Danieli Minimill - Danieli Centro Combustion

ALSO IN THIS ISSUE
Continuous casting
leadership with over
3-strands-per-month
startup pace.
Page 5
STEELMAKING
5 SPECIAL STEEL CASTER
STARTED UP IN SPAIN.
7 NEW STEELMAKING PLANT
AT AL RAJHI, SAUDI ARABIA.
FLAT PRODUCTS
8 THIN SLAB CASTER AT
TONGHUA, P.R. CHINA.
11 5TH TURBOFLO
PICKLING LINE ORDER
13 DANEWS INTERVIEW.
LONG PRODUCTS
14 PRODUCTION RAMP-UP
AT BAOSTEEL SHANGAI.
15 TWIN BAR MILL AT TIANJIN
TIANGANG, P.R. CHINA.
16 ALL-TIME RECORD
AT FENG HSIN, TAIWAN
AUTOMATION SYSTEMS
19 HW AND SW TOOLS FOR
COLD MILL COMPLEXES.
SERVICE
20 GUIDING EQUIPMENT FOR
TOP-PERFORMING MILLS.
ALUMINIUM
23 MARKET SUCCESS FOR
EXTRUSION PRESSES.
Technologically
advanced 2-Mtpy
Hot Strip Mill
at Tangshan Xinfeng,
P.R. of China.
Page 9
DANEWS
During the last 30 years it has been
proven that the most competitive way
to produce steel, initially at around
200,000 tpy but nowadays at up to 1.5-2 M tpy,
is by the minimill route.
Danieli’s experience in minimills, EAF-based
steelmaking and rolling facilities dates back to
the 1960s, and its first minimill was installed
in Germany in 1964. The concept was
and still is successful, thanks to its flexibility,
lean company structure and low transportation
costs due to the nearby markets for raw
materials and the finished steel products.
Around 80% of the minimills operating
worldwide were supplied by Danieli or operate
Turnkey Cold Mill
Complex (pickling, rolling
and galvanizing) at
Unicoil, Saudi Arabia.
Page 10
Danieli News n.137
March 2004,
Danieli Group
33complete minimillssupplied in the last 15 years
Danieli Minimill:
a winning concept also
for the new Millennium
with some Danieli equipment.
From the beginning minimills have increased
output and product range while retaining
a very compact layout thanks to the following
innovations: EAFs tapping 35 heats/day,
the use of DRI for demanding steel qualities
such as IF steels speciality steel billet casting
at 6 m/min, endless rolling by billet welding,
40 m/sec bar cooling beds, twist-free spooled
bars in up to 5-t coils, 120 m/s wirerod
production, and flexible Thin Slab Rolling.
In 2000 Danieli installed the world’s first
Endless Casting Rolling plant with on-line
heat treatment for speciality steel bars
and bar in coil production.

DANEWS
China Iron and Steel Industry report
A booming market soon overcoming a production of 300 Mtpy
2
by Li Shijun
Vice Secretary-general
of China Iron and
Steel Association,
Vice Secretary-general
of Chinese Society
of Metals.
I. High-speed growth of China economy has
given impetus to great increasing of steel
product demand.
In 2003 China economy developed fast and the
average GDP per capita topped US$ 1000 for
the first time, reaching US$ 1090. The GDP
was increased by 9.1% in comparison with
previous year.
In 2003, China steel output was increased
rapidly and broke through 200 Mtons for the
first time and it was up to 220 Mtons, which
was increased by 21.2% in comparison with
previous year.
The strong growth of China's economy and
vigorous demand of the steel products market
for the recent 2 years have indicated that
China's economy has entered in a new growth
period taking heavy industry and chemical
industry as leading industry, and formed the
high growing industry group taking auto, real
estate and equipment manufacturing industry
as main industry. The consumption structure
has been changed from subsistence level to
well-to-do level and urbanization progress has
been obviously accelerated and created the
final demand of new market.
In 2003 China' steel output reached 235.8
million tons (increased by 21.5%), imported
steel product was 37.17million tons (increased
by 51.8%), exported steel product was 6.96
million tons (increased by 27.5%) and steel
product consumption was 246 million tons
actually.
China's steel product consumption was
increased from 9.2% in 1991 to 23.6% in 2002
of the world's consumption. As estimated by
International Iron and Steel Institute at 37th
annual meeting in Chicago in November 2003:
in 2003 growth of China's steel product
consumption was 86.8% of the total world's
steel products consumption growth.
China has 13 iron and steel producers with
steel output of over 5 Mtons: Shougang: 8.17
Mtons, Tangshan Steel: 6.1 Mtons, Handan
Steel: 6.0 Mtons, Baotou Steel: 5.2 Mtons,
Anshan Steel: 10.2 Mtons, Benxi Steel: 7.2
Mtons, Baosteel: 19.9 Mtons, Shagang Steel:
5.0 Mtons, Maanshan Steel: 6.0 Mtons, Jinan
Steel: 5.0 Mtons, Wuhan Steel: 8.4 Mtons,
Hualing Steel: 5.2 Mtons and Panzhihua Steel:
5.3 Mtons.
II. Consumption structure feature
of China's steel products: high proportion
for long product.
Consumption development trend of China's
steel products: fast development for steel
flats.
The largest consumption market for China's
steel products is of the building steel for
housings. In 2002 the as-built area of the
housing construction of the city and town in
China was 1.1 billion square meters, of which
resident housing was 57.8% consuming 79.1
Mtons of steel products accounting for 40.4%
of the total steel consumption of the year.
The consumption structure taking the building
steel as prevailing has made China mainly
produce the long products such as rebar and
wire rod etc. In 2003 China's small size section
steel output was 68.2 Mtons, wire rod output
was 40.3 Mtons and long products output was
accounted for 57% of the total steel products.
The ratio of the flats output was low, which
was only 34%.
With development of China's manufacturing
industry, the consumption growth speed of the
flats for recent years is faster than the long
products. The consumption ratio of the steel
flats has been increased to 42% from 39.9% in
2002. Because the flats rolling mill
construction in China is late,the steel flats are
mainly imported for complementing the

The Chinese steel products import
in 2003 was of 37.169 Mtons
CR coil 26.0%
Flat 89%
Common steel sheet/strip 65.2%
HR band 18.8%
Galv. sheet 14.5%
Top 8 Steel Companies: > 6 Mt/a (2003)
Other 2%
Tube 3%
Long 6%
Plate 10.3%
Shougang: 8.2
Wuhan: 8.4
Handan: 6.1
Tinned plate 7.7%
Aluminized sheet 0.9%
3
Anshan: 10.2
8
Color-coated 3.0%
Other coated sheets 0.5%
Silicon sheet 4.3%
Alloy steel
sheet/strip 1.1%
Stainless steel
sheet/strip 7.4%
Strip 1.2%
Seamless pipe 1.3%
Welded pipe 1.7%
Sections 5.6%
7
2
5
4 6 Benxi: 7.2
Tangshan: 6.1
Baosteel: 19.9
Maanshan: 6.1
1
DANEWS 137
Danieli business in China
backs to 1979.
Since than it supplied
over 200 plants / single
unit equipment.
The company operates
through two main offices
and service centers
for a better customer
assistance.
shortage for domestic demand in the recent
years. In 2003 the proportion of the imported
flats was 89% of the imported steel products
including 9.7 Mtons of common cold rolled
sheet, 7 Mtons of common hot rolled sheet,
5.4 Mtons of galvanized sheet and 1.1 Mtons
of coating steel sheet.
In recent years, China has accelerated the
construction of the steel flats rolling mills. By
end of 2003, China has built up 10 sets of hot
rolling wide strip mill, 7 sets of CSP and 2 sets
of Steckel mill. The annual capacity of the hot
wide strip mill is up to 46 Mtons.
III. Growth of China's steel products market
demand is not a short-term action.
China will basically realize industrialization
in the year 2020. Currently China is in mid
stage of industrialization. Till 2010, GDP
will be doubled in comparison with the year
2000 that is increasing to US$ 2000 billion
from US$ 1000 billion. Among the three horse
carts such as fixed assets investment, export
and resident consumption driving economic
growth the fixed assets investment has direct
relationship with the iron and steel industry.
In 2003 the fixed assets investment
of the whole society in China was increased
by 26.7%. The great growth of the fixed
assets investment has driven the growth
of the steel products consumption.
Our opinion is that the industrialization
cannot be realized without growth of the
fixed assets investment. Therefore, during
China's GDP increasing from US$ 1000 billion
to US$ 2000 billion at least for the first
10 years of the century there will be a large
development space for China's steel products
market.
The fast economic development of China and
the economic recovery increasing of the world
provide the good development opportunity for
China's iron and steel industry and the iron
and steel industry in the world.
Today, the progress of the economic
globalization accelerates. The world is an
interdependent world, so China's iron and steel
industry is willing to strengthen cooperation
and to have joint development with the world's
colleagues. ■
3

