Bar and Wire Rod Mills. Solutions made by SMS group

Transcription

1 Bar and Wire Rod Mills Solutions made by SMS group

2 Bar and Wire Rod Mills by SMS group State-of-the-art and one step ahead, we are your partner Your expectations Planning and building a new production plant or revamping existing facilities requires a broad range of knowledge, experience and reliable expertise. SMS group offers you complete tailor-made bar and wire rod mill solutions that include everything you want: best technological solutions, comprehensive support, integration in existing mills, logistics, and sub-systems - all with cutting-edge technology. Our solutions We offer you tailor-made bar and wire rod mills, covering your expectations. Included in our full spectrum of services are highly skilled project management, configuration of project scope, basic and detail engineering, procurement and manufacturing, transportation to site, comissioning and site management, construction, and/or installation services. All services in one hand minimize interface drawbacks. We are with you all the way. We rise to the challenge by combining our leading metallurgical technology more rapidly, flexibly, and efficiently with our know-how in the construction of bar and wire rod mills. All under one roof is our mission statement to create the synergies that produce innovative solutions for you. That is expertise from one source for even better performance. A sound basis for success given that demands worldwide are changing and growing fast along with your expectations. 2

3 Wire rod mills 6 High speed wire rod mills 8 Wire rod mill for quality steel 10 Wire rod mill for high precision 12 Bar mills for quality and special steel 14 SBQ bar mill for straight bars and coils 16 Combined bar and wire rod mill for total range of steel grades 18 Rebar and merchant bar mills 20 Single-strand high speed bar mill 22 Slit rolling bar mill 24 Combined bar mill with vertical compact coiler VCC 26 Merchant bar mill 28 Section mill for medium-light profiles 30 3

4 Your benefits You can rely on our overall responsibility for planning and execution because we offer you a high degree of know-how, flexibility, and an excellent track record. As a turnkey contractor or leading partner in consortia, SMS group draws on long experience in implementing small and large bar and wire rod projects for the industries. Our in-house technologies and the engineering expertise are state-of-the-art. Wherever your project is based, you benefit from our worldwide network. It includes strategic partnerships covering the whole range of mill solutions for bar and wire rod mills, as well as electric and automation and package unit. The benefits for you are that SMS group works with engineering companies, representatives, and local partners all over the globe. They strengthen our position in handling all aspects of your project 4

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6 Wire rod mills Economic success with sophisticated solutions PQA - Product Know-how transfer Control and Integrated solutions Starting material Billets/blooms of various material grades Heating Heating and reheating furnaces Pusher-type furnaces Walking beam furnaces Walking hearth furnaces Rolling HL stands CL stands High-speed wire rod blocks MEERdrive technology Life cycle 6

7 Wire rod is a great all-rounder: from high-quality components for the automotive sector, chemical industry and mechanical engineering through to fasteners it is all based on wire rod. Accordingly, the solutions SMS group offers for wire rod mills are just as versatile: all sizes, materials and alloys can be efficiently produced on the wire rod mills. Complete wire rod mills, where all components are perfectly matched this is the success formula for enhanced competitiveness. This guarantees that technology, automation and the individual processes work in perfect harmony. The result is top quality, high productivity, lower capital and operational costs. SMS group designs wire rod mills in close cooperation with the plant owners based on the relevant requirements. Regardless of which demanding grades are rolled the wire rod experts offer the precise technology package to maximize the benefit to the customer. And always with an eye on the overall process. Temperature-controlled rolling and heat treatment in the rolling line enable precise adjustment of the desired properties. The process control systems and process models from SMS group help plant owners optimize their processes, quality and productivity. Together with transport systems, the advanced user-friendly control system ensures a high capacity utilization of the plants and makes it easy for the operators to find the ideal settings. The SMS group service technicians support the plant owners in exploiting the full potential of the systems. quality analyzer by MET/Con and production assistance automation - intelligently networked Cooling and inline heat treatment Waterboxes shiftable Loop technology: flexible cooling and equalizing zone Thermomechanical rolling technology Finishing High-speed laying heads Loop cooling conveyor LCC Three fan technology for LCC Coil handling systems Coil compactors Tying systems Products Wire rod with diameters between 4.5 and 27 mm in various material grades partnership 7

