DANIELI UNIVERSAL ENDLESS - DUE THE FIRST-EVER UNIVERSAL SOLUTION FOR FLAT PRODUCTS

Transcription

1 GEORGIOS XIMERIS DANIELI GROUP 2018 SEAISI CONFERENCE & EXHIBITION JUNE 2018 JAKARTA DANIELI UNIVERSAL ENDLESS - DUE THE FIRST-EVER UNIVERSAL SOLUTION FOR FLAT PRODUCTS DANIELI / SINCE 1914 PASSION TO INNOVATE AND PERFORM IN THE METALS INDUSTRY This document contains proprietary information of Danieli & C. Officine Meccaniche S.p.A., not disclosable, not reproducible. All Rights Reserved.

2 DANIELI UNIVERSAL ENDLESS - DUE INDEX 1. MARKET REQUIREMENTS 2. DUE CONCEPT 3. DANIELI EXPERIENCE 4. SUMMARY 5. SGJT PROJECT

3 >DANIELI UNIVERSAL ENDLESS - DUE 1. MARKET REQUIREMENTS 2. DUE CONCEPT MARKET REQUIREMENTS 3. DANIELI EXPERIENCE 4. SUMMARY 5. SGJT PROJECT

4 MARKET REQUIREMENTS MARKET EXTRA PRICE VS. STEEL GRADES 250 Cold form. & deep drawing HSLA grades API grades HC grades AHSS grades Structural grades [ /t]

5 MARKET REQUIREMENTS MARKET EXTRA PRICE VS. STRIP THICKNESS Strip thickness wise market recognizes significant extra price for thin and ultra-thin gauges Massive production of soft grades generates lower revenues compared to high-strength grades [ /t]

6 >DANIELI UNIVERSAL ENDLESS - DUE 1. MARKET REQUIREMENTS 2. DUE CONCEPT DUE CONCEPT 3. DANIELI EXPERIENCE 4. SUMMARY 5. SGJT PROJECT

7 DUE CONCEPT 100% COIL-TO-COIL PRODUCTION HIGH REDUCTION STANDS FINISHING STANDS DOWN COILERS WD1 PS TF + SHUTTLE TC WD2 H2 H1 F1 F2 F3 F4 F5 CS LAMINAR COOLING DC1 DC2 EDGER IC+ WD3

8 DUE CONCEPT 100% ENDLESS PRODUCTION HIGH REDUCTION STANDS FINISHING STANDS DOWN COILERS H1 H2 H3 PILER IH F1 F2 F3 F4 F5 LAMINAR COOLING DC1 DC2 WD1 PS CS WD2 HSS

9 DUE CONCEPT TECHNOLOGICAL FEATURES 100% COIL-TO-COIL PRODUCTION Caster and mill operate independently with different mass flow Slab is cut to length by the pendulum shear at the caster, one slab for each coil 100% ENDLESS PRODUCTION Caster is directly connected to rolling mill Coil generated by the high speed shear before the downcoiler > WIDE PRODUCT MIX > OPERATIONAL FLEXIBILITY > BUFFER TIME > ULTRA-THIN HOT BAND DOWN TO 0.8 MM > EXTENDED PRODUCT RANGE FOR HIGH STRENGTH GRADES > TIGHTER PRODUCT GEOMETRICAL TOLERANCES

10 DUE CONCEPT MERGING OF WINNING CONCEPTS 100% COIL TO COIL 100% ENDLESS > To improve existing processes / technologies > To overcome their limitations > To unify in a single production line all winning features DUE

11 DUE CONCEPT MAIN TECHNICAL FEATURES Vertical curved caster Torch cutter Crop shear Laminar cooling HP descaler Edger Induction heater High speed shear Pendulum shear HP descaler Intensive cooling + HP descaler Downcoilers Tunnel furnace High reduction stands Finishing stands

