PR of China

Second Danieli slab
caster in six months at
Baosteel, P.R. of China
Page 11
ALSO IN THIS ISSUE
IRONMAKING
4 SUCCESSFUL CASE-HISTORY
PROJECT AT ACESITA, BRAZIL.
STEELMAKING
8 ACERBRAG: ARGENTINA’S
MOST MODERN MINIMILL.
9 37 HEATS/DAY FOR
THE DANARC EAF AT ACEROS
AREQUIPA, PERU.
FLAT PRODUCTS
12 EXCELLENT THICK SLAB
CASTER STARTUP
AT XIN YU, P.R. OF CHINA.
13 THIN SLAB CASTER EXTENDS
CASTABLE STEELS RANGE
AT BENXI, P.R. OF CHINA.
LONG PRODUCTS
30 SECOND HIGH-CAPACITY
SBQ MILL AT JIANGYIN
XINGCHENG, P.R. OF CHINA.
34 MODERN BAR AND SECTION
ROLLING MILLS STARTED UP
AT MAGNITOGORSK, RUSSIA.
AUTOMATION
38 PLATE MILL UPGRADDING
AT BHILAI (SAIL), INDIA.
EXTRUSION LINES
40 INNOVATIVE 32-MN
EXTRUSION PRESS
AT PROFERALL, ITALY.
Cold steel mill complexe
started up at VSC,
Vietnam.
Page 18
DANEWS
V
yksa, Russia, June 11th, 2005.
The cornerstone laying ceremony was
opened by Mr. A. Sedykh, President
of the OMK Group, who addressed a warm
welcome to the authorities and the
distinguished guests, testifying to the
importance of this event for the City of Vyksa
and the Nizhny Novgorod Region of Russia.
Mr. S. Kirienko, the Delegate of the President
of the Russian Federation and Supergovernor
Major casting and rolling
facilities modernization
at Corus Scunthorpe (UK)
Page 28
Danieli News n.143
September 2005,
Danieli Group
The new 1.2-Mtpy fTSR steel complex
>Cornerstone< laying
ceremony at OMK
of the Volga Region, Mr. M. Khodyrev, the
Governor of the Nizhny Novgorod Region,
Mr. M. Fadeev, the President of the Russian
National Railway Corporation, of Mr. A.
Antonov, VP of Investments of United
Metallurgical Company, Mr. G. Lavaroni,
VP of Italy’s Danieli, the supplier of the steel
complex equipment and technology,
Mr. E. Inanc, Chairman of Gama, Turkey,
the supplier of the construction package
→ Page 2

135 ELECTRIC ARC FURNACES 210 SECONDARY METALLURGY STATIONS 389 CONTINUOUS CASTING
STRANDS FOR BLOOMS 1041 CONTINUOUS CASTING STRANDS FOR BILLETS 28 HEAVY SECTION MILLS
85 SPECIALTY STEEL AND SUPERALLOY ROLLING MILLS 266 BAR MILLS 139 WIREROD MILLS
117 SECTION MILLS 14 ENDLESS WELDING ROLLING UNITS 8 SPOOLER LINES 450 DRAWING LINES
12 FORGING SHOPS 246 EXTRUSION PRESSES 783 GRINDING MACHINES FOR BILLETS AND BLOOMS
717 BASIC AUTOMATION AND PROCESS CONTROL SYSTEMS
FACTS
CONFIRM
DANIELI LEADERSHIP
IN LONG PRODUCT
STEEL PLANTS

Danieli News n.143
Danieli Publicity Dept.:
Tel. (39) 0432.598244
E-mail: info@danieli.com
Graphic Project: Polystudio
DTP: Danieli Publicity Dept.
Printing: Grafiche Filacorda.
Approved by the Court of Udine
under authorization n.16
dated 21.04.83
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Via Nazionale, 41
33042 Buttrio (UD) Italy
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Dear reader,
We are pleased to present you this issue of the Danieli quarterly journal
which, as you may have already noticed, features some layout re-styling aimed
at providing you with better information and more enjoyable reading.
The last three months have been characterized by some
significant events such as the OMK cornerstone laying
ceremony for the first fTSR thin slab casting rolling minimill
complex in Russia; the second slab caster order received from Baosteel
in six months; and the VSC cold mill complex in Vietnam, which
reached full operation in one month from commissioning.
We have also seen new examples of excellence in casting technology
with the startup of slab casters at Xin Yu and Benxi (second line)
together with a productivity record with 6-strand >FastCast< billet
caster at Mechel, and the second order from Corus which chose Danieli
to enhance product quality at Scunthorpe, among others.
The top performances at Aceros Arequipa (up to 37 heats/day),
Acerbrag and Arcelor's Belgo Piracicaba plant, which has become
a benchmark, confirm the Danieli leadership in minimills in Latin
America. We also record the hot startup of the rolling mill of SSC
minimill whose meltshop is scheduled to spark by the end of the year.
A new meltshop and casting plant order was received from Sidertul.
Two strip processing lines are fully producing at the cold mill complex
of the leading Chinese producer, TISCO.
KME, Germany, one of the largest copper producers worldwide,
has ordered the third rolling mill from Danieli Froehling.
Two out of the new three long product rolling mills ordered
by MMK have been started up, also.
You will find this and more information browsing through the pages
of this issue of DaNews.
Thank you for your attention.
Paolo Messina
Danieli, Executive Manager
PR and Information
p.messina@danieli.it
1

DANEWS
1
2
>Cornerstone< laying ceremony for the OMK 1.2-Mtpy
complete fTSR flexible Thin Slab Rolling plant
1 Mr A. Sedykh, President
and CEO of OMK
addresses his speech
at the first stone laying
ceremony.
2 3D representation of
the fTSR process to be
implemented at OMK.
2
COVER STORY
FROM FIRST PAGE
of the steel complex, Mrs. A. Ricci,
Vice President of Medio Credito Centrale,
the Italian financing bank for equipment and
technology, Mr. N. Fychev, Director
of Investments of Sverbank, the Russian
financing bank for the local construction
package, took part in this meaningful event.
The ceremony was an essential element
of the greater project, confirming its industrial
feasibility, being financially supported by
shareholders, the Italian and international
3 Schematic layout of the
whole new complex.
The blu dashed lines
show the possible future
expansion.
4 A Danieli Wean United
6-stand finishing mill
equipped with f 2 CR stands.
5 Close-up of a f 2 CR stand,
capable of crossing rolls
while rolling for a
superior strip flatness
and crown control
capability.
banking system and the Russian banking
system. This event also marked the beginning
of project execution. Industrial operation
is expected by the end of 2007, with a capacity
of 1.2 Mtpy of hot rolled coils to feed the pipe
mills of the OMK Group.
The new steel complex will be composed
of an electric steel meltshop with EAF, ladle
furnace, vacuum degassing station, a medium
slab caster with hot strip mill for a continuous
casting and rolling process.

The technologies applied in the new steel
complex are unique both in Russia and
all over the world, as they meet high-quality
steel demanded for the production of arctic
steels, resistant to acid aggression (natural gas
and crude oil) at very low temperatures (-65°C).
The new plant will employ 2000 workers
(direct and indirect manpower) thus being an
important prospect for young engineers and the
population of Vyksa City, which is now
celebrating 250 years of steelmaking history. ■
4 5
>fTSR<
3

DANEWS
Customer satisfaction
for Danieli Corus blast furnace repairs
at Acesita (Arcelor Group), Brazil
The successful project is already referred to as a case-history
inside Arcelor Group.
MMr Paulo Magelhaes, Director
of Acesita, signed the acceptance
letter for the full and complete
finalisation of the repair of BF No. 2 performed
by Danieli Corus on July 12.
It took place during a luncheon also attended
by Mr Marcondes (plant manager),
Mr. Cardoso (BF manager), Mr. Helvio (project
manager), Mr. Yamana (project engineer) from
Acesita, and Mr. P. Hemels (project manager)
and Mr. F. Kaptein (sales manager) from
Danieli Corus.
Danieli Corus was paid compliments
for the excellent results of the project.
Moreover, Acesita stated that, within the
Arcelor Group, this project was selected
to be discussed and assessed at higher
management level as an excellent example
of project management and working methods
in order to achieve a similar great success
in future projects.
The first project step was taken in December
2002 with an order for operational assistance.
In November 2003, Danieli Corus received
the order for the design and supply of new
refractory and cooling system to be installed in
the tuyere zone, the bosh and the so-called belly.
Included in the design is a state-of- the-art
heat flux monitoring system measuring the
heat load on the furnace wall in the different
sections; it enables the operator to adjust and
improve the charging of the furnace to obtain
an optimum process.
A fast track supply schedule could be
maintained due to worldwide sourcing
for supplies by Danieli Corus who also had
on site supervisors to guarantee the proper
construction. Training and startup supervision
were also part of the contract.
4
IRONMAKING
I
The furnace was blown down on April 10
and started up on May 8, four days ahead
of schedule. The repair was executed without
any accident. The ramping up to the aimed
production of 1270 tonnes per day was reached
as planned. Noteworthy is that the furnace
uses fuel coke in the charge and charcoal as
injectant in the tuyeres- a system developed
by Acesita. ■
Director Paulo Magelhaes
of Acesita signing the final
acceptance letter for the
repair of Acesita BF No. 2
performed by Danieli Corus.

Danieli Corus Blocktectors
and tuyere cameras
at Taiyuan I&S, P.R. of China
This is the same furnace for which Danieli Corus
supplied a PCI system in 2004.
Blocktector
JB
T
aiyuan Iron & Steel (Group)
Co. will install 40 Danieli
Corus Blocktectors and 3
tuyere cameras on its new BF #1.
The delivery time for the equipment
will be approximately 3 months.
Blocktectors & Cameras have been
operating at Corus IJmuiden since
the late 80’s and are well-proven
for detecting the onset of a blocked
tuyere and turning off coal supply
to that specific tuyere. In this way,
they help to prevent explosions or
other potential hazards of pulverised
coal collecting in the tuyere.
Blocktectors are also very useful
instruments during blowing in a
chilled furnace, to identify blocked
tuyeres would be very useful in
deciding prior to injecting fuel
into the furnace. If pulverised coal
continues to be injected when the
tuyere is blocked, it may lead to:
spillage of pulverised coal
around the mouth of the tuyere;
tuyere burn-out;
damage to the hot blast main,
where combustion of coal
in the bustle pipe would lead to
extreme heat resulting in hot spots
and pipe rupture;
Pulverised Coal
Purge N 2
Individual tuyere injection stops
automatically in case of blockage
explosion in the hot blast
main, when sufficient quantities
of burning coal come into contact
with oxygen-rich blast.
The use of Blocktector offers many
advantages:
proven technology, specifically
designed and developed for the
BF environment;
easy installation and use;
no additional maintenance;
no special (expensive)
instrument piping close to the tuyere
is required.
These instruments will enhance
the operation of the PCI system
at Taiyuan, especially with
high injection rates expected
of the system. ■
New Pulverised
Coal Injection
system at
Shougang I&S,
P.R. of China
DANEWS 143
This is Danieli Corus' 5th
order for a PCI system
in China to date.
anieli Corus was awarded a contract
for design, supply and services
by the Shougang Iron & Steel (Group)
Co. at Qian'an for a new injection system
for the PCI facility serving their new Blast
Furnace No. 2.
BF No. 2 has an inner volume of 2650 m3 D
and
is expected to produce in excess of 6500 thm/d.
The PCI system will inject a minimum of
200 kg/thm and ensure that the BF consumes
the injected coal in an efficient manner.
This BF has 30 tuyeres. The system will be
constructed during 2005/2006 and ready for
operation later in 2006.
The contract also includes supervisory services
during the equipment installation, and training
of BF personnel at Danieli Corus offices
in The Netherlands. ■
5