8 High speed wire rod mills High speed mills for high production 1- or 2-strand high speed wire rod mills from SMS group roll small sizes with high production capacities up to over 1,000,000 tons per year. Speeds up to 120 m/s are possible and enable high productions also for small finishing diameters. Even at full speed, the mills achieve a very good laying pattern. The layout mainly consists of: Reheating furnace Roughing mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement, with the possibility of quick-changing device Intermediate mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement, with the possibility of quick-changing device Pre-finishing stands of cantilever design Finishing block with group drive or MEERdrive design Laying head Loop cooling conveyor (LCC ) Coil handling system with coil compactor Furnace 2 Roughing mill 3 Isolated free run out 4 Intermediate mill 5 4 CL-stands in H/V arrangement 6 2 water boxes with equalizing line 7 10 stand high speed wire rod block

9 Loop laying head Maintenance-friendly and flexible The modern loop laying heads from SMS group reliably lay uniform wire rod loops even at high speeds and irrespective of the wire rod diameter. The difference compared with conventional systems: SMS group loop laying heads easily handle widely differing steel grades even those that are rolled at low temperatures in order to improve the metallurgical properties. Depending on the application laying angles of 10, 20 or 30 are possible. The maintenance is quick, wear parts such as the laying pipes can be replaced in a minimum of time. That improves the profitability of the plant as a whole. The next step moveable laying heads Changing between laying heads (increasing of operating time) Changing between several laying pipe geometries (form, diameter, material => e.g. between small to medium/large dimensions) Possibility of offline-implementation of varying laying angles Stabilization of laying pattern Reducing of downtime Water boxes with equalizing line 9 Pinch roll unit, laying head 10 Loop cooling conveyor (LCC ) 11 Coil handling system 12 Horizontal coil compactor 9

10 Wire rod mill for quality steel Thermomechanical rolling of the complete size range The thermomechanical rolling of wire rod with small dimensions at high production rates is not possible with a conventional 10-stand finishing block. Due to the number of passes required, heating is too high to achieve the required metallurgical properties. Splitting the wire rod block into a 6-stand and a 4-stand unit allows wire rod of any dimensions to be finish-rolled in a maximum of four passes. With sufficient cooling and good temperature equalization over the cross-section, thermomechanical rolling at high production rates is also possible. The layout mainly consists of: Reheating furnace Roughing mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement Intermediate mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement, with the possibility of quick-changing device Pre-finishing stands of cantilever design Cooling and equalizing line 6-stand finishing block with group drive or MEERdrive design Cooling and equalizing line 4-stand finishing block with group drive or MEERdrive design Laying head Loop cooling conveyor (LCC ) Coil handling system with coil compactor Furnace 2 Roughing mill 3 Intermediate mill 4 4 CL-stands in H/V 5 Cooling and equalizing loop 6 6-stand wire rod block 7 Water boxes with equalizing line 10

11 Loop technology The best way to optimum quality With the loop technology from SMS group, wire rod producers can set the desired metallurgical properties of their products flexibly, precisely and reliably for any steel grade and any diameter. No matter whether the material used has to be rolled at a high or low temperature, the variable equalizing sections and cooling systems ensure that the steel is always at the optimum rolling temperature. Multiline Loop then enables the wire rod block to be changed over ready for the next size while production is still running. Nevertheless, wire rod producers can choose freely between hot and cold rolling. Thermomechanical rolling For finish-rolling at low temperatures in wire rod mills, the material entering the wire rod block is intensively cooled. This is then followed by a sufficiently long equalizing section to allow the desired metallurgical properties to be achieved uniformly over the crosssection of the finished product. That ensures a uniform temperature profile and hence a homogeneous microstructure. For steel grades that have to be rolled as hot as possible, the wire rod goes into the wire rod block directly without the detour via the equalizing section. The loop technology thus enables mill owners to react quickly and flexibly to widely differing order requirements. In wire rod mills in which all sizes are finish-rolled with MEERdrive PLUS, the Multiline Loop is an optimum variant. The mill operators guide the wire rod via switches through various parts of the equalizing section and cooling systems to achieve the best results, irrespective of diameter and steel grade. When rolling final sizes with larger sizes, the wire rod block upline of the MEERdrive PLUS is not used. The Normal rolling stand wire rod block 9 Pinch roll unit, laying head 10 Loop cooling conveyor (LCC ) 11 Coil handling system 12 Horizontal coil compactor 11

