DANIELI MINIMILLS

A WINNING CONCEPT
SINCE 1964

Over the past

50 years the minimill
route has proven
to be one of the most
competitive ways
to produce steel,
starting with a rated
capacities of
60-150,000 tpy
and now at rates
of up to 3 Mtpy
and more.

MIDA MIcromill DAnieli

the breakthrough innovation in rebars production

The first Micromill plant started

operation at Commercial Metals Co.
(CMC) Arizona, USA, in Autumn
2009. The Micromill is based on
the ECR Endless Casting Rolling
process. Among its advanced
processes and components, the
MIDA plant features unique
innovative characteristics, such as:
> The Direct Casting & Rolling
process (ECR), involving the direct
connection of the continuous casting
strand to the first rolling stand, with
the endlessly-cast billet of indefinite
length through an induction furnace
for temperature equalization.
The traditional reheating furnace
and all associated facilities are
therefore no longer necessary.
> The Direct Rolling & Bundling
system (DRB), the revolutionary
innovation that enables bar cutting
to commercial length directly at
delivery side of the finishing mill and
right before the bundle forming and
tying station, making the traditional
long-type cooling beds and cold cutto-length services no longer
necessary. This low-cost mill concept
finds ideal application for greenfield
sites, but also for existing mills with
excess liquid steel capacity.

MIDA main highlights:

> Market-oriented plant, to cover
regional or local market demand;
> Product range focused on a
single-type product;
> Typical capacity of 250,000350,000 tpy;
> Typical finished product range:
8 to 36-mm-dia straight or spooled
rebars (equivalent round and square
bars), with production campaigns
dedicated to a large amount of a
single product, resulting in
minimized changes.
> Ultra-compact arrangement:
covered area approx 11,000-mq
(less than half the space required
by a traditional minimill of
correspondent capacity)
> Minimized investment
> Reduced manning
> Energy saving
> Environmental friendly
> Higher yields in melting and rolling
> Reduced storage space when
compared to traditional minimills.
> Superb quality of the finished
product, either in bundles or coils
(thanks of the DRB or SPO systems)
> Shorter construction time and fast
ramp-up time
> Faster return of investment.

COST ADVANTAGES

VS

COMPETING MILLS

> LOWER LABOR COST.

> LOWER NATURAL
GAS COST.
> HIGHER YIELD DUE
TO CONTINUOUS /
CONTINUOUS PROCESS.
> LOWER COST
OF ALLOYS DUE
TO USE OF QUENCHING
SYSTEM.
> LOWER COST
OF INVENTORY.

305 m

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MIN MIL
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Scrap yard
Fume dedusting plant
Electric Arc Furnace
Ladle furnace
Meltshop maintenance area
Continuous casting plant
Induction furnace

8 16-stand rolling mill

9 QTB line
10 DRB-Direct Rolling & Bundling
system
11 Finished product collecting
services
12 Rolling mill maintenance area

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Danieli Minimills

Fully integrated services

Danielis experience in minimills,

EAF-based steelmaking and rolling
facilities, dates back to the 1960s.
The concept was -and still issuccessful, thanks to its flexibility,
lean organization and low
transportation costs relating to
nearby sourcing for raw materials
and distribution of the finished steel
products.
Around 80% of the minimills
operating world-wide today have
been supplied by Danieli, or operate
with some Danieli equipment.
In 2006 Danieli started supplying
the first integrated minimills: DRI,
EAF, CCM and rolling plants, all
connected through a continuous
process by a compact layout -to be
applied where scrap is not available
and/or gas is available at
competitive costs.

In addition to innovative production

processes and first-class equipment
Danieli provides customers with fully
integrated services which include
turnkey plants, auxiliary plants,
process control and basic
automation, and continuous support.

Turnkey plants (LSTK)

Danieli has thorough capabilities to
provide Customers with plants
according to the EPC (Engineering,
Procurement and Construction)
formula for overall turnkey
responsibility. Design, engineering,
manufacturing, construction, startup,
and commissioning activities are
provided by our own divisions and
companies that operate with own
logistics, equipment, and tools,
worldwide.

Process control and basic

automation
Danieli Automation assures the
perfect integration of the different
process units for a totally integrated,

efficient production plant. The

automation philosophy is built on
different levels (L1 to L4) for each
plant function, and physically
integrated by means of the most
modern networking technologies.
The automation systems are made
up of proven packages, optimized on
the specific process, and tailored to
meet specific customer needs.

Customer service
Danieli Service provides interactive
services to expedite solutions to
technical problems: training services;
metallurgical and process know-how
packages; maintenance
management systems; remote
solutions for real-time support;
original spare parts, equipment
refurbishing, repairs and upgrades;
on-site inspection and technical
assistance.
Thanks to this organization, and to
the team-work established with the
Customer, quality results and on-time
installation are guaranteed.