DANEWS
New orders from the Chinese market
for hot blast stoves
In both cases Danieli Corus received
an order for engineering, refractory
supply material inspection and
installation supervision services.
Both projects foresee stoves designed for a
constant hot blast temperature of 1250 ºC
to optimize the production and minimize
fuel consumption of the new blast furnace.
Shougang Qian’an
The first order, signed on April 19, 2005,
with the China Shougang Trade & Engineering
Corp., calls for three new hot blast stoves
for the new 2650-m 3 inner volume BF No. 2,
as well as a complete new hot blast system,
containing a hot blast main and bustle pipe
with tuyere stocks.
Thanks to the reliable performance of the
Danieli Corus stoves, hot blast system and
ceramic burners supplied through the previous
orders, the Shougang Design Institute wished
to continue that excellent relationship with
its order for one of its new high productive
blast furnaces.
The total order volume over the last five years
makes Shougang I & S Corp, together
with China Shougang Trade & Engineering
Corp, one of the most valuable customers
for Danieli Corus in the P.R. of China.
6
IRONMAKING
I
Danieli Corus expertise will provide Shougang Qian’an and Taigang
Taiyuan with state-of-the-art equipment and services.
View of the hot blast
stoves erected during
a previous Danieli Corus
project at Shougang.
Contract signing ceremony for the Taigang Taiyuan project.
From left to right: Mr. Wang, Vice Mgr. for Ironmaking plant, Mr. Liang, Ironmaking Mgr.
responsible for all Taigang BFs, Mr. R. Stokman, Senior Sales Mgr. of Danieli Corus,
Mr. Zhang, Contract Mgr., Mr. Xu, Project Mgr. of Taigang Design Institute, Mr. Wei,
Danieli Corus Beijing representative.
Taigang Taiyuan I&S Corp.
The second order (July 2, 2005) relates
to five new hot blast stoves for the existing
blast furnaces No. 3 & 4, which will be
reconstructed in the coming years to increase
their inner volume up to 1800 m 3 .
Thanks to this order, Taigang I & S Corp,
together with the Taigang Group Intl.
Trade Co. Ltd. made an important step toward
modernizing the existing facilities at Taiyuan,
Shanxi Province.
This order is the logical continuation of the
cooperation between the two companies which
is based on the excellent performance of the
Danieli Corus technology already applied
to one of the BFs at Taiyuan some years ago.
Moreover, this is the first contract in the
history of Danieli Corus to call for five Danieli
Corus hot blast stoves. ■

DANEWS
STEELMAKING
S
New order for steelmaking and continuous
casting plant at Sidertul, Mexico
The project also involves the modernization of the 75-tph bar and section mill.
From left to right: Mr. Samuel Nanes, Financial Director (Sidertul), Mr. Don Israel Feldman,
Chairman (Sidertul), Mr. GP Benedetti, President and CEO (Danieli), Mr. Ernesto Edelstein, Plant Director (Sidertul)
and Mr. A. Zanoni, Executive Manager, Sales (Danieli).
Other pictures show production units similar to those to be installed at Siderurgica Tultitlan.
Siderurgica Tultitlan S.A. de C.V. (Sidertul) will completely reconstruct
its steelmaking facilities to increase billet production
from present 350,000 tpy to 600,000 tpy. Also included in the
project is the upgrading of the rolling mill, originally supplied by Danieli
in early 90's. Major modification will basically include:
Replacement of the electric
arc furnace with a new 60-t
Danarc EAF.
Complete revamping
and modernization of the
three-strand conticaster with new
tundish, tundish car, moulds,
oscillating tables, secondary
cooling system and withdrawal
straightening units, plus
provision for the fourth strand.
New primary and secondary
fume dedusting system.
Plant auxiliaries, including
a new water treatment plant.
All electricals, automation
and process control system.
The installation
of a ladle furnace is foreseen
at a later stage.
The new meltshop's capacity will
be suitable to meet billet demand
of the existing bar and section
mill, and to supply billets to the
market, too.
The rolling mill will be
modernized by extending the
cooling bed and installing a CCL
system (multi-strand straightener
and pendulum-type cold shear)
at the delivery side to keep pace
with mill's production capacity
and enhance finished product
quality.
New bending machines for bar
bundles will also be installed.
DANEWS 143
The mill's operations will be
optimized thanks to a new
complete automation system
(up to Level 2) supplied by Danieli
Automation.
The mill is designed to produce
small bars and profiles at a rate
of up to 75 tph. ■
7

DANEWS
Acerbrag: the new meltshop
of the most modern and competitive minimill
in Argentina starts operation
On May 26th 2005, the new meltshop
successfully started operation by
delivering its first billets and enabling
Acerbrag to enter the modern era of minimill
layout design.
The state-of-the-art steelmaking plant basically
includes a 50-t Danarc EAF fitted with two
Modules for O2 and C injection and a 2/3-strand
billet caster directly connected to the rolling mill
for hot-charging operation. The supply also
included plant auxiliaries such as Fe-alloy
system, fume dedusting plant, an 80/130-t ladle
handling crane and Danieli Automation
electricals and automation for the whole plant.
This was the last step of the modernization
Layout legend
1 Scrap yard
2 50-t AC EAF and LF
3 3-strand billet CCM
4 FTP
5 60-tph WH reheating
furnace
6 19-pass rolling mill
7 QTB bar quenching
and self-tempering
system
8 Cooling bed and
automatic bar cold
finishing services
9 8-pass high-speed
wire rod finishing
block
10 Wire rod controlled
cooling line (QTR
system) and
automatic cold
finishing services
8
STEELMAKING
S
7
8
6
1
9
10
2
3
1
4
The 350,000 tpy
minimill is now the
most modern and
competitive minimill
in the country.
of the existing steelworks, a project that also
included a bar and rod mill multi-stage
reconstruction program concluded in March
2004 with the startup of the rebuilt hot rolling
mill area. The 60-tph Danieli rolling mill is
designed to produce 8 to 25-mm-dia
plain/deformed bars, up to 50-mm angles,
corresponding flats and 5.5 to 14-mm-dia wire rod
in up to 1.5-t coils. Acerbrag's new minimill, with
a 350,000-tpy nominal capacity, is now one of the
most modern and complete steelmaking and
rolling plants in operation in the country and
will grant both higher productivity and efficiency
in the manufacturing of long products. ■

Top-performing minimills:
up to 37 heats/day and regularly over 30
at Aceros Arequipa, Peru
Benchmark results from the upgraded EAF.
Best results obtained at the EAF (*)
Min tap-to-tap time 36 min (or 40 heats/day)
Productivity +10%
Electrode consumption -22%
Electr. energy from 490 to 420 kWh/ton
consumtpion of good billets
(*) With a charging mix based on 35-40% DRI content
T
he 40-t EAF at Aceros Arequipa in Pisco
performs at top levels, after the major
improvements carried out by Danieli Centro
Met. The furnace, which restarted in December 2004,
was upgraded with the installation of a new electrode
regulation system, a completely new automation
system and a "burnjector" unit for better chemical
energy utilisation.
This was part of an overall meltshop upgrading
that also included a new fume treatment plant
and the modernisation of a billet conticaster.
The burnjector gives operators the advantage
of keeping the EAF door closed during almost 95%
of the entire process, helping to increase the
slag volume inside the furnace, resulting in better
performances and efficiency.
The Pisco minimill also includes a 320,000-tpy
bar and rod mill upgraded in 2002 and completed
by Danieli Morgårdshammar in 2004 with the
installation of a new high-speed wire rod line. ■
Major upgrading of the fourth 150-t EAF
at Essar Steel, India
DANEWS 143
A confirmation after the excellent results achieved by the other upgraded Essar’s EAFs.
E
ssar Steel placed the
order for the major
upgrading of a fourth
150-ton DC EAF for its Hazira
steelworks, to increase
productivity and optimise furnace
operation. Danieli was already
contracted to upgrade three other
electric arc furnaces of the same
size at the same plant, two
of which are successfully
operating since December 2004
and May 2005.
Satisfactory results were achieved
after the EAFs’ modification, with
tap-to-tap time down to 52
minutes and electric power
consumption equal to 450 kWh/t
(against original values of 80 min
and 564 kWh/t, respectively)
with furnace operation based
on combination of 45% hot DRI
and 55% cold DRI.
The extent of the EAF No. 4
modification will be the same
as that of the other three furnaces
and will include:
Enlarging the furnace shell to
bring heat size to 155 t and hot
heel from 40 to 70 t.
Installation of the latest
generation multi-purpose
oxigen/carbon injectors, with Cu
cooling blocks.
Installation of pneumatic
lime injection system.
Automatic temperature
and sampling devices to optimise
on-line process control.
Logistics optimisation.
Level 2 automation system
for the supplied equipment. ■
Hot DRI charging into
the 150-t Electric Arc
Furnace.
9

DANEWS
New turnkey order
for a second 75-t ladle furnace
at Highveld, South Africa
Danieli Centro Met will supply Highveld
Steel with a 75-t ladle furnace
-complete with materials handling
system and water treatment plant- on a turnkey
basis. The new unit will allow an optimized
production process and an improved cleanliness
of the liquid steel coming from the LD converter
shop. Another LF of the same size was supplied
by Danieli in 1993 and operates successfully
at the same plant since then. The new inert-roof
type LF, served by a 13-MVA transformer, will be
fitted with automatic sampling equipment, wire
feeding system, emergency stirring lance and
will be suitable for granting a heating rate equal
or higher than 4.5 °C/min.
The new unit features all the latest advances in
steel refining technology and also is completely
interchangeable with the previous one for
operation and spare parts optimization. The hot
startup is expected in October 2006. ■
10
STEELMAKING
S
Since the early 80’s,
Danieli has been one of the
leaders in secondary refining
for ordinary, specialty and
stainless steels, with more
than 135 units supplied all
around the world.
The know-how gained over
many years has been used
to develop and optimize
equipment and process
so as to also meet the most
stringent customers’ requests.
Steelmaking
120-t LF
starts operation
at Hunan Valin
(Xiangtan),
P.R. of China
At the end of July 2005,
a new 120-t ladle furnace
was successfully started
up at Hunan Valin I&S Group Co.
Ltd. (Xiangtan), Hunan Province,
as part of the existing steelworks
upgrade project, which also
includes a second LF and a VD unit
of the same capacity, scheduled
for startup later this year.
When in full operation the two
ladle furnaces and the degasser,
designed to process 2.5 Mtpy
and 1.2 Mtpy of liquid steel
respectively, will be an integrated
part of Xiangtan No. 1 new
steelmaking plant and feed the
existing bloom and slab casters.
Steel grades to be processed are
high-quality tube and pipe steels,
high-pressure boiler steel, carbon
structural, shipbuilding, pipeline
and pressure vessel steel plates. •