12 Wire rod mill for high precision For closest tolerances and small lot sizes The MEERdrive PLUS technology from SMS group is a high-precision and flexible solution for the finish-rolling of wire rod. The 4-stand block is installed downline of the wire rod block and finish-rolls all sizes between 4.5 mm and 26 mm diameter. With the special pass design of the last two stands high precision rolling is realized. With a gearbox in each block stand, MEERdrive PLUS covers a wide range of speeds. It permits single-family rolling in the upline stands: Only one groove size is used in each stand over the whole size range. The required initial pass cross-sections for the MEERdrive PLUS block are created by inserting or omitting two passes in each of the upline stands. This arrangement with a cooling section in between allows high-precision and thermomechanical rolling of all sizes and significantly reduces the amount of roll changing. Complemented with a quick change system, also small lot sizes can be rolled efficiently. The layout mainly consists of: Reheating furnace Roughing mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement Intermediate mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement, Pre-finishing stands of cantilever design Cooling and equalizing line 8-stand MEERdrive wire rod block Cooling and equalizing line 4-stand MEERdrive PLUS finishing block Laying head Loop cooling conveyor (LCC ) Coil handling system with coil compactor Furnace 2 Roughing mill 3 Intermediate mill 4 4 CL-stands in H/V 5 Cooling and equalizing loop 6 6-stand finishing block 7 Shiftable water boxes with equalizing line 12

13 MEERdrive technology More flexibility at lower cost The MEERdrive technology is a revolution in the field of wire rod blocks: It enables infinitely variable setting of the diameter, close tolerances, very good metallurgical product properties and last but not least significant cuts in operating costs. At the same time, MEERdrive reduces the energy consumption and thus improves the environmental balance. With MEERdrive technology the motors are controlled relative to one another so that the stands behave like a conventional wire rod block and can also be set far more precisely. Together with the total flexibility in roll pass strategy a sizing system for wire rod can be realized. By a 4-stand MEERdrive PLUS block, with an oval-roundround-round pass design and a minimized stand distance at the last two stands closest tolerances for wire rod between Ø 5.5 mm and Ø 27 mm can be realized. Only one switch gear unit is required per stand for the speed range to realize a One Family Rolling in the previous rolling mill. This generates additional cost savings by reduced changing time in the rolling mill. Advantages of MEERdrive A comparison of a conventional solution with MEERdrive Conventional solution Heavy distribution gear Longitudinal drive shafts Many bearings and couplings Bevel gears Large motor with up to 7,000 kw Medium voltage supply Fixed roll pass design Fixed reduction ratios of stands within the block Narrow limits for roll adjustments to compensate wear/varying speed Mechanical facts Operational facts MEERdrive technology No distribution gear Individual short drive shafts Fewer bearings and couplings Only spur gears Small individual motors with 290 1,450 kw Low voltage supply Total flexibility in roll pass strategy Infinite reduction ratios due to electrical shaft Less maintenance Free adjustment range stand MEERdrive PLUS wire rod block 9 Pinch roll unit, laying head 10 Loop cooling conveyor (LCC ) with 3-fan technology 11 Coil handling system 12 Horizontal coil compactor 13

14 Bar mills for quality and special steel Special quality solutions PQA - Product Know-how transfer Control and Integrated solutions Starting material Billets/blooms of various material grades Heating Heating and reheating furnaces Pusher-type furnaces Walking beam furnaces Walking hearth furnaces Rolling HL stands (H; V) 3-roll PSM sizing blocks Life cycle 14