DANEWS
4
IRONMAKING
The order for the repair of the cooling
system and refractory lining in the tuyere
zone, the bosh and belly of BF No. 2 was
awarded at the end of October 2003.
Acesita, located 600 km north of Rio de Janeiro,
is part of the Arcelor Group, the largest steel
producer in the world, and Brazil’s largest
integrated stainless steel making company.
Upon completion of the repair, a Danieli Corus
proven integrated cooling and lining system,
successfully applied in over 30 BFs around the
world, will allow for seven to ten years of
uninterrupted campaign.
A Heat Flux Monitoring system will provide
information of heat load on the furnace wall and
allow the operators to reduce it by distributing
the burden materials charged into the top of the
furnace. Thus, it provides a very important tool
for achieving optimum longevity of the cooling
system and refractory lining.
A particular feature of this furnace is that,
further to the conventional coke charged at the
The BF No. 1 of Anshan
Iron & Steel Co. Ltd.
is supported by 3 Hot
Blast Stoves of Danieli Corus
design. The order for design,
supply and supervision services
was awarded in the summer
of 2001.
The installation was finished
in November 2002.
However, due to the severe
weather conditions in Liaoning
Province during the winter of
2002-2003, the heat-up of the
stoves was delayed until early
spring 2003. After heating up,
the stoves were handed over
in March 2003, ready for
production. Since then, the
complete BF system has
I
Repair of BF No. 2 at Acesita, Brazil
A further
acknowledgement
of Danieli Corus
world-renowned
technology.
top of the furnace, it also uses charcoal
as fuel injected through the tuyeres. Brazilian
steelmakers are permitted to use charcoal but
need to re-forest as per Government regulations.
The order also involves site supervision services
and technical assistance and training
of the personnel. Installation will take place
in the second half of 2004. ■
Successful performance test of hot blast
stoves at Angang, P.R. of China
Main stoves characteristics
Process
Inner volume BF 3200 m3 Hot Blast volume, operating 6700 m3 /min
Hot blast temperature 1250 °C
Dome temperature, set point 1300 °C
Fuel Blast furnace gas with
coke oven gas enrichment
Equipment
Number of stoves 3
Stove diameter 11.2 m
Checker height 36 m
Checker height of silica 9 m
Internal burners, length 5.0 m
1
1 View of the Acesita
No. 2 Blast Furnace
where Danieli Corus
will carry out the repair
of the cooling system
and the refractory lining.
operated on a steady learning
curve. A performance test was
carried out in the first week of
November 2003.
The result was that the stoves
performed well within the design
parameters and the project
was successfully concluded. ■

DANEWS
2 View of the casting floor.
3 Billets exiting the caster.
STEELMAKING
K
houzestan Steel
Co steel plant in
Ahwaz made the
first heat on its six-strand
Conticaster No. 2 on February
1st 2004.
The heat was performed
with 130-mm billets, casting
peritectic steel grade with
good results.
Level 1 and 2 automation
system allows full control
of all machine functions.
Cast sections are 100,
130 and 150 mm. Ladle size
S
Special steel billet caster
started up at Aceralia Redondos,
(Arcelor Group) Spain
First billets were successfully cast at
Aceralia Redondos Zumarraga (Arcelor
Group) on 15th February 2004.
The new state-of the-art six-strand caster
features open stream or submerged nozzle
operation (stopper rod system), mould EMS
and hydraulic oscillators.
The 7-m radius multibending machine is
designed for high-speed casting of 160-mm
billets in a wide range of special engineering
steels including free-cutting, cold heading,
cold drawing and forging qualities for the
automotive industry.
Caster productivity will be over 180 tph,
depending on steel grade.
The new conticaster was “tailor-made” for the
replacement of a 7-strand 5-m radius machine,
utilising as much as possible existing
foundations, civil works and auxiliary plants.
Another Danieli billet caster has been
successfully operating at Aceralia Redondos
Azpeitia since 2002 at a rate of 180 tph. ■
2nd six-strand caster started up
at NISCO KSC, Iran
is 150 t. Steel grades to be
cast are low C and low alloy
steel for merchant bars and
wire rod.
Startup of Conticaster
No. 2 was part of a wider
KSC steel plant upgrading
project carried out by Danieli,
which also included another
six-strand Conticaster
(started up in 2001),
modernization of two 150-t
EAFs, new ladle furnace and
plant auxiliaries including a
new water treatment plant. ■
83
CASTING
STRANDS
STARTED UP
IN THE PAST
24
MONTHS
4 Six-strand highspeed
billet caster
for specialty
engineering steels.
5

DANEWS
6
STEELMAKING
S
More Danieli secondary metallurgy
technology in P.R. of China
Secondary metallurgy station
for Hunan Valin, Xiangtan.
Danieli has been awarded an order from
Hunan Valin I&S Group Co. Ltd. (Xiangtan),
Hunan Province, for the supply of two 120-t
ladle furnaces and a 120-t Vacuum Degassing
unit for treating 2.5 Mtpy and 1.2 Mtpy of
liquid steel respectively.
Steel grades to be processed will be high
quality tube and pipe steels, high pressure
boiler steel, carbon structural, shipbuilding,
pipeline, boiler and pressure vessel steel plates.
The ladle furnaces and the degasser will be
an integrated part in Xiangtan No. 1 new
steelmaking plant and feed the existing
round and square conticaster as well as the
Slab Caster. Danieli will supply the key
On December 12th, 2003,
ed a contract with Hunan
Valin I&S Group Co. Ltd.,
in Xiangtan, Hunan province,
awarded an order for two
sublance systems, including the
latest generation of data
processing units (Dirc-5) and the
Static and Dynamic level 2 model
developed by Corus and Danieli
Automation.
On January 8, 2004 Benxi Iron &
Steel Group Co. Ltd., awarded an
order for three sublance systems
-including Dirc-5 and the static
and dynamic model- which
doubles the three Danieli Corus
sublance systems operating
since 2001. The Danieli Corus
Sublance system permits stateof-the-art
control of production
and offers major cost savings and
excellent quality control. It can
be implemented in operating
BOF shops without noticeable
interference to production.
Moreover, it incorporates various
unique tools and features easy
maintenance and operatorfriendly
operation. ■
equipment and Level 1 and 2 automation
systems. Startup will take place at the end
of year 2004.
Ladle furnace contract at Benxi
Danieli will supply key equipment and Level 1
and 2 automation systems for the new Benxi
I&S Group Co. Ltd 150-t ladle furnace that
will be installed as an integrated part of the
new thin strip line. Danieli was awarded the
contract in January 2003.
The ladle furnace will feature swivelling
electrode arms and two heating positions, and
will treat up to 1.5 Mtpy of liquid steel in
carbon structural, quality carbon structural and
low alloy grades. Startup of the ladle furnace
will take place by the end of year 2004. ■
48
LF, VD, VOD
UNITS
SUPPLIED
IN THE
LAST FOUR
YEARS
Danieli Corus Sublances: the ultimate steelmaking tool
Contracts at Hunan Valin and Benxi, P.R. of China, bring to over
50 the sublance systems supplied to satisfied customers all over the world.
Hunan Valin I&S and Danieli Corus Teams
at the contract signing ceremony.

