W2 W3-302E Long Products Bulletin 2016

LONG PRODUCTS BULLETIN
EDITION 2016
EXTRACTS
FROM NEWSLETTER
EDITIONS 2010 – 2015
1
CONTENTS LONG PRODUCTS BULLETIN 2016
Contents
BAR AND WIRE
ROD MILLS
High-Tech:
MEERdrive® Technology..................... 36
Saarstahl relies on SMS
Technology.......................................... 38
Centerpiece: Innovative 3-roll
PSM® (SDI, USA)................................. 40
Precise measurement technology
(DEW, Germany)................................. 43
Rabigh Steel orders Rebar Rolling
Mill...................................................... 44
Quick cutting....................................... 45
Steel location Duisburg, Germany,
SECTION AND BILLET MILLS with the new wire rod mill.................. 46
Steel at an altitude of 1,007 Meters... 48
Expansion at Tung Ho in Taiwan........ 51
Steel beams and sections for the Siam Yamato, Thailand: Order from Russia.............................. 52
Middle East........................................... 6 Minimill for maximum benefits......... 26 Close tolerances /
SMS supplies steel complex Siam Yamato, Thailand: 32 mill.tons of wire rod /
to Bahrain............................................. 8 Minimill for medium steel sections High-quality SBQ steel....................... 54
Sulb enlarges major order: in operation......................................... 30 Cutting edge core /
Fourth casting strand re-ordered...... 10 Peiner Träger: First PSM in China /
Erection close to completion............. 11 Medium-Section Mill upgraded......... 31 Precisely and automatically............... 55
Automatic roll adjustment................. 13 Hoesch Schwerter Profile: A strong combination for Kardemir... 56
A long runner becomes a Modernization in three steps............. 32 Abinsk Electric Steel Works
monument.......................................... 14 commissions two roughing stands.... 58
China: Baotou orders another Amsteel Mills brings modernized
section mill......................................... 15 wire rod mill on stream...................... 59
Jiexiu Xintai, China: heavy section Warehouse in Duisburg-Ruhrort,
mill successfully started.................... 16 Germany, opened............................... 60
Turnkey order / Innovative 3-roll technology............... 61
SMS revamps section mill................. 17 500,000 tons of rebar.......................... 62
Technical Control System – in top Wire rod mill with high productivity... 63
form thanks to service contract ........ 18 Wire rod outlet for special steel
Stahlwerk Thüringen commissions mill...................................................... 64
two-high reversing roughing stand... 19 High quality SBQ products /
New major orders from Handan, Stainless Steel rolling mill ordered... 65
China................................................... 20 Abinsk Electric Steel Works orders
Bhilai Steel: In future, 130-m-long roughing stands /
rails from India................................... 22 First MEERgauge System.................. 66
JSPL, India: CRS straightener with Letter of intent for PSM signed
ninth straightening roller................... 23 on a soccer shirt................................. 67
Russia’s most modern rail mill......... 24 Minimill order for Brazil..................... 68
2
CONTENTS
Wire a success story more than Orders for 10 wire rod blocks BRIGHT STEEL
250 orders since 1950........................ 70 and 45 coil compactors...................... 91
Modernziation completed, MEERdrive® – more flexibility
PROCESSING LINES
ArcelorMittal Hamburg / and less costs..................................... 92
100 m of wire rod per second............. 73 Faultless bars at any diameter.......... 95 New grinding and polishing
Deutsche Edelstahlwerke At Hmisho: New technology machines minimize setup and
expansion of bar mill.......................... 74 increases production by 5%............... 96 changeover times /
Fujian Wuhang: Economical South Steel, Saudi Arabia: Grinding line for Outokumpu
stainless-steel rolling mill................. 75 Minimill order for rebar production... 97 VDM.................................................. 110
Faster rolling speed/ Tung Ho Steel, Taiwan: Minimill New peeling machine /
Lower costs for subsequent sets new standards for rebars........... 98 Large order from India /
treatment............................................ 76 Layout of the minimill at New bright steel center for
MoVE: The camera calibration Tung Ho Steel....................................101 Flanschwerk Bebitz, Germany ....... 111
system for MEERguides..................... 77 Rebar Mill with VCC ordered /
Minimill for Bar and wire rod con- Bar mill put into operation................102
vinces through high productivity........ 78 Service & advice for wire-rod
China: Xining orders two new
rolling mills......................................... 82
producers /
New roller guides .............................103
IN FOCUS
ArcelorMittal Poland: Overhaul of South Steel, Saudi Arabia:
wire rod mill in record time................ 83 New Guide series ordered.................104 Fruitful cooperation......................... 112
ArcelorMittal modernizes wire Nucor Steel Darlington, USA: Ecoplants from SMS ....................... 116
rod mill in Hamburg........................... 84 New finishing mill with benefits.......105
Continuous mill train impresses “Minimill” – The highlight at the
with high quality and rolling speed.... 85 wire rod Symposium in Kolkata .......106
More efficient production with Hamriyah Steel, UAE:
CARTA® PSM® system........................ 86 bar mill taken into service................107
Amsteel Mills, Malaysia: New wire
rod outlet for bar and wire rod mill... 89
Optimal coiling of rebars with
VCC machines.................................... 90
3
4
5
SECTION AND BILLET MILLS
PROJECTS LONG PRODUCTS BULLETIN 2016
STEEL BEAMS AND SECTIONS

FOR THE MIDDLE EAST
United Steel Company (SULB), based in Hidd in the Kingdom of Bahrain,
has successfully commissioned its minimill for beams and sections. The plant
was supplied by companies of the SMS group.
In Hidd, SULB operates an integrated ladle furnace, a four-strand continu- ble-supported rollers and hydraulic
steel complex covering the complete ous caster, associated ancillary equip- roller adjustment.
production chain from pelletizing down ment, including a conveyor system and Thanks to the hydraulic adjustment
to the finish-rolled product. The local a dedusting plant to ensure compli- systems, the products can be rolled
concentration of these facilities forms ance with the demanding environmen- with tight tolerances. The entire plant
the basis for highly efficient production tal standards. The electric arc furnace is so designed as to allow quick format
at low operating costs. In Bahrain, is charged with direct reduced iron changes in no more than 20 minutes.
SULB produces about 15 percent of all (DRI) produced in a newly built direct The rolling mill produces beams in the
steel beams and sections currently reduction plant. DRI is directly hot- size range from 100 x 100 millimeters
imported into the Middle East region. charged into the EAF via a material to 900 x 300 millimeters, channels,
SMS had supplied the complete me- transport system. angles and sheet piles.
chanical and electrical equipment for The continuous caster can produce This complex built by SULB is the
this steel complex – including the a wide range of formats – from billets first fully integrated iron- and steel-
workshops and laboratories. The to heavy beam blanks. The steelworks’ works in the Gulf region producing the
steelmaking plant and the complete annual capacity amounts to 800,000 complete range of light, medium and
section mill including the walking- tons, enough to also supply a SULB heavy sections.
beam furnace were supplied by SMS. medium-section mill in Saudi Arabia.
The plant was built on a turnkey ba- www.sms-group.com
sis in cooperation with South Korean COMPACT DESIGN
Samsung Engineering (SECL). SECL The section mill has an annual capac-
was responsible for the foundations, ity of 600,000 tons. Designed for a wide
halls and buildings, ancillary facilities range of product dimensions, it com-
as well as the assembling activities. prises a walking-beam furnace with a
The foundations were laid on re- capacity of 180 tons per hour, a revers-
claimed land to the southeast of Mu- ing breakdown mill, a compact rolling
harraq Island. SMS supplied a total of group, a cooling bed, a straightener
16,000 tons of machinery – including and finishing facilities. The plant is of a
parts weighing as much as 300 tons compact design in order to make best
and screws of just a few grams. The use of the available space. The com-
steelworks is of the latest state of the pact rolling group consists of three
art. It consists of an electric arc fur- CCS® stands with hydraulic roll screw-
nace with a tapping weight of 120 tons down. The CRS® straightener is de-
and a 96 MVA transformer an 18 MVA signed as a 9-roller machine with dou-
6
PROJECTS – SECTION AND BILLET MILLS
From above:
Look into the steel-
works.
The tandem group in

the rolling mill pro-
duces the full range
of sections.
180
tons is the hourly capacity of a walking-beam
furnace. SULB accounts for 15 percent of the
products in the Gulf market.
7
SMS SUPPLIES STEEL

COMPLEX TO BAHRAIN
600,000 tpy of blooms/beam blanks and heavy sections
United Steel Company (Sulb) in the Kingdom of Bahrain The contract is for the construction and supply of one
awarded SMS the order to design and supply on a turnkey 120-t electric arc furnace, one ladle furnace, one bloom/
basis a steelworks for blooms/beam blanks and heavy sec- beam blank casting plant and one heavy-section rolling
tions. The minimill will be part of the new, fully integrated mill. The order will be realized in cooperation with Sam-
steel complex in Al Hidd, a town on a sand spit on the sung Engineering as EPC partner (Engineering, Procure-
south-eastern extremety of Muharraq Island. ment & Construction). Commissioning of the overall plant
is planned for the second half of 2012.
8
Layout of the plant.
With the awarding of the order for Planning and civil engineering,
the technological core equipment in- erection and ancillary equipment will
cluding the complete automation be provided and coordinated by Sam-
system to SMS group, United Steel sung Engineering. For many years,
selected best performing production Samsung Engineering has been ac-
technology for long products. tive in the region as a project partner.
SMS will supply a state-of-the-art Together with Foulath’s existing
steelworks with an annual capacity of pellet plant, which will be further ex-
850,000 t. It will comprise one 120-t panded for the new steelworks proj-
Ultra-High-Power EAF for continu- ect, and the DRI plant awarded to
ous DRI charging, a ladle furnace and Kobe/Midrex, a remarkable fully inte-
a three-strand continuous casting grated steel complex will be estab-
machine for various near-to-net- lished at Al Hidd, covering the com-
shape bloom and beam blank sec- plete production chain from
tions. The delivery also includes the pelletizing to the finish-rolled prod-
material handling system for ferroal- uct. This excellent setup allows high-
loys addition and a powerful dedust- ly efficient production at low operat-
ing system. ing costs.
The here realized beam blank Furthermore, this investment will
casting technology was launched create 1,000 new jobs in the Kingdom
onto the market by SMS group, a of Bahrain. The total order volume for
pioneer in continuous casting tech- the project amounts to some EUR 1.2
nology. billion. With the new steel facility,
The heavy-section rolling mill will United Steel plans to cover about
feature the latest state of the art in 15 % of the current imports of steel
rolling mill technology. The mill beams and sections into the coun-
stands will come with hydraulic roll tries of the Middle East.
adjustment systems, while the roller
straightener will be equipped with
hydraulic roller adjustment. De-
signed for an initial capacity of
600,000 tpy, the plant will boast high
flexibility in terms of product mix and
format changes. For example, a pro-
gram change will be realizable within
20 minutes.
9
Sulb enlarges major order:
Fourth casting strand re-ordered
United Steel Company (Sulb) in the Kingdom of Bahrain has awarded SMS group
the order to supply the fourth strand for the continuous casting plant No. 1, which is
presently being engineered – and partly already implemented. With this order, the
casting plant is being expanded from an originally three- to a four-strand design.
Project Manager Salvatore Pantano of The steelworks will be designed for draulic roll adjustment systems, the
SMS explains: “We had already in ad- a capacity of 800,000 tpy. It will com- straightener with hydraulic roller ad-
vance agreed with our customer to prise a 120-t ultra-high-power EAF justment. The rolling mill had origi-
plan a four-strand option. The fact that with DRI feeding system, a ladle fur- nally been designed for an annual ca-
the new order was placed only six nace, the handling system for ferroal- pacity of 622,000 t. Now, with the
months after the main order is proof of loy additions and a high-capacity de- fourth strand added, the annual ca-
the customer’s satisfaction with the dusting system. The supply package pacity will be increased to 650,000 t
project management so far. For us, also includes the above-mentioned – and a wider product and format range
this is a great sign of trust.” and now to be expanded – three-strand is to be produced.
Turnkey from the meltshop caster for different bloom and beam
through to the section rolling mill. blank formats. Commissioning of the RÉSUMÉ BY SALVATORE PANTANO:
The overall order placed by United casting plant with all four strands is “Sulb was very impressed by our abil-
Steel Company (Sulb) encompasses slated for mid-2012. ity to supply the new casting plant in-
the design and the turnkey supply of Section mill for 650,000 tpy. SMS cluding the additional strand within
an integrated steelworks for the pro- will supply a section mill of the latest the original project schedule. The cus-
duction of beams and heavy sections. state of the art for this turnkey project. tomer greatly appreciated our flexibil-
The mill stands will come with hy- ity and commitment.”
10
ERECTION CLOSE TO
COMPLETION
“SULB” is one of the largest projects ever undertaken in the SMS group Business
Area. The minimill for beams and sections in Bahrain is now nearing completion
and the erection work is almost finished. The start of commissioning will follow
the cold tests, with the first section to be rolled in September 2012.
In the meantime, SMS has supplied stands with hydraulic roll adjustment to finished-rolled product. This con-
some 18,000 tons of material and and a straightener with double- figuration permits highly efficient
equipment to Bahrain. While the core supported rollers featuring hydraulic production at low operational cost.
components come from the SMS group adjustment. The mill has an initial SULB is creating 1,000 new jobs in
workshops and from suppliers in Ger- capacity of 600,000 tons per year and the Kingdom of Bahrain with this in-
many, Italy and other EU countries, is highly flexible in terms of product vestment. The project has a total or-
components have also been supplied mix and sizes. The complete line is der volume of 1.2 billion dollars. SULB
to Bahrain by the subsidiary SMEC in designed for fast program changes in plans to produce on this plant around
Shanghai. Specialists from SMS have a space of just 20 minutes. 15 percent of the steel beams and
been on site since fall of 2011 for as- Together with the existing pelletiz- sections currently being imported in
sembly and commissioning. ing plant from GIIC (Gulf Industrial the entire Near and Middle East.
The order was placed in March Investment Co.) in Hidd, which is be-
2010. The integrated steel complex in ing extended, and a plant for DRI,
Hidd includes an electric arc furnace, SULB will operate a fully integrated
a ladle furnace, a bloom and beam- steel complex from pelletizing through
blank casting plant and a heavy-sec-
tion mill. The project is being imple-
mented together with the Korean
company Samsung, which is respon-
sible for the necessary infrastructural
measures.
SMS is supplying a state-of-the-art
steelworks with an annual capacity of
850,000 tons. It comprises a 120-ton
electric arc furnace for charging DRI
(direct-reduced iron), a ladle furnace
and a caster for various bloom and
beam-blank sizes. The scope of sup-
ply also includes the material trans-
port system and a high-performance
dedusting system.
SMS is supplying an ultramodern
heavy-section mill including mill The assembly teams of SMS group pose for a group picture.
11
The continuous caster
will be taken into operation
shortly.
The tandem mill TDM-

CCS® shortly before
complete installation.
The mounted EAF (electric

arc furnace) during final
assembly.
The dedusting plant

ensures clean production.
12
AUTOMATIC ROLL
ADJUSTMENT
For its new rail and section mill Panzhihua
Steel & Vanadium Co. Ltd. in Panzhihua, China, has awarded a contract
to SMS group for the supply of a three-stand CCS® tandem group.
With this order, a successful coopera- designed for an annual capacity of is utilized as active roll protection in
tion between the two companies will be 700,000 tons of rails (up to 100 m), the case of rolling force overloads.
continued. In 2005, a rail and section beams, channels, angles and special With the new section mill Panzhihua
mill from SMS Meer had already been sections. The three-stand CCS® tan- is able to react flexibly to different
taken into operation successfully.“ The dem group with hydraulic adjustment degrees of demand from its customers
effective operation of our rail and sec- systems and automatic quick-change for rails, beams and special sections,
tion mill purchased from SMS has im- system ensures minimum program and strengthen its position as a re-
pressed us so much that we have again changing times and close rolling toler- nowned rail manufacturer in China.
ordered the core components known to ances. The Technological Control Sys- Commissioning is scheduled for spring
us for our new rolling mill from SMS,“ tem (TCS) developed by SMS provides 2015.
says Wang Renfu, Assistant to the Fac- for automatic roll adjustment after roll
tory Director of Panzhihua Steel & change, measurement and compensa- www.sms-group.com/long-products-
plants
Vanadium Co. The section mill is tion of mill spring, roll gap control and
Rails are in demand

in China. Panzhihua
therefore ordered,
among other things a
new rail and section
mill.
13
In December 1932, the first rail was produced.
A long runner becomes a monument
80 years after commissioning a rail rolling mill, the roughing stand becomes a
monument of a partnership that has lasted for several decades. EVRAZ ZSMK from
Novokuznetsk, Russia, is setting up a part of the plant on the works premises.
Within the last 80 years, up to 1.1 mil-

lion tons of steel were processed year-
ly on the old rail rolling mill. In April
2012, the last rail was produced. After
i
that, the plant was closed down. Now,
SMS group
the roughing stand is positioned on the
works premises, directly in front of the SMS group is the
production facilities. expert for section
“It is amazing to see how respect- and semi-product
fully an old plant from us is treated by mills. The plants are
the customer,“ says Ulf Höltge, Proj- designed for a wide
ect Manager from SMS group’s Long range of products
Products Plants Business Unit. In – from standard via
2013, SMS delivered a new universal sheet piling sec-
mill to EVRAZ ZMSK where the com- tions and rails up
pany is producing among others to special profiles.
100-meter-long rails for high-speed Integrated in the
tracks. The plant is designed for an rolling lines is also
annual capacity of 1.3 million tons, and the respective heat
400,000 tons alone are for rail produc- treatment.
tion. But beams, channels as well as
rounds and squares are also manufac-
tured on the plant.
www.sms-group.com/long-products- In new splendor: The roughing stand of the plant in front of the Evraz
plants
production facilities.
14
CHINA: BAOTOU ORDERS

ANOTHER SECTION MILL
Inner Mongolia Baotou Steel Union, China, belonging to Baotou Iron & Steel,
has placed an order with SMS group for the supply of a heavy-section rolling mill.
This means that Baotou will receive another rolling facility of this type after
a section mill had been supplied by SMS in 2006. Commissioning of the mill is
intended for the end of 2012.
BROAD DIMENSIONAL RANGE AND HIGH CAPACITY

In future, the mill will produce heavy beams with a web
height of 200 to 1,000 mm, rails with meter weights be-
tween 52 to 75 kg/m and U-shaped sheet piles with a span
width of up to 600 mm. The annual capacity is 1.2 million t.
With this mill, the capacity of parallel-flanged beams and
rails for high-speed traffic in China will continue to in-
crease.
Supply including training. The supply package of SMS in-
cludes planning and engineering, technological core equip-
ment, customer training as well as supervision of erection
and commissioning.
Benefits from CCS® mill stands. The heavy-section mill is Finish-rolling group of the section mill put into service at Baotou in 2006.
equipped with universal mill stands of the CCS® type (Com-
pact Cartridge Stand). Hydraulic adjustment control and rigid
stand design enable section rolling with end dimensions
within narrow tolerances.
CRS® straightening machine for good straightening re-
sults. A 9-roller CRS® straightening machine (Compact Roll-
er Straightener) serves as straightening unit. To achieve par-
ticularly good straightening results for beams and rails the
machine is equipped with straightening rolls supported at
both sides, and with hydraulic adjustment. For the production
of rails, a vertical straightener is additionally used which is
also provided with individually-driven rolls.
Cold saws with high throughput. The rolled product is cut Rails manufactured on the section mill at Baotou built by SMS.
into finished lengths by cold saws. This technology from SMS
is characterized particularly by low cutting costs, a high
throughput rate and a high level of plant availability. means that all stands are used with each pass. With the XH®
Economical XH® rolling process. The heavy section mill rolling process, Baotou is able to e.g. produce beams very
operates according to the universal XH® rolling principle, economically since this rolling method is highly productive
making rolling on a compact tandem group possible. This and roll wear is very low.
15
Finish-rolled beam on
transport roller table.
Owing to rigid CCS®
mill stands, the rolled
products achieve close
tolerances.
Jiexiu Xintai, China:

heavy-section mill succesfully started
Commissioning | At Jiexiu Xintai Iron & Steel Co. in Jiexiu, Shanxi
Province, China, a rolling mill for heavy steel beams supplied by
SMS group has been successfully taken into operation.
Already the first four I-beams rolled TECHNOLOGY FOR HIGHEST

with dimensions of 400 mm x 400 mm FLEXIBILITY AND TOP QUALITY
were within the tolerance range. The beam mill is equipped with universal mill stands of
CCS® design (Compact Cartridge Stand). These highly rigid
FIRST FOUR BEAMS ALREADY mill stands with hydraulic roll adjustments allow final di-
WITHIN TOLERANCE RANGE mensions to be rolled within a very close tolerance range.
In future, beams with web heights up In addition, a nine-roller CRS® straightener with hydraulic
to 1,000 mm shall be produced. The adjustment and automatic roller change ensures high flex-
mill is designed for 1.2 million tpy of ibility and optimum straightening quality with minimum re-
such products and the plant at Jiexiu sidual stresses.
Xintai is the ninth section mill which
has been supplied to China by SMS. XH® ROLLING METHOD
This mill also operates according to the XH® universal beam
rolling principle developed by SMS. This process allows par-
ticularly large beams to be rolled with close tolerances and
thus increases the quality of the products at Jiexiu Xintai. In
the meantime, this technology is used in 16 section mills
worldwide.
16
Straightening roller change for a CRS® Revamp of No. 1 section mill.

straightener.
Turnkey SMS revamps

order section mill
Belval receives new Nucor-Yamato Steel,
CRS® straightener. U.S.A.
ArcelorMittal Belval, Luxembourg, Modernization. Nucor-Yamato Steel The finishing mill can be operated in
has awarded SMS an order to supply in Blytheville, Arkansas, U.S.A., has two different ways: either in two-high
a CRS® straightening machine (Com- placed an order with SMS, Germany, mode for rolling structural shapes or as
pact Roller Straightener) for sheet for the modernization of its NYS No.1 a universal edger for finish-rolling
pilings. The machine allows straight- section mill. SMS is supplying the beams. The new stands of the CCS®
ening of the world’s largest sheet rolling mill equipment which will en- type enable wide sheet pile production
piles at a width of 1,100 millimeters. able the rolling of wider sheet piling and contribute to increase the produc-
SMS delivers a turnkey CRS® straight- products. tivity and the quality of beam produc-
ening machine for sheet pilings sup- The package from SMS includes tion. The existing BD 1 stand will be re-
ported on both sides with all the re- charging and discharging machines placed by a new one with an increased
quired changing devices. It is the first for the heating-up furnace, modern screwdown range for large slabs as
fully hydraulically adjustable straight- primary descaling equipment, a new well as a higher screwdown speed and
ener exclusively used for sheet piles BD 1 (Break Down) stand and three accuracy. New features such as break-
and it is tailor-made for straightening new CCS® (Compact Cartridge Stand) away cylinders for overload protection
sheet piles of U- and Z-shape. Thanks finishing stands. The core of the proj- and rolling force measurement as well
to the double-supported design, the ect is a new three-stand finishing as high-strength holding flaps provide
straightener achieves better and train which replaces the existing uni- more advanced functionality and higher
more homogenous straightening re- versal finishing stand. In addition to reliability compared to the existing
sults than conventional machines the replaced stand, two more stands stand.
with flying support. All straightening will be installed in order to provide
rollers can be changed at the same the required passes for rolling wide
time, reducing the changing times sheet piles. All new finishing stands
and increasing plant availability. employ the CCS® design with hydrau-
lic screwdown, adjustment under
www.sms-group.com/long-products- load and quick program change in www.sms-group.com/long-products-
plants only 20 minutes. plants
17
LONG PRODUCTS BULLETIN 2016
In future, the section mill of Celsa will be taken care of properly by SMS group.
”Technical Control System” –

in top form thanks to service contract
Section steel producer Celsa, Barcelona, Spain, has signed a service agreement
with SMS group ensuring reliable functionality of the ”Technical Control System”
(in short TCS) and offering optimal support during rolling. The TCS provides an
exact roll position and, consequently, allows top product quality.
THE AIM: ERROR PREVENTION FAST FAULT DIAGNOSIS