15 Typical applications for SBQ bars (Special Bar Quality) can be found in the automotive and mechanical engineering industries. The closest tolerances and maximum consistency are what is needed here and competition is intense, especially among sub-suppliers. With bar mills from SMS group, rolling mill operators can meet all their customer s needs, both flexibly and efficiently giving them a real competitive advantage. For SBQ production SMS group has specifically developed machinery and systems that enable plant owners to offer customers products they can rely on even with small batch sizes special product requirements can be met cost-effectively. In terms of quality steel, in particular, every rolling mill operator has different demands to meet in order to deliver perfect products to customers. That is why SMS group develops customized solutions for each SBQ producer. The dedicated process control systems and process models supplied by SMS group are setting standards in the market in terms of both quality and costs. The systems are based on a holistic approach: They monitor the entire production process and automatically intervene if potential for optimization is identified. By adapting the programs individually and using learning data bases, SBQ technology systems can deliver the right product, no matter how specific the customer s requirements may be. quality analyzer by MET/Con and production assistance automation - intelligently networked Cooling and inline heat treatment Cooling and equalizing lines with waterboxes shiftable Cooling bed with systems - for retarded cooling - for integrated fast transport Coil handling/finishing Pouring reel lines Saw and shear units Bundling equipment Products Round SBQ grades with diameters of 13 mm to 160 mm Hexagonal SBQ grades with diameters of 13 mm to 103 mm partnership 15

16 SBQ bar mill for straight bars and coils All market requirements are met with flexibility and precision The 3-roll PSM (Precision Sizing Mill) technology from SMS group is a high-precision and flexible solution for the finish-rolling of bars and a core element of a high quality SBQ mill. One of its outstanding principal features is its capability to adjust each roll under load fully automated and in real time. With the PSM one family rolling in the roughing and intermediate mill as well as the infinitely variable production of all finishing sizes by using the free size range is possible. The high roll force capacity allows thermomechanical rolling. The subsequent equipment like a cooling bed as well as a pouring reel line are consequently designed for scratch prevention. The metallurgical aspects like fast or retarded cooling are considered in the equipment. Walking beam coil transport with blowers or hoods for the reeled coils, or fast transport included in the cooling bed allows an inline treatment of the high precise rolled bars. The layout mainly consists of: Reheating furnace Roughing mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement Intermediate mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement Cooling and equalizing line Precision sizing mill (PSM ) MEERgauge true shape measuring system with inbuild surface defect detection SurfTec Cooling bed with fast transport Finishing equipment Pouring reel line Coil handling system with cooling equipment Furnace 2 Roughing mill 3 Intermediate mill I 4 Intermediate mill II 5 Cooling line 6 PSM

17 PSM Precision Sizing Mill Best sizing technology - major improvements through process transparency One of the outstanding principles of a PSM is its capability to adjust each roll under load fully automated and in real time. The adjustment under load function is made possible thanks to the advanced design of the 3-roll cassette in combination with three hydraulic cylinders. It provides the operator with the opportunity to optimize the bar shape during the rolling process. The hydraulic cylinders can adjust all three rolls concentrically. Where required the system is also able to individually adjust one or all three rolls independently. As a result, symmetrical as well as unsymmetrical positioning adjustments of individual rolls under load provide opportunities for final tuned optimization of the net shape tolerances. This is made possible thanks to the advanced closed loop Technological Control System (TCS), which also provides plant operators with full process transparency, including pass and roll position and on-line correction, as well as rolling force measurement and active, fully automated overload protection. Together with sophisticated control and automation systems, this opens up unique possibilities for optimizing products and processes. Furthermore, the system is able to automatically compensate individual mill spring, feeder variations and bar entry impacts. It is also able to level out temperature variations along the bar. A combination of the MEERgauge true-shape measuring system and the hydraulic adjustment under load feature is another revolutionary milestone in advanced 3-roll technology, offering the measurement accuracy to optimize and fine tune the product online during rolling. The combination of the highly dynamic control system and the true-shape measurement unit means a fully automatic rolling operation of the 3-roll block can be successfully realized independently of the operator Cooling bed with fast transport 8 Cooling bed with slow transport 9 Finishing area 10 Pouring reel 11 Walking beam with blowers or hoods 12 Coil handling 17