New
Orders
Major meltshop
upgrading of
Aceros Arequipa,
Peru
The project aims
at increasing tonnage and
product quality
Once revamped, Aceros
Arequipa minimill in Pisco will
reach a capacity of up to
400,000 tpy.
The order signed in December
2003 is the first step of a new
major minimill modernisation
plan and includes:
A completely new fume
treatment plant for ladle
furnace and EAF.
New electrode regulation,
complete automation system,
new burnjector and burners
(for improving chemical energy
utilisation) for the 40-t EAF.
HiREG electrode regulation system.
Modernisation of the
technological area as well as
a completely new automation
system for the conticaster
to increase productivity and
improve billet quality.
Startup of the upgraded
facilities will take place in the
second half of year 2004.
Conticaster
upgrading at Ori
Martin, Italy
The project aims at
improving billet quality on
the whole range of special
engineering steels.
Delta-type tundish heating.
According to the contract
signed in January 2004, the
project will include the
installation of new moulds as
well as a complete package for
submerged stream casting with
stopper rod.
A new Delta-type bigger-size
tundish (and tundish car) will
be used for an increased steel
residence time to favour
inclusions flotation.
Modifications will also be made
to the mechanical parts of the
hydraulic oscillators, to the
strand structures and to the
secondary cooling system.
ORI Martin five-strand
conticaster produces 140-mmbillets
in a wide range of special
quality and engineering steels.
Fume and water
treatment
plants at Sonasid,
Morocco
In January 2004, Danieli
was awarded the order for
completion of the Société
Nacionale de Sidérurgie
minimill located in Jorf Lasfar.
The 625,000-tpy steel
meltshop will be equipped
with a 1,600,000-Nm 3 /h
fume treatment plant and a
water treatment plant ensuring
an environmental-friendly
operation. •
C
orus Engineering Steels will install
a new 700,000-tpy bloom caster
in Rotherham.
The 10-m radius, 5-strand machine will cast
180- and 210-mm square blooms in topquality
high carbon, boron, spring, bearing
and free-cutting grades for the most
demanding applications. The machine is of
utmost strategic importance to Corus, being
heart of the restructuring programme
underway at Rotherham and will replace a 16m-radius
larger-size bloom caster (casting 560
x 400 mm blooms). The smaller size blooms
coming from the new caster will bypass the
blooming mill operation and be directly fed
into the hot-rolling facilities.
A key feature of the new caster will be the
independent tundish car lateral exchange
system which will enable uninterrupted
operation of a second existing large bloom
caster, located close to the new one.
Level 1 and 2 automation systems will be
supplied by Danieli Automation.
Startup is planned for January 2005. ■
DANEWS 137
New bloomcaster
for Corus Engineering
Steels, UK
The state-of-the-art 5-strand caster
will be supplied on a turnkey basis.
Complete 850,000 tpy
steelmaking plant for
Rajhi Steel, Saudi Arabia
Anew 850,000-tpy steel
making plant will be
installed in the Jeddah
Industrial area.
The new state-of-the art plant
will feed Rajhi Steel hot rolling
mill division, designed to
produce 750,000-tpy of
merchant long products.
The order, awarded to Danieli
Centro Met in February 2004,
foresees the supply of new
steelmaking plant basically
composed of a 100-t fullplatform
EAF, ladle furnace
and 5/6-strand conticaster
for 100 to 160-mm billets,
plus materials handling system,
fume treatment plant and
meltshop auxiliaries.
Plant startup is scheduled
in the second half of 2005. ■
7

DANEWS
8
FLAT PRODUCTS
T
onghua Iron & Steel Group Co. Ltd.
(Jilin Province) awarded the order for
the fTSC caster for its new Ultra Thin
Strip production line on December 12, 2003.
The plant is designed for producing up to 1.4
Mtpy in coils (through thin slab route, 90 mm
thickness at the mould exit, soft-reduced to 70
mm, 900 to 1570 mm in width) of low, ultra-low
and medium carbon, peritectic and low alloy
steels. Main applications are automobile
structures, welded and general structures, pipes
and tubes, oil pipelines, CR and HR mechanical
applications, weather resistant applications.
Provision for a future doubling of plant
productivity by adding a second twin casting line
has already been considered.
As far as production flexibility is concerned, the
caster is one of the most versatile plants in the
world, being able to cast top quality slabs within
an extremely wide range of working conditions.
Namely, the equipment allows a "full quality"
casting speed ranging from 2.5 up to 6 mpm and
it is able to dynamically modify slab profile
during the cast both in thickness (soft reduction
dynamic control) and width (mould automatic
width adjustment system) covering "in line" the
full range of product dimensions. Also, the
machine is already conceived for the future
installation of electromagnetic stirring and
braking facilities in the mould and additional
horizontal segments, in order to increase the
containment and reach up to 7.5 mpm casting
speed, in full quality. ■
F
Thin Slab Casting facility at Tonghua, P.R. of China
It is the 10 th fTSC strand featuring Danieli
exclusive long funnel mould and dynamic soft reduction.
On November 22nd, the
first stainless steel slab
was cast through the new
conticaster at Walshin Lihwa.
The ceremony was attended by
Mr. Wen-Chung Chang,
Managing Director of Special
Steel Group, and by Mr. Tain-
Rong Chen, Director of Production.
The new slab caster is the result
of a major revamping aiming at
the conversion of a 2-strand billet
caster to a single strand slab
machine, specifically dedicated
to the production of stainless
steel grades (AISI 300 series).
The 10.2-m radius curved
machine, designed to produce
175 to 200-mm-thick slabs at a
speed of 1 mpm (1.2 mpm when
the foreseen additional segment
will be installed).
Worth underlining is the fact that
ed, the project has been
successfully completed within the
contract schedule of 14 months
from contract signing to first cast,
thanks to the joint and full
commitment of both Walsin Lihwa
and Danieli teams. ■
Section view of the slab casting facilities
Signing ceremony
Mr. An Fengcheng,
President of Tonghua
(2nd from right)
and Mr. Bendetti
CEO and President
of Danieli (2nd from
left) at the signing
ceremony.
1st stainless steel slabs cast at Walshin Lihwa, Taiwan

2-Mtpy Hot Strip Mill at Tangshan Xinfeng,
P.R. of China, for high-quality carbon steel strip
Signing ceremony. From left to right:
Mr. Yang Zixing, Director of MCC Hightech Company,
Mr. Zhangzhen, President of Tangshan Xinfeng Steel
Ltd, Mr. G. Ximeris, Director of Sales, Danieli.
T
he order from
Tangshan Xinfeng Iron
and Steel Co. Ltd.was
awarded on January 18th 2004.
The new facility will be located
in Tangshan City and have a
product mix of 35% of carbon
steel, 55% of high-quality
carbon steel and 10% of low
alloy steel.
Tangshan Xinfeng will take
advantage of the most up-todate
and proven HSM
technology coming from
Danieli Wean United.
Plant layout
The project execution will be
based on a full co-operation
between Danieli, Erzhong and
the Yanshan University. Each
party will bring its own
expertise into the project in
order to accomplish the
strictest quality requirements of
the market.
The main equipment included
in the line:
Slab descaler;
4-Hi reversing roughing
stand with attached vertical
edger;
Hot coil box;
Rotary drum shear;
Water descaler;
Six 4-Hi finishing stands;
Cooling section (U-tube
type);
Two downcoilers
Coil conveyor line.
The mill incorporates the most
modern design concepts, such
as edger with Hydraulic
Automatic Width Control
(HAWC), HAGC, positive
bending, WR shifting, Roll
Main material data
Incoming slab
DANEWS 137
Thermal Crown (RTC) control
system and shaped roll (to
improve flatness control
capability). Rolling of the first
coil is expected in 20 months
from the contract coming into
force. ■
Thickness 135 (mm)
Width 600 - 1,300 (mm)
Length 15,600 (mm)
Weight 21 (t)
Hot Strip Mill
Thickness 1.2 - 12.7 (mm)
Width 600 - 1,300 (mm)
Coil OD 762 (mm)
Coil ID (max) 1,850 (mm)
Weight 21 (t)
Specific coil weight 16 (kg/mm)
9

DANEWS
Turnkey Cold Mill Complex at Unicoil,
Saudi Arabia
It will be the first private sector facility
in the country for the production of galvanized coils.
Unicoil (Universal
Metal Coating Co.),
owned by Al Zamil
and Al Rashed Groups,
currently operates a paint line
in Al-Jubail to produce
colour-coated coils from steel
sheet and aluminium coils.
The plant expansion to be
supplied by Danieli on a
turnkey basis includes a pushpull
pickling line, a singlestand
cold reversing mill and a
continuous hot dip galvanizing
line, as well as a slitting,
recoiling and inspection line,
to produce 250,000 tpy of
galvanized coated coils.
According to the contract
signed in Damman on
November 11, 2003, Danieli
will supply all production
lines as well as all necessary
auxiliary facilities and services.
Main features of the supplied
equipment are:
Push-pull pickling line: the
world-renowned Danieli Wean
United's Turboflo TM pickling
line technology will be used.
A pre-cleaning unit, side
trimmer and scrap choppers
will be located at line entry
and line exit respectively.
Cold reversing mill: the 4-
High single-stand mill is rated
for 2000 t roll separating force
and is equipped with top
mounted HAGC cylinders,
bottom mounted wedges for
automatic pass line
adjustment, E-blocks to
accommodate WR bending
and balancing cylinders,
selective cooling headers, and
an automatic quick change
system for work rolls.
A pay-off reel and two
reversing tension reels, both
with belt wrappers, will
10
FLAT PRODUCTS
F
1 Push-pull pickling
line.
2 Single-stand cold
reversing mill.
3 Hot dip galvanizing
line.
4 Inspection, recoiling
and slitting
combination line.
5 Coil packaging
station.
6 Water treatment
plant.
Main product characteristics
Incoming Hot Rolled coils
Strip thickness 1.6 - 4.0 mm
Strip width 650 - 1400 mm
Coil weight 25 t max
Outgoing Galvanized coils
Thickness 0.25 - 1.5 mm
Width 600 - 1350 mm
Coating weight 100 - 350 g/m2 Coil weight 25 t max.
complete the installation.
Hot dip galvanizing line:
the vertical configuration will
produce high quality
galvanized thin-gauge sheet
at speeds of up to 185 m/min.
Danieli Centro Combustion
will supply the heat treatment
furnace while air knives and
pot equipment will be from
Danieli Kohler.
An in-line skinpass mill and
tension leveller will ensure
top quality surface finish and
flatness.
Slitting, recoiling and
inspection line.
It will be designed to slit,
inspect and recoil to divide
coils in smaller sizes according
to final customer
requirements. It will also be
equipped with a slit coil
packing line.
Electrical and automation.
The complex will be
controlled by level 1 and level
2 automation systems supplied
by Danieli Automation.
Plant construction will start
in April 2004 and production
is expected to start in early
2006. ■