The modules of the service contract with SMS have been Thanks to advanced technology – per email, phone and in-
customized in cooperation with Celsa. The main goal is to ternet system (VPN) – you can look at the plant directly. A
make sure that problems on the plant are prevented in the fault diagnostics can thus be generated rapidly by our ex-
first place. Should a fault occur despite all the efforts to perts. Regular checks, maintenance measures and local
prevent this, it will be eliminated quickly and expertly in a staff training are rounding off the range of services.
very short time.
ANNUAL SYSTEM CHECK
The second module includes the annual system check.
For this purpose, a technician from SMS is on site for at
least three days, installs new computer systems and then
informs customer’s staff on their handling. Moerover, he
also provides training.
OTHER CUSTOMERS
Besides Celsa, other customers rely on our service for
TCS equipment, including among others Gerdau Ameri-
steel and Steel Dynamics in the U.S.A. as well as Chang-
The TCS system provides an exact roll position. zhi in China.
18
Stahlwerk Thüringen commissions

two-high reversing roughing stand
More economical rolling of larger sections
At the beginning of 2011, Stahlwerk

Thüringen GmbH has taken a new heavy
roughing stand into operation in its sec-
tion mill in Unterwellenborn. The rolling
unit configured as two-high reversing
stand has been designed for a rolling
force of 10 MN with a driving power of
4,400 kW. Technical features are among
others an automatic roll gap opening in
case of overload, partly automatic axial
shifting of the top roll for groove adjust-
ment and considerably simplified roll
changing. This enables the rolling mill in
Thuringia, Germany, now to produce
heavier and larger sections than before
and even more economically.
The rolling mill was shut down at the
end of November 2010. After the old The old roughing stand.
roughing stand had been dismantled, the
new one was installed including the
whole drive train, the work roller tables,
the sideguard manipulators and the
complete electrical and automation
equipment. The new facility went on
stream at the beginning of 2011.
At the beginning of the 1980s, the
heavy section mill had been built by SMS
as a combined section mill by order of
Maxhütte Unterwellenborn. In summer
1984, the initial test rolling was per-
formed and at the beginning of 1985
commissioning took place. In mid-2002,
key components of the rolling train were
modernized or renewed, i.e. the reheat-
ing furnace, the finishing stands, the
straightening machine, the saws and the
automation.
Stahlwerk Thüringen GmbH is a com-
pany of the Spanish Grupo Alfonso Gal-
lardo. The new heavy roughing stand (breakdown stand).
19
As from September 2011, rails for high-speed trains will also be produced in the new universal mill of Handan Iron & Steel.
NEW MAJOR ORDERS FROM

HANDAN, CHINA
SMS group has received two new orders from Handan Iron & Steel Company for
the supply of a new universal mill for rails and heavy sections as well as a rail-
head hardening line with Rail Cool® system. The mill is slated to begin operation
already in September 2011 and the railhead hardening line is scheduled to go on
stream in spring 2012.
UNIVERSAL MILL FOR RAILS AND HEAVY SECTIONS stands are characterized by high rigidity, fully hydraulic roll
The universal mill has a total capacity of 1.38 million tpy. In gap adjustment and fully automated stand change.
addition to the rolling technology and engineering, SMS Horizontal roller straightener. For the straightening of
group’s scope of supply also comprises core facilities in- the complete rolling program SMS uses its CRS® horizontal
cluding the rail straightening technology. roller straightener. The CRS® machine (Compact Roller
Broad production range. About one third of the annual Straightener) provides a hydraulic adjustment system and a
production comprises 100-m-long rails which meet the straightening roller pitch of 1,800 mm. Due to the two-sided
high requirements for high-speed railroad tracks. In addi- bearing of the straightening axes the straightening ma-
tion, Handan will produce beams with dimensions up to 600 chine offers optimal straightening characteristics for high-
mm x 300 mm as well as channels and special sections for speed rails and the section program. Change of the
shipbuilding. straightening rollers during a program change is fully auto-
Solid stands. The latest CCS® stands (Compact Car- matic.
tridge Stand) will be used in the universal mill. These mill
20
Vertical roller straightener and

other supplies. SMS will also supply
the vertical roller straightener, the hot
saws as well as the cold saw line and
other key components. The scope of
supply moreover includes the supervi-
sion of erection, the training of cus-
tomer’s personnel and various spare
parts.
Extensive references in China. For
the rolling of rails, Handan will use the
universal rolling method making
Handan already the fifth customer who
opted for the rail rolling technology of
SMS group. On the other hand, the
XH® reversing rolling technology is
used for the rolling of beams. In the
meantime, this technology of SMS has
successfully been applied in nine roll-
ing mills alone in China.
RAILHEAD HARDENING LINE:

HANDAN OPTS FOR RAIL COOL® SYSTEM
For the hardening of rails, Handan
Iron & Steel Company, China, also re- For the production of durable vignole rails, Handan Iron & Steel will
lies on the know-how of SMS and has receive an inline rail head hardening plant from SMS group.
ordered a railhead hardening line with
Rail Cool® system for its new universal
mill. These rails achieve a much longer
Inline hardening of up to 100-m- service life than standard rails and are
long rails. The inline hardening plant best suited for an application under
produces head-hardened rails directly high stress – for example due to in-
from the rolling heat according to Chi- creasing train frequencies, speeds and
nese and other international stan- axle loads.
dards with lengths up to 100 m. Hard- Numerous benefits. At present,
ening or fine pearlitizing is performed only a few inline railhead hardening
by specific thermal treatment of the systems are in use. In most cases,
railhead by means of spray water. they were self-developed by the users
Supply of process technology up to and were not marketed. With the Rail
automation. SMS will supply the pro- Cool® system, SMS group is now able
cess technology, the engineering, the to offer a hardening system which
mechanical and electrical equipment shortens the process route compared
and the automation. The supervision to the widespread offline systems,
of erection and commissioning, the which reduces the energy and operat-
training of customer’s personnel as ing costs and enables the hardening of
well as spare parts are also included long rails in the production cycle.
in the scope of supply.
Production of vignole rails. With
the novel line, Handan Iron & Steel will
soon be able to produce head-hard-
ened vignole rails for railroad traffic.
21
Bhilai Steel:
In future, 130-m-long rails from India
Annual capacity totaling 1.2 million t
Bhilai Steel Plant (BSP), India, a com- CCS® STANDS IN THE UNIVERSAL the Indian market. The package in-
pany of the SAIL Group, in the Chhat- ROLLING MILL cludes two automatic test centers, vi-
tisgarh Province in Central India, has The latest CCS® (Compact Cartridge sual inspection lines, several sawing
commissioned SMS group to supply a Stand) stands will be used in the uni- systems, straightening presses, drill-
universal rail rolling mill. The capacity versal mill. This stand type is charac- ing facilities and loading equipment
of the production plant totals 1.2 mil- terized by high rigidity, fully hydraulic for long and short rails.
lion tpy. The mill will produce rails with roll gap adjustment and fully automat- For railhead hardening our Rail
lengths up to 130 m in a wide product ed stand change. Cool® system with selective water
range. For example, this includes rails spray system is applied. SMS Elo-
for high-speed traffic or rails for CRS® STRAIGHTENER therm will deliver the inductive heat-
freight transportation with high axle For the straightening of the entire rolling equipment which enables a spe-
loads or even railhead-hardened prod- ing program a horizontal CRS® (Com- cific temperature control in the
ucts for special applications. The roll- pact Roller Straightener) is used. Due fine-pearlitizing process.
ing of the first rails is scheduled for to vertical hydraulic screwdown and
spring 2013. double-sided bearings of the straight-
ening axes, this machine provides op-
SUPPLY INCLUDES TECHNOLOGIES timal straightening characteristics for
The rolling mill will be supplied by an high-speed rails.
SMS-led consortium. SMS will also
supply the technology and the com- RAIL FINISHING WITH RAIL COOL®
plete process equipment including the SYSTEM
railhead hardening technology. ABB The complete rail finishing line is also
India will be responsible for the elec- part of SMS’s scope of supply. It will be
trical equipment, automation and its particularly designed for the needs of
installation and commissioning. Local
manufacture and assembly of the me-
chanical equipment will be realized by
SMS India, Kolkata.
COMPREHENSIVE PROGRAM TO
INCREASE CAPACITY
The new rolling mill is part of an ex-
tensive program for the modernization
and capacity increase at BSP and SAIL
respectively. With the new mill, the
Central-Indian company secures and
strengthens its position as a nationally
and internationally leading rail pro-
ducer.
Rail cooling bed.
22
JSPL, India: CRS® straightener with ninth

straightening roller
Straighter rails with less internal stress
i
Since December 2010, the Indian Jindal Steel & Power
Limited (JSPL) is operating a CRS® roller straightener from SPECIAL
SMS in its rail and beam mill. What makes the new ma- FEATURES
chine so special is the fact that an adjustable ninth roller
of the CRS® roller straightener
has been installed for the first time on the new machine.
Consequently, not only beams but also rails can be straight- ydraulic adjustment systems on
H
ened in the CRS® facility. This has many advantages: the top straightening rollers
”Thanks to the ninth roller, the product quality is even bet- Adjustable last roller (roller 9)
ter because we have greater opportunities to affect the ouble-bearing straightening shafts
D
straightness and the residual internal stresses of beams with single drive
and rails,” explains Markus Willems, Design Engineer ully automatic straightening roller
F
change of all nine rollers
at SMS. Another benefit of the patented CRS® technology
is that the straightening rollers can be changed in just
20 minutes which increases the availability of the machine.
Furthermore, the customer is able to optimally adjust the In the past, JSPL has repeatedly ordered facilities from
facility with the straightening model from SMS. SMS group. Two continuous billet casters are already in
The novel machine was set up and put on stream by operation, two more plants with eight casting strands each
SMS and JSPL in only five months which is remarkably will come on stream in 2012.
quick because key components of the extensive foundation
were also constructed during this time. And to keep the
production losses as small as possible, beam production
continued during the entire construction and commission-
ing time via a second cooling bed outlet. For this purpose,
the old horizontal straightening machine had been relo-
cated from the start of construction.
The assembly crew at JSPL. CRS® straightening machine.
23
Two-high reversing roughing stand in CCS® design. Use of a laser profile gage.
RUSSIA’S MOST MODERN

RAIL MILL
Southwest Siberian Metallurgical Plant Novokuznetsk, a company of the
EVRAZ Group, modernizes its production facilities for heavy sections in the
city of the same name. To achieve this, the plant operator has placed an order
with SMS group, Germany, for the supply of a new universal mill for rails and
other sections.
To set up Russia’s most advanced rail and section mill, the ALTOGETHER, 1.3 MILLION T OF SECTIONS PER YEAR
production with the old equipment will only be stopped for The new mill with a total capacity of then 1.3 million t of
four months. Thereafter, the steel company will be able to sections per year is scheduled to go into production in Oc-
produce 100-m-long rails. tober 2012. 950,000 t of the annual production are rails, in-
As the largest rail producer in Russia, the customer including 400,000 t with a maximum length of 100 m. Such
tends to manufacture the rails with state-of-the-art pro- long rails can be used for high-speed rail tracks or, with
cesses which meet all current needs. Therefore, rail rolling hardened rail heads, also for high axle loads on heavy goods
operation will be modernized with a comprehensive pro- trains. In addition, the new mill produces beams, channels,
gram. By using our new rolling methods and advanced mill rounds and sections.
stand concepts, the productivity, flexibility and availability of
the plant will be increased. In addition to that, top-quality LATEST CCS® TECHNOLOGY IN THE ROLLING MILL
finished products can be produced. Upgrading is realized in several sub-projects. For the roll-
ing area of the section mill, SMS supplies the rolling tech-
nology, the complete mechanical and electrical equipment
24
The core element of a modern heavy-section mill: Tandem reversing rolling group in The new universal mill produces rails for
CCS® design. highly demanding applications.
With inline measure-

ment, the quality of
rolled rails can be
checked.
i
Novokuznetsk
on the Tom River
is a large Russian
and the automation system. The latest EXTENSIVE ADDITIONAL SUPPLIES city in the Coal
CCS® stands will be used in the uni- The key components of the mill also Basin of Kusbass
versal mill. This stand type is charac- include manipulators, grip-type tilters in the Kemerowo
terized by high rigidity, hydraulic roll upline and downline the tandem stand Oblast in Southwest
gap adjustment and fully automated group, transport facilities and a hot Siberia. The city
stand changing devices. With the tan- saw. For the quality check, a laser pro- has a population of
dem reversing rolling group, it is pos- file gage (Propgauge) is employed for about 560,000 (as
sible to produce not only rails but also inline measurement of the finished of 2009) and is situ-
beams and channels in the universal profiles. The supply package from SMS ated approx. 300 km
rolling process. This cost-efficient also includes the supervision of erec- south of the regional
beam production is performed by tion and commissioning, the training capital Kemerowo.
means of our proven XH® reversing of customer’s personnel, and spare
rolling method. parts.
25
The mill of Siam Yamato, south of Bangkok.
SIAM YAMATO, THAILAND:

MINIMILL
FOR MAXIMUM BENEFITS
Piya Chairat, Plant Manager of Siam Yamato and his col-

leagues, remain convinced of the decision in favor of SMS:
”With the minimill for medium sections from SMS at the
Map Tha Put location we have bought the right equip-
ment,” said the manager of the Thai/Japanese steel en-
terprise. ”My customers believe in technology from SMS
and we had to invest significantly less money than for a
conventional plant. In this way, we are able to produce at
lower cost and even the ecological values are excellent.”
Since several months, this perfectly producing mill has
been in operation.
26
»SMS enjoys worldwide a distinguished reputation

and we benefit from this every day especially when
our customers visit us. They see the company signs
from SMS on the plant and are positive right away:
German and Swiss technologies sell extremely well
also in Thailand.“«
Piya Chairat, Plant Manager of Siam Yamato, is full of praise
40-YEAR-OLD IDEA MORE RELEVANT

THAN EVER
”Minimill” – this 40-year-old idea is to-
day more relevant than ever. Germa-
ny’s Willy Korff had designed the mill
in the sixties. In 1968, he inaugurated
his steel plant in Kehl, Baden, Germa-
ny, the first of its kind with electric arc
furnaces and an associated rolling
mill for the production of rebars from
SMS, at that time worldwide an abso-
lute novelty.
The idea was revolutionary. From
then on, steel could no longer be only
produced where the coal was located
but at any location. The Kehl port area The finishing train.
with easy access to waterway, rail and
highway was ideal to deliver scrap as
starting material. GOOD FOR ECOLOGY SUCCESSFUL MINIMILL TEAM
Just one year later, nearly 149,000 AND “GREEN“ STEEL SMS has reacted to the market de-
t of steel were produced in Kehl. In the age of ecology and “green“ steel, mands with a comprehensive team.
Meanwhile, annual production is Korff’s idea which was realized by ap- Under the direction of Paolo Cancian
more than 2.2 million t which corre- plying SMS technology has consider- from SMS, Italy, colleagues from all
sponds to 23,500 charges per year. In ably regained attraction. Steel produc- over the world closely cooperate with
the early years, the smelting staff re- tion and further processing in an each other.
quired a few hours for a charge but integrated factory saves energy. At the The success justifies the concept:
today the time required for loading same time, the customers benefit large and significant reference plants
scrap up to liquid steel takes just 38 from highly flexible SMS plants which such as those at Siam Yamato (medi-
minutes. can be revamped within very short pe- um sections), Tung Ho in Thailand
riods of time and thus the demand is (bar mill) or a combined plant from
correspondingly high. SSM in Košice are already running
27
Eric Hetzel (left), Site Manager, assists in the control room.
at full speed just like a mill in the TWO STEEL PLANTS ALREADY REALIZED
USA. With a planned works for heavy Such is the case also for the Japanese Siam Yamato Group,
beams in Sulb, Bahrain, another a joint venture between the Thai family-owned Siam Group
milestone will be added soon and also and the Japanese Yamato Group. Two large steel plants
in Saudi Arabia a mill is under con- have been built in the Map Tha Put Industrial Zone, 100 km
struction. south of Bangkok. Plant No. 2 has been planned and con-
structed together with SMS as general contractor. 400,000
COST-EFFICIENT SOLUTION t per year of medium sections will be produced. The min-
FOR GROWTH REGIONS imill technology from SMS ensures favorable production
Especially when a project needs to be costs, high productivity and necessary flexibility for the pro-
completed ”on a greenfield site” the duction of different sizes and products.
customers often choose a cost-effi-
cient minimill solution. This type of
plant pays off particularly for steel
producers in the growth regions of
Asia, the Middle East or South Ameri-
ca, but also in the established markets
of Europe and the USA the minimills
are becoming more and more impor-
tant.
Next to the sector of tourism, the
heavy industry in Thailand has devel-
oped in recent years to the most im-
portant source of income for the Thai
population. Economies such as the
USA, Australia and Japan use the fa-
vorable conditions in the country of or-
chids to invest in new production fa-
cilities.
Advanced SMS technology ensures smooth production.
28
MOST MODERN PLANT OF ITS KIND

IN SOUTH EAST ASIA
In close cooperation between Swiss and German experts
from SMS the most modern plant of its kind was built in
South East Asia. SMS realized a steel plant with state-of-
the-art technology. The associated section mill features
different levels and has a capacity of 400,000 t. Sections
with edge lengths between 100 x 50 and 350 mm x 175 mm
are predominantly produced.
THE MINIMILL FOR MEDIUM SECTIONS

OF SIAM YAMATO
Steel plant. The steel plant has been designed for a capac-
ity of 700,000 tpy and it comprises an 80-t electric arc fur-
nace, a ladle furnace as well as a combined continuous
caster. Various auxiliary plants such as scrap transport, The breakdown stand.
dedusting system and material feed are also included in the
supply package.
Continuous casting plant. The continuous bloom caster
features five casting strands and allows for a production of
a wide format range from 150 x 150 mm up to 230 x 450
mm. Simultaneous casting of various formats is possible.
Medium section mill. The semi-continuous medium sec-
tion mill produces beams from 100 x 50 up to 350 x 175 as
well as channels and angles. The annual capacity of fin-
ished products is approx. 400,000 t. A future expansion of
the mill to rounds and flats and an increase in production at
the same time is possible in a further expansion stage. The
mill comprises a walking beam furnace with a capacity of
130 t/h, a two-high reversing stand as well as a continuous
finishing train with nine stands, of which six stands are
equipped as universal/two-high stands.
The mill stands. The mill stands are modular compact
stands of the CS type. The stands are interchangeable and The cooling bed.
can be used alternatively as horizontal/vertical or universal
stand. A quick stand change can be executed without the
need for a crane.
The finishing line. It consists of a rake-type cooling bed,
a nine-roller straightening machine with adjustable pitch, a
sawing line with three cold saws, five stacking machines,
binding and loading devices.
Most modern mill in Asia. The mini steel mill is the most
modern plant in Asia for the production of medium sections
and it takes the latest technologies into account.
The binding machine.
29
Siam Yamato, Thailand: Minimill
for medium steel sections in operation
Combi-caster casts several formats at the same time
In October/November 2009, Siam Yam- LOW ENERGY CONSUMING EAF to produce steel sections from 100
ato Steel Company (SYS) started pro- The electric arc furnace is equipped mm x 50 mm to 350 mm x 175 mm as
duction of medium steel sections at its with the latest generation of Conso well as channels and angles. Adding
new minimill in Rayong, Thailand. oxygen technology. This technology re- rounds and flats to the product range
First, the medium-section rolling mill duces electrical energy consumption at a later stage is possible within the
was commissioned, followed by the while enhancing the productivity of the framework of a future expansion proj-
meltshop and the five-strand combi- furnace. The dedusting system for the ect. The mill features a 130-t/h walk-
caster. The first heat was cast on all meltshop conforms with the high ap- ing-beam furnace, a two-high revers-
five strands with a common casting plicable clean-air standards. ing roughing stand as well as a
size of 200 mm x 230 mm. After that continuous finishing train made up of
also blooms of 230 mm x 450 mm cast- SEVEN BILLET/BLOOM FORMATS PLUS nine roll stands, six of which being uni-
ing size were successfully produced on BEAM BLANKS versal/two-high stands. The roll
the new combi-caster. The combi-caster is a new develop- stands are modular compact stands in
ment by SMS. This is the first casting CS design. They are interchangeable
STEELWORKS FOR 700,000 TPY machine enabling different billet and and can be used alternatively as hori-
The steelworks and rolling mill have bloom formats to be cast at the same zontal/vertical or universal stands.
been designed in such a way that the time. A total of seven different billet/
billets and blooms produced in the bloom formats can be cast, ranging OVERALL PLANNING
steelworks can be directly hot-charged from 130 mm x 130 mm to 230 mm x The overall planning of the works
into the rolling mill. The new steel- 450 mm. If required, the plant can even was realized by SMS. The successful
works has a production capacity of be converted to beam blank produc- commissioning of the meltshop and
700,000 tpy. It features an 80-t electric tion. the rolling mill is a demonstration of
arc furnace, a ladle furnace and a the SMS group’s competence and in-
combination caster. MEDIUM SECTION MILL FOR 400,000 TPY novative power in the long-products
The semi-continuous medium section sector.
mill, for an annual production of
400,000 t of final products, is intended
30
PEINER TRÄGER:
MEDIUM-SECTION MILL
UPGRADED
Production increased very quickly
At Peiner Träger GmbH, Germany, SMS group has modern- dition, a large number of supply systems were mounted still
ized the medium-section mill which was re-opened on during rolling operation and almost 60 km piping was in-
September 1, 2009. After the restart, the mill could be stalled. Parallel to dismantling, cleaning work had already
ramped up very rapidly whereby a large number of sections been carried out, new foundations were laid, anchor holes
were rolled at various dimensions in ”running-in mode” drilled as well as new bedplates installed.
from the very beginning. In the first 18 days already 25,000 To minimize storage requirements on the site and to save
t of salable sections were produced. An extended product costs we have delivered the materials and mill components
range now comprises beams with a web height of up to 450 required for erection ”just-in-time”. In the peak phase al-
mm and a flange width of 260 mm as well as channels up to most 100 specialists worked around the clock.
400 mm, equal and unequal angles up to 250 mm and a Together with the CRS® roller straightener supplied by us
large number of special steel sections. which already went on stream in 2008, the mill train is now
Owing to a very detailed planning and partial pre-assembly able to fulfill increased market demands with regard to flex-
of the mill stands during production, the modernization and ibility, profitability and quality. Due to the modernizations by
cold commissioning could be completed during a standstill SMS, the modernization project ”UMIT 2010” has been com-
period of only six weeks. In such a short time, the mill equip- pleted and the technological leadership of Peiner Träger
ment weighing a total of approx. 3,000 t had to be handled for GmbH has been strengthened.
the purpose of disassembly or re-assembly and tests. In ad-
31
HOESCH SCHWERTER
PROFILE: MODERNIZATION
IN THREE STEPS
”Just like an open-heart surgery”
Upgrading the mill train at Hoesch CUSTOMIZED MILL STAND SOLUTION THE THREE UPGRADING STAGES
Schwerter Profile GmbH, Germany, The CS concept enables a high flexi-
®
The three-stage modernization con-
was a special challenge for both the bility and is optimally suited for the re- cept consisted of the following stages:
operator and the machine builder quirements when rolling special sec-
SMS. What made this job so special tions. For this customized mill stand Stage 1: It mainly comprised the prep-
was the three-stage modernization solution it was considered that the ex- aration of the foundations, the instal-
concept, enabling shutdown periods to isting rolls and guides could be re- lation of new stand bedplates, the me-
be minimized to the greatest possible used. As a result, the special section dia facilities and the assembly of the
extent and ongoing production of the mill became notably efficient. In total, media platform for the accommoda-
mill between short shutdown periods. four universal and four two-high tion of the valve stands, the local con-
stands as well as one edger were sup- trol pulpits, the electric cabinets and
AMBITIOUS GOALS plied and an existing edger was up- the cables and piping and eventually
In August 2007, Hoesch Schwerter graded. The four universal stands the resumption of production with the
Profile GmbH, a member of Calvi Hold- were pre-assembled in our workshop existing mill stands.
ing, Italy, had commissioned SMS and the complete stand piping was
group to upgrade the mill train for mounted. Stage 2: Installation of new stand
special sections. The goal was to in- changing devices and assembly area.
crease the availability, the yield and EXTENSIVE ANCILLARY FACILITIES Assembly and resumption of produc-
the flexibility as well as to improve the Likewise modernized were descaling tion with new and existing stands on
quality of the finished products. and centering devices as well as grip- place P2 and the edger.
type tilters ensuring optimal condi-
NEW CS® MILL STANDS tions of the rolled material when spe- Stage 3: Installation of the new cen-
The modernization concept perfectly cial sections are rolled. Our scope of tering and descaling devices and the
tailored to customer’s demands com- supply included also the mill stand grip-type tilters as well as the comple-
prised an exchange of the existing uni- changing devices and the assembly tion of place P3. Resumption of pro-
versal and two-high mill stands with area in a new pre-assembly workshop duction with the new stands P2, edger,
the CS® mill stands (Compact Stands) for stands and the required supply sys- P3 in tandem rolling operation.
developed by SMS. These stands offer tems as well as the electrical equip-
automatic quick changing for an in- ment and the automation for the new After the completion of stage 3 the
crease in flexibility and a reduction of facilities. The IBA-Logic system in ver- mill train has been put back into oper-
setup times as well as a compact de- sion 4 was applied first for the whole ation in fall. The tandem rolling opera-
sign, very high stand rigidity and high control. The implementation was real- tion was realized shortly afterwards.
adjusting accuracy. Key assembly ized by Fest, our electrical equipment On October 12, 2009, a 16-week trial
groups such as the adjusting equip- partner, on our behalf. operation with optimization phase fi-
ment could be standardized for all nally started.
stand types.
32
Left:
Universal stand
pre-assembled in
the Mönchenglad-
bach workshop.
Rolls with new mill
stands.
Right:
The new pre-as-
sembly bay.
Component instal-
lation.
Foundation and
media platform
construction.
Pre-assembled
universal stand in
the workshop.
Such complex modernization steps executed in an ex-