12 DUE CONCEPT CURRENT MARKET REQUIREMENTS 1. HIGH 2. ULTRA-THIN 3. VALUE ADDED 4. LOWEST PRODUCTIVITY STEEL GRADES Productivity Production of up to 3.0 Mtpy of thick gauge API & HSLA grades GAUGE Ultra-thin low carbon and thin, high strength grades ENERGY CONSUMPTION Optimized OPEX and energy savings

13 Productivity DUE CONCEPT DUE FULFILLS MARKET REQUIREMENTS 1. HIGH PRODUCTIVITY 800 DUE vertical-curved caster > Slab thickness of 110 mm after dynamic soft reduction > 26 m containment length Casting speed range > Coil-to-coil 2.5 to 6.5 m/min > Endless 4.0 to 6.5 m/min > Optimized combination of slab thickness and casting speed [t/h] 6.5 m/min 6.0 m/min 5.0 m/min 4.0 m/min [mm] Slab width

14 strip thickness DUE CONCEPT DUE FULFILLS MARKET REQUIREMENTS 2. ULTRA-THIN GAUGE [mm] % 52% 58% [mm] 60% 54% 47% 29% 18% % reduction 0.8

15 strip temperature DUE CONCEPT DUE FULFILLS MARKET REQUIREMENTS 2. ULTRA-THIN GAUGE [ C] 1180 C 925 C 1175 C 890 C 690 C

16 DUE CONCEPT DUE FULFILLS MARKET REQUIREMENTS 3. VALUE ADDED STEEL GRADES Intensive cooling below T NRX Homogenization of slab temperature before roughing Roughing above T NRX Induction heater deactivated Finishing below TNRX Early accelerated cooling Coarse irregular grain as cast Grain refinement Pancaking Phase transformation Fine microstructure

17 DUE CONCEPT DUE FULFILLS MARKET REQUIREMENTS 3. VALUE ADDED STEEL GRADES

18 Energy consumption [%] DUE CONCEPT DUE FULFILLS MARKET REQUIREMENTS 4. LOWEST ENERGY CONSUMPTION Energy reduction DUE to selective rolling modes Endless mode Grade LC Slab thickness 110 mm Casting Speed 5.5 m/min TF discharge temp 1180 C (endless) 1150 C (coil-to-coil) Coil to coil mode 20 [% ] 0,6 0,8 1,0 1,2 1,4 1,8 2,0 2,2 2,4 2,8 3,0 3,2 3,4 3,8 4,0 [mm] Strip thickness

19 DANIELI UNIVERSAL ENDLESS - DUE > 1. MARKET REQUIREMENTS 2. DUE CONCEPT DANIELI EXPERIENCE 3. DANIELI EXPERIENCE 4. SUMMARY 5. SGJT PROJECT

20 DANIELI EXPERIENCE THIN SLAB CASTER > Original vertical curved thin slab caster design > Based on more than 25 years experience > Remarkable increase of total reduction from slab to strip thickness > Ultra-high speed casting up to 7.0 m/min for LC steel > Dynamic soft reduction for best inner quality > High slab temperature at tunnel furnace entry

21 DANIELI EXPERIENCE TUNNEL FURNACE > Buffer time for utmost production flexibility > Work roll change within the casting sequence > In-house design and manufacturing by Danieli Centro Combustion

22 DANIELI EXPERIENCE HOT STRIP MILL > State-of-the-art features for optimum strip shape control > Under-load shifting system > Separation of high-reduction and finishing stands

23 DANIELI EXPERIENCE TRANSFER BAR AREA Why separation of high reduction and finishing stands? CROP SHEAR INTENSIVE COOLER + DESCALER INDUCTIVE HEATERS

24 DANIELI EXPERIENCE DRUM TYPE CROP SHEAR > Head and tail end cuts of transfer bar > Safe threading into finishing mill > Higher rolling stability, especially at thinner gauges > Reduced tail end chewing