18 Combined bar and wire rod mill for the total range of steel grades Total flexibility tight tolerances The demand for wire rod and bar steel is changing continuously: Today structural steel for new buildings, tomorrow wire rod for the automotive industry. Manufacturers who can react quickly to market changes, who are flexible in the product formats and can produce varying lot sizes cost-effectively have a clear advantage. That is why SMS group offers combined mills in which both wire rod and bar steel can be produced cost-effectively and in high quality. The individual components from the SMS group portfolio for SBQ plants form a broad basis for combined mills. SMS group links the components into plants with a very high level of flexibility in the finished product dimensions and metallurgical properties, so generating added value for its business partners. No matter whether wire rod or bar steel - SMS group gives comprehensive advice and designs the plants individually to the customer s needs. The layout mainly consists of: Reheating furnace Roughing mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement Intermediate mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement Cooling and equalizing line Precision sizing mill (PSM ) MEERgauge true shape measuring system HSD System Cooling bed Finishing equipment Pouring reel line Coil handling system with cooling equipment Wire rod line with MEERdrive block and MEERdrive PLUS block Pinch roll laying head LCC with three fan technology 2nd wire rod line for small sizes on cooling bed Coil handling system with compactors Furnace 2 Roughing mill 3 Intermediate mill 4 PSM 5 10-stand MEERdrive block 6 4-stand MEERdrive PLUS block 18

19 High speed shear Quick and cost saving The high-speed shear provides in-line trimming of hot and out of tolerance head and tail ends. The high-speed shear is based on a simplistic design with minimal disturbance of the rod path. For different applications in the mill SMS group offers two types of the high- speed shear: one for speeds up to 85 m/s and one for speeds up to 120 m/s. With an installation immediately in front of the laying head ensures substantial savings in operational costs are. High speed shear: Technical data HSS 85 HSS 120* Ingoing diameter mm mm Shearing resistance 180 N/mm 2 Shear force kn kn Design speed m/s m/s Rotor speed 300-2,800 min ,820 min -1 Motor power approx. 315 kw chopping shear (similar to laying head) Chopping length approx. 475 mm Blade radius 300 mm *HSS 120 can be realized as 1 or 2 shear system Loop laying head 8 LCC 9 Pooring reel line 10 Coil handling facilities 11 Quenching and tempering facilities 12 HSD system 13 Cooling bed 14 Finishing area 19

20 Rebar and merchant bar mills Solutions for a wide range of products PQA - Product Know-how transfer and Control and Integrated solutions Starting material Billets Heating Heating and reheating furnaces Pusher-type furnaces Walking beam furnaces Walking hearth furnaces Rolling HL stands (H; V, convertible) CL stands Finishing blocks 2, 3 and 4-strand slitting Life cycle 20

21 SMS group offers all types of merchant bar mills: For bars and small sections, rebar mills with high-speed delivery system (HSD ) or slit rolling technology as well as machines for coiling rebar (VCC ) and billet welding machines for endless rolling. High flexibility and reliability are the trademarks of SMS group merchant bar mills. State-of-the-art mills of this type are capable of producing various products such as angles, squares, flats and small channel steel sections in one plant. Rounds can be produced too. The smooth interaction between these machines is what ensures very high productivity and availability levels. A high degree of efficiency is also guaranteed thanks to the technology systems, actuators and quick-changing equipment: Size changes and adjustments to the product lengths can be performed very fast, while downtimes are reduced to a minimum. SMS group rolling mills boast typical capacities of around 300,000 to 800,000 tones every year. Rebar mills can also be designed as high-performance plants with a capacity of 1,400,000 tones per year - depending on the capacity requirements customers request from rolling mill operators. The production process itself is fast-moving too: for example, rebar rolling speed can reach up to 50 meters per second. quality analyzer by MET/Con production assistance automation - intelligently networked Cooling and inline heat treatment Quenching and self-tempering facilities Cooling beds HSD high-speed delivery system Finishing VCC vertical compact coiler Straighteners Piling machines Bundling and tying machines Products Rebars Round, flat, squares Angles, channels partnership 21