tremely confined space require a high degree of profession-
alism and cooperation of the project teams from Hoesch
Schwerter Profile GmbH and SMS. With this upgrading
measure the company in Schwerte, Germany, has further
expanded its leading position in the production field of spe-
cial sections.
33
34
35
BAR AND WIRE ROD MILL S
IM FOKUS SMS group newsletter 02 / 2015
Convincing: MEERdrive® is manufactured in the workshop of the SMS group in Mönchengladbach, Germany.
HIGH-TECH: MEERDRIVE®
TECHNOLOGY
Flexible and efficient: The MEERdrive® concept simplifies roll ring
management, creates greater flexibility in roll pass design and minimizes
maintenance efforts. The efficient individual motors help to improve
roll ring utilization and to reduce energy consumption.
T
he MEERdrive® concept enables customers to se- from 5.0 millimeters up to 26 millimeters at speeds up to
lect pass reductions according to their require- 120 meters per second. Because of the great speed range
ments. Roll pass designs can be customized with in this block for rolling speeds between ten meters and 120
regard to the finished size and the steel grade con- meters per second, SMS combines compact switch gears
sidering the varying spreading behavior. Consequently, wire with individual motors.
rod manufacturers do not have to stick to standard sizes
only. Different cross-sectional reductions allow rolling any REDUCED ROLL RING STOCK REDUCES COSTS
intermediate sizes that exactly meet the customer’s de- In a conventional wire rod block the reductions and thus
mands. also the roll ring diameters are fixed (roll ring family). If a
MEERdrive®PLUS is a variant, which represents a separate roll ring is worn, either a second or even a third identical
4-stand sizing block for final rolling, allowing conventional roll ring diameter is required or the whole roll ring family
as well as thermomechanical rolling. All finished sizes are has to be replaced. This is not the case with MEERdrive®
rolled in this rolling block from a one-family roll pass de- as every roll ring pair is driven by an individual motor. Vari-
sign. MEERdrive®PLUS blocks roll-typical diameter ranges able roll ring diameters can be used on individual block
36
PROJECTS – BAR AND WIRE ROD MILLS
Saving operating costs

A comparison of operating costs on different blocks
-31 %
oll ring
R
management
Electric energy
Maintenance
Redressing
Roll rings in
operation
Conventional MEERdrive®
Drive train of a MEERdrive wire rod block.
®
positions and the required reduction ratio will be adjusted to a conventional wire rod block, the
by relevant speed settings of the individual motors. As a
result, the stock of roll rings can be reduced by approx. 60
percent. The huge medium-voltage motor of the wire rod
MEERdrive® allows for operating cost
savings of approx. 31 percent. During
METEC 2015, interested visitors can
i
block is replaced by numerous small, low-voltage motors. find out on the stand of the SMS group
Service
This also has advantages for spare parts, as no similarly which further advantages MEERdrive®
huge motor with a long delivery time is required as a has for wire rod manufacturers and The worldwide
spare. Furthermore, the individual drive concept replaces how precisely the system operates. service network of
a vast amount of mechanical gear equipment, which is the SMS group with
subject to wear and maintenance. Thus, wear of the equip- Günther Schnell 60 locations ensures
guenther.schnell@sms-group.com
ment is reduced significantly in comparison with any con- quick and safe
ventional solution. service not only for
wire rod manufac-
ELECTRICS AND AUTOMATION turers. With remote
The advanced electrics and automation technology enables maintenance, ware-
a reliable and stable synchronization of the individual drives housing solutions
and motors for speeds higher than 120 meters per second. and local support,
The heart of this system is the control logic, which is incor- SMS experts ensure
porated in a standard highly dynamic modularly designed maximum plant
PLC. Since 2006, the highly flexible MEERdrive® technology availability. Since
has already been realized successfully in AC and DC appli- 1950, SMS has
cations and it can be combined with any existing mill auto- installed more than
mation system. The MEERdrive® system is modularly con- 250 wire rod mills.
structed and can be applied to any wire rod block or
combination of blocks, independent of the number of
stands. Thus, MEERdrive® blocks can be integrated into ex-
isting rolling mills without any problems.
LOWER OPERATING COSTS

With MEERdrive®, the operating costs of wire rod blocks
can be substantially reduced due to simplified roll ring
management, including redressing effort, lower electrical
power consumption and reduced maintenance. Compared
37
SAARSTAHL RELIES
ON SMS TECHNOLOGY
For its Völklingen, Burbach and Neunkirchen plants, Saarstahl AG, Germany,
has placed three upgrading orders with the SMS group in recent months.
The aim of all these measures is to be able to react to the needs of Saarstahl
customers more quickly and flexibly.
Model of con-
tinuous wire rod
mill with seven
stands to be
installed at the
Völklingen site.
38
The Völklingen site is provided with a When the new facilities are put into
seven-stand continuous wire rod mill service a guide trough will be placed
replacing an existing blooming stand. into the location provided for the fin-
For the Burbach site, two stands, a ishing block for bridging. Commission-
shear, a four-strand switch and a four- ing of the LOOP is scheduled for Janu-
strand pinch roll unit were ordered. In ary 2016. The remaining new facilities
this way, the roughing train of the wire will go on stream in August 2016.
rod mill in Burbach is expanded. For
the wire rod mill in Neunkirchen, a www.sms-group.com/long-product-
plants
new wire rod outlet is supplied where
the existing wire rod block will contin- Hot wire rod in an outlet section of a wire rod
ue to be used. The aim is to be able to mill.
offer various qualities, dimensions and
tolerances in response to the demands
when rolling wire rod and bars. ferent leading pass sections may be
employed without conversion mea-
PRODUCTION CONTINUES sures. The final section from the
Construction work in Völklingen will roughing mill is the same for all input
take place in summer 2015 during sections and will then be distributed to
ongoing production. An additional all four strands of the wire rod mill by
roller table will be installed ensuring means of the new switch. In this way,
that production continues during the
construction and commissioning
quality and plant availability of this al-
ready high-performance train will be i SERVICE
phases. The continuous wire rod mill further improved. Commissioning is
for the Völklingen site consists of sev- scheduled for the summer of 2016. Equipment to be installed in
en mill stands in CS (Compact Stand) Neunkirchen
design and vertical/horizontal ar- BETTER ROLLING TOLERANCES
rangement. This stand design is di- The new wire rod outlet in Neunkirch- oop cooling line and cooling line
L
downstream of ten-stand finishing
mensioned for high loads and large en will be installed downstream of the block
formats and is characterized by com- four CL (cantilever) stands parallel to hear upstream of four-stand
S
pact construction, and higher stand the existing rolling line. The key objec- MEERdrive®PLUS block
rigidity compared to conventional tives of this conversion are quality im- Four-stand MEERdrive®PLUS block
housingless stands. The last two provements, better rolling tolerances with quick-change devices
stands are equipped with a quick- and shorter construction times thanks ooling line downstream of four-
C
stand MEERDrive®PLUS block
change device. The new continuous to a MEERdrive®PLUS block with quick-
inch roll units and loop laying head,
P
wire rod mill rolls different initial sec- change devices.
loop cooling conveyor including
tions from several bloom sizes for the The existing ten-stand finishing three-fan system and coil station
down-line intermediate train. block will be relocated after commis- with dividing shear and pallet
With the expansion of the one- transport system
sioning of the new installation and
strand roughing mill in Burbach, dif- taken into operation in January 2017.
39
CENTERPIECE: INNOVATIVE
3-ROLL PSM®
The SMS group has successfully upgraded the existing bar mill at Steel Dynamics
(SDI) in the USA. This modernization has enabled SDI to increase
its production capacity by 50 percent and expand its product portfolio –
with high-quality bars of SBQ (Special Bar Quality) grade.
SDI now has two production routes. The required shutdown period was kept to since the system operates without
old line (16" mill) produces rounds with a minimum. The rolling stock is en- any moving or vibrating parts, it is vir-
diameters ranging between one and closed in four cassettes comprising tually maintenance-free. The MEER-
nine inches (25.4–228.6 millimeters). three rolls each. The PSM® is the key gauge® precision measuring device
The new line produces high-precision element in SBQ production. One out- takes 500 scans per second of the hot
SBQ bars within the one to 3 ½ inches standing feature is its ability to posi- bar and calculates the deviation from
diameter range (25.4–88.9 millimeters). tion each roll under load – fully auto- the ideal contour in real time. The val-
Together, their annual production ca- matically and in real time. The ues taken from the individual mea-
pacity is 850,000 tons, including 500,000 advanced design of the 3-roll cassette surements are transmitted via a di-
tons of SBQ bars. The SMS group’s in conjunction with three hydraulic rect process field bus link, also in real
scope of supply for the new bar mill in- cylinders is what makes adjustment time, to the TCS (Technological Con-
cluded a descaler, a two-high reversing under load possible. This allows the trol System) of the PSM®. Based on
rougher, eight housingless roll stands bar to be optimized under load during this data, the TCS levels out size fluc-
in an H/V arrangement, a 90-degree the rolling process, while balancing tuations dynamically using closed-
roller table, PSM® precision sizing out fluctuations in the temperature loop control circuits. The entire cross-
block, shearing lines, handling and and size of the incoming bar. The hy- section is captured during this
bundling equipment, as well as the roll draulic cylinders are used for precise process.
shop, technology system and measur- adjustment of all three rolls concen-
ing technology including MEERgauge®. trically or of each individual roll within
The new equipment was integrated into fractions of a second. As a result, RELIABLE, MAINTENANCE-FRIENDLY
the existing finishing train. The old fin- both symmetrical and asymmetrical CASSETTE CHANGES
ishing stands can be incorporated into adjustments to the position of the in- The roll shop set up by the SMS group
the process, depending on the desired dividual rolls under load can be made. enables the rolls in the cassettes to be
cross-section of the bars. This fine adjustment during ongoing replaced quickly and easily. Calibration
production guarantees high output is assisted by optical measuring de-
3-ROLL PSM® PRECISION SIZING BLOCK with consistently high quality. vices and fully automatic measure-
The quality-critical PSM® is the cen- The MEERgauge® installed at the ment of the roll positions on the moni-
terpiece of the new bar mill. PSM exit end of the PSM® is a laser mea- tor. The setting data are transmitted to
stands for Precision Sizing Mill. Prep- suring device used to measure the the automation system, thereby creat-
arations for its installation were made cross-section. Four sensors conduct ing the ideal conditions for hydraulic
while production was still ongoing at non-contact measurements over the roll gap adjustment directly after a
Steel Dynamics. This meant that the entire cross-section of the bar. And cassette change.
40
i
3-roll PSM®
PSM® stands for

Precision Sizing Mill
and was further im-
proved by integrat-
ing the cross-section
measuring device
MEERgauge®. In
addition to greater
precision, material
and energy costs can
be significantly re-
duced, which means
saving up to ten eu-
ros per ton of steel.
41
From top to bottom:

The centerpiece of
the plant – the 3-roll
PSM®.
Good cooperation
between SDI and
SMS. The picture
shows Tim Petti-
grew, SDI, and Maxin
Kruschinski, SMS
group.
MEERgauge® –
cross-section
measurements
on the hot bar.
Operating errors are thus avoided.

The fully automatic cassette changer
is just as fast and easy. A mere five
minutes after the new cassette is
pushed in and the stands are closed,
the plant is ready for operation again.
By operating the PSM® in combina-
tion with the MEERgauge®, TCS and
monitor control system, tolerance val-
ues of up to DIN EN 10060 can be
achieved. With its SQB bars, Steel Dy-
namics has opened up new and lucra-
tive sales markets, for example the
aerospace industry, automotive indus-
try as well as the transport and energy
sectors. Since 2006, already eleven
customers have decided in favor of the
new PSM® with hydraulic roll gap ad-
justment from the SMS group.
www.sms-ecoplants.com
42
Precise measurement technology
Deutsche Edelstahlwerke (DEW) is operating the first

3-roll PSM® (Precision Sizing Mill) of SMS group worldwide with
hydraulic roll adjustment under load. The plant impresses
with MEERgauge® measuring technology.
F
or its location in Siegen, Ger-
many, DEW has now ordered a
new rake-type cooling bed. With
the cooling bed the steel manu-
facturer is upgrading its bar mill. The
new cooling bed allows controlled bar
cooling, conveyance gentle to surfaces
and very straight end products. Conse-
quently, all requirements on quality
steel are fulfilled. Apart from bars in the
round size range from 21.5 up to 90
millimeters hexagonal profiles can also
be deposited on the cooling bed in fu-
ture. “The goal of this modernization is
to achieve a homogeneous temperature
distribution of the bar layer,” says roll-
ing mill manager Jens Eisbach. “This
enables us to prevent inaccuracies Cooling bed of a bar mill.
when cutting the bars and to improve
our productivity and quality in the finish-
ing line.“ Commissioning of the new simultaneously senses up to 500 measuring points per sec-
cooling bed is scheduled for the third ond at the cross-section, which are directly shown in a coor-
quarter of 2015. dinate system. This high-precision measuring device provides
the data for monitor control, controlling the rolls by means of
FIRST 3-ROLL PSM® a hydraulic adjustment system. Fluctuations in cross-sec-
DEW is operating the first 3-roll PSM® tion, temperature or steel grade of the feedstock are auto-
(Precision Sizing Mill) of SMS in the matically corrected allowing close rolling tolerances, inde-
world with hydraulic roll adjustment un- pendently of the operating staff.
der load. The plant was put into service Meanwhile, an automatic surface inspection is per
in 2008. Four years later, the plant was formed to detect surface defects in the rolling line during
expanded by DEW by the precision mea- rolling. In connection with hydraulic adjustment and control
surement technology MEERgauge® and systems the PSM® together with this measurement tech-
a dynamic monitor control. The MEER- nology is a milestone in the production of quality and stain-
gauge® laser measuring device displays less steel.
the complete product cross-section on
the basis of the light section process. It www.sms-group.com
43
RABIGH STEEL ORDERS

REBAR ROLLING MILL
Rabigh steel from the Kingdom of

Saudi Arabia has ordered a rolling
mill from the SMS group, with diame-
ters from 10 to 36 millimeters.
The rolling mill consists of a pusher-type furnace with a

capacity of 62 tons per hour, twelve housingless stands in
horizontal and vertical configuration, an 8-stand finishing
block in V-configuration, a thermoprocessing system, HSD®
system (High-Speed Delivery), cooling bed and finishing
end. The water treatment plant is also a part of the supply.
Straight bars are produced by the HSD® system of SMS,
which ensures that bar steel safely arrives on the cooling
bed even at high speeds. The HSD® system offers several
advantages compared to the slitting process, like higher
metallic yield, higher mill utilization, reduction of losses
and better quality of products.
EFFICIENT PLANT CONCEPT

The rolling mill will be installed in the Rabigh industrial
area. Commissioning is scheduled for the first quarter of
2016. This plant concept enables high efficiency, reducing
the cost of the initial investment.
From 2016, the rebar rolling mill supplied by SMS will be
producing 300,000 tons of rebars per year at Rabigh Steel.
www.sms-group.com/long-products-plants
44
Quick cutting
Kardemir orders shear
for rolling mill.
For the wire rod outlet of its new wire

rod and bar mill Kardemir A.S., Tur-
key, has ordered a high-speed shear.
The scope of supply includes a pinch
roll unit, the high-speed shear with
control, engineering for scrap remov-
al, motors and converters, integration
into electrics and automation as well
as supervision of erection and com-
missioning. In 2008, a rail and section
mill from the SMS group had already
been successfully put on stream, and
in 2013, Kardemir A.S. ordered a wire The team of Kardemir and SMS when signing the contract.
rod and bar mill for 700,000 tons of
quality steel per year. “We are con-
vinced that the high-speed shear from
SMS is the best solution for cutting
safely and repeatably even at the high-
est rolling speeds,” says Ragip Parlak,
Continuous Rolling Mill Manager of
Kardemir A.S.
www.sms-group.com/long-products-
plants
45
STEEL LOCATION
DUISBURG, GERMANY,
WITH NEW WIRE ROD MILL
Since the beginning of this year, ArcelorMittal has been operating
a wire rod mill in Duisburg-Ruhrort with state-of-the-art
technology. Almost coinciding with the closure of
the old plant in Duisburg-Hochfeld, the wire rod mill at
the Ruhrort location is ready to take up production.
Duisburg as steel location has a more than 150-year tradi-
450,000
tion. The very first blast furnaces along the Rhine were lo-
cated in Duisburg-Hochfeld. Here, wire rod was rolled in
1913 for the first time. In 2010, ArcelorMittal and SMS signed
a contract for the supply of a wire rod mill at the new Duis-
burg-Ruhrort location. At that time, the plant in Hochfeld
tons of high-grade steels can be rolled to
was 40 years old and could no longer satisfy the demands of wire rod in the dimensional range from 5.5
continuing to offer a competetive production service. Ruhrort up to 25 mm by ArcelorMittal every year on
became attractive as new location; a steel plant from Arce- the Duisburg-Ruhrort plant in a tempera-
lorMittal with direct accessibility to billet production was ture-controlled manner. The maximal rolling
already in operation. speed is 120 m/s, corresponding to 432 km/h.
NEW CONFIGURATION
In the boom phase up to 570 staff members were working on dimensions given. The product range
the construction site. “It was a challenge for the team to of the plant extends from spring steels
retrofit the closed-down building complex of an earlier in Superclean quality, case-hardening
blooming and continuous mill for the new wire rod mill,” says steels, cold-heading grades, free-cut-
Stefan Etges, Project Manager at ArcelorMittal. Following a ting steels as well as tool and anti-fric-
two-year construction period and an intensive alignment and tion bearing steels up to carbon and
initial period of about one year, the plant has been operating alloyed steels, welding wire and pure
at almost full capacity since the beginning of 2014. iron steel. The products from altogeth-
The supplied wire rod mill of the MEERdrive® type pro- er 200 steel grades are applied in the
vides a configuration used in Europe for the first time: the automotive industry as valve springs
finishing block is divided into two parts, a 6- and 4-stand fin- and screws of the highest quality.
ishing block allowing exact process control and best thermo-
mechanical characteristics of the end product. The surfaces www.sms-group.com/long-products-
of the rolled wire rod are of high quality and always keep the plants
46
From top to bottom:
LLC® (loop laying
heads with cooling
conveyor) at Arcelor-
Mittal in Ruhrort.
The steel location