DANEWS
FLAT PRODUCTS
F
Signing cermony, 1st row from left to right: Mr. Chen Weidong, GM of Baosteel International Trading Co.,
Mr. Jiang LiCheng, President of Baosteel Pudong Steel Co., Mr. J. Lester, Director Danieli Davy Distington,
Mr. O. Pinarello, Area Sales Manager, Danieli.
Second Danieli high-tech slab caster
at Baosteel, P.R. of China
After 6 months from the first order to Danieli Davy Distington, Baosteel awarded
the order for a second thick slab caster, to be installed in No. 3 plant in Shanghai.
T
he contract calls for the supply of a single-strand machine
with a yearly production exceeding 1.5 Mtpy of qualified slabs
in special steels, structural steels, vessel, boiler and ship
application steels. Slab sizes are 200 and 250 mm in thickness,
1500 to 2300 mm in width. The main features of the machine include:
Vertical curved design
with a vertical length exceeding
2.6 m, a 9.5 main radius and
continuous bending and
unbending roll diagram.
Top feeding dummy bar.
Complete breakout
prevention system with thermal
mapping of the mould.
State-of-the-art INMO
mould, including in-line width
adjustment during casting.
Hydraulically operated
oscillator.
OPTIMUM type segments,
designed for the application
of Dynamic Soft Reduction
process.
Air mist secondary cooling,
controlled by a dynamic model.
Complete automation
system including predicting
mathematical models for Liquid
Pool Control (LPC) and
Solidification process used for
Dynamic Soft Reduction (DSRC)
and Dynamic Secondary Cooling
(DSC) system.
DANEWS 143
Of particular note, this is the 20th
Danieli slab strand (8 in China)
adopting INMO mould technology,
the last generation patented
mould, designed with superior
zero-clearance guidance system
for outstanding slab surface
quality.
This second order awarded
to Danieli in just a few months
by Baosteel (the largest Chinese
steel producer) confirms the
leading technical position of
Danieli Davy Distington as supplier
of superior slab casting
equipment, as well as customer
satisfaction reached during the
execution of the contract of the
caster for plant No. 4, presently
under advanced design stage. ■
11

DANEWS
Thick slab caster successfully started up
at Xin Yu, P.R. of China
Excellent performances thanks to the advanced and reliable
mechanical and electrical/automation equipment supplied.
The single-strand medium slab caster
was successfully started in Xin Yu Iron
& Steel Co. Ltd. in Jianxi province on
May 12th, 2005.
It is a medium slab caster that has been
equipped with the most advanced casting
technology, such as soft reduction, hydraulic
oscillation and mould width taper adjustment.
A wide range of steel grades can be produced
at high rates, as the advanced process control
system supplies a stable and reliable condition
for the caster to maintain the high productivity
and prime quality rate.
A total of 300 t from three ladles were cast
at startup, and a daily production of more than
2200 t from 20 ladles was reached after only
12 days from the first cast. An even more
important performance achievement was
reached on July 3, 2005. After only 54 days from
the startup, the caster had processed a long
sequence of 42 ladles. During the sequence,
12
FLAT PRODUCTS
F
three different tundishes have been used by
successfully realizing two fly tundish change.
The short period between the first slab and this
goal proves that the equipment is "user-friendly"
and how easily the customer can become familiar
with the equipment. ■
Danieli high-tech
slab casting
technology
commissioned
at Jiu Quan,
P.R. of China
First slab coming out
of the conticaster
on May 12, 2005.
The automation and process
control system features
several Danieli technological
packages such as MLC,
HOC, WAM, LPC, DSRC
and QUART.
ADanieli technological
package composed of
cassette mould and hydraulic
oscillator was successfully
integrated and started up at Jiu Quan
Iron & Steel Co. Ltd. plant on April
25th, 2005. Equipped with
hydraulically actuated, mould width
taper adjustment, the Danieli Davy
Distington mould can cast 160 or
220 mm thickness of a wide range
of steel grades. The Mould Breakout
Prevention System controlled by
Danieli Automation Mould Detector
Server Software detects any sharp
temperature variations on the mould
surface and prevents any risk
of strand breakout slowing down
the casting speed. •

T
he smooth and fully
automatic commissioning
confirms the high reliability
of Danieli TSC equipment.
Benxi I & S Co. is now focusing its
production on a wide range of steel
grades, aiming to become a
reference Thin Slab Caster in China,
covering the whole range of
production both in width (850
up to 1750 mm) and slab thickness
(70 and 85 mm).
Both strands have now entered the
performance test period and up
to now several grades have been
tested for all the steel groups, from
IF steel grades to high carbon,
achieving very high quality
standards.
For the very first time in Thin Slab
Casting, silicon steel has also been
successfully cast in different grades,
as have been HLSA and peritectic
grades.
In detail, the following steel grades
have already been cast: IF steel
(St16), ELC (St 14, St 12F), low
carbon (SPHC, St12, SS330, SPH-T1,
SPH-T2, BG510-L1), medium carbon
(SS400, Q345 A, Q235 B), peritectic
steel (SS400P), HLSA MC (J55),
HLSA LC (X46, X52, SPAH), high
carbon (C45), Si steel (50BW600,
BGD, 50BW400). Processing of
additional steel grades is scheduled
in the near future.
This second strand flanks the first,
in operation since November 2004
and will allow Benxi Group to reach
the production target -as soon as the
second shuttle furnace is
commissioned.
This wide range of steel grades cast
right from the very beginning of
production confirms Danieli as the
top supplier and technology partner
in Thin Slab Caster. ■
DANEWS 143
Successful startup of the 2nd flexible Thin Slab Casting
strand at Benxi Iron & Steel, P.R. of China
Since the first heat was cast on June 19, 2005, an impressive list
of different steel grades has already been successfully commissioned.
1
2
3 4
1 Overall view of the
casting floor with the two
strands in operation.
2 Mr. Qi Zhen, Caster
Responsible (Benxi I&S)
congratulates Mr. F. Faivre,
Danieli Site Manager.
3 Pendulum shear at the
exit of the cooling
chamber.
4 Front view of the
conticaster. In the
foreground the tunnel
furnace and the dummy
bar parking.
13

DANEWS
>Work in progress<
at the 2-Mtpy hot strip mill complex
of Tangshan Guofeng, P.R. of China
W
ork on the Tangshan Guofeng
2-Mtpy hot strip mill complex,
located in Tangshan City, is
proceeding rapidly. The target for the plant startup
is 20 months from order date.
As of the end of June, all main civil works in
the rolling mill area are completed and erection
activity of Danieli Wean United equipment has
started. Danieli equipment is already on site
ready for installation and most of the locally
Incoming slab
14
FLAT PRODUCTS
Thickness 135 (mm)
Width 600 - 1,300 (mm)
Length 15,600 (mm)
Weight 21 (t)
F
Hot Strip Mill
Plant layout and main material data
Thickness 1.2 - 12.7 (mm)
Width 600 - 1,300 (mm)
Coil OD 762 (mm)
Coil ID (max) 1,850 (mm)
Weight 21 (t)
Specific coil weight 16 (kg/mm)
Roughing area Finishing area Coil conveyor line
Downcoiler area
manufactured equipment has been delivered.
Erection of the finishing mill has begun
and F5 and F6 stands are already aligned
on foundation.
The new facility will have a product mix
of 35% of carbon steel, 55% of high quality
carbon steel and 10% of low alloy steel.
Plant configuration features a reversing
roughing stand with attached edger, coilbox,
rotary crop shear, water descaler, six 4-hi
finishing stand, waterwall cooling system
and downcoiler.
The Tangshan Guofeng HSM takes
advantage of the most up-to-date and proven
rolling technology coming from Danieli Wean
United and includes the newest technology
for strip shape control:
edger HAWC (Hydraulic Automatic
Width Control);
HAGC (Hydraulic Automatic Gap
Control);
positive bending;
WR shifting;
roll thermal crown (RTC) control;
shaped roll technology to improve
flatness control.
Project development and progress are based
on a full co-operation between Danieli,
Erzhong and the Yanshan University. Each
party brings its own expertise to the project
in order to achieve the market’s strictest quality
requirements. ■

FE model for prediction of strip profile
in a 6-high cold rolling stand
The results of simulations are now used to tune
the analytical model of roll stack deflection
which is included in the control system of the stand.
I
n order to satisfy the highest quality
requirements, an accurate knowledge of rolling
parameters and strip profile is very important.
The key to achieving precision shape control is
to know the mechanical behaviour of the roll stack
and its effect on the strip.
The way to obtain a good strip profile is through
shape actuators: these devices deform rolls to give
the strip the desired shape.
To investigate the behaviour of roll stack, two fully
deformable FE models have been prepared: the first,
symmetrical, to study work roll bending and
intermediate roll bending, the latter, asymmetrical,
for intermediate roll crossing. Rolls were modeled
as perfectly elastic bodies, strip as an elastoplastic
body with exponential hardening.
Although BUR has a great stiffness (compared
to other rolls), treating it like a rigid body may give
inaccurate results in terms of strains of the strip.
Several rolling conditions were taken into account:
each shape actuator acting alone and together.
Mesh of models is uneven: in contact zones (strip-
WR, WR-IR and IR-BUR), there are small elements,
while in other parts mesh is coarse.
There is also a mesh refinement along the width
of the strip to evaluate the edge drop phenomenon.
The entire contact procedure was managed by
software; the contact algorithm automatically
detects nodes coming in contact and generates the
appropriate constraints to ensure that no penetration
occurs and the compatibility of displacements across
all touching surfaces is maintained. Every simulation
brings more results: the main ones are total rolling
load, deflection of rolls axes, shape of roll gap and
profiles of the strip. The effect of shape actuators
is described in terms of shape coefficients which
are a useful indicator of how much the stand can
change the strip profile. A new procedure to obtain
shape coefficients has been developed.
A comparison between FE simulations and real
rolling conditions was made on the total rolling load.
Results agree with experimental measurements;
in the best cases, the difference between measured
and calculated values is less than 4% (usually this
figure is considered very good when below 10%). ■
1 2
4 5
1 Stresses in the mill
housing under max
rolling load.
2 FE model of the 6-hi
roll stack.
3 Strain on the rolled
stock.
4-5 The 6-hi 3C cold
reversing in operation
at Shougang Iron &
Steel, P.R. of China.
3
DANEWS 143