22 Single-strand high-speed bar mill Limited investment meets high productivity These mills ideally combine limited investment with high productivity. A solution which guarantees the fastest return of investment. Generally these mills are sized for a medium range production up to 500,000 tpy. The typical product sizes range from 8 to 32 mm diameter round and rebars, which are the predominant sizes in commercial bar rolling. The layout mainly consists of: Reheating furnace Roughing mill, with stands of cantilever or housingless design, in alternating horizontal-vertical (H-V) arrangement, with the possibility of quick-changing device Intermediate mill, with stands of housingless design, in alternating horizontal-vertical (H-V) arrangement, with the possibility of quick-changing device Finishing block Quenching and self-tempering facilities Single-strand HSD High-Speed Delivery System Cooling bed Finishing facilities with cold shear, bundling system with bar counter and wire tying machines Furnace 2 Roughing mill 3 Intermediate mill 4 Finishing block 22

23 HSD High speed delivery system for straight bars The main advantages of this process can be summarized as follows: Yield increase due to close tolerance on each strand: When slitting, the worst bar determines the size of all bars (in case of differential wear on the rolling passes it is very common to have one bar in the correct size and the others slightly oversized) Yield increase due to better bar counting: Since the HSD system delivers one bar per notch, bars can be kept separate throughout the finishing end greatly facilitating bar count and, with the SMS group bar counting system, limiting bar over-count to a maximum of one bar per bundle Cobble reduction: The slitting area is the most prone to cobbles. With the HSD system, the two bar slitting is performed on larger diameters and thus the bar is easier to control For small diameters (8-10 mm), a two-strand HSD system achieves a productivity increase of 70% compared to the three-strand slitting and a cost advantage of up to 13 euros/t. HSD : Technical data Size range for rebars/rounds 5.5 mm 43 mm Temperature range 500 C 900 C Speed range 2 m/s 50 m/s Cooling bed length 54 m 102 m Single HSD capacity up to 120 t/h approx. Double HSD capacity up to 240 t/h approx. Steel grades/standards DIN 488, NBR 7480, BS 4449, ASTM-A615-A706, GB 13014, GOST 10884, KSD 3504, IS 1786 TMbaR Thermo-mechanical rolling of reinforcing steel In order to meet the increasing quality requirements for reinforcing steel with regard to higher strengths and a finer microstructure, SMS group combines the knowledge of rebar and thermomechanical rolling to TMbaR. The advantage of this process is the drastic reduction of alloying elements such as manganese, combined with higher-grade mechanical material properties Quenching and self-tempering facilities 6 HSD system 7 Cooling bed 8 Finishing facilities 23

24 Slit rolling bar mill Economical solutions for high rolling production This bar mill operates at relatively low speed in multiple lines, normally consisting of 2 to 4 strands, with a common starting material stock. Even though the slit rolling process is employed only for production of rebars, this process is a very economical solution to achieve high rolling production, even for small sizes. The annual production may vary, depending on the number of strands, but tonnages in the range of 1,000,000 tpy can be achieved with product sizes from 10 to 50 mm. The layout mainly consists of: Reheating furnace Roughing mill with horizontal-vertical (H-V) stands either of housingless or cantilever design Intermediate mill with horizontal-vertical stands (H-V), housingless design Finishing mill with horizontal, vertical and convertible stands, housingless design and quick-changing device Quenching and self-tempering facilities Drop wall roller way with lifting aprons Cooling bed Finishing facilities with cold shear, bundling system and wire tying machines Furnace 2 Roughing mill 3 Intermediate mill 4 Finishing mill 24