Danieli milestones in minimill process

Danieli first minimill
Danieli was pioneer in developing
the minimill concept and installed
its first minimill in Germany. 1964
Black box
Direct charging technology for
special steel conticast blooms,
coupled with a surface quenching
system to achieve operating flexibility
and product quality, and to minimize
energy consumption, handling and
delivery time. 1990
ECR-Endless Casting Rolling
Uninterrupted production from liquid
steel to finished long products,

including in-line heat treatments

and inspection procedures leading
to higher productivity, superior
product quality and material yield.
2000
EWR-Endless Welding Rolling
Uninterrupted production of straight
bars, sections, and wire rod in by
continuous on-line welding of billets
at the reheating furnace delivery side.
2001
DRI-based integrated minimill
Danieli started the construction
of the first two integrated DRI-based
minimill complexes for long

and flat products, which is the most

competitive production route where
gas is available at low costs
and/or scrap is not available. 2006
MIDA-Micromill Danieli
The new generation of Danieli
continuous casting-rolling, compact,
micromills designed to serve a limited
market (local or regional) and to be
competitive even for small production
capacities. 2009

Danieli Leadership Highlights:

> Vast experience, gained in an unsurpassable number
of projects carried out successfully all over the world.
> Top conticasting technology for casting speed/productivity,
castable sections, castable grades, product quality.
> Top rolling technology to produce profitably an extremely
wide product mix in in a single mill.
> Capability to provide plants on LSTK basis, with overall
turnkey responsibility for design, engineering, manufacturing,
construction, startup and commissioning activities, worldwide.

Direct reduction (up to 2 Mtpy per

module)
Reference best performance: 250
tph of highly-metallized and
passivated product with controlled
carbon content (from 1.5% to 4%).
Cash-cost reduction in EAF
steelmaking
Reference best performance: 42
heats/day, energy consumption 350
kWh/t, oxygen consumption 38 Nm3/t.
Twin-cathode DC FastArc EAF
(up to 420 t)
fed with 100% hot and cold DRI
Reference best performance: active
power > 160 MW, T-T-T time 45 min,
energy consumption < 450 kWh/t,
oxygen consumption < 40 Nm3/t.
Secondary metallurgy
Reference best performance: heat
sizes up to 350 t; 90% S removal;
50% N removal; H content less 1 ppm.
ECR Endless Casting Rolling
system
Reference best performance:
average cash-cost savings of 40
Euro/t in specialty steels, and 20
Euro/t in commercial steel
production.
EWR Endless Welding Rolling
process
Reference best performance:
average production cost save of
3.5-4.0 Euro/t.

FastCast billet, bloom, and

beam blank casters
Reference best performance:
up to 90 tph per strand.
PSP Profile Sizing Process
process
Reference best performance:
production of H-beams up to
1,000 mm (flange height of up
to 400 mm). Product size changes
in just 20 minutes thanks to the
SCC-Stand Core Concept stand.

Layout legend
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Spooled bar-in-coil
Reference best performance:
production costs savings of up
to 18 Euro/t. Product range is
8 to 52-mm-dia plain bars.
Operating speed is up to 35 mps.
Up to 5-t ultra-compact coils.

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High-productivity, small-size
straight bar production lines
Reference best performance:
over 120 tph of 10-mm-dia
bar/rebar production. Speeds
of up to 50 mps onto cooling bed.

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Ultra-high speed wire rod lines

Reference best performance:
over 125-mps regular production
speed of down to 4.5-mm-dia
(and up to 25 mm) special and
commercial grades, with strict size
tolerances, in up to 3-t coils.

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Incoming oxide storage

area
Direct Reduction Plant
Product storage silos
for hot charge
Product storage open
yard
Product storage silos
for cold charge
Meltshop plant
FastCast continuous
casting machine
Billet storage area
200 tph superflexible
medium section mill
200 tph superflexible
bar and wire rod mill
Rolling mill Water
Treatment Plant and
compressed air plant
Ferroalloy, lime and
additives storage
Electrical substation
(plus electrical
substation HV side)
Air separation plant
DR plant and Meltshop
daily maintenance
workshop, general
warehouse and central
maintenance workshop
Fume dedusting plant
Water Treatment Plant
(Meltshop)
Water Treatment Plant
(DR plant)
Future meltshop
expansion (plus
FastCast for blooms
and beam blanks)
Future rolling mill
for heavy sections

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MINIDA
MINImill DAnieli
1

Layout of a typical
multi-product,
super-flexible,
DRI-based minimill.

DANIELI
YEAR 2010