25 DANIELI EXPERIENCE INDUCTION HEATING SYSTEM > Consistent production of thin and ultra-thin gauges in endless rolling mode > In-house design and manufacturing by Danieli Automation

26 DANIELI EXPERIENCE INTENSIVE COOLING + DESCALER > Intensive cooling system embedded into the descaler box at finishing mill entry > True thermomechanical rolling of HSLA and API grades > 380 bar high pressure for excellent surface quality

27 >DANIELI UNIVERSAL ENDLESS - DUE 1. MARKET REQUIREMENTS 2. DUE CONCEPT SUMMARY 3. DANIELI EXPERIENCE 4. SUMMARY 5. SGJT PROJECT

28 SUMMARY DUE ADVANTAGES DUE combines all advantages of endless and coil-to-coil production 1. HIGH 2. ULTRA-THIN 3. VALUE ADDED 4. LOWEST PRODUCTIVITY GAUGE STEEL GRADES ENERGY CONSUMPTION

29 SUMMARY DUE - PATENTED SOLUTION Italy Europe USA Mexico Brazil Russia Ukraine India China Thailand Japan Korea UAE

30 >DANIELI UNIVERSAL ENDLESS - DUE 1. MARKET REQUIREMENTS 2. DUE CONCEPT SGJT PROJECT 3. DANIELI EXPERIENCE 4. SUMMARY 5. SGJT PROJECT

31 SGJT PROJECT

32 SGJT PROJECT PRODUCTION CAPACITY Production capacity of this plant is required to be 2,100,000 ton/year of HR coils > up to 1,500,000 ton/year in endless mode > 600,000 ton/year in coil-to-coil mode SLAB SIZE Thickness Slab width Lenght (max) 110 mm (up to 123 mm) mm 24.5 m Weight (max) 33.6 t

33 SGJT PROJECT PRODUCTION CAPACITY Production capacity of this plant is required to be 2,100,000 ton/year of HR coils > up to 1,500,000 ton/year in endless mode > 600,000 ton/year in coil-to-coil mode COIL SIZE Thickness Coil width Specific weight Weight (max) mm mm 21 kg/mm 24 kg/mm (endless only) 33.6 t Coil ID / max OD 762/2050 mm 762/2150 mm (endless only)

34 SGJT PROJECT PRODUCT MIX DISTRIBUTION Group Grade 1 Low carbon 2 Peritetic 3 Medium carbon 4 High carbon 5 LC MA 6 PE MA 7 MC MA 8 Weather resistance 9 TR IP/DP 10 Alloy steels High Cu, Cr, Ni or Mo % 1% 1% 5.5% 2% 4% 2% 4% 20.5% 29% 31%

35 SGJT PROJECT PRODUCT MIX DISTRIBUTION Width 900-1, ,050-1,250 1,150 1,250-1,400 1,325 1,400-1,600 1,500 Average width 1,283 mm % 8% 25% 33% 34%

36 SGJT PROJECT LAYOUT Thin Slab Caster Vertical-curved type with Pendulum Shear and high pressure descaler No.3 High Reduction Stands with attached Vertical Edger and high pressure descaler No.5 Finishing Mill Stands High Speed Shear and No.2 high speed downcoilers Ladle Turret Tunnel Furnace with Emergency shuttle Transfer Area with Crop Shear, No.9 Induction Heaters, intensive cooling and high pressure descaler Laminar cooling with power and normal units

37 GEORGIOS XIMERIS DANIELI GROUP 2018 SEAISI CONFERENCE & EXHIBITION JUNE 2018 JAKARTA DANIELI UNIVERSAL ENDLESS - DUE THE FIRST-EVER UNIVERSAL SOLUTION FOR FLAT PRODUCTS DANIELI / SINCE 1914 PASSION TO INNOVATE AND PERFORM IN THE METALS INDUSTRY This document contains proprietary information of Danieli & C. Officine Meccaniche S.p.A., not disclosable, not reproducible. All Rights Reserved.