DANEWS
The new temper mill at Baotou,
P.R. of China, starts operation
Another successful commissioning completed in short time.
On June 29, 2005, an official ceremony
was held to mark the first coil
successfully processed by the new
temper mill in Baotou I&S (Group) Co. Ltd.
in Baotou City, Inner Mongolia.
Mill commissioning was quite smooth and
quick, and the results exceeded all the most
optimistic expectations of both customer and
supplier.
Maximum rolling speed of 1,000 mpm and
high separating force of 1,000 t were tested
just days after the first coil.
Surface quality and metallurgical effects
of the processed strip are good and steady,
thanks to accurate strip tension control.
A reliable mechanical and hydraulic
equipment design is improved by very efficient
Level 1 and Level 2 hardware and software,
16
FLAT PRODUCTS
F
Official opening ceremony at the presence of Mr D. Li (Director of Flat Product Division,
VP of Baotou I&S), Mr. Z. Lu (Deputy Director of Flat Product Division, Baotou I&S),
Mr. Z. Bin, (Level 2 Engineer, Baotou I&S) and Danieli Project Managers.
both developed by Danieli Automation.
The final CQ, DQ, DDQ and HSLA steel
quality are guaranteed by the mill’s wet rolling
system and an electrostatic oiler downstream.
They assure the cleanliness and surface
conditions of the higher quality, saleable
product for construction and household
appliances, and later on for the automotive
industry.
A high, daily strip production rate (in its whole
dimensional range -thickness from 0.25 to
3.0 mm; width from 960 to 1600 mm- and
all steel grades) is a good guarantee of the full
potential of the temper mill (designed for
0.8 Mtpy), which was reached by the end
of August 2005, when the Final Acceptance
Certificate was signed by both parties, as
scheduled. ■

New hot skinpass mill
for Lianzhong
Stainless Steel Corp,
P.R. of China
On June 9, 2005, Danieli
and Lianzhong Stainless
Steel Corp. signed a
contract for the complete supply
of a new hot skinpass mill,
to be installed in Economy
& Technology Development Zone
of Guangzhou.
The new mill will process both
stainless and carbon steel strip
with the following dimensions:
Strip thickness: 1.2 to 6.5 mm
Strip width 800 to 1,600 mm
Max coil weight 30 t
for a maximum elongation of 4%
With a 1500 t rolling load
capacity, the mill is equipped
with HAGC, positive and negative
bending system, constant passline
and backup roll brushes.
An in-line inspection station will
allow visual check of both strip
surfaces. Main motors, for a total
of 4 MW, will allow a maximum
speed of 600 mpm.
Danieli will supply the complete
technological equipment, both
imported and local; the latter
will be delivered by Danieli
Metallurgical Equipment (Beijing)
Co. Ltd., while Danieli Automation
will supply the electrical and
automation portion, including
Level 1 and Level 2.
The startup of the plant is
expected within 18 months from
the contract placement. ■
F
Mr. Li Pi Hsien (Chairman
Lianzhong Stainless Steel
Corp.) and Mr. A. Mordeglia
(Vice President Sales, Danieli).
SSAB selects again
Danieli technology
New cold plate leveller order
for Oxelösund plant
DANEWS 143
Contract signing. From left: Mr. P. Hyvönen (Sr Contract Mgr., SSAB),
Mr. M. Righini (VP Sales, Danieli Wean United), Mr. J. Steninger
(Project Mgr., Head of Supporting, Production, SSAB) Mr. H. Eidelöf
(Project Mgr., New Investments, SSAB).
Danieli cut-to-length lines for ultra high strength steel in operation
at SSAB Tunnplåt in Borlänge, Sweden.
urther to the startup of the innovative cut-tolength
lines for high strength strip in Borlånge,
SSAB has awarded a challenging new order
to Danieli. In fact, as of June 29, a contract is in force
for the supply of a new cold plate leveler for high strength
steel, to be installed at the Oxelösund plant.
The new machine will be part of a completely new
expansion project to increase the production of the
well-known SSAB Oxelösund steel plates. The leveler
will have a 9-roll design. Rolls will be independently
driven. The roll barrel length will be 3.4 m. The design
of the machine will incorporate outstanding features
such as HAGC, roll bending, top roll independent height
adjustment, automatic cassette change. The maximum
leveling force will be 18,000 kN. The frame sturdiness
will be enhanced by four pretensioned tie-rods.
A completely innovative design will be applied to the
drives in order to optimize their performance while
keeping the maintenance as simple as possible.
Beside the complete machine supply,
Danieli will be in charge of the auxiliary equipment,
as well as the interconnecting piping. Production
for the new line is expected to start in March 2007. ■
17

DANEWS
FLAT PRODUCTS
Successful and fast startup of the cold mill complex
at Vietnam Steel Corporation
Only one month after the completion of the construction activities,
the entire facility has started its production phase.
In 2002 Danieli Wean United received an
order for a new Cold Mill Complex to be
installed at VSC in the Phu My industrial
area, Ho Chi Minh City. After a very fast period
of manufacturing and installation of the new lines,
the commissioning period started. Only one month
after the completion of the construction activities,
the entire facility started its production phase.
The following lines are now running:
a Push-Pull Pickling Line,
a Single Stand Cold Reversing Mill,
a Single Stand Cold Reversing & Temper Mill,
a Batch Annealing Plant,
a Recoiling and Tension Levelling Line.
Since the beginning, the equipment has performed
at a very high level.
The plant soon will reach its maximum yearly
production of 405,000 tpy; material that will be
used in the local construction industry, automotive
Customer satisfaction
Mr. Huynh Quang Bau,
General Manager of Phu My
cold rolling complex (PFS),
VSC Group, congratulating
with Mr. Antonello Mordeglia,
Vice President Sales, Danieli.
F
1
2 Cold mill complex
layout:
Pickling line
Provision for
cleaning line
Batch annealing
furnaces
Cold reversing
mill
Cold reversing
and temper mill
Coil transfer
Coil transfer and
tilter
Recoil and tension
level line
BAF control and
electrical rooms

2
industry and home appliances. Until now,
Vietnam has been importing this kind of product.
The special design of the pickling tanks grants
a constant and defect-free flow of pickled coils
for the downstream lines.
Thanks to a perfect optimisation of mechanical
equipment and automation process, the CRMs
are now rolling thickness down to 0.25 mm,
reaching a maximum speed of approx. 1,200 mpm.
The complex is controlled by Level 1 and Level 2
automation systems including all mathematical
models for quality control.
A common server will provide coils tracking during
the production cycle.
The maintenance system will be based on Fast
Data Analyzer (FDA) server/client configuration
that will allow the system monitoring from every
electrical cabin or pulpit.
The surprising results achieved by Danieli indicate
a highly professional level of job execution and
project management, and the key has been the
coordination between Danieli Wean United,
Danieli Automation and Danieli Service. ■
3
4
5
6
DANEWS 143
1 Entrance of the Office
building.
2 The Turboflo push-pull
pickling line.
3 Cold rolling mills bay.
4 Control pulpit of the
push-pull pickling line.
5 Batch annealing bay.
6 Close-up on the cold
reversing and temper mill
stand.
19

THE MOST MODERN MINIMILL
FOR ULTRA-LIGHT GAUGE HOT STRIP
Without any doubt a highly competitive minimill complex thanks to: Danarc EAF, long funnel mould
and soft reduction Thin Slab Caster, flexible crown-free rolling HSM, Self-learning automation.
FACTS CONFIRM
DANIELI WORLD-CLASS
ACHIEVEMENTS
IN INTEGRATED AND
FLAT PRODUCT PLANTS

FROM DANIELI SCORECARD (FLAT PRODUCTS) 96 BLAST FURNACE PROJECTS 135 ELECTRIC ARC FURNACES
210 SECONDARY METALLURGY STATIONS 71 THICK SLAB CASTING STRANDS 24 MEDIUM/THIN SLAB
CASTING STRANDS 150 HOT STRIP AND PLATE MILLS, 4 OF WHICH THIN SLAB ROLLING PLANTS
14 STECKEL MILLS 86 COLD ROLLING MILLS 282 NARROW COLD ROLLING MILLS FOR NONFERROUS
METALS AND STAINLESS STEELS 144 STRIP PICKLING LINES 89 HOT DIP GALVANIZING AND ALUMINIZING
LINES 108 ELECTROLYTIC TINNING LINES 23 COLOR COATING LINES 332 SLITTING AND SHEARING LINES
267 GRINDING MACHINES FOR SLABS 717 BASIC AUTOMATION AND PROCESS CONTROL SYSTEMS
IN FLAT PRODUCTS
Danieli Headquarters
Via Nazionale, 41
33042 Buttrio (UD) Italy
Tel. (39) 0432.5981
Fax (39) 0432.598289
www.danieli.com

DANEWS
Strip processing lines full on-stream
at Tisco, P.R. of China
Final Acceptance Certificate for both the pickling line (CPL1)
and the galvanizing line (CGL1) was signed on June 21, 2005.
The strip processing lines successfully
put into operation at Tangshan I&S Co.,
with full customer satisfaction, once
again confirmed the leading position of Danieli
Wean United technologies for strip pickling and
galvanizing lines. The pickling line is designed to
process HR steel strip at a rate of about 1.5 Mtpy
of pickled coils. The strip ranges from 0.8 to 4.0
mm in thickness and 850 to 1,680 mm in width
with a maximum coil weight of 30 t. The process
section of the line, based on the patented Danieli
Turboflo system, consists of three tanks with
backup rinse cell, a five-stand rinsing section and
three horizontal accumulators for continuous
operation, allowing a maximum process speed
of 306 mpm. The galvanizing line has a capacity
of 450,000 tpy for galvanized (GI) and galfan (GF)
products with CQ, DQ and HSLA grades, and is
1
22
FLAT PRODUCTS
F
2
designed to supply galvanized steel to all major
markets, including products for construction and
domestic appliances. The line processes HR
pickled and CR steel strip with a thickness range
from 0.3 to 2.0 mm and a width range from 850
to 1,680 mm at speeds up to 180 mpm.
Final products include normal, minimized and
no-spangle coating, with coating weights ranging
from 60 to 600 g/m 2 . The first coils were produced
at the end of November 2004 (pickling line) and
of December 2004 (galvanizing line). Since then,
the two lines have produced galvanized and
pickled strip of excellent quality with an optimal
learning curve.
Another pickling line and galvanizing line
are being supplied by Danieli to Tisco.
Installation works are expected to start at the
beginning of August.
These new lines will enable Tisco to achieve
a remarkable position in the Chinese market
as a reliable supplier of high quality pickled and
galvanized products and, at the same time, will
strengthen the success of Danieli technology and
equipment for strip processing lines. ■
1 DFF and radiant
tubes vertical
annealing furnace in
the galvanizing lines.
2 Overall view of the
Turboflo continuous
pickling line.
3 4-hi skinpass mill
at the exit of the
galvanizing line.
3