Second Turboflo pickling line
at Tangshan, P.R. of China
The high-speed line will bring total pickling capacity to 2.4 Mtpy
Following the success of the plants
previously supplied to Tangshan I&S
Co., in December 2003 Danieli was
awarded the order for a new 1-Mtpy semicontinuous
pickling line.
This is the 3rd Danieli processing line installed
at Tangshan I&S Co. after the hot dip
galvanizing line and the continuous pickling
line, confirming Danieli as one of the leading
companies in the design and manufacture
of state-of-the-art and proven-quality
equipment.
The line will incorporate the latest Turboflo
pickling technology, consisting of three highspeed
turbulent pickling tanks followed by five
cascade-type rinse tanks, to obtain the most
effective and flexible pickling action.
The line entry consists of two payoff reels,
welder, scalebreaker and six-strand horizontal
accumulator.
The line exit includes a 1,000-t skin pass mill
to provide proper strip surface properties, fourstrand
horizontal accumulator, side trimmer
HDGL erection progress at Marcegaglia, Italy
In December 2002, Danieli
Wean United received from
Marcegaglia the order for the
design and supply of a 300,000tpy
new hot dip galvanizing line
to be installed in their Ravenna
works. The line will process
CR strip with thickness ranging
from 0.25 to 1.4 mm and max
width of 1550 mm for profiling/
pressing and standard use
applications.
Today, the erection of the line,
including a DFF vertical furnace
from Danieli Centro Combustion,
is in the final phase, perfectly
respecting the time schedule.
The startup of the line is foreseen
by mid 2004, 18 months after the
signing of the contract. ■
1
1
with scrap chopper and exit recoiling facilities.
The skin pass mill and all exit section equipment
will be removed from continuous pickling line
No. 1 when coupled to the new tandem cold mill.
Danieli Automation will supply the electrical and
automation systems.
Plant startup will take place within July 2005. ■
The new 300,000-tpy Hot Dip Galvanizing Line under construction.
2 3
DANEWS 137
Tangshan I&S relies
again on Danieli Wean
United processing line
technology
Main features of the new line
Annual production 1,000,000 t/y
Strip width 850-1,680 mm
Strip thickness 0.8-5.0 mm
Max process speed 300 m/min
1 Tangshan No. 2 semicontinous
pickling line
signing:
Mr. Liu Shao Li, Vice
President of TISCO,
Mr. Peter Kobayashi,
Director, Danieli Davy
Distington.
1 Line view from the
entry side.
2 Detail of the electrolytic
cleaning tanks.
3 The skinpass mill area.
11

DANEWS
12
FLAT PRODUCTS
T
he orders placed in
December 2003 by
Nanshan Group for an
aluminium edge trimming line
and a slitting line follow the
slitting line ordered by Yun Cheng
Aluminium in October 2003.
The edge trimming line will be
one of the fastest lines in the
world with a speed of up to 1500
m/min. Strip dimensions are 0.15
to 2.0 mm x 950 to 2100 mm.
Max coil weight is 30 tonnes, with
O.D. of 2800 mm.
Special features of the line are:
High speed cropping
(up to 200 m/min) of strip ends
by drum shear;
Edge trimming shear with
automatic adjustment of cutting
gap, immersion and cutting head
positioning according to strip
dimensions;
Trimming scrap suction
device to ensure scrap removal
even at highest speeds;
Dedicated design of the exit
F
Slitting line starts full production
at Bilstein, Germany
Since November 2003, a new Danieli
Fröhling slitting line has been producing
high quality slit strip in 3-shift operation
at Bilstein in Hagen-Hohenlimburg.
Messrs. Bilstein were established in 1911
and have become the European leading
producer of cold rolled steel strip.
The slitting line includes the complete
equipment from feeding and uncoiling area
via entry leveller, slitting head and scrap cutter,
braking and tensioning unit with strip oiler up
to the recoiler, and is followed by a packaging
system for the slit strip coils.
Steel strip in the range of 0.4 - 4.0 mm x 650
mm at coil weights of up to 13.4 tonnes will be
cut into a maximum of 20 strips. Cutting speed
ranges up to 400 m/min.
Highlights of the line are automatic gap
adjustment at the scrap cutter, leading to
improved lifetime of knives, fast automatic tool
New cutting lines for Nanshan Group, P.R. of China
It is the 3rd high-speed cutting line sold in China in the last 3 months.
guide to have the shortest
distance between the cutting and
recoiling area to avoid air being
drawn in-between the laps at the
recoiler.
The slitting line will process
different Al alloys used for can
stock as well as for air conditioner
foil stock. Strip dimensions range
3D representation of the new Bilstein slitting line.
changing at the slitter head and automatic
clamping of change mandrels with different
diameters at the recoiler.
The co-operative work between customer and
Danieli Fröhling ensuring the stable operation
of the line will help keep Bilstein in a leading
position in the market. ■
Contract signing ceremony.
Sitting from left to right:
Mr. Neumann, Executive
Sales Mgr. Danieli
Fröhling, Mr. Cheng,
General Mgr. Nanshan,
Mr. Tonello, Executive V.P.
Danieli, and Mr. Wang,
Financial Director of
Nanshan.
Slitting Lines
is 0.10 to 1.0 mm x 950 to 2100
mm; max coil weight is 30 tons.
The line will cut up to 80 strips
with a minimum width of 10 mm.
Special features are:
Automatic adjustment of knife
immersion and axial clamping
of tools at the slitting shear.
Slitting shear quick change
system, resulting in a 50% time
reduction as compared to
conventional solutions.
Vacuum technology used
for transporting rolls with lead or
lag for safe transport and braking
of numerous strips. This prevents
contact with the upper side of
the material and possible damage
to its surface.
Both the lines will be controlled
by a tailor-made automation
system. A number of "recipes"
for different applications stored
in the system provides the
operator with a high level of
control and ensure repeatability
of process functions. ■

Riding China’s growth curve <
Mr. Wang Tian Yi, President of Tangshan Iron & Steel,
one of China’s major steelmakers, interviewed by Paul Millbank.
T
he growth of China’s steel demand and
the expansion of the domestic industry
that is striving to supply it continues to
astound the global steelmaking community.
One of the steel companies riding this wave
of growth is state-owned Tangshan Iron & Steel
Group Co (Tisco), a long-established integrated
producer of long, flat and tubular steel products
in the northern province of Hubei. With an
output of 6 Mtpy it is one of the top ten largest
steelmakers in China.
As such, company president Wang Tian Yi
is fully conversant with the changes taking place
in the country’s steel market, and of the
opportunities that this presents for producers
like Tangshan to expand and diversify.
In 1996 Tisco’s steel output was only 2 Mtpy,
and its expansion is in line with steel demand
growth in China, notes Mr Wang. “The two
objectives of Tisco’s investment have been the
adjustment of the product structure to increase
the proportion of flat products, and upgrading
equipment by investment in new plant and
revamping existing facilities. This has been done
with the main aim of strengthening Tisco’s
competitive position and profits,” he says.
Although Tisco is focused on meeting
home demand, it by no means rules out exports
in the future.
But can the rapid expansion of China’s
economy, and with it steel demand, continue?
The Tisco president is confident that it can,
principally because China’s industrialisation
is still in its early stages with low per capita
consumption of steel.
As for which sectors will show most growth,
Mr Wang singles out construction and the
automotive sector. “But manufacturing industry,
such as equipment manufacturing and
shipbuilding will also strongly push up steel
demand,” he adds.
Tisco’s president thinks that imports will
continue to play a prominent role in the country’s
steel supply for the foreseeable future despite
increasing domestic capacity and improving
quality, with a particular need for higher-value
products.
The company is a prominent iron ore
importer – buying about 7 M tonnes last year and
likely to source more than 10 M tonnes this year
– and is a member of a consortium of 12
Chinese steel mills set up to negotiate iron
ore import prices. Wang Tian Yi says they need
such an organisation in order to deliver benefits
to the steelworks.
Steelworks the size of Tisco are the exception
Mr. Wang Tian Yi,
President of Tangshan
Iron & Steel.
With 6.1 Mtpy production
of long and flat products
it is one of China’s major
and most innovative
steelmakers.
DANEWS 137
DaNews Interview
rather than the rule in a country where around
half of production is from mills with a capacity
below 500,000 tpy, so what does the company’s
president think of the Western trend towards
consolidation into large steelmaking groups?
They will emerge in China he says, but it is
difficult to predict precisely when. “Large-scale
companies need some time to come into being,
and there are still other non-market factors
involved in China.”
Tisco, supported by Danieli, pioneered
the endless-welding-rolling of long products
in China, but most of Danieli’s recent
involvement has been linked to Tisco’s drive to
raise output of flat rolled steel. A 1.5 Mtpy thin
slab casting-rolling plant was commissioned in
late 2002, and a second casting strand for this
installation is scheduled to start-up in the first
half of this year.
Danieli is also supplying new continuous
pickling and continuous galvanizing lines for a
cold mill complex being added downstream of
the fTSR plant to process 150,000 tpy of hot
rolled strip or 300,000 tpy of cold rolled steel
for the construction market.
By next year almost half of Tisco’s output will
be flat rolled steel, with bar and wire rod
products accounting for most of the remainder –
a significant shift in emphasis. The main target
markets for the strip output are the automotive,
domestic appliance, light industrial and
chemicals sectors.
So, given Danieli’s significant involvement in
Tisco’s expansion, what is Mr Wang’s opinion of
the company as a supplier and partner in
metallurgical projects? “Generally speaking,
Danieli provides lots of advanced and practical
technology to the Chinese market and to Tisco,”
he comments. “This is the basis for our cooperation,
and the co-operation between us is
fairly good.” ■
13