25 The slitting process Many steel producers operate mills based on multi-slit technology. The majority of those mills have a size range of 10 or 12 to 40 mm. In some applications, 8 mm is also rolled. Depending on furnace capacity and product size, 4-slit, 3-slit and 2-slit operation is used. Even if the design speed of the mills may be higher, these mills run at rolling speeds ranging in most cases from 13 to 18 meters per second. The reason for such low speeds is the fact that operation is sensitive at small sizes and mill setting requires fine accuracy. In this regard, the experience of the rolling crew plays a key role. The design of the guiding equipment inside the mill (even for looper arrangement) and the cooling bed run-in system have to take account of the special requirements of the multiple running strands. Benefits of slitting technology The possibility of producing also flats, squares and hexes to complement rounds and rebar production A minor saving in total investment costs since the cost of two high speed blocks, with associated additional electrics, piping and foundations, is avoided. This is partially offset by the need of two additional convertible housingless stands. The high speed blocks require a higher degree of mechanical knowledge from operators and maintenance personnel Quenching and self-tempering facilities 6 Drop wall roller 7 Cooling bed 8 Finishing facilities 25

26 Combined bar mill with vertical compact coiler VCC Highly productive and cost-efficient A highly flexible and productive solution is the bar mill combining 2-slit rolling via high-speed finishing blocks and a double strand HSD High-Speed Delivery System. The presence of the finishing blocks allows a further extension either for the production of wire rod (normally for 5.5 to 16 mm in coils) or for the production of bar in coils with the VCC Vertical Compact Coiler line (normally for 8 to 16 mm in compact coils), which is the most innovative way of producing rebar today. The layout mainly consists of: Reheating furnace Roughing mill with horizontal-vertical (H-V) stands, cantilever or housingless design Intermediate mill with horizontal-vertical (H-V) housingless stands with quick-changing device 2 finishing blocks Quenching and self-tempering facilities Double strand HSD system Cooling bed Finishing facilities with cold shear, bundling system with bar counter and wire tying machines VCC line (or wire rod line with laying head, controlled cooling conveyor, coil forming and handling line with compactor and wire tying) Furnace 2 Roughing mill 3 Intermediate mill 4 Finishing block 26

27 VCC - Compact and torsion-free coils SMS group s VCC is today s state-of-the-art solution for producing compact and torsion-free coils, and is now increasingly in demand by rebar post-processors. The VCC concept combines the best elements of modern mechanical engineering for rolling mill applications: industrial design standards, including heavy duty service factors, focus on maintenance minimization, easy erection and start-up, effective safety features and a design that perfectly suits the overall production process. One of the most important features of VCC is its method of coiling the bar directly in the vertical position. Plant operators can therefore eliminate the need for turning manipulators and at the same time reduce the process cycle time, as all coils are formed in the final position. The coils are ready to be stored immediately once coiling has been completed and the coils have cooled down. Reduced handling also minimizes the overall risk of damaging the coil. VCC : General characteristics Product range Coil weight Plain rounds diameter 8 mm 50 mm, rebars diameter 6.3 mm 40 mm, as well flats, squares and hexagons up to 8 t Temperature range 450 C 900 C Speed up to 40 m/s Winding temperature 550 C 850 C Coil dimensions internal diameter mm height mm, external diameter 1,500 mm max. Steel grades/standards DIN 488, NBR 7480, BS 4449, ASTM-A615-A706, GB 13014, GOST 10884, KSD 3504, IS Cooling line 6 Vertical coil compactor (VCC ) 7 Unloading device and strapping machine 8 Cooling and transferring device 27