Danieli Kohler
technology
for Hyundai plant
Revamping of the combined
pickle-galvanizing line at the Dangjin
Works in Chungnam, Korea.
DDanieli Kohler will upgrade the wiping
equipment at Hyundai HYSCO’s combined
pickle-galvanizing line at the Dangjin Works
in Chungnam. The original equipment was purchased
by Hanbo Steel and installed in 1995, but never
commissioned.
After a thorough analysis, the mechanical equipment
was found to be in excellent condition. Minor
upgrades had to be made to the elevator/positioners,
while the only parts replaced were seals and
instrumentation and the edge baffle rig with a more
modern design. Demand for high quality coating
on HR product will be met by Dual Kohlerjet Airknives,
elevator/ positioners, edge baffles, roll equipment
and completely new automation. Danieli Automation
will supply a complete new automation package of
PLC with remote I/O, operator desk with HMI, local
control panel and MCC. Working within HYSCO's
demanding schedule, Danieli Kohler's innovative
design and production team was able to modernize
the equipment with minimal changes to reach
the required performance. •
F
our slitting lines have
been set for delivery since
beginning of 2005 for
Danieli Fröhling. This includes the
aluminium slitter for Yun Cheng,
the two slitting lines for Tong Ling
(all to P.R. of China) and the
slitting line for steel products to
Zaporozhstal (Ukraine). The Yun
Cheng line is already under
construction. Good cooperation
with the customer, which had
already been established in the
joint design effort, was a proper
basis for the following cold and
hot test phase, and acceptance.
Mr Peng, Deputy General Manager
of Yun Cheng stated in a letter
after the meetings were finished:
"…I would like to take this
opportunity, on behalf of our
management and the project
team, to extend our sincere
thanks to you and your excellent
project team…".
Danieli Fröhling's experienced
DANEWS 143
Timely supply and
installation of four Danieli
Fröhling cutting lines
Tong Ling (two lines)
and Yun Cheng in P.R. of China,
Zaporozhstal in Ukraine.
1
2
commissioning staff supervises
the activities and supports
customer in on-site training and
production startup. Tong Ling's
line installation will start soon,
as the equipment for Zaporozhstal
is right now on the way to
Ukraine. Sixteen trucks were
needed to ship the complete
equipment from Germany to the
site of the third largest Ukrainian
steel producer. Despite the strict
time schedules and complexity
of the lines, Danieli Fröhling
was able to keep the deadline
for supply in order to meet the
tight further schedules
of the project itself. ■
1 Danieli Fröhling and Yun
Cheng design liaison
teams.
2 Installation of the
800-mpm slitting line
for aluminium strip
(thickness from 0.05
to 0.4 mm; width up to
1400 mm) at Yun Cheng’s
Kunshan facilities.
23

DANEWS
Rolling mill modernization
at KM Europa Metal AG, Germany
This is the third consecutive order for a rolling mill awarded
by KME and represents the most extensive revamping project
ever carried out by Danieli Fröhling.
24
FLAT PRODUCTS
KM Europa Metal AG (KME) has been
a satisfied customer of Danieli
Fröhling for more than 30 years, both
for rolling mills and cutting lines. KME is the
worldwide largest copper and copper alloy
manufacturer, and produces more than
700,000 tpy of high value material.
In spring 2005, Danieli Fröhling was awarded
a contract for the modernisation of a cold mill.
The primary goal of the project is to increase
rolling speed up to 600 mpm, and of the torque
of all related machines as a result
of optimisation of the drives, combined with
completely new dimensioning of main drives.
For further improvement of material qualities,
additional actuators for flatness control will be
implemented. This includes the positive and
negative bending of work rolls combined with
a sophisticated selective cooling system.
The necessary shapemeter roll of the latest
design features zone distances of 26 mm
F
even in the edge area of the rolled material.
In order to obtain wide tension range,
the two reversing reels will be equipped
with a combination of two different drives.
The stop times shall be drastically reduced
by means of a new work roll changing car,
leading to changing times less than five
minutes.
A special design is foreseen for the mill
stand itself: the new diagonal arrangement
of bending blocks will allow an exact and
symmetric distribution of bending torque
toward work rolls and bearing arrangements.
This ambitious order emphasizes both the
trust in available know-how and the good
experience gathered by the Customer during
previous order executions. Danieli Fröhling
will demonstrate that it has earned this trust
and do the utmost to set another benchmark
in design, supply and execution.
Startup is planned for early 2006. ■
1 A Danieli Fröhling 4-high
cold reversing mill at KME
in Stolberg.
2 Detail of the reversible
coiler.
3 Close-up of WR and BUR
package and actuators for
flatness control.

DANEWS
LONG PRODUCTS
L
FastCast bloom casting technology in India:
New special steel conticaster
for SISCOL (India)
Siscol (Southern I&S Co Ltd)
has contracted Danieli
to supply a bloom caster
for the production of 600,000 tpy
of large-size special steel blooms
at Tamil Nadu.
The 3-strand, 12-m-radius
conticaster will be designed
to cast 200 to 400-mm-dia round
and 200x200 to 340x400-mm
square or rectangular sections
in a wide range of top-quality
steels such as high carbon,
free-cutting, cold-heading, ball
bearing, and low alloy grades.
The new caster's capacity will be
in line with the existing
meltshop's 90-tph rated output
Tangshan I&S chooses Danieli
technology for its new high capacity
quality steel billet caster
I
n June 2005 Tangshan I&S
Group Co. Ltd awarded
Danieli the order for the
supply of a new 6-strand billet
caster for quality steel grades.
The 9-m radius CCM will have a
1.2-Mtpy nominal capacity for
production of 150x150-mm billets
in different quality steel grades,
including low, medium and high
carbon and low-alloy fine-grain
steels. Ladle shroud, tundish
stopper rod device associated
with submerged nozzle and mould
powder practice will allow a
complete protection of liquid steel
stream, thus reducing the oxygen
pick-up and consequently the
capacity and it will be equipped
with all the latest technology
available for quality steel bloom
casting, such as submerged
nozzle, electromechanical stopper
rods, radioactive mould level
detection, EM stirrers, hydraulic
oscillators and air mist secondary
cooling. The caster's outlet
will be equipped with oxy-cutting
torches and a cooling area with
slow-cooling facilities for
the most sensitive steel grades.
Level 1 and 2 automation and
process control systems will be
supplied by Danieli Automation.
Startup is planned in the third
quarter 2006. ■
non-metallic inclusion content.
Thanks to a 1.000-mm-long mould
copper tube, high speed casting
will be available and steel output
from the individual strands will
range 28 to 30-tph/strand,
according to the specific steel
grade being cast. The machine
also will be equipped with Danieli
Rotelec mould EMS, to achieve
high sub-surface and internal
quality, and hydraulic mould
oscillation to enhance billet surface
quality. Complete process control
with Level 2 automation
will be supplied. The new casting
machine will deliver its first billet
in September 2006. ■
DANEWS 143
>FastCast<
25

DANEWS
Casting quality: evolution in CCM technology
The latest generation of Danieli hydraulic oscillators
Product quality in continuous casting
mainly originates in the mould.
For this, great efforts have been made
to optimize mould level control, tapers,
lubrication and oscillation. To date, Danieli
hydraulic oscillator technology has been
adopted in 29 continuous casting machines,
for a total of 135 billet strands, worldwide (see
References Table).
Different mechanical design and two main
families of hydraulic driving units are available,
as reported in the following table:
26
LONG PRODUCTS
Mechanical Guides Drive location
Short lever
(No cantilever weight)
Bearings On the lever
Short lever Leaf springs On the oscillator
(Cantilever weight) table
The most significant parameters are stiffness
of the design, levers and leaf springs compact
shape, pivot point proximity to the machine
radius and minimization of the inertia.
A family of moulds featuring stationary EMS
supported by a dedicated frame was developed
by Danieli in order to reduce the oscillating
mass. This way, it is now possible
to consistently achieve the tightest mechanical
tolerances, as reported in the following table:
Typical tolerance achieved (acceleration

FastCast<
Radial deviation
@ 6 mm stroke (mm)
Specialty steel casters equipped with hydraulic oscillators.
Customer Year Strands Outfit for Steel
and
radius (m)
grades
29 Corus Scuntorpe, UK 2005 6 12 230x283 CS, AES
28 Benxi I&S, P.R. of China 2005 4 14 350x470 CS, AES
27 Nanjing I&S, P.R. of China 2005 6 14 rd 380, rd 450, rd 500 CS, AES
26 Tangshan I&S, P.R. of China 2005 6 9 sq 150 CS, AES
25 Siscol, India 2005 3 12 sq 250, 350x400, rd 200, rd 310 CS, AES
24 AG Siderurgica Balboa, Spain 2005 6 10 sq 140/160/250, bb 220x280x90,
320x400/610x100 CS
23 Seah-Besteel, Korea 2005 2 16.5 390x510 CS, AES
22 Deacero SA de CV, Mexico 2005 6 10 sq 170 CS, AES
21 Republic, USA 2005 5 10 sq 6 3/4”, 9 3/4”x7 1/2” AES
20 Qasco, Qatar 2005 4 8 sq 130, sq 150, sq 200 CS, AES
19 Charter Steel, USA 2004 4 9 sq 7”, sq 1/2” AES, SS
18 Sail - DSP, India 2004 4 9 sq 200, 160x210, 160x230,
150x300, 150x350 CS, AES
17 Mechel I&S works CCM4, Russia 2004 6 9 sq 100 CS
16 Hunan Valin I&S, P.R. of China 2004 4 12 rd 220, rd 280, rd 330 AES
15 NAS, USA 2004 4 10 sq 165, sq 200 SS
14 Corus Aldwarke, UK 2003 5 10 sq 180, sq 210 CS, AES
13 Aceralia Zumarraga , Spain 2003 6 7 sq 160 CS, AES
12 Baosteel Shanghai #5, P.R. of China 2002 3 9 sq 160 AES, SS
11 Mechel I&S works CCM3, Russia 2002 6 9 sq 100 CS
10 Taiyuan I&S Co, P.R. of China 2001 4 8 sq 220, 175x215 CS, AES, SS
9 Acciaierie Valbruna, Italy 2001 4 10 sq 145, sq 160, sq 180, sq 220 SS
8 Acciaierie Venete, Italy 2001 4 7 sq 160 CS, AES
7 ISPAT Stahlwerk Ruhrort, Germany 2001 6 9 sq 130 CS, AES
6 ABS Acciaierie Bertoli Safau, Italy 2000 2 9 160x200, 200x240 AES, SS
5 Sidor, Venezuela 2000 6 8 sq 130 CS, AES
4 Shougang I&S, P.R. of China 2000 4 10 sq 180, 160x200, 160x245 CS, AES
3 Sidenor, Spain 1999 6 9 sq 155, sq 185 CS, AES
2 Tung Ho Steel, Taiwan 1999 4 10 sq 130, sq 150, sq 200 CS
1 Ori Martin, Italy 1998 5 5 sq 140 CS, AES
Carbon Steels: CS Alloy Engineering Steels: AES Stainless Steels: SS
1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
Old New
0 50 100 150 200 250 300 350
frequency (OPM)
1 Comparison of actual
results from an SBQ
shop, before and after
oscillators eplacement.
2 Performance
monitoring.
DANEWS 143
Actual measurements made in an SBQ shop
(before and after the replacement of
oscillators) are shown in Figure 1. All these
indications brought us to the use of hydraulic
oscillators capable of exceeding 400 OPM,
without affecting mechanical performances.
Maintenance-free design (with no moving
parts, no joints and no need of lubrication) is
another important feature of Danieli oscillators.
Their performances can be continuously
monitored via accelerometer or through the
trending snapshot function, typical of our high
sampling rate control units (Figure 2).
The large number of the latest generation
compact hydraulic oscillators in operation has
proven the achievement of tight mechanical
tolerances and high performances, introducing
outstanding quality improvements in cast
products. A significant practical example is
reported in Quality Improvement Table:
Quality improvements on SBQ billets with hydraulic oscillators
Item All strands Danieli compact
(previous design) (latest generation)
Powder Occasionally Fully absent
entrapment present
Surface
scrap/downgrade
2.2 % 0.6%
a latest generation Danieli compact design
hydraulic oscillator was run for 4 months, enabling
a full and detailed tracking of the results, in
comparison with the rest of the strands, still
equipped with the previously designed oscillating
tables. ■
Simmetrical shape
of the frictional pattern
Unconsistent behaviour
2
27