DANEWS
14
LONG PRODUCTS
Plant hot trials started with the first bars
rolled and the first billets delivered
by the CCM on October 31st 2003.
Wire rod coils were successfully produced for
the first time at the end of November.
In the second half of January 2004, the barin-coil
production line was also started up.
At the beginning of February 2004 hot tests for
the production of stainless steel billets,
involving operation of EAF, LF, AOD and
CCM, were initiated at the meltshop.
Plant tuning and setup is gradually going ahead
for reaching the performance test stage for the
various technological areas and production
outlets that make up the plant.
Shanghai No 5 minimill, features all the latest
Danieli technologies in steel making, casting,
rolling, on-line processing and heat-treating of
speciality steel bars, wire rod and bar-in-coils.
The plant is designed for production of 14 to
50-mm-dia round bars, 18 to 40-mm-dia barin-coil,
5.0 to 20-mm-dia wire rod in coils
weighing up 2,000 kg, in stainless steels, valve
steels and other speciality steels including
superalloy, bearing, spring, cold-heading and
free cutting steel. ■
L
Production in progress at Baosteel
Shanghai No. 5, P.R. of China
The minimill for stainless steel is stepping fast towards
completion of plant commissioning.
1 60-t/55MVA AC Electric
Arc Furnace.
2 10 MVA Ladle Furnace.
3 Tank-type VD/VOD
station.
4 60-t AOD converter.
5 3-strand hi-tech billet
caster.
6 Walking Hearth type
reheating furnace for
cold and hot charging.
7 18-pass roughing,
intermediate and
pre-finishing mill.
8 Water cooling line
for Low Temperature
finishing Rolling process.
9 Finishing mill: 4-pass
Kocks/Danieli Reducing
and Sizing Block.
10 Bar cooling and
finishing services.
11 Danieli DSC wire rod
controlled cooling line.
12 Bar coiling, controlled
cooling and heat
treatment line.
13 Coil finishing services.

Europe's most modern minimill
starts operation in Greece
olling mill hot running
started at the end of
November 2003 fully
on schedule, with the first bars
delivered onto cooling bed and
later on with the full range down
to 4 x 8-mm-dia slit bars. Startup
of the wire rod line took place
on January 30th, 2004. EWR ®
R
endless-rolling operation at the
mill and conticasting of the first
billet at the meltshop will take
place within February, as per
schedule. Featuring all the latest
technologies in long products
production, the new minimill is
the most advanced superflexible
steelmaking and rolling plant
in Europe and one of the most
advanced worldwide. ■
T
he order for the two
superflexible highcapacity
bar mills was
awarded in November 2003.
The 18-stand mills will produce
12 to 60-mm-dia SBQ bars and
rebars, in alloy and carbon steels
at rates of up to 160 tph each.
The "twin" plants, featuring all
latest technology available in long
product rolling, will be located in
two adjacent parallel bays and
will be fed by the existing
meltshop. Multi-strand slit rolling
will give high output rates even
Mr. C. Angelopoulos, owner of Halyvourgiki Inc.
and Mr. G. Skindilias, CEO, congratulate
Mr. F. Tedesco, Chairman and CEO of Danieli
Hellas at the official plant inauguration ceremony.
when processing higher grade
steel bars. Danieli Automation will
supply two HiGAUGE ® bar
measuring units and an
advanced automation system for
LTR process control. Startup is
scheduled for the end of 2004,
challenging another job execution
time record. This "twin" plant
further enlarges Danieli scorecard
in P.R. of China, which lists seven
other new orders for complete
long product mills, with capacities
of 600-800,000 tpy, awarded in
the last 12 months. ■
DANEWS 137
Hot-run stage
goes ahead at
Halyvourgiki
500,000-tpy plant
in Elefsis.
1.5-Mtpy "twin" bar mill for Tianjin Tiangang Group
The two superflexible high-capacity bar mills will integrate
the most advanced technology in long products rolling.
1 1 2 3 4 5 6 8 7
7 7
2
3 4 5 6 8 7
with smaller rebar sizes, while the
LTR Low Temperature Rolling
process applied to the finishing
mill will enhance material quality
1 Walking Beam type
reheating furnaces.
2 Roughing/intermediate
mills: 14+14 SHS H
and V stands.
3 Water boxes (Low
Temperature finishing
Rolling process).
4 Finishing mills: 4+4
SHS H and V stands.
5 HiGAUGE ® contactless
bar diameter measuring
units.
6 Water quenching
systems: Quenching
and self-Tempering
of Bars.
7 Cooling beds.
8 Cold finishing services.
15

DANEWS
Record startup time at Chengde, P.R. of China
The 800,000-tpy bar mill began production
exactly 12 months after contract signing.
On December 26, 2003 Chengde and
Danieli teams succeeded in rolling
the first billet through the new ultrahigh
capacity structural and engineering steel
bars superflexible mill.
The mill was started up in the record time
of 12 months, from contract signing in
December 2002 and first billet rolling, exactly
one year later. The 18-stand bar mill will
16
LONG PRODUCTS
T
he 2003 #1 bar and
section mill output
was 613,000 t,
operating on two daily shifts.
This means about 900,000 tpy
should production of the
Danieli mill -in operation
since 1996- be based on 3
shifts. This value surpasses
the year 2002 production
record (585,000 t) and
confirms previous years’
positive growth (470,000 tpy
in year 2000 and 500,000 tpy
in 2001, respectively).
Plant production mix is based
on 47 % rebar / round bar (10
to 57 mm) and 53 % sections
(channels, flats and angles up
to 150 mm), with
an average of more than 60
product changes per month.
Company President Mr. Mark
L
All-time productivity record at Feng Hsin, Taiwan
Lin expressed his satisfaction
in a letter addressed to
Danieli management. An
excerpt from the letter:
"…I am pleased to advise you
of this new production record
and share our joy with you at
produce 800,000-tpy of 12 to 60-mm-dia
quality plain and deformed bars, and squares,
hexagons and flats up to 100 x 35mm
in carbon and alloy steels including spring
steels and cold-heading qualities, at a rate
of up to 150-tph.
The next target is to commission the complete
plant and start commercial production within
March 2004. ■
this achievement. You are a
reliable and excellent steel
equipment supplier".
Sincere congratulations to
all Feng Hsin's management
and team for the 2003
results, their "Proud Year". ■
Rolling mill >RM #1< overview. Feng Hsin mill #1 productivity.
ktpy
700
600
500
400
300
200
100
0
420
613,000 t, operating
on two daily shifts with
more than 60 bar and
section changes/month.
460
470
500
585
613
1998 1999 2000
Year
2001 2002 2003