of ArcelorMittal
Ruhrort at Duisburg
viewed from the air.
47
STEEL AT AN ALTITUDE OF
1,007 METERS
South Steel is producing steel on SMS group plants for the highest
building in the world: The Kingdom Tower in Saudi Arabia. The minimill went
on stream in 2013. The skyscraper is scheduled to be completed in 2018.
It will be a truly exceptional building: Red Sea Region. On its 530,000 square the architects Adrian Smith and Gor-
never before in history has a building meters, the Kingdom Tower provides don Gill developed a shape offering a
surpassed the magic altitude of 1,000 space for offices, apartments and a point of attack as small as possible to
meters. With exactly 1,007 meters the luxury hotel. A round observation deck the airstream. The “footprint“ of the
Kingdom Tower in Jeddah, Saudi Ara- with a diameter of 30 meters located building is constructed as a Y-Shape
bia, will reach up to the sky. For the on the 157th floor, at 502 meters high, with flanks spreading at 120 degrees.
foundation and the construction of the is the highest in the world – offering a Apart from good wind compatibility
tower, SOLB Steel from Jizan, Saudi breathtaking view over Jeddah. The this shape allows large window areas.
Arabia, will supply steel from a mini skyscraper is also the heart of the An important aspect for future users is
mill of the SMS group. planned Kingdom City. The construc- that anyone residing in the highest
tion project next to the Red Sea total- building in the world wants to have at
MAJOR PROJECT KINGDOM CITY ing approx. 20 billion US dollars, which least one window in their room and en-
The Burj Khalifa, with an altitude of accommodates houses, hotels and of- joy the view.
828 meters the highest building world- fices on an area of 5.2 square kilome-
wide since 2010, is located in Dubai ters aims to up the value of the region GERMAN KNOW-HOW
and will be outreached by another 179 from an economic perspective and to Whether it is the civil engineering
meters already in 2018 – by the King- attract financially strong high-tech en- company Bauer for the foundations,
dom Tower in Jeddah, Saudi Arabia, terprises. The statics of such building the concrete pump specialist Putz-
Photo: Jeddah Economic Company/Adrian Smith + Gordon Gill Architecture
with an altitude of 1,007 meters, the heights are faced by exceptional tech- meister or the elevator expert Krone –
construction of which is already un- nical challenges. Wind and even small without the know-how of German
derway. The project developer and fu- earth tremors tremendously pull at companies the Kingdom Tower could
ture owner is the Jeddah Economic the construction. In wind tunnel tests not be realized. For example, Krone
Company and the responsible building delivers 57 elevators, of which seven
company is the Saudi Bin Laden Group. are of the two-storied type, and eight
The design for the skyscraper comes escalators. With the development of
80,000
from the architect offices Adrian Smith lightweight carbon fiber strands, being
and Gordon Gill (AS+GG) from Chicago, lighter by around 80 percent compared
U.S.A. who were also responsible for to a conventional steel cable, Krone
the Burj Khalifa. The building costs of was able to more than double the max-
this mammoth project are approx. 1.2 imum travel height of the super sky-
billion US dollars. tons of rebars alone for the founda- scraper elevators from 500 to approx.
The slim, streamlined shape of the tions have been supplied by SOLB. 1,000 meters. Until now, this would
building is a symbol in the emerging have failed due to the dead weight
48
The Kingdom
Tower in Saudi
Arabia will be the
highest building in
the world. (photo:
Jeddah Economic
Company/Adrian
Smith + Gordon
Gill Architecture)
49
A special “footprint”
allows for an aerodynam-
ically favorable overall
construction of the build-
ing against wind forces.
of the steel cables. The elevators in furnace for secondary metallurgy as mill of the plant. Besides structural
the Kingdom Tower travel at a speed of well as a five-strand continuous cast- steel SOLB supplied roughly 80,000
ten meters per second. er. The production capacity of the plant tons of rebars alone for the founda-
The steel for the heavy-loaded foun- is approx. one million tons of square tions. SOLB enjoys a long working re-
dations and the structure of the build- billets per year in the 130 millimeter lationship with the Saudi Bin Laden
ing is produced by South Steel (SOLB) or, respectively, 150 millimeter format. Group and has already delivered steel
from Jizan on a modern minimill of the Half of the billets are sold on the re- for expansions of the mosques in
SMS group. The minimill was taken gional market and the other half, Mecca and Medina.
into operation in July 2013 and it com- which is still in a warm condition, is
prises an electric arc furnace, a ladle further processed in the rebar rolling www.sms-group.com
Photo top: Jeddah Economic Company/Adrian Smith + Gordon Gill Architecture
i FACTS + FIGURES
SELECTION OF HIGHEST BUILDINGS THROUGHOUT HISTORY
BUILDING COMPLETED ALTITUDE COUNTRY
Pyramid of Cheops 2,500 BC 146.59 m Egypt
Cologne Cathedral 1,880 AD 157.38 m Germany
Empire State Building 1931 381 m U.S.A.
Taipei 101 2004 508 m Taiwan
One World Trade Center 2014 541 m USA
Burj Khalifa 2010 828 m United Arab Emirates
Sky City Planned for 2014 838 m China
Kingdom Tower Planned for 2018 1,007 m Saudi Arabia
50
Expansion at Tung Ho
in Taiwan
Tung Ho Steel Enterprise Corporation from Taipei hot, warm or cold charging mode. It
allows for a uniform temperature of
(Taiwan) has ordered a second rolling mill and
the billets lengthwise, which are
another induction heating system from the therefore able to flow directly into the
SMS group for its CMTTM minimill at Taoyuan site. rebar mill. A holding chamber is in-
stalled upstream of the multi-zone
heating system in order to increase
the flexibility if the billets cannot be
rolled immediately. The chamber can
store the billets in a warm condition
The rolling mill No. 2 can handle bil- 850 ton shear force and two finishing for the following warm charging mode.
lets with dimensions up to 160 mm x sections of 18 and 24 meters, each It functions with the “first-in/first-out”
16 meter length, coming from the up- with four wire rod tying machines. principle so that temperature losses
stream continuous caster. The Multi- Rebars with diameters from 8 to 57 are minimized to the greatest-possi-
Zone Induction Heating Technology mm can be produced on the mill. The ble extent.
(MZT) will come from SMS Elotherm. production of a special “screw shape”
The new mill will be equipped with with a diameter of 19 mm will now al- ECOPLANTS
14 rolling stands, an eight-stand fin- so be possible for the first time. The second rolling mill and the sec-
ishing block, a high-speed delivery Due to its special design and flexible ond induction heating system will ren-
system (HSD®), a cooling bed fitted technical features the multi-zone der it possible to roll 100 percent of
with lifting aprons, a cold shear with heating will be able to roll billets in the billets produced by the upstream
continuous caster – at very low oper-
ating costs.
The second mill is nearly identical to
the first – a reference for SMS group’s
ecoplants. This benefits Tung Ho in that
the operating personnel can be quickly
familiarized with the mill operation.
www.sms-group.com
Cooling bed with HSD® System.
51
160tons per hour is the capacity of the walking-

beam furnaces, which will provide the feed
A continuous billet caster is part of the equipment stock for the two light-section mills supplied
supplied by SMS to Tulachermet-Steel. by SMS group.
SMS group will also be responsible for the supply of the 160-ton converter shop.
52
ORDER FROM RUSSIA

Tulachermet-Steel orders complete steelworks with two connected
light-section mills from the SMS group.
Tulachermet-Steel and SMS group CASTING OF SQUARE SECTIONS

have concluded a contract for the sup- SMS group is supplying a ladle fur-
ply of a complete steelworks with a nace, a twin-tank vacuum degassing
connected continuous billet caster and facility for the secondary metallurgi-
two connected light-section mills. The cal treatment and a six-strand billet
order value comes to around EUR 180 caster. The continuous caster will be
million. The contract was signed on the equipped with CONVEX technology®
SMS group booth at the Tube & Wire and be able to produce square sec-
fair in Düsseldorf, Germany, in the tions in sizes from 150 x 150 to 180 x
presence of the State Secretary of the Back row from left to right: Ulrich Svejkovsky, 180 millimeters. Two almost identical
Ministry of Economic Affairs of the Fed- SMS; Reinhard Reddel, SMS; Yevgeniy Shma- light-section mills, each of which will
gin, Consul General of the Russian Federa-
eral State of North Rhine-Westphalia, tion; Dr. Günther Horzetzky, State Secretary
receive their feed stock from a walk-
Dr. Günther Horetzky, and the Consul of the Ministry of Economic Affairs, Energy, ing-beam furnace will have a capacity
General of the Russian Federation, Yev- Industry, Small and Medium-Sized and Craft of 160 tons per hour. One of these
Trades of the Federal State of North Rhine-
geniy Shmagin. light-section mills will be equipped
Westphalia; Jens Barth, SMS; front row from
It was agreed to construct a convert- left to right: Sergey Frolov, Vice President, with a wire rod line for the production
er-based steel and rolling mill complex Strategy & Communications KOKS Group; of quality steel in the form of bar steel
in the immediate vicinity of the Tulach- Konstantin Pitjul, Director General Tulach- and wire rod. The SMS group is also
ermet-Steel; Andrey Zubitskiy, Senior Vice
ermet iron works located in Tula, President KOKS Group; Burkhard Dahmen, supplying the electrical and automa-
around 200 km to the south of Moscow. SMS; Bernhard Espendiller, SMS. tion systems for all production lines.
Tulachermet-Steel will assume the Tulachermet-Steel is a Russian-based
project management and the construc- company established by several in-
tion activities. The contracts for the chanical engineering and automotive vestors with the participation of
construction and installation work will companies. The steelmaking and roll- shareholders of the KOKS Group. The
be placed with Russian companies. ing mill complex will go into operation KOKS Group is a leading producer of
in 2016. SMS Siemag is supplying a merchant pig iron and coke. Further-
WITH ENERGY RECOVERY SYSTEM 160-ton converter shop, equipped with more, the group possesses various
The rolling mills, which will make light a restraint-free lamella suspension assets for the production of high-
sections, bar steel and wire rod, will be system and a dedusting plant. The lat- quality coking coal and the extraction
designed for an annual capacity of 1.5 ter will be fitted with electrostatic pre- and processing of iron ore.
million tons in the first phase, with the cipitators from SMS Elex. SMS Siemag
possibility of a later increase to two will also be supplying an energy recov- www.sms-group.com
million tons. The major part of the pro- ery system. For the further optimiza-
duction will be supplied to Moscow and tion of energy efficiency, SMS Siemag
to other regions in Central Russia. can provide a converter-gas recovery
Here, there is a demand for high-quali- and mixing plant for subsequent com-
ty steel products, above all from the bustion of the gas in the existing Tula-
construction industry and from me- chermet power station.
53
Acciaierie Valbruna has commissioned four Three high-speed wire mills from SMS Meer Formosa Hà T nh Steel will produce 160 mil-
mill stands. went on stream at Rizhao. limeters and 180 millimeters square billets on
the new mill.
Close 3.2 mill. tons High-quality

tolerances of wire rod SBQ steel
Acciaierie Valbruna, Four wire rod mills at Formosa Hà T nh Steel
Italy. Rizhao Steel. orders new mill.
Acciaierie Valbruna from Vicenza, Rizhao Steel from Rizhao City, Shan- For its new integrated steel plant in
Italy, has commissioned four mill dong Province, China, has commis- Hà T nh Province, Vietnam, Formosa
stands for the intermediate train sioned three high-speed wire rod Ha Hà T nh has placed an order with
supplied by SMS. This state-of the- mills from SMS. All three new mills SMS, Germany, for a semi-continu-
art rolling mill enables Acciaierie have been installed at the Ying Kou ous billet mill. The produced billets
Valbruna to fulfil different require- City location in the Province of Liaon- will be used within the Formosa
ments of the customer: Bars can be ing. With the three wire mills Rizhao Group as starting material for the
produced in a diameter range from is able to produce different steel production of wire rod and bars.
20 to 73 millimeters (round bars), grades and offer more quality prod- With the mill, Formosa Hà T nh Steel
rebars in a range from 14 to 50 mil- ucts on the market. The startup of will be able to use continuously
limeters and hexagonal material in the first mill took place already nine casted billets as well as rolled bil-
a range from 20 to 57 millimeters. months after the contract came into lets for the downstream process.
Further products are wire rod with force. Another, fourth wire rod mill is Thereby, Formosa Hà T nh Steel is
diameters from 5.5 to 12 millime- to be installed at the same location. gaining quality and flexibility in pro-
ters and bar-in-coil from 12.5 to All four wire rod mills will achieve a ducing high-quality SBQ steel prod-
32 millimeters. total capacity of 3.2 million tons per ucts. Formosa Hà T nh Steel will
Acciaierie Valbruna has found a year. produce 160 millimeters and 180
reliable partner in SMS – for the This wire rod mill concept devel- millimeters square billets on the
supply of technological equipment oped by SMS with a six- and four- new mill. The maximum production
and for services. stand wire rod block in the wire rod capacity is one million tons per year.
finishing line allows grades of car- It is possible to increase the produc-
bon up to spring steels to be rolled. tion capacity up to two million tons
in a second expansion phase.
www.sms-group.com/long-products- www.sms-group.com/long-products-
www.sms-group.com
plants plants
54
An important detail: The wire rod finishing With the PSM® technology Xining produces also The laser measurement system MEERgauge®
block with MEERdrive® technology. small lot sizes economically. is employed at Timken, U.S.A.
Cutting-edge First PSM® Precisely and

core in China automatically
Fujian Wuhang takes 3-roll sizing block in op- MEERgauge® system
plant into service. eration at Xining. commissioned.
Together with SMS, the Chinese Xining Special Steel from Qinghai Timken from Canton, Ohio, USA,
company Fujian Wuhang Stainless Province, China, has commissioned a has successfully commissioned the
Steel Products Co. Ltd. from Chan- 3-roll sizing block (PSM®, Precision MEERgauge® laser-based precision
gLe City, Fujian Province, has suc- Sizing Mill) supplied by SMS, thus op- measuring system supplied by SMS.
cessfully commissioned one of the erating the first PSM® in China. With The system displays the complete
most modern stainless steel the PSM® Xining rolls all final sizes product cross-section on the basis of
rolling mills for the production of from diameter 16 to 100 millimeters. the light section method. With the
wire rod and bar in coils. The rolling Thanks to the hydraulic roll adjust- new measurement technology, Tim-
mill achieves an annual production ment performed under load, the ken can reduce tolerance deviations
capacity of more than 300,000 tons company produces any desired size fully automatically during the rolling
and rolls high-grade special steels. from a single-pass family. Depending process. “The results produced by the
The core facilities include a state- on customer requirements, Xining is MEERgauge® made a lasting impres-
of-the-art 3-roll sizing block (PSM®) hence also producing small lot sizes sion on us. We can further improve
with hydraulic roll adjustment per- economically. our already very good rolling toler-
formed under load which finish-rolls “The concept and the technical ances, particularly with the single-
all final sizes for bars from diameter know-how from SMS have convinced pass system running under load,”
13 to 38 millimeters from a single- us from the very beginning. With this says Perry Petrullo, Plant Manager at
pass family. In addition, the PSM® special rolling mill we will be able to Timken. Up to 500 measurement
also provides all the required initial further expand our leading market po- points around the cross-section are
cross-sections for the wire rod sition,“ says Dang Fufei from the Xining recorded simultaneously in a coordi-
block. All the finished products of Special Steel Group. The PSM® pack- nate system displaying the actual
the sizing block are coiled on a new- age also comprises an automatic stand cross-sectional form. MEERgauge®
ly designed coiler. changing system, a stand workshop was completely installed and inte-
and a software system. grated in just one week.
www.sms-group.com/long-products- www.sms-group.com/long-products- www.sms-group.com/long-products-

plants plants plants
55
PSM® cassettes in the Mönchengladbach workshop.
i ADVANTAGES
MEERdrive® compared to conventional
wire rod technology:
Conventional MEERdrive®
Fixed gear ratios defined reat flexibility in roll
G
pass design
ixed reduction ratios
F
between the stands ree choice of reduction
F
conditions between indi-
arrow limits for roll ad-
N
vidual stands
justments to compensate
wear or varying spread Free adjustment range
Improved dimensional tolerances and metallurgical

properties Highest mill flexibility
56
A STRONG COMBINATION
FOR KARDEMIR
Karabük Demir Celik (Kardemir), Turkey, has ordered a combined
rolling mill for quality steel from SMS group. The plant, designed for a broad
quality and dimension range, is able to produce bars and wire rod.
Consequently, Kardemir can produce at low cost even small lot sizes.
The core is a 3-roll precision sizing reheating furnace with a capacity of
700,000
block (PSM®) offering the possibility 150 tons per hour, 18 up-to-date
to adjust the rolls even under load. In housingless two-high stands in H/V
addition to that, the advantages in- arrangement, shears, cooling lines, a
clude a close tolerance range for roll- cooling bed with finishing lines and a
ing. From the roll pass of a precision laying head, LCC®, coil handling tons is the annual capacity of the rolling mill
size greater and smaller infinitely equipment and two coil compactors. in the first stage. In a second stage, this can
variable dimensions are generated A coiling line with two coilers and be expanded to 1.4 million tons.
(”Free Size Rolling“). Quick program cooling devices allows the production
changes are also possible. With the of coils. It was particularly designed
control system TCS (Technological for scratch-free handling of the fin-
Control System) differences due, for ished products. In the first stage, the
exeample, to various cross-sections rolling mill achieves an annual capac-
of the starting material or other entry ity of 700,000 tons which can be in-
conditions can be compensated. creased in the second expansion
Moreover, differences in temperature stage to 1.4 million tons.
can be balanced out.
SURFACE-QUENCHED REBARS
FEWER ROLLING RINGS THANKS TO PRODUCED AS BARS
FLEXIBLE ROLL PASS DESIGN The plant contains three outlets: bars a self-developed CCT® system (Con-
The wire rod line is equipped with a in the 20- to 100-millimeter diameter trolled Cooling Technology). With this
MEERdrive® wire rod finishing block. range are directly rolled from the system, the process parameters can
Here, each mill stand is driven by an PSM® on the cooling bed and bars in be set for attaining the d esired me-
individual motor resulting in reduced the 20- to 55-millimeter diameter chanical properties and microstruc-
energy consumption and mainte- range are coiled via the coiling line. tures. Commissioning is scheduled
nance effort. Besides, roll passes are Wire rod can be produced in the 5.5- for the first quarter of 2015.
highly flexible. As a result, Kardemir to 25-millimeter diameter range via
requires fewer rolling rings. The mill the wire rod line. In addition, quenched www.sms-group.com/long-products-
plants
is designed for a maximum speed of rebars in the 8- to 40-millimeter di-
120 meters per second for wire rod ameter range can be produced as
and 16.5 meters per second for bars. bars by means of a high-speed deliv-
The plant consists of a walking-beam ery system (HSD®). SMS also supplies
57
The experts of SMS group commissioned the rebar rolling mill of Abinsk.
Abinsk Electric Steel Works commissions

two roughing stands
A wider range of products and higher productivity are the result

of the expansion in the high-speed rebar rolling mill
of Abinsk Electric Steel Works in Krasnodar (Russia).
Abinsk Electric Steel Works from the Furthermore, the two new stands
550,000
Krasnodar Region, Russia, has suc- will increase the rolling mill’s produc-
cessfully commissioned an expansion tivity by two to three percent for 8- to
of its high-speed rebar rolling mill sup- 10-millimeter rebars.
plied by SMS, Germany. The two new Abinsk’s high-speed rebar rolling
roughing stands will enable Abinsk to mill was supplied and commissioned tons a year are produced by the rebar rolling
roll larger square billets than to date. by SMS in 2011. It operates at a rolling mill at Abinsk, ten percent more than the
This will enhance the company’s com- speed of 40 meters per second, allow- original capacity
petitiveness on the local market. ing a rolling production of more than
Until now Abinsk has fed its rolling 550,000 tons per year, thereby exceed-
mill with 130-millimeter square bil- ing the original capacity by ten per-
lets purchased from other suppliers. cent.
The two new roughing stands will al-
low 150-millimeter square billets to www.sms-group.com/long-products-
plants
be rolled which are produced in
Abinsk’s own new steel plant.
58
Amsteel Mills brings modernized

wire rod mill on stream
SMS group, Germany, has successfully upgraded the core components
of a wire rod mill at Amsteel Mills in Banting, Malaysia.
The modernization will enable the

company to boost its productivity and
to roll surface-quenched and tem-
pered rebars at a speed of up to 105
meters per second.
Less standstill, more throughput:
These were SMS group goals in bring-
ing the outdated wire rod mill at Am-
steel up to the state-of-the-art. The
original plant had been delivered by
Danieli in 1995.
The plant’s ten-stand wire rod
block and the high-speed loop laying
head were replaced with SMS group’s
modern technology. In addition, the
17-year-old water cooling section
with pinch roll unit was replaced. A
process model for optimum tempera- SMS guarantees a high quality of wire rod
ture control will now ensure that the mills through its employees’ know-how.
demanded microstructure properties
250
are reliably achieved – while main-
taining the close tolerances.
Amsteel together with Megasteel
belongs to the steel division of the Lion
Group, one of the largest companies in
Malaysia, a conglomerate with head-
quarters in Kuala Lumpur.
www.sms-group.com/long-products-
plants
wire rod mills have been installed worldwide
by SMS group since 1950. SMS is today the
The modernization will enable Amsteel to leading supplier of such mills. The first wire
boost its productivity and to roll rebars at a rod mill from SMS was supplied to Aciaieria e
speed of up to 105 m/s. Forriera del Caleotto in Lecco, Italy.
59
A good team: Wolfgang Goerke, ArcelorMittal, and Dr. Dirk Oedekoven (r.), SMS group.
WAREHOUSE IN DUISBURG-
RUHRORT, GERMANY, OPENED
MEERcare®: Since 2013, SMS group has been operating a warehousing project
in Duisburg-Ruhrort for the wire rod mill of ArcelorMittal.
It consists of a consignment ware- express deliveries are possible within experts of SMS. The customer, here
house with more than 600 places re- 90 minutes – also during weekends ArcelorMittal, is focusing on its core
quiring sophisticated planning and lo- when most of the scheduled servicing business and not on logistics and
gistics. “The warehouse helps us since measures are performed. warehouse management. Last but not
we are now able to focus on our core “In addition we offer on-call duty least, working capital is hardly affect-
business,“ says Wolfgang Goerke, around the clock and on weekends ed and the customer therefore saves
Project Manager at ArcelorMittal. which means a 24/7 service is avail- time and money.
Together with a global logistics able,“ adds Dr. Dirk Oedekoven, Head
partner the experts from SMS group of Product Management at SMS. Dirk Oedekoven
dirk.oedekoven@sms-group.com
Service manage the warehouse in Oedekoven and his team have every in-
close proximity to the plant. The ben- terest in the success of this project. “In
efit to the customer: he pays only af- warehousing we see real potential,“ he
ter the parts have been withdrawn. reports. The advantages of SMS ware-
This means a significant cash-flow housing are obvious: permanent avail-
advantage. Deliveries take place ability of all agreed parts and auto-
within one day, and on demand matic replacement is taken over by the
60
Innovative
3-roll
technology
Thanks to MEERgauge®,
SMS has optimized the
PSM® (Precision Sizing
Mill) process and thus
fulfills the highest re-
quirements of wire rod
and bar production.
With MEERgauge® the 3-roll PSM® achieves
tolerances of 1/8 DIN EN10060 and better.
The outstanding characteristic of the PSM® process will again become more
innovative 3-roll technology is the pos- precise, efficient and sustainable by in-
sibility to adjust the rolls even under tegrating MEERgauge®. At the Siegen-
load by means of hydraulic cylinders. Geisweid location in Germany Deutsche
Combined with the technical control Edelstahlwerke primarily produce ma-
system TCS the rolling processes can terials for the automotive industry. In
thereby be finely adjusted in real time 2011, SMS was awarded the order to
and the final product can be decisively expand the installed 3-roll PSM® by a
improved. The 3-roll PSM® successfully precision cross-section sensing system
used since 2006 can also be applied in with integrated automatic dimension
fully automated mode by combining it control. With the implementation of the
with MEERgauge®. The new technology MEERgauge® process the efficiency of
consists of a precision laser measuring the rolling mill and the quality of the
instrument for the most accurate steels produced were able to be im-
cross-section sensing and a highly dy- proved even further.
namic monitor control. For rolling a
perfect end product, dimension and FROM THE CUSTOMER’S POINT OF VIEW
temperature variations in the feedstock “With the 3-roll PSM® we are able to
can be independently corrected by achieve tolerances of 1/8 DIN EN
means of MEERgauge®. As a result, 10060 and better in a safe and objec-
rolling tolerances of 1/8 DIN EN 10060 tive manner.“ Jens Eisbach, Rolling
or better can be achieved, significantly Plant Manager, Deutsche Edelstahl-
reducing the peeling quantities pro- werke Siegen.
duced and the expenditure required
for peeling. With dimensionally more www.sms-ecoplants.com
accurate rolling, energy as well as
Dr. Thomas Helsper (left), Head of Rolling
Mill and Bright Steel Shop Rolling Mill
material expenditure can be decisively Siegen, and Günther Schnell, SMS group,
reduced even further. Altogether, the in front of a PSM® stand.
61
500,000 tons
of rebar
South Steel has
commissioned a minimill
from SMS group.
The steelworks in Jizan, Saudi Arabia,

produces up to one million tons of bil-
lets, the rolling mill up to 500,000 tons
of rebar. The electric arc furnace is
equipped with eccentric bottom tap- The very first cast in the continuous caster was successful.
ping and a full platform, and is de-
signed for 24 charges per day. The la-
dle furnace is used for secondary
metallurgy treatments. It is planned to
use 80 percent HBI (hot-briquetted sists of 16 housingless stands followed downline by a finish-
iron) and 20 percent scrap as charge ing block with six stands. The compact design of HL (hous-
material. However, the furnace can ingless) roll stands and the use of a finishing block ensure
also process up to 100 percent HBI. compliance with close tolerances. Thanks to the HSD® (High
The electrode control system and Speed Delivery) system, final rolling speeds onto the cooling
the process automation in the steel- bed of up to 41 m/s are possible. Therefore, even with small
works meet very high requirements, product dimensions, the plant can reach a high hourly pro-
providing the basis for a homogeneous, duction rate.
highly flexible, and productive process. “We are very pleased with the successful cooperation dur-
The continuous caster has five ing this project,” says Stefan Rutishauser from SMS group.
strands and can produce one million “Thanks to the high capacity of the components, the perfor-
tons of billets in the formats 130 mm mance and the productivity of the minimill are impressive,
and 150 mm square. exactly as South Steel had expected them to be.”
Half of the cast billets are sold on The South Steel minimill is regarded as a major mile-
the regional market, the other half is stone in setting up a steel cluster. Jizan Economic City is
further processed while still hot in the one of six newly constructed cities with which the Kingdom
rebar mill. aims to make the Saudi economy less dependent on the
export of crude oil by 2030.
REDUCED FUEL CONSUMPTION
The rolling mill is equipped with a www.sms-group.com/long-products-
plants
walking-beam furnace having several
control zones. The fuel-air ratio is sep-
arately monitored in each zone, con-
siderably reducing fuel consumption.
The fully automated rolling mill con-
62
A staff member from SMS group during checking of the CL modules.
Wire rod mill with high productivity