DANEWS
28
LONG PRODUCTS
Corus chooses Danieli again for major
steelworks modernization at Scunthorpe (UK)
Danieli will install a new bloom caster, reheating furnaces
and a 7-stand breakdown mill.
Contract signing ceremony at Danieli headquarters with the presence of Mr. A. Page, Managing
Director (Corus Construction), Mr. P. Hogg, Director (Wire Rod Business), Mr. D.B. Lawson,
Director Scunthorpe Cast Products. Pictures at bottom and right show the bloom caster
successully started up at Corus Aldwarke in Rotheram, UK in February 2005.
T
he contract is part of Corus' previously announced £130 million investment at Scunthorpe steelworks, and
includes the installation of a new bloom caster and the development of the Rod Mill to accept direct-cast
bloom feedstock. Mr Andrew Page, Managing Director of Corus Construction and Industrial commented:
>Danieli has an excellent reputation for innovative caster design and offered us the best technical
solution to meet our product requirements. The enhancements will deliver consistently high product quality
and create a shorter, more efficient process route.<
>The benefits of the total investment will extend the scope of the whole Scunthorpe operation, significantly
improving the Medium Section Mill's rolling capability by enabling the introduction of rail manufacture to
the site alongside structural sections and by delivering a world class supply chain for wire rod manufacture.<
Plant modification will include:
1) A new 6-strand Danieli bloom caster.
2) Major upgrading of the 4-strand wire rod mill.
3) Bloom reheating facilities for the medium
section mill.
1) The new 6-strand, 12-m-radius conticaster will
be suitable for casting 1 Mtpy of 283x230mm
blooms at a rate of 230-250 tph. A wide range
of steels will be cast, including low carbon, high
strength structural, tyre cord, free cutting, cold
heading, spring, bearing and commercial grades.
The machine will be equipped with all the latest
conticasting technology such as a long tubular
L
mould (equipped with a radioactive mould level
control), a mould powder measuring device
(MPMD) and a mould EMS (external type),
hydraulic oscillating tables, extensive below
mould support, an air-mist secondary cooling
system and a dynamic soft reduction system with
six modules per strand.
The conticaster will operate with protected
stream technology using a liftable ladle turret
(300 t capacity), liftable tundish cars and an
electromechanical stopper rod. A flexible dummy
bar system will be used, with the dummy bar
parked on transport roller tables. An oxy-cutting
system, complete with sample cutting system,
>FastCast

will cut the blooms into 5 to 9.4-m long sizes.
A mechanical deburring system, a marking system
that hard-stamps blooms with a bar code, a lateral
lifting system, walking beam cooling beds
and a collecting table for normal and slow cooling
processes, will complete the machine.
The conticaster was designed for high levels
of casting speeds and productivity. In addition,
the low internal strain during straightening and
the control of the liquid and mushy zones for soft
reduction will result in consistently high quality
products.
2) The 4-strand wire rod mill will be upgraded
with new reheating facilities, a single-strand
compact breakdown mill and a heated roller
table for connection to the existing 4-strand mill.
This will allow the increase of billet size to
283x230mm or 180x180mm conticast blooms,
weighing up to 4.5 t. The new 200-tph Danieli
Centro Combustion walking beam reheating
furnace with feeding, delivery and descaling
facilities is designed to grant high productivity,
minimized fuel consumption, as well as low
decarburization and scale losses. The singlestrand,
high-speed, twist-free breakdown mill will
be made up of seven heavy-duty SHS housingless
stands arranged in V and H positions. A Danieli
Centro Combustion heated roller table will be
provided for temperature equalization and proper
delivery of the feeding section to the 4-strand
rolling mill. A crank shear, located at new
breakdown mill's exit, will enable the cropping
of 283x230 mm, 4.5 t blooms in order to cope
with mill's present coil weight dimensioning
(up to 2.2 t coils).
3) Danieli Centro Combustion will also be
responsible for the relocation of an existing
reheating furnace to Scunthorpe's medium
section mill. This will also include the upgrade
of some furnace components (e.g. burners,
combustion and process control system).
The furnace will process up to 355x305 mm
blooms at output rates of up to 160 tph.
Scunthorpe Steelworks' upgrade programme
will be carried out on a turnkey basis which
will include electric and automation systems
from Danieli Automation as well as various
plant auxiliary systems. Civil works and buildings
modification for the new conticaster will also
be part of the supply. ■
>Fast Cast< billet casting technology
Record productivity
at Mechel, Russia
Since the middle of last
year, the 6-strand
FastCast billet caster in
operation at Mechel -Chelyabinsk
Metallurgical Plant- has
performed at record levels,
reaching a productivity rate
in excess of 90,000 t/month
of cast billets. The installation
of the new conticaster introduced
a radical change in the
Chelyabinsk plant production
route, enabling the existing rolling
mills to be directly supplied with
100-mm conticast billets,
eliminating the need of the
existing blooming mill, and thus
DANEWS 143
enhancing plant productivity
and efficiency, and reducing
production costs.
A second 6-strand FastCast
conticaster, presently under
construction, will be installed
and started up in the second
quarter of 2006.
Mechel is one of Russia's leading
metals and mining companies
and has a total capacity in excess
of 6 Mtpy of carbon and specialty
steels. ■
29

DANEWS
Second high-capacity SBQ mill
at Jiangyin Xingcheng, P.R. of China
Two orders of this kind in just few months prove
full confidence in Danieli Morgårdshammar technology.
Just a few months afteer the order
of a 500,000 tpy SBQ mill, Jiangyin
Xingcheng Special Steel Co. Ltd., No.1
producer of bearing steels in China, awarded
Danieli a contract for a second, larger SBQ
mill to be installed beside the first one.
The project will be executed by DME - Danieli
Metallurgical Equipment (Beijing) Co. Ltd.,
the recently established company located in
the Beijing BDA area.
DME is also in charge for part of the other
XingCheng mill under construction.
The new 180-tph rolling mill, one of the largest
plants for long products in China, will produce
800,000 tpy of 120 to 250-mm-dia SBQ bars
and 100 to 180-mm squares for automotive
and engineering applications.
Starting material will be 370x490-mm blooms,
weighing from 6.2 to 9.4-t in carbon and alloy
structural steels, ball bearing, spring, cold
heading and pipe blank grades.
The rolling mill will be basically made up
of a reversing Break-Down stand (mechanized
with front and back work tables and
manipulators), plus a continuous finishing mill
made up of six-stands in H and V arrangement.
Fast changing systems will be provided for
both BD and finishing stands ("ready-to-roll"
concept). This, together with the dedicated
roll-pass design arranged in “families,” will
enhance the mill's efficiency and operation
flexibility.
State-of-the-art finishing facilities will include
online hot saws for "net-end" cut-to-length
of bars to further enhance product
marketability.
Plant startup is scheduled for spring 2007. ■
30
LONG PRODUCTS
L
6
1
Rolling Mill No.1
1 WB reheating furnace
2 18-stand mill
(SHS housinless stands)
3 5-pass Kocks-Danieli RSB-
Reducing & Sizing Block
4 Cooling bed
5 Cold bar finishing services
7
2
Layout of the two Jiangyin Xing Cheng SBQ mills.
8
3
Rolling Mill No.2
6 WB reheating furnaces
7 Reversing Break-Down stand
8 6-stand finishing mill (SHS
housingless stands)
9 On-line hot saws
10 Cooling and collecting
services
5
9
4
10

FACTS CONFIRM
DANIELI LEADERSHIP
174
DWB
AND TMB
HIGH-SPEED
BLOCKS
SUPPLIED
SINCE THE
MIDDLE 70’s
New wire rod line at INCA, Dominican Republic
The new production line will complete the Danieli bar mill operating since 2001.
The new wire rod line
at INCA (Industrias
Nacionales, C por A) in
Santo Domingo will be made up
of an eight-pass twist-free
finishing block, water-cooling
line, loop layer, roller cooling
conveyor and coil finishing
facilities.
This will allow the production
of 5.5 to 12.7-mm wire rod in
coils at speeds of up to 80 mps.
The Danieli bar mill has always
performed at high levels and far
above its nominal capacity.
An upgrade project was carried
out at the beginning of 2005
aimed at doubling present output
capacity to 50 tph, particularly
for the smallest-size rebars
production. This included the
New wire rod mill
at Talleres Y Acero,
Mexico
After a steelmaking plant and
a rolling mill, again Talleres
Y Acero relies on Danieli.
The new mill will have a nominal capacity
of 300,000 tpy and will be made up of 14 SHS
housingless stands and a 10-pass twist-free
finishing block plus DSC-controlled cooling line and
coil finishing facilities. The scope of supply also
includes electricals, automation and process control
systems, as well as auxiliary plants and services such
as water treatment plant, compressed air system, roll
turning shop, etc. The product range will be 5.5 to
16-mm-dia wire rod in low and medium carbon and low
alloy steels, in coils weighing up to 1.5 t. Plant startup
is scheduled for the second quarter of 2006. ■
introduction of two-strand slitrolling
technology, extension
of the cooling bed and associated
feeding and delivery facilities,
as well as various auxiliary
equipment.
The plant, a typical example of
small-scale, highly productive and
efficient long product rolling mill,
produces 9.5 to 25.4-mm-dia
rebars for concrete reinforcement
that are supplied to the entire
Caribbean area. ■
1 External view of the rolling
mill building.
2 The finishing mill features
H and V SHS housingless
stands.
3 The 42-m-long cooling
bed with “twin channel”
high-speed bar delivery
system.
1
2 3
DANEWS 143
10-pass high-speed Delta-type
wire rod finishing block, laying
head and controlled cooling
conveyor similar to those being
supplied to Talleres y Acero.
31