Rolling Mills
High-speed wire rod
cropping at Böhler
Edelstahl, Austria
A Danieli HSS unit has been
successfully integrated in
the stainless steel wire rod mill.
The high-speed shear began
operation in January 2004.
Located directly in front of the
loop layer, it performs automatic
on-line cropping of 5.0 to 13.5mm-dia
stainless steel wire rod
head and tail ends at speeds
of over 50 mps. HSS is the ideal
solution for improving material
yield, coil quality and reducing
manpower in wire rod mills, thus
decreasing transformation costs.
Wire rod line upgrading also
included modification of the
controlled-cooling conveyor
with installation of a new RRT
rotating-type reforming pit.
Eccentric wire rod loops
distribution and regular coil
formation substantially benefit
finished product quality and
coil supply condition. •
ESS stands endless success:
2nd compact rougher
startup at Nizhnie
Sergi, Russia
The commissioning stage of the
compact roughing mill was
successfully completed at the
end of December 2003 and
the final acceptance certificated
was released to full customer
satisfaction. The new roughing
mill, in operation on the wire
rod line, is entirely made up
of horizontal and vertical ESS
compact cantilever stands.
A similar rougher was started
up in June 2003 on the bar
line of the same steel works.
The new continuous roughers
provide twist-free break-down
rolling operation for safer rolled
stock supply to the existing
downstream rolling facilities.
Use of bigger billets will enhance
plant productivity and efficiency,
also enabling production
of heavier wire rod coils. •
Rolling Mills
Bar mill restarts
at Ferrosider, Italy
First bars were rolled at the
beginning of February 2004.
Plant upgrading, aimed at
increasing plant productivity
and efficiency, included the
addition of two new SHS
housingless stands in H and
convertible H-V arrangement
with quick changing facilities, as
pre-finishing or finishing stands.
The mill produces up to 60 tph
of merchant rounds, squares
and flat bars. Danieli Automation
supplied electricals and
automation system. •
Rolling Mills
Rolling Mills H
Danieli Miniblock
startup at Davsteel,
South Africa
Upgrading of the Davsteel (Cape
Gate Group) wire rod mill was
successfully concluded on
January 9th 2004, with the
release of the final acceptance
certificate. Plant modification,
carried out during the Christmas
2003 plant shutdown, consisted
of the installation of a 2-pass
Danieli Miniblock downstream
of the existing 8-pass block for
boosting wire rod finishing
speed from 70 to 90 mps,
and consequently increase
production capacity.
Modifications were also made
to the controlled cooling lines
for improving fast and slow
cooling efficiency. The mill
produces 5.5 to 14-mm carbon
steel wire rod in 1-ton coils. •
Ultra-light H-beam
rolling technology breaks
through in P.R.ofChina
Hengshui Jinghua starts up
its 750,000-tpy medium section mill.
1 2
ot run stage of the Hengshui Jinghua
Steel Pipe Co. Ltd. (Shandong
Province) super-flexible medium
section mill started in mid February 2004.
The new mill is designed for the production
of up to 150-mm angles, 300-mm I-beams
and channels and 350-mm parallel-flange
H-beams, including ultra-light beams with
web thickness down to 3.2 mm and linear
weight of 5.4 kg/m.
This special product, introduced for the first
time in P.R. of China but already successfully
produced in other similar Danieli mills
in the USA, is a real breakthrough innovation
for the H-beams market in China.
The state-of-the-art mill, fed by a 120-tph
Danieli Centro Combustion WB furnace, is
made up a 1,000-mm-dia reversing BD stand,
ten 850-mm-dia SHS intermediate/finishing
housingless stands in H, V and Universal
arrangement with quick-changing facilities,
plus cooling bed, in-line straightening and
automatic finishing and stacking facilities.
Danieli Automation supplied electricals and
Level 2 automation system. ■
DANEWS 137
1 Intermediate mill
with SHS Universal
stands in a 750,000tpy
plant for medium
sections and ultralight
beams.
2 In-line single-strand
straightening unit
for sections.
17

DANEWS
New
18
LONG PRODUCTS
Orders
Bar-in-coil line
for Corus Engineering
Steels, UK
Up to 3.2-t coils will be produced
at Thrybergh speciality steel bar
mill.
The order involves the supply
of a state-of-the-art coiling line
consisting of on-line controlled
cooling facilities, two Garret
coilers of the latest Danieli
generation equipped with a
special feeding system for better
coiling of smaller bar sizes, coilhandling
system, walking-beam
coil conveyor for fast and
retarded cooling, and coil
compacting, strapping and
collecting. The electricals and
automation system will be
supplied by Danieli Automation.
The line is designed for a
production of up to 320,000 tpy
of 13.5 to 60-mm-dia round bars
and equivalent squares and
hexagons, in a wide range of
steels including free-cutting,
carbon, alloy, spring and stainless
grades. Startup is scheduled for
early 2005.
L
New bar line at SSE,
Vietnam
The order completes the wire rod
mill in operation since 2001.
As a proof of a job well done, in
December 2003 Structure Steel
Engineering Ltd confirmed its
confidence in Danieli, awarding
the order for adding a bar
production outlet to its Danieli
high-speed wire rod mill in Hai
Phong. The supply includes
additional SHS housingless
stands, new automatic cooling
bed outlet and cold finishing
services. Provision for the future
production of profiles is also
made. Further to 5.5 to 16-mm
wire rod in coils the mill will then
produce 10 to 41-mm-dia rebars
at rates of 50 tph. The electricals
and automation system will be
from Danieli Automation.
Bar line startup is scheduled
for the end of 2004.
Rolling mill upgrading
at Nucor (SC), USA
New housingless stands will
increase uptime and efficiency at
Darlington mill No. 2.
The existing 9-stand horizontal
intermediate finishing mill will be
replaced by a 10-stand twist-free
mill made up of SHS stands,
arranged in H, V and convertible
configuration. All new stands will
be served by automatic quickchanging
facilities. The order was
awarded in mid January 2004,
reconfirming Nucor and Danieli’s
long-standing successful
relationship. In 1998, in the same
mill, a CCL on-line multistrand
continuous straightening and
cutting-to-length station was
installed after the cooling bed.
In 2003, the No. 1 “small-size”
mill was upgraded by replacing
cooling bed, stacker and
finishing facilities.
The No. 2 mill produces 16 to
35-mm-dia rebars (multistrand
slitting for the smaller sizes),
41 to 90-mm-dia round bars,
75 to 200 mm flats, 45 to
127 mm angles and channels at
rates of up to 75 tph (90 tph in
hot-charge mode). Startup will be
carried out at beginning 2005.
New cold finishing
station at SMI (TX),
USA
The 800,000-tpy bar and section
mill of SMI (CMC Group) in
Seguin will be upgraded with the
installation of a 136-tph
automatic stacking and bundling
system.
The 18-m-long lance-type nonmagnetic
automatic stacker will
either pile flat and square bars
or form regular sub-bundles
of round bars.
Sund units will perform subbundle
and master-bundle tying.
Product range is 12 to 85-mmdia
round bar and equivalent
squares, 9.5 to 57-mm rebar
and up to 150 mm flats.
Startup will be in early 2005.
More QTB lines,
worldwide
On-line quenching and selftempering
enables the production
of high-strength/high-ductility
rebars starting from low carbon
steels instead of microalloyed
grades, with considerable savings
in transformation cost.
3rd QTB line at Dongkuk
Steel, Korea.
At the end of 2004, Dongkuk
Steel awarded the order for
another QTB line for upgrading
its Inchon works No. 1 bar mill.
Located at the exit side of the
last finishing stand, the line will
process 16 to 29-mm-dia rebars
at a max speed of 16 mps.
Another Danieli QTB line has
been operating at Inchon works
OVER
60
QUENCHING
AND SELF-
TEMPERING
LINES
FOR REBARS
SUPPLIED
SINCE
LATE 80’s
No. 2 bar mill since September
2001. A third QTB line is installed
at Dongkuk-Pohang works 80-tph
flexible bar and section mill
supplied by Danieli in 1998.
Startup of the new line is
scheduled for Autumn 2004.
QTB line for Deacero Celaya
endless-rolling bar mill, Mexico.
The 600,000-tpy plant, part of
the 1.1-Mtpy minimill supplied
by Danieli in 1998, features highspeed
4-strand slit rolling of
small size rebars at rates of over
100 tph. EWR ® Endless rolling
together with high-speed
multistrand operation make
Deacero Celaya one of world's
most productive bar mills.
Rebar size range is 9.5 to 38mm-dia,
processed at speeds
of up to 14 mps. ■