Rolling speed of 120 meters per second
Xilin Iron & Steel from Heilongjiang high demands on the equipment and the process manage-
Province, China, is increasing its pro- ment. “Xilin Iron & Steel can depend on all the processes
duction capacities with a new high- running stably and reliably, allowing high availability and pro-
speed wire rod mill from SMS group. ductivity to be achieved,” adds Zuo-Guo Xiao.
The two-strand mill with ten-stand Xilin Iron & Steel will make quality products for the Chi-
wire rod blocks achieves a rolling nese market on the new wire rod mill such as C-steel, cold-
speed of 120 meters per second. The heading grades, welding wires and spring steels in the size
plant can produce one million tons of range from 5.5 to 20 millimeters in diameter.
wire rod per year.
“Our high quality combined with the www.sms-group.com/long-products-
plants
proximity to the Chinese market con-
vinced Xilin Iron & Steel,” says Zuo-Guo
Xiao, Managing Director of SMS group
in China. The maximum rolling speed of
120 meters per second – corresponding
to 432 kilometers per hour – makes
63
Jiangsu ShenYuan Special Steel, China
Wire rod outlet for special

steel mill
New order. The Chinese company Jiangsu Shen Yuan The wire rod section consists of
Special Steel from Shenyuan, Jiangsu Province, has compact CL stands in H/V arrange-
awarded an order to SMS for the supply of the wire rod ment renowned for their especially
outlet of a special steel rolling mill. The mill will have an high load-bearing capacity. Installed
annual production capacity of more than 180,000 tons and downstream are an eight-stand wire-
will roll top-quality stainless steels and high-grade valve rod finishing block, a pinch-roll unit
steels. and a loop laying head as well as the
Diameters from 5.5 to 20 millimeters will be produced LCC® (Loop Cooling Conveyor). The
with a maximum capacity of 60 tons per hour and a max. LCC® is designed in such a way that
rolling speed of 70 meters per second. The envisaged ex- the heated wire rod coils can be col-
pansion of the mill to include steel bars in coils will cover a lected directly downstream of the lay-
size range from 21 to 40 millimeters in diameter. ing head in order to subsequently feed
them to an inline heat treatment sys-
tem. Commissioning is scheduled for
the end of 2013.
64
Steel Dynamics, U.S.A.
High-quality SBQ products

New order. Steel Dynamics (SDI) from produce specialty bar qualities with
Fort Wayne, Indiana, U.S.A., awarded a the highest precision and maximum
contract for a major expansion of the flexibility”, states Barry Schneider,
SBQ (Special Bar Quality) plant at its Vice President and General Manager
Pittsboro/ Indiana works to SMS group. of SDI in Pittsboro. The PSM® is able to
This upgrade is to integrate a roughing roll out of a single-pass family any
mill and a new three-roll PSM® (Preci- steel grade and any size and ensures
sion Sizing Mill) into the facility. With maximum availability of the rolling
this investment, the 5th biggest steel mill. The new roughing mill will be op-
producer in the U.S.A. strengthens its erated in semi-continuous mode, con-
market position: In future, SDI will be sisting of a two-high reversing mill fol-
able to roll high-quality SBQ products in lowed by eight rigid housingless stands
the small-diameter precision range. in H/V configuration which will feed the
”We wanted the most advanced existing finishing mill. The advanced
three-roll sizing technology available three-roll PSM® will finish all SBQ
in the market – that’s why we selected bars in the range of ¾ to three inches
SMS. With the PSM® we will be able to round.
FuJian WuHang, China
Stainless steel rolling mill ordered

New order. The Chinese company sections for the wire rod block. The drive® technology. The special feature
FuJian WuHang Stainless Steel from scope of supply of the PSM® includes of this facility is that each stand is
ChangLe City, FuJian Province, has the automatic stand-changing system, individually driven by its own motor.
placed an order with SMS group, Ger- the workshop for preparation of the The wire rod dimensions range from a
many, for the supply of core equipment stands and guides, and also the CAR- diameter of five to 20 millimeters.
for the construction of a new stainless TA® system which provides the specific
steel rolling mill. The mill will produce setting values depending on the prod-
wire rod and bars in coils. The core fa- uct and dimension.
cilities include a modern 3-roll PSM® All the finished products of the
(Precision Sizing Mill) with hydraulic 3-roll PSM® sizing block are wound on
roll adjustment performed under load a newly designed coiler ensuring top
which finish-rolls all final sizes from a quality by producing scratch-free fin-
diameter of 13 to 38 millimeters from a ished products, and optimum shaping,
single-pass family. height and winding densities of the
Furthermore, the PSM® also pro- coils. Another core component is the
duces all the necessary initial cross- wire-rod finishing block with MEER-
65
Larger initial pass cross-section
Abinsk Electric Steel Works

orders roughing stands
New order. Abinsk Electric Steel Works from the Krasno- So far Abinsk has fed its rolling mill with 130-mm
dar Region, Russia, has placed an order with SMS to up- square billets purchased from other suppliers. The two
grade its high-speed rebar rolling mill. With two new new roughing stands from SMS will extend the range to
roughing stands, Abinsk will be able to roll larger square 150-mm square billets which will be produced in Abinsk’s
billets than to date. own new steel plant. Furthermore, the two new stands will
increase the rolling mill’s productivity by two to three per-
cent for 8- to 10-millimeter rebars.
With this investment, Abinsk wants to become the lead-
ing iron and steel producer in the Krasnodar Region. The
company intends to also increase its production volumes
and extend its product range. Abinsk’s high-speed rebar
rolling mill was supplied and commissioned by SMS in
2011. It operates with a rolling speed of 40 millimeter per
second and reaches a monthly production of 47,000 tons.
This amounts to more than 550,000 tons per year and
exceeds the agreed nominal capacity by almost
10 percent. Commissioning of the new stands is sched-
uled for April 2013.
The existing roughing mill at Abinsk.
Deutsche Edelstahlwerke
First MEERgauge® system

Commissioning. Deutsche Edelstahlwerke (DEW), Germa-
ny, operates the first 3-roll block in the world with hydraulic
adjustment under load from SMS. At the Siegen-Geisweid
site, the so-called PSM® system (Precision Sizing Mill) now
replaces two 3-roll blocks. The integrated MEERgauge®
system enables fully-automated operation of the 3-roll
PSM®, independent of the operating staff.
In the case of size and temperature variations in the input
material, the new system reduces potential tolerance devia-
tions in the finished product independently during rolling
operation. This technology consists of a laser precision gage
for cross-sectional detection and a highly dynamic monitor
control. ”The control system operates reliably and has sur-
passed our expectations. The entire process from the proj-
The MEERgauge® system enables fully-automated operation. ect phase through to a successful realization was very suc-
cessful,” says Dr. Thomas Helsper, Head of the Rolling Mill
Division at DEW’s Siegen-Geisweid location.
66
“Letter of Intent” for PSM®

signed on a soccer shirt
Unusual tentative agreement
Swapping shirts after a soccer game no longer causes a and each size can be rolled at any time with highest preci-
sensation – but a contractual letter of intent on a soccer sion ensuring maximum availability of the rolling mill. Af-
shirt does. ter the expansion, the mill will produce 500,000 tons per
During the European Football Championship SMS and year. Commissioning of the modernized plant is scheduled
Steel Dynamics Inc. (SDI) agreed on an expansion of the for the end of 2013.
SBQ plant at the Pittsboro location in Indiana, USA – and
captured the cooperation spontane-
ously on a German soccer shirt.
The responsible people from SDI
spent three days in Germany. The aim:
successful negotiations and a signed
letter of intent. ”Unfortunately, time
was too short to draft a document,”
said Günther Schnell, Head of Sales
and Project Engineering Wire Rod and
Bar Mills. ”Therefore, we had to think
of something else. Both parties signed
a German soccer shirt.”
SMS group in Mönchengladbach,
Germany, will integrate a new 3-roll
precision sizing mill of the PSM® type
into the existing plant and the col-
leagues from Tarcento will moreover
install another roughing mill. ”We
wanted the most advanced sizing
technology available in the market –
we therefore opted for the 3-roll PSM®
from SMS,” says Barry Schneider,
General Manager of SDI Pittsboro.
The spontaneous contract signing
on the soccer shirt was not just a ges-
ture for the US-American guests: in
America, such an act together with a
handshake is considered as binding.
In the meantime, a formal contract
has also been signed by all parties
and has come into force. For SDI the
PSM® is of great importance: from a
single-pass family, each steel grade Fully dressed for the common project: the collective team of SDI and SMS.
67
MINIMILL ORDER
FOR BRAZIL
New order: SMS group was contracted by Mexican Grupo SIMEC
for the construction of a minimill, which is to be built in the Brazilian state
of São Paulo.
68
The new minimill, to be named GV do cooling system designed to markedly THE ROLLING MILL
Brasil, will be installed near the city of reduce the air flow around the elec- The roughing train will consist of six
Pindamonhangaba. It will comprise a trodes in order to reduce their con- HL stands in H/V arrangement, the in-
steelmaking plant and a bar and wire sumption of energy. termediate train of eight HL stands in
rod mill. The works will be designed Ferroalloy system. A fully auto- H/V arrangement. Downstream, the
for an annual production capacity of matic system will supply ferroalloys bars will be quenched and tempered in
520,000 tons of billets and 400,000 to the ladle furnace and the EAF the rolling line to give them the de-
tons of rebar in the diameter range through the fifth hole and at the ta- sired mechanical properties in an in-
from 6 to 16 millimeters and wire rod phole. A modern and powerful de- line process.
in diameters from 5.5 to 16 millime- dusting system will provide the filter- The rolling mill will be equipped
ters. ing of the off-gases generated during with a wire rod and a bar outlet. The
Grupo SIMEC belongs to the Mexi- furnace operation. wire rod line will produce wire rod in
can holding Industrias CHSA de CV The billet caster. The continuous diameters from 5.5 to 16 millimeters
(ICH), the main activities of which are casting machine will feature three at rolling speeds of up to 105 meters
the production, processing and sale of strands with the option for an expan- per second. The wire rod line will be
steel products. The products include sion to five. The casting radius will be made up of a ten-stand finishing
construction steel grades, merchant nine meters. Billets ranging from 127 block, a high-speed laying head and
bar, welded pipes and SBQ steel to 200 millimeters square will be pro- an 80-meter-long loop cooling con-
grades for the automotive industry. duced. The casting machine will be veyor (LCC®). Two water cooling sec-
Production facilities are in Mexico, the equipped with Convex Technology® tions and the LCC® enable optimal
U.S.A. and Canada. and hydraulic mold oscillation. The material properties through con-
cast billets can be used either as in- trolled cooling. The line will be com-
THE STEEL PLANT put material for the rolling mill or re- pleted by downstream coil handling
The steel plant, which will produce removed for use as semi-products. The facilities including a coil compactor.
bar and, at a later stage, also quality entire plant concept boasts a layout The bar outlet with the HSD® sys-
steel grades (SBQ), will comprise a 65- that enables both efficiency and pro- tem will enable bar diameters from
ton AC electric arc furnace based on ductivity. It meets all requirements in six to 16 millimeters to be rolled at up
100 percent scrap charging. The EAF terms of reduced maintenance, high to 38 meters per second. By means of
will deliver 30 heats per day and fea- operational reliability and high pro- the HSD® system, it will be possible to
ture a full-platform design with eccen- ductivity. also deposit small sizes rolled via the
tric bottom tapping. In conjunction The supply includes all electrical finishing block onto the cooling bed at
with the Consotech equipment for equipment and a modern level-2 au- high speed, making for a highly pro-
electrical energy input, an 80-MVA tomation system. All the plant facili- ductive process. The plant will be
transformer will supply the power for ties feature latest state-of-the-art completed by a fully automatic bundle
the EAF. The melting unit will be environmental equipment, including forming and tying station with coil
equipped with the latest generation of high-efficiency dedusting systems. transport equipment.
electrode control and process automa- The reheating furnace. The 100- The electrical and automation sys-
tion systems. This will make for high- tons-per-hour walking-beam furnace tems for the mill will also be supplied
est flexibility in furnace operation. for billets twelve meters long and 127 by SMS group. Commissioning is
Secondary metallurgy. The sec- millimeters square will feed a con- scheduled for the middle of 2013.
ondary metallurgy treatment will take tinuous single-strand rolling mill. To
place in a 65-ton ladle furnace, which reduce energy consumption, the fur-
will be separately fed by a 10-MVA nace can be directly charged with hot
transformer. The ladle furnace cover billets.
will be equipped with a special water-
69
WIRE – A SUCCESS STORY
MORE THAN 250 ORDERS
SINCE 1950
2012 will be a very special year for the SMS group in the wire rod mill sector:
The machine and plant manufacturer will put 14 mills with 19 wire rod blocks
into service worldwide which is the result of a successful strategy in the long-
product sector and it is the continuation of an impressive success story which
had begun in 1950. With more than 250 wire rod mills installed, SMS is
today the leading global supplier of such mills for quality and stainless steels.
70
In 1950, the first wire rod mill from SMS

was supplied to Aciaieria e Forriera del
Caleotto in Lecco, Italy, and in 1955 the
wire rod mill III went on stream at Nie-
derrheinische Hütte in Duisburg, Ger-
many (today belonging to ArcelorMit-
tal). At that time, it was Europe’s most MEERdrive® technology
advanced wire rod mill which was fol- in a wire rod finish-roll-
ing block with six rolling
lowed by wire rod mill IV in 1967 – at the units.
time again the most modern mill for
wire rod. The wire rod mill IV was then a
milestone in the history of wire rod roll- configuration. With sufficient intercool- available which is centrally driving the
ing and a world premiere at the same ing between the wire rod blocks a high individual roll pairs via a distributor
time: four industrially used no-twist production without overheated wire rod gear, longitudinal shafts and a bevel
rolling blocks were introduced for the is now possible. The required inlet tem- gear. The disadvantage is that the gear
twist-free rolling of wire rod. To this perature of up to 750 °C in the four- ratios are rigid. In this design, a roll
day, the four-strand mill has been suc- stand finishing block is achieved by the ring pair has to be replaced as soon as
cessfully in operation producing ap- loop technology of SMS making sure it is worn with an identical pair of the
prox. 40 million t of wire rod in over 55 that a homogeneous cross-sectional same diameter to make sure that the
years. In spring 2012, history will again temperature is reached with the lowest required reduction ratios in the wire
be written in Duisburg – the world’s temperature coefficient. This will allow rod block are fulfilled.
most modern wire rod mill will go on thermomechanical rolling for all wire For the MEERdrive® system this is
stream in Duisburg-Ruhrort – and it rod sizes. Optimum plant parameters not required since each roll ring pair is
does not come as a surprise that this are simulated offline with the CCT® driven via an individual small motor
mill has also been supplied by SMS like process model (Controlled Cooling reducing maintenance efforts and op-
all others before. Technology) and are controlled online erational costs of the finish-rolling
during rolling. mill by approx. 30 %. Rolls on stock
MOST MODERN ROLLING MILL AT can also be reduced by up to 60 %
AM RUHRORT, GERMANY MEERDRIVE® REDUCES COSTS since roll ring diameters are used in-
The new rolling mill at ArcelorMittal Particularly with the new drive technol- dependent of each other. The required
Ruhrort is designed for an annual ca- ogy MEERdrive® SMS stands out reduction ratios between single stands
pacity of 690,000 t. On this mill, de- against other plant manufacturers. can be realized by individual speed ad-
manding high-quality steel grades from Since 2008, the innovative drive tech- aptation.
low- to high-carbon, cold-heading, nology MEERdrive® has been success- Owing to the modular structure of
free-cutting, alloyed, spring, ball-bear- fully in use without any problems at the MEERdrive® blocks, non-used roll-
ing, stainless and tool steels but also Siderúgica Norte Brasil S.A., Brazil. In ing units do not have to be driven;
welding wire are produced. The plant the meantime, five rolling mill opera- thereby energy consumption of the
configuration particularly considers the tors worldwide have already been con- plant is significantly reduced. “This ex-
thermomechanical rolling of top-quali- vinced by the reliability and the poten- tends the service life of the modules
ty steels. Typical production dimen- tial of MEERdrive® and have opted for not in use but also greatly reduces the
sions are in the diameter ranges of 5.5 this revolutionary technology. At the energy costs of our customer,” says
mm to 25 mm. The plant is configured beginning of 2012, the latest generation Günther Schnell, Sales Manager, Wire
for rolling speeds of up to 120 m/s. of MEERdrive® technology will be com- Rod and Bar Mill Product Area at SMS.
missioned at the world’s largest steel But not only the cost advantages
6+4-STAND WIRE ROD BLOCK producer ArcelorMittal at its Ruhrort are decisive but also higher flexibility,
ARRANGEMENT FOR plant. for example in roll pass designing, i.e.
THERMOMECHANICAL ROLLING Significant benefits of the MEER- different cross-sectional reductions
At ArcelorMittal Ruhrort, all dimen- drive® technology lie in the individual can be implemented depending on the
sions are finish-rolled on a four-stand drive of the wire rod blocks. For con- demand for the process or the steel
wire rod block by means of a 6+4-stand ventional units, a powerful motor is grade. The roll pass design and the
71
reduction ratios can be individually
i
6+4-STAND ALTERNATIVE FOR
adapted at any time e.g. for the rolling THERMOMECHANICAL ROLLING
of new materials in future even long SMS has developed another mill con-
after commissioning. In the case of a cept ensuring thermomechanical roll-
conventional rolling block this is im- ing with a 6+4-stand wire rod block Conclusion
possible. The adaptation of the rolling arrangement with respective roll pass
speed and the tensile force can also be design. It differs from the afore-men- With the commission-
individually controlled and optimized tioned solution in that not all dimen- ing of the wire rod mill at
with MEERdrive®, enabling lower roll- sions are rolled in the four-stand ArcelorMittal Hochfeld,
ing tolerances. finishing unit. Thicker sizes are finish- SMS will further expand its
rolled in a six-stand wire rod block in leading position in the wire
THREE-FAN TECHNOLOGY four passes. Corresponding cooling rod mill sector. The MEER-
Another highlight of the rolling mill at and equalizing sections in front of the drive® technology sets
ArcelorMittal Ruhrort is the three-fan wire rod blocks allow thermomechani- new benchmarks and will
technology applied on the LCC® (Loop cal rolling of all wire rod dimensions. revolutionize conventional
Cooling Conveyor). Thanks to the LCC®, For this alternative no gearboxes are rolling of wire rod. The
properties of most different steel used in the wire rod block which 6+4-stand wire rod block
grades can be set in a targeted way. means that investments are saved sig- option in combination with
Apart from selected rolling tempera- nificantly. MEERdrive® technology
tures, cooling settings and equalizing This novel 6+4-stand concept for convinces customers with
sections, the rolled material is condi- thermomechanical rolling of wire rod high flexibility, improved
tioned via the ring cross-section in con- has been successfully introduced in tolerances and lower
sideration of transportation speed and 2009 at Weifang I&S Co. Ltd., in China. operational and investment
cover position but also with regard to “The wire rod finishing mill concept costs. A large number of
specific blower power. For “forced cool- with a 6+4-stand block configuration is individual solutions and
ing”, air is blown with highest fan power well accepted in the Chinese market more than sixty years of
through fanned out loops when the cov- since it combines metallurgical bene- experience in rolling mill
ers are opened to make it possible that fits with low investment and mainte- technology show SMS the
the material is cooled down as quickly nance costs,” says Mr. Li, Head of Con- SMS group as reliable
as possible and to receive fine-laminar struction, Yugang Project at JISCO partner – an experience
perlite. For selective setting of material Yuzhong I&S Co. Ltd. In 2011, the com- from which many custom-
properties, the required air volume is pany from Gansu Province has already ers benefit today and also
optimally blown onto the loops by three ordered two new high-speed wire rod in future.
individually controllable fans depend- mills with this concept. Meanwhile,
ing on its application. With the aid of eight wire rod mills with a 6+4-stand
special cooling rates the wire rod pro- block configuration including the
ducer is thus able to attain highly de- state-of-the-art CCT® process model
manding material properties. are already in operation or are being
set up.
72
Modernization 100 m of wire