DANEWS
Rolling mill starts operation
at Southern Steel Corporation (VSC Group), Vietnam
It is the first startup step for the 500,000 tpy minimill supplied on a turnkey basis.
1 External view of the
rolling mill building.
In the forefront the
electric substaion and the
oxygen plant are shown.
2 The first billet enters the
roughing mill stands.
3 First rolled bars on the
cooling bed.
32
LONG PRODUCTS
The 400,000-tpy bar
and rod mill started its
commissioning stage
at the beginning of August 2005.
The 500,000-tpy steel meltshop
section, featuring 70-t EAF, LF,
three-strand billet caster and
auxiliaries, is foreseen to start
operation by the end of 2005.
The new Southern Steel
Corporation steelmaking and
rolling plant (part of VSC-Vietnam
Steel Corp.), features all the latest
Danieli technologies in long
products production and is the
largest and most advanced project
ever undertaken in Vietnam
in this field.
The 80-tph state-of-the-art bar
and rod mill is fed by a Danieli
Centro Combustion walking hearth
reheating furnace and it is made
up of 18 SHS housingless
stands, a 10-pass Delta-type
high-speed wire rod block, plus
1
L
2 3
1 Scrap yard
2 Fume dedusting
plant
3 Ferroalloy and
additive storage
4 Meltshop
5 Casting bay
6 Reheating furnace
and rolling mill
7 Roll shop
8 Wire rod line
9 Cooling bed
10 CCL system and
stacking station
11 Water treatment
plant
12 Maintenance
workshop
8
9 10
12
7
11
6
1
3
4
2
5

production outlets for structural
and quality steel straight bars,
wire rod coils and sections.
Product range is 10 to 50-mm-dia
plain and deformed bars, 40 to
100-mm angles, corresponding
channels and 5.5 to 16-mm-dia
wire rod in coils weighing up to
2000 kg.
Danieli Automation supplied all
electricals, automation and process
control systems. ■
Southern Steel
Corporation Project
Milestones from
the contract signing
to startup
500,000-tpy rolling mill for
large-size SBQ bars started up
at Shijiazhuang, P.R. of China
nother high-productive rolling mill
for special steel long products has
started up successfully in P.R. of China,
extending the long list of the Danieli plants in
operation there. At the end of June 2005, the
first bars were rolled and the commissioning
stage started at the new 500,000 tpy large size
bar mill for automotive special steels at
Shijiazhuang Iron and Steel, Hebei province.
The 15-stand bar mill is designed to produce
50 to 150-mm-dia SBQ bars with strict
dimensional tolerances, optimal surface quality
and suitable technological properties, at rates
of up to 100 tph. Entirely made up of SHS
housingless stands in H and V arrangement with
automatic fast changing facilities, the mill also
features a Danieli Automation HiPROFILE ®
A
laser measuring unit. The state-of-the art
finishing facilities, featuring slow and natural
cooling, enable on-line thermal treatment of bars,
according to needs. ■
On June 30th hot rolling
of the first bars was
celebrated with a
ceremony, held in the
company of high-ranking
local authorities, top
company responsible and
suppliers representatives.
DANEWS 143
33

DANEWS
34
LONG PRODUCTS
L
Two high-capacity bar and section mills
started up at Magnitogorsk, Russia
The most modern rolling mills for long products in Russia.
One of the largest single-step reconstruction projects ever
undertaken in recent years in the field of long products mills
in Europe is coming to a conclusion after the successful startup
of two of the three new high-capacity rolling mills at MMK.
The new 800,000 tpy section mill and the 600,000 tpy bar mill started
operation in mid-June and July, respectively.
1
8
15
2 3 4 5 6
9
10
The MMK project to completely
replace the hot-rolling facilities
in a single step also includes
a 130-tph, two-strand high-speed
wire rod mill, to be started up in
January 2006. Full satisfaction
on the quality of the job done
and the collaboration with Danieli
was expressed by Mr. Ghennadij
Senicev, MMK General Director,
who also recalled the company’s
previous positive experience
with Danieli thanks to the hot dip
galvanizing line in operation
since 2002.
The three superflexible rolling
mills will together comprise
a capacity of over 2 Mtpy.
This was one of the most ambitious
16 17 18
13
11
14
19
recent projects for MMK, Russia's
largest single-site integrated steel
works with a 10-Mtpy overall
capacity, and one of world's
largest steelmaking companies.
The main features and highlights
of the two plants:
The 16-stand, 130-tph bar
and section mill is designed to
produce 22 to 75 mm plain and
deformed bars, up to 125-mm
angles, up to 180-mm channels,
flats, I-beams and special profiles.
The 18-stand, 100-tph bar
and bar-in-coil mill is designed
for producing 10 to 50 mm plain
and deformed bars, corresponding
small sections and 14 to
12
7

36-mm-dia bar-in-coils in quality
structural and alloy steel grades.
The 800,000 tpy wire rod mill
will produce 5 to 22-mm-dia plain
and 6 to 16-mm-dia deformed
quality structural and engineering
steel wire rod, in 2-t coils at
speeds of up to 110 mps.
Danieli Centro Combustion
supplied the walking hearth
reheating furnaces for the three
rolling mills, while all electricals,
automation and process control
systems up to Level 2 are supplied
by Danieli Automation. ■
Wire rod mill
1 WH reheating furnace
2 Single-strand high-speed
rougher
3 Double-strand intermediate
mill
4 Single-strand twist-free
prefinishing mills
5 High-speed finishing blocks
6 DSC controlled-cooling lines
7 SUND coil finishing facilities
Bar and bar-in-coil mill
8 WH reheating furnace
9 18-stand rolling mill
10 QTB line
11 Cooling bed and services
12 Finishing facilities
for straight bars
13 Coilers
14 On-line coil controlled
cooling and handling
facilities
Bar and section mill
15 WH reheating furnace
16 16-stand rolling mill
17 Cooling bed and services
18 On-line multistrand
straightening and
cut-to-length services
19 Automatic stacking,
bundling and collecting
services
Worldwide new orders for section
and bar rolling mills
Upgrading of Celsa rolling mills
in Spain and Poland
Celsa (Compañía Española de Laminación,
S.L.) has contracted Danieli Morgårdshammar
to upgrade two of its rolling mills in Spain and
Poland.
Celsa Barcelona bar and rod mill: two SHS
housingless stands added to the four-stand
Danieli compact rougher in operation since
2000 and various auxiliary equipment will
enable rolling of larger-size billets, increasing
the rolled stock weight up to 3 t. Startup
of the new stands is scheduled for Q1, 2006.
The upgrading of the double-strand
bar and section conti-mill at Celsa Huta
Ostrowiec is aimed at expanding the product
range for smaller sizes. On each strand, two
vertical stands will be replaced with combined
H/V P-624-series housingless stands to allow
rolling down to three-strand slit 8-mm-dia
rebar. The supply also includes quick rollchanging
facilities (also for the existing stands),
guides, and auxiliaries. New equipment
installation will start in November this year.
Jumbo-size straightener
at Dongkuk, Korea
In June 2005, Dongkuk Steel Mill Co. Ltd.
awarded Danieli Morgårdshammar the order
for a nine-roll double-support Jumbo-size
straightener for its Pohang Works section mill.
The unit, located at the delivery side of the
cooling bed, will perform on-line straightening
of up to 600x300 or 400x400 mm H-beams,
up to 150-mm angles and 250-mm channels.
The new design will allow production of highquality
finished products with very close
tolerances. The machine, sized for a maximum
straightening modulus of 2000 cm 3 , will be
equipped with five powered bottom rollers,
four adjustable top rollers, load cells for
straightening load monitoring, and it will
feature an adjustable pass line in relation to
the product being processed. An automatic
robotized quick roll changing system will be
added too. Danieli Automation will supply
electricals and controls. The commissioning
of the new straightener is scheduled for August
2006. The order also includes a new advanced
DANEWS 143
descaling system for H-beams to be installed
at entry side of stands #7-8-10 of the rolling mill.
This order extends Danieli record for Jumbo-size
straighteners which already lists several similar
units supplied in the Far East, Europe and
P.R. of China for in-line straightening of largesize
profiles and rails.
Stacking plant extension
at Nucor Jewett (TX), USA
The Danieli single-head 18-m-long magnetic
stacker in operation since 2000 at the Nucor
Steel, Jewett No.1 bar and light section mill will
be extended -as originally foreseen- by a 6-m-long
section. The additional section will be added at
the cooling bed side in order to allow operation
in one 24-m-long or in two independent and
symmetrical 12-m-long sectors. Thus, the stacker
will be able to handle four 6-m-long or two 12-mlong
or one 18-m-long bar layers for a range of
products that includes up to 75-mm angles and
channels, 25- to 100-mm flat bars and up to
35-mm plain and deformed rounds, in stacks
weighing up to 5 t, at rates of up to 110 sht/h.
Danieli Automation will supply the electricals
and automation and process control system. ■
35

DANEWS
Second Danieli Spooler line
at Nervacero (Spain)
Full customer satisfaction for this revolutionary technology.
Afew months after the starup
of the first Danieli Spooler line,
now in commercial production
to full Customer satisfaction, Nervacero SA
(Celsa Group) placed the order for the second
line to be installed at its double-strand rolling
mill in Vizcaya.
Installation of the second Spooler line
will take advantage of the mill’s full potential
capacity (150 tph) for coiled bars. Presently,
the rolling mill operates with on one strand
delivering to the Spooler line and the other
to the cooling bed for straight bars.
Startup of the new line has introduced
for the first time in Spain the revolutionary
spooling technology, bringing-in important
innovations and substantial benefits
36
LONG PRODUCTS
Overall view of the Spooler line in operation since December 2004, detail
of the twist-free winding of bars and spooled coils ready for shipment.
L
in bar-in-coil production. The highlight
of the Spooler process is twist-free winding
of bars into ultra-compact, ultra-heavy coils,
resulting in a unique cobble-free uncoiling
capability. This enables spooled coils direct
feeding to the downstream cold processing
lines without any intermediate operation
(like uncoiling, stretching and regular recoiling)
with consequent significant savings in
transformation costs.
The Nervacero Spooler lines are designed
for twist-free-winding of 8 to 32-mm rebars
or up to 22-mm plain bars, in up to 3.5-t
ultra-compact coils, at finishing speeds
of up to 35 mps.
The second Spooler line will be started up
in the third quarter of 2006. ■
>Spooler<
Layout arrangement
of the two twist-free
Spooler lines (highlighted
in red) in the existing
double-strand rolling mill,
beside the cooling bed
for straight bars.