DANEWS
AUTOMATION
Danieli Automation ramps up
in cold mill applications
Unicoil (Saudi Arabia), Vietnam Steel Corp.
(Vietnam) and Tianjin NewNorth Rolling
Corp. Ltd. (P.R. of China) are the newest
projects where worldwide customers have
choosen Danieli Automation as the supplier
of innovative electrical and automation systems
for their high tecnology cold rolling plants,
whose production ranges from construction
industry to household appliances and the
automotive industry.
The configurations of these complexes are
different, including plants such as:
Continuous or Push-Pull type pickling line.
Tandem or Reversing Cold mill.
Batch Annealing plant.
Temper mill.
Hot Dip Galvanizing lines (including also
Annealing furnace), Colour Coating lines.
Finishing Lines to perform other operations
such as recoiling, slitting and inspection.
The above mentioned complexes feature
capacities up to 500,000 tpy with CQ, DDQ,
DQ, LFQ, FH and structural qualities, with
strip thickness down to 0.15 mm.
Automation systems
The automation system is designed to be
scaleable and compatible with different
capabilities and performances.
The basic automation, supervision and Level 2
systems are connected through a reliable100
Mbps Ethernet LAN. The Process Control system
(Level 2) is based on a client/server configuration
with relational DBMS, and ranges from
technological control up to statistical process
analysis providing:
Automatic setup values to basic automation
of process units.
Advanced autoadaptive mathematical models
and algorithms, such as Turboflo ® pickling, roll
gap, roll stack deflection, force and torque,
temperature, flatness, annealing and coating.
Coil scheduling and tracking.
A
Recent orders
witness Danieli
Automation
expertise in hi-tech
automation
systems for cold
rolling complexes.
Reporting of coils produced as well as
Quality assessment.
Process variables acquisition and analysis
through Fast Data Analyzer (FDA) unit.
Process and software engineering functions.
Interface with upstream Production control
(Level 3) system and other external systems.
The Basic Automation provides automatic
control of regulation loops and operating
sequences. The hardware is based on HiPAC,
the Danieli Automation high performance
system for Flat Products featuring:
Optimized sequencing for coil
loading/unloading and strip threading/tailout.
Technological control functions (such as
automatic thickness control, automatic flatness
control, automatic elongation control).
Enhanced automatic open and closed
control loops (such as hydraulic gap control,
hydraulic bending control, coating weight
control).
Accurate line speed coordination and
tension diagram control.
Strip tracking along the line for set point
actuation.
Operator interface based on user-friendly
HMI, with pop-up screens to activate in
a top-down method, any machine of the line.
Alarm logging and quick fault finding tool.
Danieli Automation also provides the
electrical system:
HV substations and transformers.
MV and LV distribution systems, power
factor and harmonics compensation systems.
MV inverters and AC synchronous
MV motors up to 6300 kW arranged in
common DC bus configuration with
regenerative features, allowing efficient
exchange of motoring and generating torque.
Fixed speed controls, cables and auxiliary
systems for plant infrastructures. ■
DANEWS 137
Automation Systems
Steckel mill back
in production
at Valsider, Italy
AGC system revamping
improved product quality beyond
expectations
Just six months after Danieli
Automation received the order
for revamping the AGC system,
the Steckel mill was brought back
to full operation with substantial
benefits in strip quality and
productivity. The different phases
of such a challenging revamping
project, from existing conditions
study, design, factory testing of
controls and capsules, installation
of equipment, cold and hot tests,
were smoothly run to reach
performances that are exceeding
expectations:
2.4 mm minimum thickness
reached against the contractually
agreed 2.85 mm.
4% increase of roll body
length within 1/4 DIN accuracy.
1/2 DIN thickness accuracy
on head and tail against 1 DIN
before revamping.
Customer operation will benefit
from:
An increase of orders thanks
to new thickness accuracy and
quality.
Reduced scrap on tail / head.
Reduced after-rolling
processing of the coils. •
Riva Acciaio relies
again on Danieli
Automation
New orders confirm the
reliability of HiGAUGE and
HiPROFILE contactless
measuring systems. More
details will be published
on the next issue •
19

DANEWS
20
SERVICE
Roller guides for slit-bar and
Rolling Mills
wire rod rolling at Feralpi, Italy
Morgårdshammar confirms its leadership in top quality
guiding equipment and customer service High-speed 4-strand
slitting at Halyvourgiki,
Greece
Higher coil quality at Lucchini Lecco, Italy
The latest generation rotor
exit special design applied
to the loop layer at
Lucchini Lecco wire rod mill gave
extremely positive results in
terms of wire rod rings shape
and correct positioning on the
roller conveyor, including last tail
rings deposited in a perfectly
round shape, substantially
contributing to final coil quality
improvement. Such
performances were obtained
producing 5.5 and 6-mm-dia
T
wo- and four-roller Danieli
Morgårdshammar roller guides will equip
a Danieli wire rod block and an upgraded
bar finishing mill. The order has been issued
after a detailed process analysis carried out by
Feralpi and Danieli Service technicians in order
to select solutions which fully cope with process
requirements, currently available guides and
minimised spare parts demands. The wire rod
block, scheduled to be commissioned during
April 2004, will be equipped with state-of-the-art
SRW and DRW guides. These two- and fourrollers
guides series are made in stainless steel
and manufactured according to the highest
production standards to grant a reliable, longlasting
guiding capacity.
The bar finishing mill, scheduled to be
commissioned during first half of 2005, will be
equipped in order to enable production of two
and three-strand slit bars according to the
worldwide-proven Danieli slitting technology.
The DR4BP guides selected possess the unique
feature to have four rollers, of two different sizes,
in order to be positioned as close as possible to
the rolling rolls bite.
The world-renowned CTD will be used as slitter
guide while RTC twist guides will be used
between the pre-finishing and finishing stand. ■
wire rod at speeds of up to 100
mps. Furthermore, the rotor's
latest design eliminates the
problem of poor quality formation
of last tail rings (normally
occurring in conventional laying
heads with smaller wire rod sizes
at speeds of 90-95 mps) helping
to reducing transformation cost.
Traditional manual removal of the
deformed tail loops on the
conveyor is in fact no longer
necessary, thus enabling the
saving of one operator per shift. ■
The sequence shows how good
are the results obtained
for wire rod rings shape during
all production phases.
Halyvourgiki has successfully
started up the 4-strand slitting
process for 10 and 8 mm rebar
at 13.5 m/sec at its new hi-tech
bar and wire rod mill in Elefsis
on January 07, 2004.
(See page 15).
MSL45 slitting guide has been
the key-point that allowed the
achievement of such an
impressive performance.
Heavy duty construction, fast
and simple maintenance, and
accuracy in rollers positioning
are the leading design concepts
which lead to absolutely
superior rollers lifetime and
consequent process reliability. •

Training of minimill operators
for Belgo Mineira, Brazil
With this in mind, Belgo
Mineira (member of the
Arcelor Group) jointly
designed with Danieli Training
Center a specific training
programme for the operators who
will run the Danieli 500,000-tpy
minimill currently under
installation in Piracicaba (SP).
The programme, which started in
Nov. 2003 and will be completed
in Feb. 2004, consisted of
theoretical activities held in the
Danieli Training Center and
practical training stages carried
out in similar facilities in Italy,
Austria, Poland and Germany.
The concept was to transfer
knowledge and make the trainees
familiar with the latest steel
making philosophies and
Well trained
personnel is one
of the keys for
the success
of any new steel
project.
technologies implemented in the
project. The whole programme
involved a total number of 64
trainees, divided in 12 groups
with a duration of up to 3 weeks
for each group. Altough meltshop
and rolling mill operators
attended separate courses on
operation and metallurgy,
mechanical maintenance and
automation systems, the courses
were flexible enough to allow the
trainees to attend other sessions
in order to provide them with a
wider knowledge of the whole
plant operation. The aim was to
build up a team of well-motivated
personnel that can easily
understand and co-operate with
colleagues in other departments
to achieve company targets. ■
Training of BH Steel personnel
A
team of key personnel
involved in the new
meltshop project
currently under erection in
Zenica, Bosnia and Herzegovina,
has attended a dedicated
training programme at the
Danieli Training Centre. The
experienced personnel from BH
Steel had the opportunity to get
familiar with the latest steel
making technologies through
interactive sessions of classroom
training and shop floor visits
to experience the knowledge
acquired. These teams will then
transfer the acquired operative
know-how to their colleagues
in all plant areas with the aim
of ensuring a quick startup and
on-going smooth operation.
BH Steel personnel appreciated
and expressed their thanks
for the professionalism the Danieli
team showed in creating a
profitable and friendly training
environment. ■
DANEWS
HEATING SYSTEMS
Danieli Centro
Combustion boosts
its sales
Orders for seven new furnaces
for long and flat products in the
last three months.
Five new orders in the last three months
confirm that the market continues to
appreciate Danieli Centro Combustion’s
efficient and flexible technological solutions.
MMK, Russia. Three Walking Hearth (WH)
furnaces for billets (1x100-tph and 2x130-tph
respectively) will be supplied within the
framework of the jumbo order awarded to Danieli
Morgårdshammar for three complete rolling mills
for long products. Commissioning will take place
during the second half of 2004.
Vallourec & Mannesmann, Brasil.
A new 136-tph Rotary Hearth furnace will be
supplied on a turnkey basis, including civil works.
The furnace will enable the customer to increase
RK pipe mill productivity to 300,000 tpy.
According to the extremely tight schedule,
commissioning will begin in December 2004.
Sonasid, Morocco. In January 2004, Danieli
Centro Combustion was awarded the order for
revamping a 120 tph WH furnace in Nador.
The order comes after the successful startup
in July 2002 of a 90-tph WH furnace awarded in
2000. The project aims at increasing output by up
to 145 tph, eliminating billet bending by modifying
the furnace profile, installing low NOx dual fuel
burners, adding a new movable hearth guiding
mechanism and installing a modern automation
and process control system. The time schedule is
extremely tight: demolition and erection work shall
be completed within August 2004; commissioning
will start in September.
Highveld Steel and Vanadium, South Africa.
A new 120-tph Pusher furnace for bloom
reheating will be supplied on a turnkey basis in
nine months from contract signing. Charging and
discharging equipment as well as a Level 2
optimisation system will also be supplied.
The furnace will replace the 60-tph No. 2 WH
unit and will feature a dual-fuel combustion
system for natural and low heating value gas.
Unicoil, Saudi Arabia. A DFF Direct Fired
furnace will be installed in the new 250,000-tpy
hot dip galvanizing line supplied as part of the new
Danieli Wean United Cold Mill complex (see
article on page 10). ■
21
H