completed rod per second
ArcelorMittal Hamburg Xinjiang Yili Iron & Steel
Commissioning. ArcelorMittal Ham- These cantilever mill stands repre- Commissioning. Xinjiang Yili Iron &
burg GmbH, Germany, has success- sent a new generation of stands which Steel Co. Ltd. from Xinjiang Uyghur
fully commissioned the two-strand are able to absorb even higher rolling Province, China, has successfully tak-
wire rod mill modernized by SMS. The forces and rolling torques. en a new wire rod outlet into opera-
annual capacity is 900,000 t. The re- Project Manager Wolfgang Preiss tion. The core components of the
vamp enables ArcelorMittal to improve of ArcelorMittal Hamburg: “This re- plant were supplied by SMS.
its product quality and thereby contin- vamp demonstrates once again the The wire rod mill has a capacity of
ue in the future to assert its leading good cooperation between Arcelor- von 600,000 tpy and an hourly output
role on the quality-steels market. New Mittal Hamburg and SMS. The two of up to 140 t during hot charging.
cantilever stands from SMS will now companies worked closely together Wire rod sizes with diameters ranging
enable higher rolling forces. from project planning through to from 5.5 to 20 mm and ribbed-rebar
It is already the fifth modernization commissioning. Erection and com- sizes with diameters between 6 and
order that ArcelorMittal Hamburg has missioning were carried out success- 16 mm are rolled at speeds up to 105
placed with SMS for the wire rod mill fully in spite of a very tight time m/s or 95 m/s.
supplied in 1969. With the present re- schedule.” ”The components supplied by SMS
vamp, ArcelorMittal is continuing the This revamp reflects the leading were functioning properly right from
replacement of the mill stands de- role played by SMS in the moderniza- the start. Immediately after commis-
signed for two-strand operation. The tion of wire rod and bar mills. Even sioning, rolling speeds of more than
last two stands of intermediate train 1 older rolling mills can be brought to 110 m/s could be attained. Assembly
in which two-strand rolling has been state-of-the-art technology and to a and commissioning were successfully
carried out until now have been con- competitive level through specific and accomplished on time,” says William
verted into two single-strand rolling individually adapted optimum solu- Li, Project Manager of Xinjiang Yili.
lines. For this purpose, the existing tions for our customers.
looper tables were relocated and two www.sms-group.com/long-products-
www.sms-group.com/long-products- plants
new mill stands of type CL 200 in H/V
plants
arrangement installed for each strand.
73
Deutsche Edelstahlwerke
Expansion of bar mill
New order | Deutsche Edelstahlwerke (DEW), Germany, has placed an order
with SMS group for the expansion of the 3-roll PSM® (PSM® = Precision Sizing
Mill) at its Siegen-Geisweid plant to include an automatic size control system
with cross-section measuring.
The PSM® forms part of the rolling tension, DEW will be able to increase additional fine optimizations of the final
mill for special steels which are used, the efficiency of the PSM®, and hence dimension tolerances,” says Jens Eis-
for example, in the automotive industry. also the quality of the bars produced. bach, Rolling Mill Manager of the bar
A new laser precision measuring device “The aim is to consistently further mill at the Siegen-Geisweid site.
for cross-section measurement is to be develop the potential of single-pass ad- SMS had supplied the world’s first
installed downline of the PSM®. The au- justment under rolling force and to three-roll block with hydraulic adjust-
tomation system is to be expanded to learn more about the behavior of the ment under load to DEW in 2006. The
include a highly dynamic monitor con- material during the rolling of highly so- so-called PSM® directly replaced two
trol module. Even in the event of fluc- phisticated products. Even today, we three-roll blocks at DEW which had
tuations in the ingoing product, the new can reliably achieve tolerances of 1/8 been in operation since 1979. “SMS
system minimizes tolerance deviations DIN EN 10060. Thanks to this control group has impressed us with its trend-
during the rolling process. With this ex- system, it will be possible to perform setting concept of a modern three-roll
technology and has opened up possi-
bilities for quality improvement which
until now had not been available on the
market,” says Dr. Thomas Helsper,
Head of the Rolling Mills Division at
DEW. The project will be implemented
in spring 2012.
Deutsche Edelstahlwerke GmbH.
DEW is a leading company in the manu-
facture and processing of specialty
steel long products and is part of the
Schmolz + Bickenbach Group. About
1 million t of strainless steel is pro-
duced and processed by approx. 4,000
employees at the German locations in
Witten, Siegen, Krefeld, Hagen and
Hattingen. The steel is used in e.g. the
automotive industry and in the aero-
space sector.
www.sms-group.com
74
Fujian Wuhang: Economical
stainless-steel rolling mill
Fujian Wuhang Stainless Steel Product Co. Ltd., from ChangLe
City, FuJian Province, China, has placed an order with SMS
group for the supply of core technologies to build one of the
most modern stainless-steel rolling mills where wire rod and
bars in coils are to be produced.
The mill will have an annual produc- nology. What makes it so special is that each mill stand is
tion capacity of more than 300,000 t individually driven by a separate motor. Wire rod sizes in
and will roll high-quality steels from diameters ranging from 5.0 to 20 mm are finish-rolled with
stainless to ferritic grades. this unique technology. With the MEERdrive® wire rod fin-
The core equipment includes a ishing block, it can be much better responded to the differ-
modern PSM® (Precision Sizing Mill) ent expansion behavior of various steel grades compared
3-roll sizing block with hydraulic ad- to a conventional finishing block and an optimal operating
justment under rolling load which is state can thus be set in a targeted manner. Moreover, the
able to finish-roll all final sizes for single-drive system offers large saving potential for the
bars from a single-pass family in coil operator.
diameters ranging from 13 to 38 mm.
In addition, the PSM® PSM® realizes www.sms-group.com/long-products-
plants
all the required initial cross-sections
for the wire rod block.
The scope of supply of the PSM®
comprises the automatic stand
changing system, the stand- and
guide-preparation workshop as well
as the Carta® PSM system presetting
the specific settings of the PSM®, de-
pending on product and dimension.
Other key equipment is the wire rod
finishing block with MEERdrive® tech-
75
Faster rolling Lower costs for

speed subsequent treatment
Xinjiang Gaoyi Smelting Jiangsu Shenyuan
New order. The Chinese company Xin- New order. SMS has been awarded an order to supply the
jiang Gaoyi Smelting Co. Ltd. from wire rod section for the construction of a stainless-steel
Houma City, Shanxi Province, has rolling mill on which wire rod is to be produced, from the
placed an order with SMS for the sup- Chinese company Jiangsu Shenyuan Special Steel Co. Ltd.
ply of a wire rod outlet for a wire rod from Xinghua, Jiangsu Province. The rolling mill will
mill. The maximum production capac- achieve an annual production capacity of more than
ity is 120 t/h, enabling Gaoji to achieve 180,000 t and will roll stainless steels as well as highly
a higher productivity than with conven- demanding valve steels.
tional plants. Diameters from 5.5 to 20 mm are produced with a
The wire rod production line has a maximum production rate of 60 t/h and max. 70 m/s. The
capacity of 700,000 tpy, rolling wire rod intended expansion to bar steel in coils will cover the size
in the size range from 5.5 to 16 mm in range of diameters between 21 and 40 mm. The wire rod
diameter and ribbed rebars with diam- section comprises compact CL stands in H/V arrange-
eters from 6 to 16 mm. Carbon as well ment characterized by a particularly high load-bearing
as low-alloy steels can be processed. capacity. This is followed by an eight-stand wire rod fin-
The mill is equipped with a 6-stand ishing block, a pinch-roll unit and a loop laying head as
wire-rod finishing block from SMS. To- well as an LCC®.
gether with water cooling sections, The LCC® is designed such that the heated wire coils are
loop laying head, loop cooling conveyor collected directly behind the loop laying head from where
(LCC®) and coil compactor, this plant they are fed into an inline heat treatment facility.
enables Xinjiang Gaoyi to manufacture ”Based on an overall plant concept which has been
high-quality products, for example for technologically and logistically developed by SMS sub-
the booming construction industry in stantial cost savings for subsequent treatment can be
China. Commissioning is scheduled for achieved,” says Ted Wu, Rolling Mill Manager of Jiangsu
the second quarter of 2012. With more Shenyuan.
than 240 wire rod mills installed, SMS
group is one of the leading suppliers.
plants plants
76
MoVE: The camera calibration system

for MEERguides®
SMS group has developed a new portable computer-based camera system
for calibrating the roller guides of the MEERguides® series. MoVE (Modular
Video Equipment) allows for quick, reproducible and precise calibration of
guide rollers to ensure that flexible production and highest rolling quality
are achieved.
Its practice-oriented control enables a high-resolution camera as well as a picture as well as the required calcu-
precise horizontal and vertical roller light source. The camera detects the lated horizontal and vertical settings.
alignment to the groove. Furthermore, current roll gap to be transmitted to The system indicates that no further
operators are able to check the rolling the Tablet PC in real time. The user adaptations are necessary as soon as
line and precisely set the guide hold- software analyzes the video picture an optically sensed image coincides
ers. A high adjusting accuracy is es- and compares it with previously stored with the calculated profile. This makes
sential particularly when working at profiles. The profile information re- sure that subjective interpretations by
high rolling speeds so that troublefree quired for rolling stock and rollers is different users are prevented. Until
operation is ensured and component taken from the drawing files which can now, this has been a disadvantage of
wear is reduced. be uploaded into the database of the conventional calibration systems when
The MoVE calibration system con- Tablet PC. A composite image is indi- shadows are cast.
sists of a portable industrial Tablet PC, cated to the user including the video The sophisticated software guides
the operator gradually through the
setting process and provides help in-
formation whenever necessary. Fol-
lowing the instructions on the screen,
users are able to carry out optimal
settings of the roller guides. All final
settings can be saved and used for fu-
ture analyses. The calibration system
can also be applied for roller guides of
third-party providers.
All MoVE system units are wireless
which allows using them for the cali-
bration of guides in the wire rod mill as
well as in the workshop. The system is
dust- and spray-water-proof and thus
optimally suited for extreme mechani-
cal stress in a rolling mill.
www.sms-group.com
77
78
MINIMILL FOR
BAR AND WIRE
ROD CONVINCES
THROUGH HIGH
PRODUCTIVITY
Commissioning | Slovakia Steel Mills,

Strážke, Slovakia, has successfully
commissioned the minimill supplied
by SMS group. The minimill consists of
an electric steelmaking shop, including
a continuous caster, with a production
capacity of 620,000 tpy and a flexible
bar and wire rod mill.
79
The 60-t EAF melts down the scrap. Quality control on the casting platform.
The roughing mill. The control room at SSM.
80
SLOVAKIA STEEL MILLS: MINIMILL FOR BAR AND WIRE ROD

The electric steelmaking shop is made up of a 60-t electric
arc furnace (EAF), a ladle furnace (LF) and a continuous bil-
let caster. The EAF is of the full-platform eccentric bottom
tapping (EBT) design and powered by a 60-MVA transform-
er. The new-generation electrode control and process auto-
mation systems ensure reproducible results – even when
having to cope with varying scrap quality. A special feature
of the furnace is the employed Conso technology which
makes for a highly efficient melting process. Oxygen injec-
tors operating at supersonic speed improve the chemical
energy input, resulting in increased productivity and lower
production costs. The downstream secondary metallurgy Successful cooperation.
treatment takes place in a 60-t ladle furnace.
The three-strand continuous casting plant has a radius The wire rod outlet consists of a ten-stand wire rod block
of 8 m. The Convex Technology®, the electromechanical os- with ancillary equipment. Sizes from 5.5 to 16 mm can be
cillation systems and the full automation make the plant rolled at a maximum speed of 105 m/s. For the production
suitable for the production of structural steel and wire rod of rebars, the wire rod block supplies the dimensions from
grades. Future plans are to also produce SBQ grades for 8 to 16 mm at speeds of up to 36 m/s to the HSD® system
the automotive and mechanical engineering industries. via a cooling section. The larger dimensions up to 36 mm
The direct link between the continuous caster and the are produced in the bar finishing train and likewise deliv-
rolling mill via roller tables and a billet hoist permits hot ered to the HSD® via a water cooling section. A further spe-
charging for the majority of the production. Billets in the cial feature is the VCC® coiler, which produces extremely
format of 130 mm square x 12 m are used for all dimen- compact coils in the size range from 8 to 16 mm at speeds
sions to be rolled. The rolling mill connects seamlessly with of up to 35 m/s. As part of the first construction stage, only
the continuous casting equipment. The walking-hearth fur- one coiler has been installed. A switch arranged behind the
nace is designed for a throughput rate of 60 t/h for cold cooling section diverts the products alternately either to the
charging and 80 t/h for hot charging. VCC® coiler or to the HSD® system.
Arranged downstream are a six-stand roughing mill and In addition to the mechanical and electrical equipment
the eight-stand bar finishing train of housingless design as of the rolling mill, SMS also supplied the utility systems for
well as the associated shearing equipment. The finishing the hydraulics and the lubricating oil. The minimill com-
train is equipped with a quick-change platform which al- plies with European environmental regulations. It is exem-
lows fast changing of the rolling program. plary of integrated solutions for long products offered by
the SMS group.
Pinch rolls. The billets are collected on the cooling bed.
81
Three-roll sizing mill,
type PSM®.
China: Xining oders two new rolling mills

Xining Special Steel Co. from Xining City in Qinghai Province has placed two orders
with SMS group for a semi-continuous billet mill and a bar mill for quality
and specials steels (SBQ grades). Commissioning of the two plants is scheduled
for the end of 2012.
The mill trains of the billet and the bar

mill will be designed for close toler-
ances to be achieved by the use of hy-
draulic underload adjustment sys-
tems. The overall dimensional range
of the two trains is from 16 to 280 mm
in diameter.
The billet mill. Compact stands with
hydraulic adjustment mechanism of the
HCS® (Hydraulic Compact Stand) type
are the key components of the new bil-
let mill and close rolling tolerances are
ensured by an automatic roll gap con-
trol and the sizing technology HSC®
(Hydraulic Sizing Control).
The bar mill. This plant provides a Representatives of Xining Special Steel and SMS group after signing of a contract for a billet
three-roll sizing block, type PSM® (Pre- and a bar mill for quality and special steels.
cision Sizing Mill). With the hydraulic

adjustment under rolling load, any cus-
tomer-specific dimension can be pro-
ducedfrom one pass series, i.e. eco-
nomically also in small batch sizes and
with close tolerances.
82
A service team of SMS group. Assembly of bevel gear.
ArcelorMittal Poland:
Overhaul of wire rod mill in record time
SMS group Service needed only two weeks
ArcelorMittal Poland operates a two-strand wire rod mill mill was resumed in a record time of only two weeks.
built in 1973 at its Sosnowiec site. During a plant standstill Perfect planning. When a general overhaul was carried
for maintenance purposes at the end of March 2011 SMS out six years ago, ArcelorMittal’s experiences with SMS had
has inspected two roughing and two finishing blocks with already been very positive. Through the detailed knowledge
ten bevel gear units each as well as two speed increasers of the staff members of SMS group the critical parts could be
which were then overhauled in the workshops of SMS group identified quickly. A preventive maintenance in the work-
in Mönchengladbach and in Hilchenbach. Production of the shops of SMS group ensured that the overhauled gears could
be taken into operation after only 14 days.
Regular overhaul. Through regular overhaul work Arce-
lorMittal Poland ensures long-term plant availability and
prevents possible malfunction, thereby assuring high pro-

duction capacity of a plant nearly 40 years old. In this particu-

lar case, SMS has performed an analysis of the actual condi-

tion of the two roughing and the two finishing blocks and the
two speed increasers. The result was: mechanical reworking

of individual gearboxes, chromium-plating of bearing seats

and shafts as well as the replacement of wear parts such as

seals and antifriction bearings.
Re-assembly at the customer was also performed by a

service team of SMS. ArcelorMittal was highly satisfied with

the quality of work and the fast handling of the overhaul.

83
ArcelorMittal modernizes
wire rod mill in Hamburg
In future, more wire rod from quality steels
New order | ArcelorMittal Hamburg directly situated on the river Elbe will SMS will be converting this section
GmbH, Germany, has placed an order then be able to produce wire rod of into two single-strand rolling lines. For
with SMS group, Germany, for the even better quality than before. this purpose, the existing looper tables
modernization of a two-strand wire To suit changing market conditions, will be relocated and two new cantile-
rod mill in its Finkenwerder plant. With the wire rod mill supplied by SMS in ver stands of type CL 200 will be posi-
this revamp ArcelorMittal aims to im- 1969 had already employed new tech- tioned in H/V arrangement for each
prove the product quality with a view to nology in several steps. With the pres- strand. These cantilever mill stands
further consolidating its leading posi- ent revamp, ArcelorMittal is continuing represent a new machine generation
tion on the quality-steels market. The the replacement of the two-strand mill and are able to absorb very high rolling
modernization is scheduled to be stands. Within these measures the forces and rolling torques.
completed in the fall of 2011. With an last two stands of the intermediate
annual capacity of 900,000 t, the plant train 1 will be exchanged.
»This revamp reflects our leading role in the modernization of wire rod and bar
mills and we are able to bring even older mills up to the state of the art and to a
competitive level through targeted and optimum tailor-made solutions.«
Hans Gerd Limper, Project Manager at SMS
84
Continuous mill train impresses

with high quality and rolling speed
Rolling of rebars with 44 m/s on to cooling bed
At the end of 2010, Abinsk Electric With the rebar train SMS confirms its
Steel Works (Novorosmetall), Russia, leading position as provider of rolling
has successfully put into operation a mills for long products in Russia. This
new rebar rolling mill in its plant near mill train is part of a whole series of
Abinsk in the Krasnodar Region on the projects which have been executed by
Black Sea. With this one-strand con- SMS group for Russian customers. This
tinuous rolling mill supplied by SMS, includes individual machines, rolling
the company achieves a high product mill upgrades and completely new fa-
quality. Thanks to an inline cooling cilities.
zone for bar quenching and temper-
Continuous mill achieves high quality. ing, the finished products exceed the
requirements of Russian quality stan-
dards such as AT500C, AT600C and
AT1000. New standards are set also
for the productivity. With 44 m/s, the
buffing speed on the cooling bed is 10
i ADVANTAGES
% higher than for conventional sys- The one-strand continuous mill
tems. This is made possible by the train at a glance
HSD® system (High-Speed Delivery)
developed by SMS. Abinsk Electric 100-t/h heating furnace
Steel Works will produce 500,000 t of oughing train with four mill
R
stands in H/V arrangement with the
rebars annually on the mill. The mill
option to retrofit two stands for
Buffing speed was increased. train is designed such that it can be larger cross-sections of the initial
expanded later by a VCC® line (Vertical pass
Compact Coiler) for the production of Intermediate train with twelve mill
stands of HL (HousingLess) type,
coiled bundles.
where six horizontal, five vertical
SMS supplied the complete rolling stands and one tilting stand are
mill including electrical equipment and used
automation. Predrag Kaljevic, Sales inishing train with a finishing
F
Representative of SMS group: “The fa- block comprising eight rolling units
cility in Abinsk is an example for inte- ” Thermoprocess lines” for the

production of edge-tempered and
grated solutions: Together with Abinsk, -quenched rebars
we were able to successfully apply new Cooling bed with HSD® system
methods such as edge tempering and Finishing lines
quenching of rebars at high speeds.“ evel-2 automation system for
L
In future, Abinsk is to produce 500,000 t of process control
rebars.
85
MORE EFFICIENT PRODUCTION

WITH CARTA® PSM SYSTEM
Technology system for bar mills
With Carta®, SMS group is able to provide computer-based The benefits are: flexibility and speediness of the mills
technology systems for the operation of rolling mills. This can be fully utilized plus the production is more efficient
means that Carta® (Computer-Aided Rolling Technology and the results are better.
Application) is a technological production planning and ”With our system, the bars made of various grades of steel
process control system which is known mainly from tube can be rolled easier and quicker,” explains Dr. Axel Körmer
production. from the Section Mills Product Area at SMS group. For ex-
Now, SMS has adapted a tailored solution for the pro- ample, predefined setpoints for mill setting can be specified
duction of steel bars: Carta® PSM for Precision Sizing Mills. in detail and transmitted directly to the mill automation.
This system enables steel bar producers to plan and opti-
mize the rolling operation in detail.
»The system is able to track the application of the rolling ring sets
and supports the operators also in the planning of tool application.«
Dr. Axel Körmer
Fast and flexible,

the Precision Sizing
Mills: The PSM tech-
nology is based on
rolls with hydraulic
mill screwdown.
86
ent production with Carta® PSM system
TCT/ IP network
TCT/ IP network Carta® of baisic automation
ure Data request &
ptable Actual value setting
Setpoint setting
arta® PSM is a central HMI rolling mill operation
rver with databases TCT/ IP-PSM-Terminal
Technology
nd result values. The Diameter data
ed with the basic au-
Carta®-PSM-Server
nked to an unlimited
, for example for the Bar – hot diameter measurement
Speeds,
em administrators or TCT/ IP-PSM-Terminal motor torques
System administration
et connection for re-
Remote servicing
Meer is also possible. PLC – rolling mill drives
or for quickly finding Screwdown forces,
capsule forces The Carta® PSM
ems occur SMS Meer
server can be con-
ays Dr. Peter Thieven nected to as many
TCT/ IP-PSM-Terminal workplaces as you
es Product Area who Workshop PLC – hydraulic screwdown HCCS
want.
ence for the transfer
gy from the tube to The Carta® PSM server can be connected
to as many workplaces as you want.
SYSTEM ARCHITECTURE to flexibly adapt the values by means of a groove editor or
INDIVIDUALLY ADAPTABLE create them completely new – from the diameter of the ini-
parametersThe core element of Carta® PSM is a tial pass via the design of the actual groove forms up to the
Dr. Axel Körmer: server with calculation
central high-performance Well equipped
of the for Simulations and visualiza-
rolling speed.
the rolling datadatabases
the for mill parameters and re- tion of the each material
systems support request
the operator at the planning
lready includessult ”During
the values. the development
The server is intercon- stage.
chnology from nected
SMS with the basic automation and Whether you require basic grades or highly
can
For special require- be we have put high priority
linked to an unlimited number WELL EQUIPPED FOR–EACH
alloyed steels MATERIAL
the Carta® PSM REQUEST
system is
of
able to flexibly adaptworkplaces, for example for the Whether you require basic grades
designed for a wide range of orsteel
highly alloyed steels
quali-
of a groove editortechnologists,
or the system
on such administra-
flexibility – the Carta
of the ties. PSM
®
system
Parameters is as
such designed
hot yieldfor a wide
stress or range of
tors or the roll shop. An internet con- steel qualities. Parameters such as hot yield stress or
ly new – from the di- shrinkage for the transition from rolling to
nection for remote service by SMS is shrinkage for the transition from rolling to room tempera-
ass via the design of system. Therefore, Carta® room temperature are determined in a
also possible. ”For the system setup or ture are determined in a material-dependent manner. In
ms up to the calcula- material-dependent manner. In this case,
for quickly finding a solution when this case, the operator can make use of predefined materi-
ed. PSM is also suited for the operator can make use of predefined
problems occur SMS is able to help als or create his own data sets. Dr. Axel Körmer: ”Here too,
online,” says Dr. Peter Thieven from the flexibility of theorsystem
materials create his
is own dataWe
shown. sets. Dr. account of
take
zation of the systems extraordinary customer Axel Körmer: ”Here too, the
the Seamless Tubes Product Area who any conceivable complex requirement on the mill flexibility of setting.”
t the planning stage.
brought in his experience for the the system is shown. We take account of
requirements. ” any
transfer of the Carta technology from REPEATING EXCELLENT
® conceivable complex requirement on
QUALITY
the tube to the steel bar sector. For each bar the setting.
the mill Carta ” PSM system stores the calibration
®
data of the rolling mill and the most important rolling re-
FLEXIBLE SIZING OF PARAMETERS sults. The data can be evaluated by means of tables and
To quickly determine the rolling data graphics. In addition, they can be deposited in the empirical
the Carta® PSM system already in- database which ensures possible reuse. The advantage is
cludes the concepts of rolling technol- as Dr. Axel Körmer stresses: ”In this way, excellent quality
f the SMS group 2/2011
ogy from SMS as presetting. For spe- is not a single incident but can be repeated and constantly
cial requirements the operator is able further improved.”
»During the development we have put high priority on such

flexibility of the system. Therefore, Carta® PSM is also suited for
extraordinary customer requirements.«
Dr. Axel Körmer
87
i PERFORMANCES
of Carta PSM at a glance
®
efinition of initial-pass diameters

D
and classification of rolling program
esign and management of roll
D
pass designing
pecification of groove adjustments
S
and calculation of roll speeds
rchiving of mill settings and of
A
technologically most important
rolling and measuring results from
rolling operation
Organization of rolling tools
BETTER PLANNING OF TOOLS

The tool management can also be
supported by the Carta® PSM system,
The material database of Carta® PSM can be extended with data sets as needed. for example by means of inventory lists
for rolling ring sets and mill stands.
”PSM mills (Precision Sizing Mills) of
SMS are equipped with quick-change
systems which means fewer mill
stands can be operated with a variety
of different rolling ring sets. Carta®
can help to keep track of these activi-
ties.” The system provides a search
function enabling to find the appropri-
ate rolling ring sets from the existing
stock. Furthermore, information on
the roll wear is available.
Carta® PSM is a technology system
specially tailored to the requirements
of the PSM (Precision Sizing Mills) mill
operators – from planning stage to
quality check. ”With the aid of Carta®,
mill operators are able to consider
very fine details,” adds Dr. Axel Körm-
er the major advantage of the system.
”These excellent features make the
With Carta® PSM, the rolling data are easily visualized with graphics. difference to the competitors.”
88
Wire rod block achieves high productivity.
Wire rod coils on

cooling roller table.
Amsteel Mills, Malaysia:

New wire rod outlet for bar and wire rod mill
Raising the rolling speed by 25 m/s
At the Banting site in the Malaysian Reconstruction measures comprise Together with Megasteel, Amsteel
state of Sengalor, SMS group will up- a new wire rod block with ten rolling belongs to the Steel Division of the
grade the bar and wire rod mill of steel units (six of type 230 and four of type Lion Group, one of the largest compa-
producer Amsteel Mills built in 1995 160), four water boxes, new pinch roll nies in Malaysia. The conglomerate is
with a new wire rod outlet. The mod- units, a high-speed loop laying head headquartered in Kuala Lumpur.
ernization has three main objectives: and a coil forming chamber. In addi-
rolling of surface-quenched and -tem- tion, the automation of the wire rod
pered rebars up to a diameter of 16 outlet will be updated and equipped
mm, enhancing the availability of the with the CCT® system (Controlled
mill and increasing the production by Cooling Technology) developed by
raising the maximum rolling speed SMS. CCT® is a process model for per-
from 80 to 105 m/s. The modernization fect temperature control which is able
is expected to be completed already at to achieve optimum microstructural
the end of 2011. properties.
89
Four VCC® machines are currently being assembled in the SMS workshop in Tarcento.
Optimal coiling of rebars

with VCC® machines
New test stand at SMS in Tarcento, Italy
The patented vertical compact coiling machine, in short Several VCC® machines at once are
VCC® (Vertical Compact Coiler), is one of the most demand- currently being assembled in SMS
ed products of SMS from the product segment light section group’s own workshop. The strong de-
mills. A new test bench in the workshop in Tarcento is now mand is a result of many advantages
to further improve the quality of the machines: Eccentrici- compared to other techniques: VCC®
ties of the VCC® machines are already reduced during as- machines enable a torsion-proof coil-
sembly. This enables the customers to coil their rebars ing operation so that the usual offline
even more effectively. working steps uncoiling, tensioning
and recoiling can be dispensed with. At
the same time, the VCC® provides a
high coiling density with advantages
for storage and transportation. Also
for installation and maintenance the
vertical VCC® coiling system is more
economical than horizontal facilities.
The equipment is simpler and can be
easily installed which minimizes the
required foundation work and the
maintenance costs.
Coiled rebars with VCC® machines.
90
The SMS group building in Shanghai.
Orders for 10 wire rod blocks

and 45 coil compactors
Successful: Market proximity through international offices
Two years ago, SMS group has started a reorientation of its In the past year, SMS has received new orders from Chi-
business in the wire rod mill sector. Since that time, new na, Malaysia, Brazil and Germany. The requirements of the
local offices have been opened in China, in the USA, in Great customers concerning quality and cost efficiency vary
Britain and in India. Meanwhile, the proximity to the inter- widely. Accordingly, SMS supplies for example wire rod fin-
national markets has been well accepted by the customers, ishing blocks of most varied configuration. This year alone,
as underlined by numerous orders. ten finishing blocks will be delivered.
Among them are wire rod blocks with the new single
drive technology MEERdrive® and a block with larger roll-
ing modules that can withstand greater stress.
With the new coil handling facilities SMS meets exactly
the needs of the wire rod producers: since 2009, a total of
45 coil compactors have been sold as single machines on
the Chinese market alone. Facilities were sold among oth-
ers to Hunan Valin Xiangtan Iron & Steel and Maanshan
Iron & Steel Company.
Coil compactor assembly in Shanghai.
91
Loup Cooling Conveyor (LCC®).
MEERdrive®– MORE
FLEXIBILITY AND LESS COSTS
In spring 2012, ArcelorMittal Hochfeld GmbH with headquarters in Duisburg,
Germany, will commence production of a complete new wire rod mill in
Duisburg-Ruhrort enabling a wire rod production of 690,000 tpy with only one
rolling strand. Tailored accordingly, the wire rod blocks in this high-performance
production line are equipped with the individual drive technology (MEERdrive®)
developed by SMS group.
High-speed loop laying head.
92
The layout, in accordance with local requirements.
The new wire rod mill has been designed to roll technically
demanding grades, which are therefore of extremely high
quality, to the closest tolerances. This line is characterized
by compactness and efficiency and achieves an annual ca-
pacity of 690,000 t.
FURNACE, ROUGHING AND INTERMEDIATE TRAIN

The walking-beam furnace for the heating of billets mea-
suring 155 mm square will have an output rate of 120 t/h.
This is followed by a four-stand roughing train comprising
HL (HousingLess) stands with downstream free runout and
an intermediate train consisting of 14 CL (CantiLever)
stands, each in horizontal and vertical arrangement.
EQUALIZING SECTION IN LOOP ARRANGEMENT

The core element of the mill begins with the cooling and
equalizing section in loop arrangement. Owing to this ar-
rangement, an optimal run-in temperature for each steel
grade can be preset in front of the wire rod blocks.
WIRE ROD BLOCKS WITH INNOVATIVE MEERDRIVE®

TECHNOLOGY
The wire rod finishing block with six rolling units and the
FRS® block with four units (Flexible Reduction and Sizing)
– both in UHD (Ultra-Heavy Duty) arrangement – are pro-
vided with our innovative individual MEERdrive® technology
offering numerous benefits. The most important ones are:
- total flexibility in roll pass designing
- essentially simplified rolling ring management MEERdrive® technology in the wire rod
- reduced operational costs finishing block with six rolling units.
93
i OPPORTUNITIES
AND BENEFITS
olled metallurgical properties such

R
as conventionally annealed wire rod
ire rod with characteristics com-
W
parable with quenched and tem-
pered steel, but with improved
formability
cale which can be easily removed
S
mechanically or chemically
Closer tolerances of 1/4 DIN
educed spreading width of me-
R
chanical properties
Coil weight up to 3 t
COOLING LINES FOR HIGH-QUALITY FINISHED PRODUCTS TEMPERATURE-CONTROLLED MAXIMUM ROLLING SPEED OF
With the water cooling lines downstream of the wire rod 120 M/S
block and the FRS® block as well as the 104-m-long LCC® These facilities allow wire rod to be produced over the full
(Loop Cooling Conveyor) for intensive and retarded cooling, size range from 5.5 to 25.0 mm by means of temperature-
all the requirements for the production of high-quality fin- controlled rolling and at a maximum rolling speed of 120
ished products are fulfilled. Furthermore, the required m/s for 5.5-mm wire rod. This enables ArcelorMittal Hoch-
cooling strategies based on the CCT® model (Controlled feld to acquire a leading position as supplier of wire rod for
Cooling Technology) developed by SMS group can be simu- the following fields of application: automotive manufacture,
lated, and then adjusted and controlled online during op- mechanical engineering, offshore technology, plants for re-
eration. The entire coil handling equipment designed to be newable energies and connective elements.
particularly protective to the finished material is also
adapted to the high-quality finished products.
Horizontal coil compactor.
94
Faultless bars at any diameter

Stahlwerk Annahütte, Germany, the oldest existing steel pant in Europe,
is pleased about a new versatile and needs-based cut-to-length group from SMS
fully meeting the demands of the manufacturer of high-quality steel bars.
CONSTANT QUALITY
The new cut-to-length group has been put into operation in
the bar mill at the Hammerau site in Southern Germany.
The cut-to-length group comprises a pinch roll unit and
a combined drum-type/two-crank shear as well as a scrap
deflector and is able to cut round bars with temperatures
up to 1,000 °C. For threaded bars i.e. rebars with a ribbing
designed as thread, the temperature is approx. 200 °C and
the maximum tensile strength of the bars is 1,800 N/mm2.
HIGH REQUIREMENTS MET

The shear operates optionally as crank shear or as rotary
shear with knife arms and cuts round bars with diameters
from 12 to 50 mm.
”The machines supplied by SMS are highly versatile and
exactly meet our high requirements which we are having
as supplier of the automotive and tool manufacturing in-
dustry. These bar steels are suited for numerous applica-
tions and range from alloyed and non-alloyed steels for
case-hardened steel grades up to and including steels for
springs, chains and ball bearings. The range also includes The new shear unit prior to delivery.
Q & T, cold upsetting and cold working steels,” Ralf Becker
stresses.
»The shear works flawlessly and we

have had good experiences working
with bars with very different
diameters cut.«
Ralf Becker, Head of Hot Rolling Mill Division at Annahütte
95
AT HMISHO: NEW TECHNOLOGY

INCREASES PRODUCTION BY 5 %
At Hmisho Trading Group, Syria, SMS group has modernized the existing rebar
rolling mill. Our engineers employed the Ebros® system for the endless rolling of
sections, leading to a significant increase of the overall annual production by 5 %.
A further benefit of the new system is: less crop-end losses for high-speed trains. The two compa-
and a reduced number of short bars, whereby the metal nies have transferred this technology
yield is improved by 1.5 %. Moreover, less labor is required to steelworks construction: to weld
since fewer cobbles means less transports of non-con- together consecutive hot billets
forming products. (1,100 °C) as they come out of the fur-
nace.
TECHNOLOGY FROM RAIL CONSTRUCTION
SMS has developed the Ebros® system under a license BENEFITS OF ENDLESS ROLLING
agreement with Steel Plantech, Japan. It is based on the This process makes ”endless rolling”
welding technology employed in the construction of tracks of sections possible, whereby produc-
tivity and material yield are increased
and a higher plant utilization factor is
achieved. At the same time it ensures
a constant product quality. In the
Hmisho mill, billets of 130 mm x 130
mm square and 12 m length are weld-
ed and the billet throughput is 60 t per
hour.
MARKET LEADER IN SYRIA

The complete rebar rolling mill of
Hmisho equipped with HSD® (High-
Speed Delivery) system was supplied
by SMS in 2007. The annual capacity
is 350,000 t and it is the fourth plant
which has been supplied by SMS
group to Syria.
The new Ebros® system pays off for Hmisho: higher productivity, improved material yield and
constant quality.
96
THE BILLET CASTER

The continuous casting plant will fea-
ture five strands and a casting radius of
9 m. It will produce billets in the size
South Steel, Saudi Arabia:

range from 130 mm x 130 mm to 150
mm x 150 mm. The casting machine
will be equipped with Convex® mold
Minimill order for rebar technology, mold stirrers and a hydrau-
lic mold oscillation system.
production THE REBAR ROLLING MILL

The rebar rolling mill will include a
About 1 million t of steel and 500,000 t of rebars walking-beam furnace with several
control zones. The fuel/air ratios can be
monitored separately for each zone.
This minimizes fuel consumption and
Last year SMS group was contracted by lationship between the melting process provides high flexibility in furnace op-
South Steel Company of Saudi Arabia, and the HBI rate with the objective in eration for all production quantities.
which is part of Pan Kingdom Invest, for mind to achieve a homogeneous pro- The fully automated rolling mill will
the construction of a minimill for re- cess running at maximum productivity. comprise 16 housingless stands in hor-
bars. The volume of this steelworks or- Power will be supplied by a 150-MVA izontal and vertical arrangement, fol-
der amounts to over EUR 90 million. transformer used in conjunction with lowed by a six-stand Mono-Block fin-
The new minimill will be designed for the Consotech equipment for chemical ishing stand for high-speed rolling of
an annual production of 1 million t and power input. The melting unit will be bars, as well as a bar-quenching sys-
is intended to supply the downstream equipped with the latest generation of tem. Downstream of these units, a cool-
rebar rolling mill with billets. The roll- electrode control and process automa- ing bed and the finishing and bundling
ing mill will have an annual production tion. This makes for maximum flexibility facilities will be arranged. The compact
capacity of 500,000 t. Commissioning is in furnace operation, providing the ba- design of the “HL” mill housings will en-
scheduled for the middle of 2011. sis for the desired variable composition sure finished products with close toler-
of the charge while ensuring a constant ances.
ELECTRIC STEELWORKS FOR UP TO 100 % and reproducible melting process. In The High-Speed Delivery System will
HBI CHARGING (HOT BRIQUETTED IRON) the design, special emphasis is placed enhance plant productivity, enabling the
The meltshop will feature a 140-t AC on aspects critical to the continuous mill to achieve a maximum finish-roll-
electric arc furnace as meltdown unit. charging of the furnace and the melting speed to the cooling bed of 41 m/s
The melting rate will be around down behavior, namely material-flow for 8- to 10-mm-diameter rebars. The
24 heats/day. The EAF will be of the full- management, EAF technology and overall plant concept meets all require-
platform eccentric-bottom-tapping de- melting profiles. ments on efficiency, flexibility and re-
sign. A highlight of this project is that it duced maintenance. At the same time it
will be SMS group’s first minimill with SECONDARY METALLURGY will provide high operational reliability
an EAF and LF which can be operated Secondary-metallurgy treatment will and high productivity. SMS group’s
with up to 100 % HBI (hot briquetted take place in a 140-t ladle furnace sup- scope of supply also includes the lev-
iron) charging, if required. Special focus plied by an own 26-MVA transformer. el-2 automation system and the com-
will be laid on the fine-tuning of the re- plete electrical equipment.
97
Joining forces: Experts from SMS and Tung Ho Steel. The works bays.
TUNG HO STEEL, TAIWAN:

MINIMILL SETS NEW
STANDARDS FOR REBARS
In mid-2010, Tung Ho Steel Enterprise Corporation, Taiwan, has successfully
taken a minimill for rebars into operation which has been built by SMS.
What is so special is that the new minimill in Taoyuan near Taipei can be
operated without a conventional reheating furnace. Instead, an inductive heating
plant from SMS Elotherm has been integrated.
Consequently, Tung Ho saves energy and the environment REHEATING FURNACE DISPENSED WITH
is less polluted, since 72,000 t less carbon dioxide (CO2) The new plant optimally implements
are produced. And the operational costs are also substan- the basic minimill concept: short
tially lower. ways and a direct linkage of the roll-
ing mill to the steel plant. The hot bil-
MINIMAL ENERGY CONSUMPTION lets running out of the continuous
For the generation of energy, Taiwan depends almost 100 caster (with a capacity of 40 to 45 t/h
percent on oil and gas imported from abroad. The country per strand) are immediately brought
generates high emissions of greenhouse gases, and as a to a uniform temperature in the in-
result of this, the government is making efforts to reduce ductive heating plant. Then, the bil-
energy consumption and the emission rate. In response to lets run directly into the rebar rolling
these efforts, we have materialized an innovative approach mill. In this way, a gas- or oil-fired
for the new minimill of Tung Ho in order to reach a mini- reheating furnace upstream of the
mum energy consumption. rolling mill could be dispensed with.
98
Under certain conditions, even an in- same time, the operational costs for each t of rebars are
ductive heating is not required since reduced by approx. 25.00 US dollars.
the billets are shaped in such a way
that they hardly lose any heat during EXCELLENT REFERENCES
the subsequent production process. In the minimill segment, SMS is one of the worldwide
leading plant manufacturers with references in the whole
GOOD FOR THE ENVIRONMENT world. Currently, we are building large plants in Bahrain
AND FOR RETURNS and Saudi Arabia.
Eyery year the steel plant with electric
arc furnace, ladle furnace and a five-
strand billet caster is producing 1.2
million t of billets and the rebar mill
has a capacity of 800,000 tpy. Due to
the innovative energy concept, Tung
Ho Steel every year reduces the emis-
sion rate of carbon dioxide (CO2) by
72,000 t, of sulfur dioxide (SO2) by 410
t and of nitrogen (Nox) by 225 t. In ad-
dition to this, the investment costs for
the inductive heating plant are ap-
prox. 25 to 30 % less than with con-
ventional furnace concepts. At the
Reliable and smooth casting.
The innovative energy concept with inductive heating reduces the carbon dioxide rate every year by 72,000 t.
99
120-t EAF with Conso-

Oxygen technology for
reduced energy con-
sumption.
The EAF has a tap-to-
tap time of 43 minutes.
Furnace tapping.
The continuous casting
plant has five strands
and is expandable by a
sixth strand.
100
Layout of the minimill at Tung Ho Steel

STEEL PLANT WITH 120-T EAF
The electric steelworks built by SMS
provides a 120-t electric arc furnace
with dedusting system. The power
consumption of the furnace is 120
MVA. To supply additional energy, we
apply our Conso oxygen technology
(oxygen/gas burner) which reduces
power consumption and increases
productivity at the same time. The tap-
to-tap time is 43 min.
Downstream of this is a ladle fur-
nace which is used for exact tempera-
ture setting providing liquid steel for
secondary-metallurgical miroalloying.
FIVE-STRAND BILLET CASTER

The casting machine has five strands
with a casting radius of 10.25 m. An The roughing train of the rolling mill.
expansion to six strands has been con-
sidered in the layout. The range of dimensions comprises
square billets in the formats of 130, 150, 160 and 200 mm.
The special equipment includes among others the Invex®
mold tube technology for high-speed casting and the hy-
draulic mold oscillation systems. The casting machine is
able cast billets in various sizes in a parallel mode.
REBAR MILL FOR BARS WITH

DIAMETERS FROM 10 TO 43 MM
In front of the rebar mill the billets are heated to an uniform
temperature by the inductive heating plant, if necessary.
The downstream rolling mill includes 14 mill stands in hor-
izontal/vertical and tiltable configuration. A compact design Induction heating section.
of the ”HL” stands ensures that close tolerances of the fin-
ished products are maintained. Bars with small diameters
are finish-rolled in two finish-rolling blocks with six rolling
units in V arrangement.
Straight bars are transported with up to 40 m/s to the
cooling bed by the H.S.D.® (High-Speed Delivery) system.
Then they pass through the finishing facilities.
The minimill is designed for 800,000 tpy of rebars.
101
Rebar mill with Bar mill put

VCC® ordered into operation
Annual capacity of 450,000 t 300,000 tpy of round bars
The South Korean steel producer Daehan Steel has com- The International Company for Steel Rolling (ICSR) in
missioned SMS to supply a rebar mill with a VCC® instal- Hassia, Syria, has successfully taken the bar mill supplied
lation (Vertical Compact Coiler) for compact coils. The by SMS into operation. On this plant, surface heat-treated
mill with an annual capacity of 450,000 t will be the first reinforcing bars are produced with speeds of up to 36 m/s
rolling mill worldwide which concentrates exclusively on in the exit section. The mill is designed for reinforcing
the production of compact coils. The plant is scheduled to steel with low and medium carbon content. The annual
go on stream in April 2011. capacity is 300,000 t of round bars with diameters from 8
SMS supplies the key equipment for the rebar mill to 40 mm.
which includes six housingless mill stands each in H/V Structure of rolling line. The pusher-type furnace for
arrangement for the roughing and intermediate trains, a the heating of square billets supplies a one-strand con-
finishing block with eight rolling units in V arrangement, tinuous rolling line comprising roughing, intermediate
facilities for the heat treatment, the VCC® installation as and finishing trains. The roughing train consists of six
well as the electrics and the automation. In addition to stands and the intermediate train operates with multiple-
this, SMS is responsible for the coordination of erection pass mill stands in HL design and H/V arrangement. The
and commissioning. finishing block in V arrangement is equipped with eight
The production line processes square billets with an rolling units and two more units can be retrofitted. In this
edge length of 130 mm. It is planned to expand the mill for way, the customer has the option to reconstruct the plant
the processing of billets 150 mm x 150 mm in size. The into a combined bar and wire rod mill at a later date.
rebar dimensions comply with D10 to D16 (according to Cooling bed with HSD® system. On the entry side of the
Korean standard) and the production of the corresponding cooling bed a high-speed delivery system HSD® (High-
round bars is also possible. Speed Delivery) has been installed. The system is equipped
For hot coiling, the VCC® installation is presently re- with a double rotating launder transporting the straight
garded as state-of-the-art procedure. The VCC® technol- bars to the cooling bed with speeds of up to 36 m/s.
ogy is also ideally suited for older mills with wire rod The scope of supply. SMS supplied the complete rolling
blocks and loop laying heads since it is possible to pro- mill including electrics and automation. The supply pack-
duce compact and stable coils. age included also the supervision of erection and com-
The Vertical Compact Coiler (VCC®) from SMS is able to missioning. In addition to this, the scope of supply com-
coil the bars directly in vertical position. Owing to this prised a fully automated bundling plant and a tying station.
technology, the customers can do without turning ma-
nipulators in the future. The throughput time is consider-
ably reduced by the VCC® system since the coils are al-
ready formed in their natural final position.
plants plants
102
Managing Director Stephen Lidgate, SMS (UK) Ltd. Mono-Block roller guide.
Service & advice for

wire-rod producers New roller guides
SMS (UK) Ltd. Robust and reliable at lower costs
OEM know-how, short reaction times and communication SMS has further developed its standard and high-speed
in the local language – all this is part of the services of- roller guides for the wire rod and bar mills area. Complete
fered by our service company SMS (UK) Ltd. which was systems are now available to our customers for the first
founded in England at the beginning of 2009. These ser- time which are characterized by robustness and reliabili-
vices are not only gladly accepted by the users of wire rod ty. In this way, the roller guides have a longer useful life
mills in Great Britain but also by the plant operators in resulting in reduced costs for the plant users.
Central Europe. Company headquarters are in Chester- By the use of identical parts with various dimensions
field near Sheffield. With 10 employees in the meantime, significantly fewer spare parts are required by the cus-
this location has grown steadily and it offers extensive tomers. Moreover, the roller guides consist of only a few
technical services and advice for all plant users in Europe. single components so that the assembly or the replace-
Core competencies of the service specialists are tar- ment of wearing parts is considerably easier.
geted and innovative modernization measures to increase Owing to a central adjustment, all guides can be aligned
the plant availability. Owing to the process know-how and in a quick and simple way. With high-speed guides, sec-
with due regard to technical innovations, the existing tions up to a diameter of 40 mm can be safely guided.
equipment is updated by the service experts in an invest- The novel systems have been particularly developed for
ment-friendly manner. A sustainable safeguarding of cus- the high-speed finishing blocks from SMS. However, they
tomer’s competitiveness is thus always in the focus. Ste- can also be used in older plants and are compatible with
phen Lidgate, Managing Director of SMS (UK) Ltd., the wire rod blocks of other manufacturers, provided that
assures: “The wishes and the satisfaction of our custom- corresponding guide holders are available.
ers are particularly important to us. For this reason, we
always offer market-driven and individually tailored solu-
tions.” In addition to the execution and further develop-
ment of service features, the latest standard and high-
speed guides are also developed and planned at the
Chesterfield location. Thanks to an extensive know-how
and many years of experience, SMS (UK) Ltd. has estab-
lished itself as a principal contact for all services in the
wire rod mill sector. Plant users worldwide benefit from
this knowledge and seek advice and support from the
Chesterfield location. Standard two-roller guide.
plants plants
103
SOUTH STEEL, SAUDI

ARABIA: NEW GUIDE
SERIES ORDERED
High-speed guides and innovative guide holders
The South Steel Company, an enterprise based in Jizan SCOPE OF SUPPLY

Economic City, Saudi Arabia, has commissioned SMS to In detail, we supply three complete
equip the bar mill of its new minimill with our newly devel- sets of guides as well as the equip-
oped guide series. The order comprises the design, con- ment for the assembly and the adjust-
struction and supply of standard and high-speed guides. ment of the guides. The roughing and
the intermediate trains are provided
with our newly developed entry and
exit guides as well as with Mono-Block
and two-roller guides. The finishing
block is equipped with the latest series
of high-speed guides and with our in-
novative guide holders.
STEELWORKS AND
BAR MILL OF SMS group
The order is part of a minimill project
which is currently handled by SMS
group. The new minimill is yet another
example for a successful cooperation
between the individual companies
within the SMS group. SMS supplies
the steel plant and the continuous
caster and is building the 22-stand bar
mill with an annual capacity of nearly
500,000 t. The mill processes square
High-speed guide. billets with an edge length of 150 mm
to round bars with diameters between
8 and 32 mm. The rolling mill is sched-
uled to be put into operation soon.
104
The finishing line.
NUCOR STEEL DARLINGTON,

USA: NEW FINISHING MILL
WITH BENEFITS
Bar mill modernized in record time
SMS group has modernized a finishing mill for Nucor Steel tensive pretests by SMS group’s production team reduced
Darlington, South Carolina, USA, in just five weeks. The the number of operations on site, thereby allowing this
new continuous finishing mill allows much shorter stand record revamping time to be accomplished.
changing times and also much reduced setup and adjust- Nucor Steel Darlington, a company of the Nucor Bar
ment times. This consequent modernization has yielded a Mill Group, is a well-known producer of steel bars in the
real competitive edge. USA.
The new intermediate/finishing mill consists of four
horizontal, one vertical and three convertible type HL
stands. The convertible stands are of dual-drive ar-
rangement, with motors and gears keeping their posi-
tion regardless of the stand configuration (either H or V),
with benefits for maintenance and plant usability, easier
access to these facilities while minimizing depth and
amount of required foundation work.
A flying shear, inter-stand equipment, quick change
devices and tools, hydraulic and lubrication units as well
as twelve additionally provided exchangeable cassettes
are also part of the new setup.
This modernization in such a short time was only pos-
sible by close cooperation between SMS and Nucor
Steel. The modular pre-assembly of equipment and ex-
105
”Minimill“ – The highlight at the