28 Merchant Bar Mill A wide range: from rounds to angles A modern merchant bar mill has the capacity to produce a variety of products such as angles, squares, flats and small channels. Round bars can naturally be produced, too. Such a mill is characterized by great flexibility and has an annual capacity of 500,000 to 600,000 tpy producing a broad product mix including plain rounds and rebars from 16 to 40 mm, flats up to 100 mm, tees up to 80 mm, angles and channels up to 150 mm and I-beams up to 120 mm. The layout mainly consists of: Reheating furnace Roughing mill with horizontal-vertical (H-V) stands, cantilever or housingless design Intermediate mill with horizontal-vertical (H-V) housingless stands Finishing mill with horizontal and convertible (H-V) housingless stands with quick-changing device Drop wall roller way with lifting aprons Cooling bed Multi-line straightener Finishing facilities with cold shear, stacker and strapping or tying machines Furnace 2 Roughing mill 3 Intermediate/finishing mill 4 Finishing mill 28

29 The HL housingless stand The housingless design stands, in short HL, are the backbone of modern rolling mills. The modular design allows the use of the HL stand cartridges in all possible configurations: horizontal, vertical, convertible and universal. Thus the HL concept is suitable for roughing, intermediate and finishing mills. Mill stand sizes vary in accordance with the required dimensions of rolls and necks, the pattern of pass, the groove design as well as the transmission and drive characteristics. SMS group design department models all load data to determine all the process variables and select the correct stand size. The HL stands operate in bar mills, wire rod mills, section mills and combined plants. The main features of the HL design are: Conservative component sizing criteria and general philosophy in order to achieve rigidity and compactness of each unit Low roll deflection modulus (favorable ratio of roll neck to roll working diameter) Long life multi-roller bearings with chocks self-alignment under load Balancing of backlash between chocks Rest bars designed to allow easy and fine adjustment of guiding devices Hence, these are the mayor benefits during operation: Finished product matching required tolerance on geometry and size, thus stricter weight control Time savings during stand changing with off-line roll replacement Flexibility of operation, same stand unit used in horizontal, vertical, convertible and universal configurations, thus minimization of spare parts inventory Highly reduced maintenance time and costs, due to a reduced number of components and easy access Automated gap adjustment Integration in fully automatic control Drop wall roller way 6 Cooling bed 7 Multi-line straightener 8 Finishing facilities 29

30 Section mill for medium-light profiles Solutions to suit all production volumes A continuous section mill with high flexibility and the capacity to roll beams, angles, channels and flats of small and medium size has a capacity of 600,000 to 700,000 tpy of sections with a product ranging from 100 to 200 mm. Continuous mills are also possible for beams up to a web height of 350 mm. The layout mainly consists of: Reheating furnace Roughing mill with horizontal-vertical (H-V) housingless stands Intermediate/finishing mill with horizontal, convertible and universal stands with quick-changing device Drop wall roller way with lifting aprons Cooling bed Straightener Layer transfer facilities Finishing facilities with saws, stacker and strapping machines Furnace 2 Roughing mill 3 Intermediate/finishing mill 4 Drop wall roller way 30

31 Electrical tying machine Final packaging is a key operation in modern production facilities: it is the business card with which steel producers introduce themselves to their customers. Long product rolling mill operators also have to pay particular attention to the form and quality of the bundles as, after this operation, the bundles of bars is delivered to the market. Each and all single bundles produced in the mill are bound by a tying machine. This operation is critical on several levels and must be: Safe: bundles have to be tied securely and consistently Reliable: any problem at the tying machines requires the whole operation to be stopped Aesthetic: bundles should be neatly tied and free of oil In standard tying machines essentially hydraulic operations are used. Yet hydraulics always require special maintenance for hoses, valves, pumps and there is always a risk of oil leakage. The electrically driven system of the SMS group tying machine guarantees cleaner, safer and more reliable operation than hydraulics especially in the severe conditions of a rolling mill. The benefits are: Oil-free operation Clean and safe technology High-precision operation and repeatability Significantly reduced maintenance Cooling bed 6 Straightener 7 Layer transfer facilities 8 Finishing facilities 31

32 SMS group GmbH Business Unit Long Products SMS group S.p.A. Business Unit Long Products Ohlerkirchweg 66 Via Udine, Mönchengladbach Tarcento (Udine) Germany Italy Phone: Phone: Fax: Fax: W3-311E Published on Circulation XXX Printed in Germany KD 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.