DANEWS
22
COLD PROCESSING
CP
Excellent peeling performances
at the new Nucor plant in Nebraska
After few months of operation,
the Danieli Centro Maskin peeling
machine CTM/PL100 working
at Nucor Cold Finishing in Norfolk (NE),
USA, confirms its excellent performances
in terms of high final bar quality.
The unit processes 19 to 100-mm-dia carbon
and alloy steel bars in up to 18-m lengths.
Latest generation Danieli peeling machines
of advanced design enable the achievement
of high dimensional tolerances (h8 and h7)
and best surface quality, with Ra values
of 0.4 µm or even 0.15÷0.2 µm respectively
before and after final polishing.
The main design highlights making these
remarkable results possible are:
Sturdy and compact design of all machine
components, leading to stable operating
conditions with minimised vibration.
Synchronization of the entry and exit bar
feeding systems, which assure the same
working conditions on the whole bar length.
Entry and exit guides, guaranteeing perfect
final material roundness.
Unique design that completely avoids
Advanced
technology leads
to excellent
dimensional
tolerances and
surface quality
backslashes inside the cutting head.
Closed loop automation system for cutting
tool position re-setting in real time, granting
constant quality output during the whole
cutting tools’ life.
For these reasons, Danieli Centro Maskin
peeling machines are particularly suitable
for applications where bar quality is of primary
importance, i.e. the automotive industry or,
even more, where high bar quality allows
skipping one-pass in the final centerless
grinding process like for the hydraulic cylinder
rods or track pin shoes manufacuring. ■
Danieli Centro Maskin latest plant commissioning
I
In January and February
2004, Danieli Centro
Maskin achieved the Final
Acceptance Test (FAC) on several
conditioning plants for slabs and
billets, namely:
Outokumpu Stainless,
Finland.
FAC was obtained for the two
grinding machines for hot
stainless steel slabs.
Posco Kwangyang CCP1,
Korea.
The in-line inspection and
surface conditioning plant was
commissioned at the end of
January with hot slabs at up to
800 °C.
Posco Pohang CCP3, Korea.
Provisional Acceptance Certificate
was obtained for the two track
grinding machines; FAC is
expected within February.
Posco SS No. 2, Korea.
Grinding facilities expansion
project with addition of the fourth
machine started cold testing;
commissioning will be completed
by the end of February.
CMC Zawierce, Poland:
billet grinder started operating
on engineering steel billets.
Final commissioning will be
carried out in February.
All other projects for raw material
conditioning awarded in the last
months (Wisco and Jisco P.R.
of China and NAS, USA) are fully
on schedule, confirming once
again Danieli market leadership
in this field. ■
1 Slab exiting the
automatic grinding unit.
The machine is
designed to grind
all four sides of highquality
carbon steel
slabs weighing
up to 22 t.
2 Slab on the handling
system ready to be
turned for grinding the
other side.

DANEWS
ALUMINIUM
> A Royal Cut <
at Hydro Precision Tubing
Tonder, Denmark
His Royal Highness
Prince Joachim
of Denmark officially
kicked off production
of the new MPE Press.
Danieli News. Danieli Publicity Dept.: Tel. (39) 0432.598244
E-mail: info@danieli.com / Graphic Project: Polystudio / DTP: Danieli Publicity Dept.:/
Color Separation: Fotolito Udinese / Printing: Grafiche Filacorda.
Approved by the Court of Udine under authorization n.16 dated 21.04.83 /
Chief Editor: Marco Pontoni / Interview by Paul Millbank: metals industry writer, editor,
researcher and consultant, London.
I
n December 2003, His Royal
Highness cut the customary ribbon
and started the festivities organised
to inaugurate Danieli Breda’s latest jewel
in the extrusion industry.
This press is in fact the second installed
by Danieli Breda for the Customer and has
a 35 MN capacity. It is equipped with all
the latest technology:
Perfect Cut system: achieves inferior
wear of both the die and the blade and
superior extruded profile quality.
In modern presses, perfect butt shearing
is guaranteed through a sequence
of automatic operations giving a
constant shear pass line and smear free
shearing.
Die heating and cooling in the press
centre line: by controlling die temperature
during extrusion, superior profile quality is
guaranteed. This especially applies to cases
where more than one profile is extruded
simultaneously (multi-hole die).
Low speed extrusion pump (0.2
mm/sec): a PID controlled low delivery
pump inserted into the main circuit
permits slower extrusion speeds and
encourages smooth profile extrusion.
Increased stiffness in the die zone allows
MPE profile production (Multi Port
Extrusion), mainly used for the
construction of heat transfer elements in
the automotive industry.
The press is already 99% efficient and
operates on three shifts, six days a week. ■
Market success
for Danieli
Breda extrusion
presses
Danieli Breda recently installed
4 new Short Stroke Back Loading
Presses.
Extr. Force Customer
18 MN Noral, Italy
28 MN Napco, Oman
with Thermal
Alignment system
(isothermal
extrusion)
28 MN Profalu, Belgium
35 MN Alumil, Greece
DANEWS 137
Over the past few years,
Danieli Breda has also stepped
into the market for extrusion of
not only aluminium but also
copper and its alloys and graphite
and is clearly leaving its mark.
Though the North American
market suffers the implications
of the country's political choices,
the European and Asian markets
continue to flourish and since
April 2003 Danieli Breda has
clocked up contract after
contract.
Four aluminium extrusion
presses: a 13 MN press in
Greece, a 18 MN press in Italy,
24 MN press with auxiliary plants
in Australia, and a 32 MN press
in Spain.
Also a 60 MN brass extrusion
press with 8 MN piercer in Italy, a
25 MN horizontal graphite
extrusion press in India, a 25 MN
forging press in Australia and
a 400 kN railbound manipulator
in Italy. ■
23

DANIELI THE RELIABLE INNOVATIVE TEAM
IN THE METALS INDUSTRY
Danieli Engineering Since 1964 Italy Turnkey Plants and Systems
Danieli Corus Since 1977 The Netherlands Integrated Steelmaking Plants
Danieli Arex Since 1987 Italy Direct Reduction Plants
Danieli Centro Met Since 1914 Italy, Sweden Steelmaking Plants
Danieli Davy Distington Since 1951 UK, Italy Slab and Bloom Casters
Danieli Wean United Since 1901 Italy, USA Flat Product Casting, Rolling and Processing
Danieli Fröhling Since 1947 Germany Speciality Mills and Strip Finishing Lines
Danieli Morgårdshammar Since 1856 Italy, Sweden Long Product Rolling Mills
Danieli Automation Since 1969 Italy, Sweden, USA Process Control Systems
Danieli Centro Maskin Since 1953 Italy, Sweden Conditioning, Drawing, Finishing Lines
Danieli Rotelec Since 1977 France EMS and Induction Heating Systems
Danieli Breda Since 1950 Italy Extrusion and Forging Plants
Danieli Centro Combustion Since 1981 Italy Reheating Systems
Danieli Environment Since 1973 Italy Ecological Systems
Danieli Service Since 1961 Italy Technical Service and Spare Parts
Innovation in action
Danieli Headquarters
Via Nazionale, 41
33042 Buttrio (UD) Italy
Tel (39) 0432.5981
Fax (39) 0432.598289
www.danieli.com
IN FLAT AND LONG PRODUCTS