Wire-Rod Symposium in Kolkata
Kolkata, India: April 28 thru 29, 2010
Mills for the production of wire rod FURTHER TOPICS

hold huge growth potential for SMS, Further papers dealt with the devel-
especially in countries with constantly opment of a high-speed looper, coil
growing economies. To take advan- compactors for wire rod, and the new
tage of this potential, we launched wire-roll mill in Duisburg-Hamborn
our own series of symposiums on this built and supplied by SMS.
issue earlier this year. After the suc- In addition, SMS presented its ma-
cessful launch in Mönchengladbach, chines for the processing of cold-fin-
The symposium was well frequented. the next event took place in Kolkata, ished steel and copper. The state of
India, from April 28 to 29. the art in inductive heating was pre-
sented by SMS Elotherm. And the
HUGE INTEREST services and products of SMS group’s
250 representatives from 68 Indian “Service Division” also aroused lively
firms attended the lectures presented interest.
at the Hyatt Conference Center in Kol- The SMS staff used the breaks be-
kata during the two-day symposium. tween the papers for in-depth discus-
The presentations focused on new sions with our visitors. According to
Detailed information package for the participants. products and technical innovations Sarkar “it is obvious that our sympo-
contributing to higher productivity in sium comes at the right time and
wire-rod rolling. tackles the right issues“.
MINIMILL FOR SMALL PRODUCTION Another wire-rod symposium took

VOLUMES place in São Paulo.
In his introductory talk, Bimal Sarkar,
Managing Director and CEO of SMS In-
In-depth discussions in the breaks. dia, presented a detailed overview of
the Indian steel market. The technical
papers that followed focused on the
rolling of wire rod, bars and sections. A
topic lively discussed was the ”Min-
imill“ concept for small production vol-
umes which combines an EAF steel-
works with a rolling mill. ”Owing to the
relatively low investment costs, plant
Ulrich Svejkovsky, Vice-President owners in countries such as India are
Long-Product Area, held the opening speech. seeing great future potential for this
concept,” is how Bimal Sarkar explains
the importance of this concept.
106
Hamriyah Steel, UAE:

Bar mill taken into service
About 1 million t of rebars per year
In January 2010, the new bar mill of Hamriyah Steel, Unit-

ed Arab Emirates, has been successfully started up. The
mill in the Emirate of Sharjah is a joint venture between the
Russian Metalloinvest Group and Sheik Sultan Bin Khalifa
Bin Zayed Al Nahyan.
The order for the supply of a turnkey plant was placed
with SMS group in June 2007. Construction work began in
March 2008 and in November 2009 about 95 % of the con-
struction measures were completed. In summer 2009,
long-term contracts for water, power and gas supply of the
mill were concluded. This was a crucial prerequisite for the
Furnace area. success of the project since large projects often fail in the
Gulf region when such guarantees have not been provided.
GRADUAL INCREASE IN PRODUCTION

Prior to commissioning and during initial tests, the bar mill
had already produced 4,000 t of salable bars. Sale takes
place through Ural Steel. The mill of Hamriyah Steel has a
capacity of 1 million t of bars per year. For 2010 a produc-
tion rate of 660,000 t is planned and production shall be
increased gradually: from 10,000 t in January to 80,000 t in
December.
According to estimates by Hamriyah Steel, the annual
demand for rebars in the United Arab Emirates is approx. 4
Intermediate train. to 5 million t. Therefore, Hamriyah could cover 20 % of the
market. In addition to this, there are plans for exporting
bar products into the neighboring Gulf States, to Iran and
Egypt.
ADVANCED COOLING AND THERMO-STRENGTHENING

TECHNOLOGY
Bars manufactured at a diameter range from 10 to 40 mm
meet the national and international standards BS4449,
ASTM A615 and DIN 488. Owing to an advanced cooling and
thermo-strengthening technology, bars can be produced
with low carbon and hardened surfaces. The bars feature
yield strengths up to 550 MPa and achieve good values in
Finishing area. terms of elongation and weldability.
107
108
109
BRIGHT STEEL PROCESSING LINES
For bars with diameters from 2 to 25 mm Round bars of high quality
New grinding and polishing Grinding line

machines minimize setup for Outokumpu
and changeover times VDM
PRESENTED AT IN-HOUSE EXHIBITION IN JANUARY FOR THE FIRST TIME New order. VDM in Altena, Germany,
New development. With a new machine series SMS started into year 2011 at its is strengthening its position in the
Aachen location. In the presence of 40 international customers, the new ma- market and has therefore ordered a
chine of the ”Schleipo N 1” series was presented during an in-house exhibition regulating-wheel grinder of the RSM
on January 27, 2011. The major focus of our design work for the new machine 60 type with complete finishing sec-
was the benefit to our customer. ”The series achieves higher flexibility by a mod- tion from SMS, Germany. From May
ern operating and setting-up concept with an increased performance at the 2013, Outokumpu VDM will be able to
same time,” says Johannes Kahlen, who together with Uwe Repschläger heads produce up to 13-m long round bars
the Schumag & Copper Product Area. of high quality in Altena.
CHANGING TIME OF GRINDING WHEELS REDUCED TO 10 MINUTES High degree of automation. The
The customers benefit especially from an integrated quick-change system re- regulating-wheel grinder from SMS
ducing the setup time from about two hours to ten minutes. ”In this way, our “pre- or finish-grinds” round bars of
customers are able to produce small lot sizes with tailored tools in a flexible and steel and NF metals in a single pass.
quick way which is increasingly demanded particularly by the automotive indus- The RSM 60 is of torsionally very rigid
try.” In addition to a new grinding spindle bearing and drive system, specific design, permits high cutting rates
devices enable a pre-adjustment of the guides and a quick grinding wheel and has a high diameter tolerance. It
change outside the machine. The polished steel bars are used for example as easily grinds even high-strength bars
piston rods and as steering and drive components in the automobile industry. and bars made of materials which
are difficult to machine. The large
WIDE RANGE OF APPLICATION AND CONSTANTLY HIGH QUALITY working range of six to 125 millime-
The new ”Schleipo N 1” processes bars with diameters ranging from 2 to 25 ters in diameter and bar lengths up
mm. The minimum bar length is 1,300 mm and a constantly high quality is en- to 13 meters makes the material
sured by an intelligent control and a laser measuring system. For example, feeding a particular challenge: bun-
grinding wheels from different material qualities can be used via a program- dles of up to 100 bars have to be reli-
mable grinding wheel dressing device. Further customer benefits are an ergo- ably separated and loaded into the
nomic operation and easy maintenance. machine, otherwise machine stand-
stills are the consequence. SMS
solves the problem with a special
step separation system.
In future, Outokumpu VDM will

monitor the sophisticated processes
on the new machine with a high de-
gree of automation: machine control,
process monitoring and diameter
control as well as the linkage to the
PDA system all form part of the or-
der. The supply is completed by sys-
tems for emulsion treatment and air
extraction. SMS also provides the
complete assembly. The new grind-
ing line is scheduled to go into opera-
The ”Schleipo N 1” convinces through its user-friendly operation. tion in May 2013.
110
PROJECTS – BRIGHT STEEL PROCESSING LINES
Peeling machine from SMS group. Sanjay Singal (fourth from left), owner of A peeling machine of the PMS 125 design.
Bhushan Power & Steel, and his team of techni-
cians after signing of the contract with SMS.
New peeling Large order New bright

machine from India steel center
Order from BGH Drawing, grinding and Flanschenwerk Bebitz,
Edelstahl, Siegen peeling lines for new plant Germany
BGH Edelstahl from Siegen, Germany, Bhushan Power & Steel Company in Flanschenwerk Bebitz GmbH in Beb-
has ordered a rotary peeling machine Thelkoloi, India, relies on technology itz, Germany, has placed an order for a
of the PMH 600 type for machining of SMS: for the new plant for the man- new bright steel center with SMS. The
forged bars. The scope of supply com- ufacture of cold-finished steel prod- plant of the BC 120 design is able to
prises the rotary peeling machine in- ucts in the state of Orissa, SMS sup- process bars with diameters up to 120
cluding finishing line, accessories, plies several drawing, grinding and mm and achieves a max. peeling speed
erection and commissioning. The plant peeling lines. The new equipment will of 40 m/min. With this capacity, the fa-
will have to meet high requirements go into operation at the end of 2011. A cility is approx. 30 % more productive
on performance, quality and flexibility, corresponding agreement was signed than conventional equipment. The
and also allow for the production of in August 2010. greater efficiency results from a par-
round material with flawless surfaces Bhushan Power & Steel Company ticularly robust construction allowing
even with close tolerances. The work- utilizes the new lines for the setup of high peeling speeds.
ing range of the finished diameter its cold-finished-steel production. In The facility peels, straightens and in-
ranges from 160 to 600 millimeters, at an intensive selection procedure, the spects round bars from different stain-
a maximum bar length of up to 18 me- lines were particularly convincing less steel grades and it processes bars
ters. By using peeling tools such as thanks to their high degree of automa- with diameters ranging from 25 to 120
tandem or trio systems, chip reduction in various diameter ranges. The mm and lengths from 3 to 6 m.The bar
tions of up to 15 millimeters are pos- new drawing, grinding and peeling diameter can be reduced by up to 10
sible. The feed speed is up to 2 m/min, lines will process feedstock with di- mm and less changing times will fur-
depending on the material quality. The ameters up to 90 mm to cold-finished thermore ensure Bebitz flexibility.
plant will come on stream in the third material. The feedstock will be deliv- “With the new facility, we will be able
quarter of 2015. ered from the rolling mill currently un- to fulfill the individual requirements of
der construction. our customers even better,” says Udo
Gebel, Bright Steel Production Man-
ager at Flanschenwerk Bebitz. “From
the SMS plant, we also expect an ex-
cellent product quality.”
www.sms-group.com/long-products- www.sms-group.com/long-products- www.sms-group.com/long-products-
plants plants plants
111
Sections in the
Kardemir plant, Turkey.
112
Interview
FOCUS
FRUITFUL
COOPERATION
The second-largest steel producer after Germany in Europe

is Turkey, and Kardemir A.S. from Karabük is one of the most
important Turkish steel manufacturers. In the following in-
terview, Fadil Demirel, CEO at Kardemir, explains his passion
for steel and why he relies on the plants of the SMS group.
Mr. Demirel, in your professional career you have always

worked for the steel industry. What makes steel so fasci-
nating for you?
Steel is the starting material for a large number of indus-
tries, which makes it so interesting. When I graduated from
university, it was my aim to choose the best industrial field.
For that reason, I decided in favor of the steel sector.
The Turkish steel industry has a 100-year-old history.

What is the market situation in Turkey today?
Today, we have the highest growth in steel production after
Fadil Demirel
China and India. Nowadays, Turkey is the eighth-biggest
CEO of Kardemir, studied mechanical
steel producer in the world. Steel is predominantly applied
engineering at Istanbul Technical University,
in the automotive industry, in mechanical engineering and
started his professional career in the steel
in the home appliance industry. These industries are the
sector as an engineer in 1977 and today he
driving force for the future demand of the products made by
is Kardemir’s CEO.
the Turkish iron and steel industry. In Turkey, the expendi-
tures on the infrastructure, the construction sector and
transportation will increase further due to major projects
such as the third Istanbul airport, the North-Marmara
highway and new high-speed train projects.
How has Kardemir developed since the privatization

20 years ago?
Established in 1937, Kardemir was the first integrated steel
plant in Turkey. It was here in Karabük where Turkish steel
was born. The history of industrialization of the young Re-
public of Turkey started with Kardemir. After privatization,
we have changed the steelmaking process with a new steel
shop including converter system and increased our capac-
ity, productivity and profitability with state-of-the-art tech-
nology. In 1999, we abandoned the Siemens-Martin furnace
technology in the steel shop and established basic oxygen
furnaces. With the rail and section mill from SMS commis-
sioned in 2007, Kardemir has expanded its product
113
FOCUS LONG PRODUCTS BULLETIN 2016
1937
is the year that Kardemir was initially estab-
lished. The company was the first integrated
steel plant in Turkey, and it was in Karabük
where Turkish steel industry was born.
A new wire rod and

bar mill is now being
built by SMS group
for Kardemir.
The steel plant of

Kardemir is located
in Karabük, around a
four-hour drive east
of Istanbul.
114
FOCUS – FRUITFUL COOPERATION
portfolio and has become the only manufacturer of rails ists has developed in a very positive
i and heavy sections in Turkey and the surrounding countries

of the region, as well. Our vision is to produce steel prod-
ucts that have not yet been manufactured in Turkey and
way, while everyone of course has
their own habits and preferences.
also to produce at least three million tons of steel per year What could still be improved?
SMS group
to be globally competitive. To reach these goals we will con- Generally, we are satisfied with SMS.
SMS group is cur- tinue to invest. With the plants, we are able to achieve
rently supplying a the desired profit and the product
combined rolling What products do you primarily produce? quality we are looking for. For us the
mill for high-grade Our main products are railroad rails, medium and heavy SMS group is of prime importance
steel to Kardemir, sections, structural steel, rounds, sectional steel, mine when it comes to new investments. We
enabling the com- props, shipbuilding sections, heavy steel plates, billets and require facilities at the lowest possible
pany to produce bar blooms. Kardemir is the only manufacturer of railroad rails cost, with minimal energy consump-
steel and wire rod. not only in Turkey but also in the neighboring countries and tion and for high-quality products. The
The core element is the entire Middle East. Our company fully covers the de- Turkish steel sector is growing rapidly.
a three-roll precision mand for rails by the Turkish State Railways and has there- SMS supplies a wide range of equip-
sizing block (PSM®) fore eliminated the dependence of Turkey on foreign coun- ment and is therefore of great benefit
and the wire rod line tries. In our rail and section mill we manufacture heavy to Turkish companies.
is equipped with sections up to 750 millimeters.
MEERdrive® technol- Fadil Demirel
fadil.demirel@kardemir.com
ogy. Commissioning What plans are you pursuing with SMS group?
is scheduled for I have known SMS for about 35 years and believe that the
2015. company has good technologies at fair prices. With regard
to upcoming investments of our company, SMS will always
be taken into account as an appropriate business partner.
For our rail and section mill we have opted for SMS; for our
continuous caster as well, and our new bar mill will also be
built by SMS. Over the last five years, we have realized a to-
tal of four major projects with the SMS group.
How has the cooperation developed so far? What are the

differences between Turkish and German engineers?
A difficult question. Of course, your engineers are well
trained, have gathered many years of experience and have
profound knowledge of our equipment. As regards the
technology and its application, Turkish engineers have
drawn even in many ways in recent years. Compared with
other countries, it is a fruitful cooperation – it can be said
that friendly business relations have developed over time.
And the cooperation between Turkish and German special-
115
QR code: Simply scan the QR code using a
smartphone and obtain further information
at www.sms-meer.com/ecoplants
116
ECOPLANTS
FROM SMS
sustainable and profitable
Act responsibly – grow sustainably: that is what ecoplants

stands for. This brings ecological and economical benefits
to the customers of SMS.
Also for plant construction, sustainability has become a
convincing sales argument. This aspect can be considered
crucial in many ways, such as with approval procedures
applicable to the installation of new plants. The employ-
ees of SMS have always worked to improve their machines
and plants. For a number of years now, the subjects of
energy saving, emission reduction, prevention of waste
and better utilization of raw materials are in the focus.
117
One of the first references for ecoplants: The CMT® minimill for Tung Ho Steel.
For all these efforts ecoplants provides an umbrella. All With MEERdrive® technology another ecoplant is now in
product areas involved will continue in systematically use in Duisburg-Ruhrort, Germany. ArcelorMittal Ruhrort,
working to make measurable improvements to machines a customer of SMS, sees similar benefits. Bernd Weber-
and plants and to communicate the benefits to the cus- sinke from AM Ruhrort: “Sustainability is a very important
tomers. production factor and we examine all investments for
For approaches with ecoplants, criteria are defined their sustainability before being implemented. All in all,
where their added value can be displayed, normally in di- the package offered by SMS Meer was the best to emerge.”
rect comparison with the predecessor technology. Eco- One of the first ecoplants references for SMS is the
plants are characterized by significant reductions when CMT® minimill of Tung Ho Steel in Taiwan. Unlike previous
using raw materials and energy, fewer operating materi- plants, the CMT® no longer requires a heating furnace. In-
als and reduced emissions as well as an improvement of stead, direct rolling of semi-liquid steel is realized and the
the recycling quote. When at least one criterion is achieved temperature profile can be adjusted flexibly via an induc-
the corresponding product is rated as ecoplants solution, tion heating. As a result, lower energy consumption and
provided that also an economic added value is attained. minimal emission values are achieved.
Norbert Theelen, Head of the Seamless Tube Plants
Product Area at SMS group: “Take the example of the CONTINUOUS DEVELOPMENT
PQF® seamless tube plant for VSB in Brazil: wall thick- OF ENVIRONMENTAL ENGINEERING
ness tolerance, thinner wall thicknesses and high- The ecoplants concept has been implemented by the whole
strength material grades have become determining topics group. For example, an energy recovery system including
in seamless tube production. The PQF® technology ad- complete dedusting equipment for two FeCr submerged
dresses precisely this issue to reduce material and energy arc furnaces has been installed at Eticrom, Turkey, where
input at the same time. The closer the wall thickness tol- energy is converted from hot exhaust gases of approx. 600
erance the smaller is the material input. Tool consump- degrees Celsius into overheated steam. The steam drives a
tion is also lower when a PQF® plant is used.” turbine generating five megawatts of electric power. “Every
»The companies of SMS are very reliable partners and we have

found the best possible supplier for our high demands on quality
and sustainability. Even during the construction phase of the
plant the experts of SMS group were always at our side.
That’s my idea of real cooperation.«
Christian Caldeira, Vallourec & Sumitomo Tubos do Brasil
118
FOCUS – ECOPLANTS FROM SMS
»The new minimill of SMS group fulfills our requirements.

We were able to increase production, lower costs with energy-
efficient processes and do something for the environment
at the same time. In this way, we not only reduce emissions
but also save ready money.«
Tim Hsu, Tung Ho Steel, Taiwan
year, about 25,000 tons of carbon dioxide are saved,” says »Sustainability is a very important
Christian Fröhling, Head of the Energy and Environmental
Technology Division at SMS. “Moreover, the customer saves production factor and we examine
approx. 3.8 million euros on electricity generation.” all investments for their sustainability
Energy recovery systems for an electric arc furnace and
an AOD converter from SMS are in use at the Chinese before being implemented. All in all,
steel producer FuXin. The systems convert hot exhaust the package offered by SMS was the
gases of up to more than 2,000 degrees Celsius into satu-
rated steam which in turn is fed into the interconnected best to emerge.«
plant system and is used for cooling the electrical units.
As a result, annual carbon dioxide emissions can be re- Bernd Webersinke, ArcelorMittal
duced by about 60,000 tons.
Another ecoplants example is installed at ArcelorMittal
Ukraine (AMKR) where hydro-hybrid filter systems are
presently being assembled by SMS on six existing convert-
ers, reaching highly restrictive pure gas dust contents
smaller than five milligrams per standard cubic meter.
“For AMKR the installation has been worthwhile also in
financial terms since a reassembly of a BOF dry-type dust
extraction system would have been expensive,” says envi-
ronmental engineering expert Fröhling. Moreover, the
customer saves approx. one million euros in electricity
costs per year due to the modernization. The advantage of
hydro-hybrid filter systems is that the existing BOF wet-
type dust extraction systems (e.g. Baumco Venturi or OG)
can only be supplemented by a wet-type electrostatic pre-
cipitator thus enabling us to minimize costs for invest-
ment and production downtimes.
ECOPLANTS – A CONCEPT COMBINING

ECOLOGY AND ECONOMY.
Bernd Webersinke, General Manager ArcelorMittal (r.) and Stefan

Schulte, SMS group.
119
© SMS group · Published on 18.02.2016 · Circulation 500 · Printed in Germany
SMS group GmbH

Long Products Plants
Ohlerkirchweg 66 Via Udine, 103
41069 Mönchengladbach, Germany 33017 Tarcento (Udine), Italy
Phone: +49 2161 350-1739 Phone: +39 0432 799-111
Telefax: +49 2161 350-1754 Telefax: +39 0432 784-556
E-mail: communications@sms-group.com E-mail: sales@sms-meer.it
Internet: www.sms-group.com Internet: www.sms-meer.com
“The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these
characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will
not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.”

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LONG PRODUCTS BULLETIN

STEEL BEAMS AND SECTIONS

The tandem group in

SMS SUPPLIES STEEL

Layout of the plant.

The tandem mill TDM-

The mounted EAF (electric

The dedusting plant

Rails are in demand

A long runner becomes a monument

Within the last 80 years, up to 1.1 mil-

CHINA: BAOTOU ORDERS

BROAD DIMENSIONAL RANGE AND HIGH CAPACITY

Jiexiu Xintai, China:

Already the first four I-beams rolled TECHNOLOGY FOR HIGHEST

Straightening roller change for a CRS® Revamp of No. 1 section mill.

Turnkey SMS revamps

”Technical Control System” –

THE AIM: ERROR PREVENTION FAST FAULT DIAGNOSIS

Stahlwerk Thüringen commissions

At the beginning of 2011, Stahlwerk

NEW MAJOR ORDERS FROM

Vertical roller straightener and

RAILHEAD HARDENING LINE:

Rail cooling bed.

JSPL, India: CRS® straightener with ninth

The assembly crew at JSPL. CRS® straightening machine.

RUSSIA’S MOST MODERN

With inline measure-

The mill of Siam Yamato, south of Bangkok.

SIAM YAMATO, THAILAND:

Piya Chairat, Plant Manager of Siam Yamato and his col-

»SMS enjoys worldwide a distinguished reputation

Piya Chairat, Plant Manager of Siam Yamato, is full of praise

40-YEAR-OLD IDEA MORE RELEVANT

Eric Hetzel (left), Site Manager, assists in the control room.

Advanced SMS technology ensures smooth production.

MOST MODERN PLANT OF ITS KIND

THE MINIMILL FOR MEDIUM SECTIONS

The binding machine.

Such complex modernization steps executed in an ex-

Saving operating costs

LOWER OPERATING COSTS

PSM® stands for

From top to bottom:

Operating errors are thus avoided.

Precise measurement technology

Deutsche Edelstahlwerke (DEW) is operating the first

RABIGH STEEL ORDERS

Rabigh steel from the Kingdom of

The rolling mill consists of a pusher-type furnace with a

EFFICIENT PLANT CONCEPT

For the wire rod outlet of its new wire

Duisburg as steel location has a more than 150-year tradi-

The steel location

Photo top: Jeddah Economic Company/Adrian Smith + Gordon Gill Architecture

Cooling bed with HSD® System.

160tons per hour is the capacity of the walking-

ORDER FROM RUSSIA

Tulachermet-Steel and SMS group CASTING OF SQUARE SECTIONS

Close 3.2 mill. tons High-quality

Cutting-edge First PSM® Precisely and

www.sms-group.com/long-products- www.sms-group.com/long-products- www.sms-group.com/long-products-

Improved dimensional tolerances and metallurgical

cility in Abinsk is an example for inte- ” Thermoprocess lines” for the

efinition of initial-pass diameters

olled metallurgical properties such