DANEWS
The 120-tph pusher-type
reheat furnace designed
and built by Danieli Centro
Combustion (see DaNews 141
page 23) was officially opened
on Friday 11 March 2005.
The new furnace replaces two
35-year-old walking-hearth
furnaces, substantially improving
product quality and productivity
with less than half of previous fuel
consumption.
Danieli Centro Combustion's
successful performance in
completing the turnkey project
1 Sir Mark Moody-Stuart,
Chairman of Anglo
American, owner of
HGVD, at the unveiling
ceremony.
HEATING SYSTEMS
in less than nine months was
witnessed in the Highveld
Newsletter:
>... One of the old furnaces,
including its foundations,
was demolished to make way
for the new one.
The project was completed
by the end of September 2004,
nine months after the signing
of the contract. This was not
only an extremely fast-track
programme for a project of this
nature, but a world first...< ■
2 Mr A. J. de Nyssehen,
CEO of HGVD, with
Mr F. Ajosa, VP and
CEO of Danieli Centro
Combustion.
H
Official opening
of new reheat furnace
at Highveld,
South Africa
DANEWS
COLD & HOT PROCESSING
Latest orders for
Danieli Centro Maskin
High-speed breakdown drawing line
for copper tubes at Golden Dragon
Precise Copper Tube, P.R. of China
The line to be installed in Xinxiang is the world’s
first application of the high-speed breakdown
drawing technology and will produce 70,000 tpy
of copper tubes coiled in a basket for ACR and
plumbing applications. The line will consist of four
chain-track drawing machines connected two
by two in cascade with a final production speed
of 400 mpm, a worldwide record!
The mother tube that will feed the breakdown
drawing line will be produced by a KRM (Kocks
Rotating Mill), the new four-roll mill engineered
by Kocks, Germany. The KRM, combined with
Danieli chain-track break-down drawing, represent
the beginning of a new era in the production
of high-quality ACR copper tube.
Conditioning line for stainless steel
slabs at LISCO, P.R. of China
Lianzhong Stainless Steel Co (LISCO)
will install a conditioning line for hot (max
500 °C) stainless steel slabs. The facility
will be made up of two grinding machines
for conditioning of the slabs’ wide faces,
assuring smooth operation and spindle long life
(minimum guaranteed 7000 working hours).
Slabs’ narrow faces will be processed by an edgegrinding
unit. The line is complete with slab
handling equipment and auxiliaries, including
secondary dust collecting filter and swarf
handling. The plant will be started up in the
third quarter of 2006. ■
37

DANEWS
38
AUTOMATION
A
Plate mill upgrading at Bhilai Steel Plant
(BSP, SAIL), India
New HAGC and PVO (Plan View Optimization) systems
will be implemented in the 2-stand plate mill.
Conventional rolling
Plan view optimization
The project is aimed at achieving improved
product tolerances and yield.
The plate mill consists of two four-high
stands to be retrofitted with new hydraulic
cylinders. The turnkey project calls for supplying
a new Level 1 system and new Level 2
mathematical models for mill setup and Plan View
Rolling (PVR), as well as a new Hydraulic Gap
Control (HAGC) with related hydraulic unit and
hydraulic cylinder installation on the stands.
The automation system will be based on the
Danieli Automation HiPAC platform, specially
designed for the critical controls of flat products.
Specifically, Danieli Automation will provide:
HAGC sequencing;
PVopt for the two stands;
new high-performance cylinders to cope
with high dynamics required by PVopt Danieli
Automation control;
revamping of the motor generator set
and drives digitalization;
modification of mechnical equipment,
thickness gauge after the finishing
stand and a laser-based plate length
measurement system.
Besides the supervisory, basic automation
and control system, Danieli Automation
will provide:
Level 2 scheduling and setup functions;
tracking of material;
hydraulic automatic gauge control
for both stands;
Plan View optimisation in the roughing stand;
edger and roughing stand setup;
finishing stand setup;
temperature setup model;
shape setup.
Danieli Automation will supply and coordinate
all the activities related to the turnkey job
in consortium with GA Danieli India (a sister
company of the Danieli group).
The project completion date is June 2006. ■

MET2000 supply chain management system
at Unicoil, Saudi Arabia
It will be used as production control system
for the new 250,000 tpy cold mill complex.
UUniversal Metal Coating
Company Ltd.’s (Unicoil)
new facility for
processing HR and galvalume
steel coils in Al-Jubail is expected
to start production in Q1, 2006.
The 250,000 tpy output will
consist of a mix of galvanized,
blanks and painted coils.
The contract reconfirms the
reliability of Danieli Automation
IT technology and its position
as a front-runner for the unique
solutions for steelmaking plants
to cover market demand for
a total integration of commercial
and production data into an
integrated system.
Furthermore, the MET2000 system
will replace functions performed
by the existing ERP system with
steel plant-specific functions for
sales and shipping.
The MET2000 main modules are:
sales and order management,
coil acquisition management,
production planning,
production scheduling,
production progress control,
quality management,
coil yard management,
shipping management,
data warehouse system
support.
The MET2000 will co-ordinate
and guarantee the synchronisation
of the entire production process.
Additional important subfunctions
are:
order entry,
receipt of coils for
production,
quality-related operations,
production tracking,
storage operations,
shipping, reports,
ERP system integration.
A wireless network supports crane
terminals and wireless bar-code
reader terminals, while label
printers ensure error-free identification
and tracking of production.
The data warehouse solution
ensures vital support of storing
and analysis of historical
documents, order, production,
and quality certification for final
product release.
The application was developed
with BusinessObjects for effective,
easily configurable reports
and queries to further support
Unicoil in the use of the available
data for their strategic decisions.
Figure 1 shows the data analysis
support for processing Customer
order stages (mean value of
Cumulative Frequency-CF
distribution for processing time).
The MET2000 will be running on
a modern, cost-effective, highlyavailable
and automatic recovery
server platform using Microsoft
INCOMING
BLACK
COILS
PC Terminal
Crane Terminal
Wireless Hand-held
Terminal
Printer
Label Printer
INCOMING
GALVANIZED
COILS
Hot dip galvanizing line
Galvanized & Color
coated storage
Windows Server 2003 and Oracle
RDBMS. To secure a maintenance
suite for Unicoil, effective tools
such as RAS-teleservice Remote
ASsistance are provided to give
direct access to and exploit the
support of Danieli Automation
experts. This important order,
besides confirming Danieli
Black coils storage Push-pull pickling line Pickled coils storage
2 Material flow of Unicoil cold mill complex.
Long term evaluation
on products lead
time and new production
potentials
Data analisys support
1for Data Processing analisys Customer support
order for Processing stages mean Customer value
of order Cumulative stages Frequency (mean value
(CF) of Cumulative distribution Frequency -
for CF processing distribution time. for
processing time).
Cold rolled storage
Color coating line
Slitting / Cut-to-lenght line
Packing station
Inspection-Slitting
Packing
Weight (tons)
DANEWS 143
Product: ASTM A653
Stage: PCK
-Pickling
-Rolling
-Galvanizing
-Cooling
Automation’s leadership in supply
chain management for the metals
industry and the process control
of steel plants, will also provide
Unicoil with a powerful tool to
exploit the full potential of the new
modern cold mill complex where
operating costs and sales will be
controlled in real time. ■
Cold rolling mill
Finished
coils
storage
Weight %
Days
-Slitting
and cut-to-lenght
-Inspection
-Packaging
95%
50%
5%
TO CUSTOMER
39

DANEWS
40
A
AUTOMATION
FORGING & EXTRUSION
Danieli Breda innovative technology
in the 32-MN extrusion press for Proferall, Italy
The press features a new concept billet loader to solve all the problems
related to short-stroke front loading cycle.
The press will be installed in the new
Proferall facilities located at Cortenova
(Lecco) and will be positioned in the same
building where a Danieli Breda 20-MN shortstroke
press has been in operation since 2000.
This new press is the first front-loading unit
designed by Danieli Breda and will be equipped
with a newly designed billet loader. This innovative
concept has been developed at the Danieli
Research & Development Centre and is now
under patent pending. This solution solves all the
problems related to the short-stroke front loading
cycle and now makes possible the extrusion
of very short billets in one or two pieces, even in
aluminium soft alloys. This new design completes
the range of extrusion presses offered by Danieli
Breda, which include conventional long-stroke
and short-stroke back- and front-loading solutions.
All these solutions will guarantee excellent
performances, reliability and top product quality. ■
Main press data
Press type SS - front loading
Extrusion force 32 MN
Billet diameter 10"
Billet length 1.300 mm
Working pressure 285 bar
Dead cycle time 13.0 sec
DANIELI BREDA NEW DESIGN CONCEPT
Movable
platen
Dummy
block
Fixed
stem
Telescopic
loader
Container
Die holder
Extrusion
platen
Scheme of the new shortstroke
front loading system.
Step 1:
- Extrusion wnd
- Container backward (Strip)
- Stem backward
- Billet ready for loading
Step 2:
- Sheared butt
- Billet to C/L
- Container and stem forward
Step 3:
- Billet in C/L
- Container and stem forward
- Telescopic loader shortening
- Loader backward
Step 4:
- Container closed
- Stem forward
- Billet upsetting
- Burp cycle

96 BLAST FURNACE PROJECTS 135 ELECTRIC ARC FURNACES 210 SECONDARY METALLURGY STATIONS
71 THICK SLAB CASTING STRANDS 24 MEDIUM/THIN SLAB CASTING STRANDS 154 HOT STRIP AND
PLATE MILLS, 4 OF WHICH THIN SLAB ROLLING PLANTS 14 STECKEL MILLS 86 COLD ROLLING MILLS
279 NARROW COLD ROLLING MILLS FOR NONFERROUS METALS AND STAINLESS STEELS
145 STRIP PICKLING LINES 89 HOT DIP GALVANIZING AND ALUMINIZING LINES
108 ELECTROLYTIC TINNING LINES 23 COLOR COATING LINES 332 SLITTING AND SHEARING LINES
267 GRINDING MACHINES FOR FLAT PRODUCTS 717 BASIC AUTOMATION AND PROCESS CONTROL SYSTEMS
FACTS
CONFIRM DANIELI
WORLD-CLASSACHIEVEMENTS
IN INTEGRATED AND FLAT
PRODUCT PLANTS

SGW
Guiding is an art.
We invented the roller guides in 1945
and ever since then MH has stood for reliability,
quality and innovation in guiding technology.
SGB SR/DR SRW/DRW FRS
PRD RTC PRG WEG MSL CTD
Danieli Headquarters
Via Nazionale, 41
33042 Buttrio (UD) Italy
Tel (39) 0432.5981
Fax (39) 0432.598289
www.danieli.com
Morgårdshammar AB
SE-777 82 Smedjebacken,Sweden
Tel (46) 240.668500
Fax (46) 240.668501
E-mail mh@morgardshammar.se
www.morgardshammar.se