mill, where the roughing mill will also be
designed for the rolling of 36” (915 mm)
ingots. The complete design of the plate mill
will be optimized for the production of thermo-mechanical
rolled plates, production of
API-grades, as well as high hardness wear
resistant plates up to a rolled width of 160”
(4,064 mm) and coils up to a rolled width of
125” (3,175 mm). Subsequent to the plate/
Steckel mill will follow the latest EVO 5 hot
leveler designed for two different types of
cassettes and a plate finishing and shearing
line for the handling and cutting of 250 ft (76.2
m) mother plates.
Final products will be plates and heavy
plates in a thickness range of 3/16” up to 14”
(4.76 to 356 mm) and coils from 3/16” up to 1”
(4.76 to 25.4 mm). When operational, the new
plate mill will capable of producing 97% of plate
products demanded in the U.S. market. The
first plate is expected to be rolled in 2022.
• Danieli
Vertical-bending slab casting machine
Nucor Corporation has selected SMS group for the supply of a single-strand
caster for ultra-wide and thick slabs. The caster will produce slabs of 8” to 12”
(200 to 305 mm) thickness up to 124” (3,150 millimeter) width. Slab lengths vary
from 104” to 600” (2,642 to 15,240 mm). To meet Nucor’s challenging project
objectives, several special technological features will be incorporated into the
new vertical bending caster. These include robotic applications on the casting
platform and an HD mold with fiber optics and electromagnetic stirring. In
addition, a customized roller apron, a quenching unit and a secondary cutting line
will also be incorporated. Various X-Pact ® technological packages like Process
Guidance, Solid Control, Tech Assist with Liquid Core Reduction ® and Dynamic
Soft Reduction ® , integrated in the SMS electric and automation system will
support the caster performance.
• SMS group
STEEL + TECHNOLOGY 2 (2020) No. 1