FLEXIBLE HIGH-PERFORMANCE PLANTS - SMSgroupsms-group.us/files/W4-303E_Flexible High-performance...Sieflex®-HT toothed universal joint shafts (HT = High Torque). These shafts have

FLEXIBLE HIGH-PERFORMANCE PLANTSReferences for hot strip mills since 2000

SMS group

METALLURGICAL PLANT- and ROLLING MILL TECHNOLOGY

Hot flat rolling mills

Hot strip rolling millsSMS group

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X-Roll® hot strip mills 4

Baosteel Zhanjiang Iron & Steel, China 12

Habaş, Turkey 14

Panzhihua Iron & Steel, China 16

ArcelorMittal/Nippon Steel &

Sumitomo, USA 18

Çolakoglu Metalurji, Turkey 20

Bhushan Steel, India 22

Shougang Jingtang United 24

Iron & Steel, China

Benxi Iron & Steel, China 26

Handan Iron & Steel, China 28

Maanshan Iron & Steel, China 30

Shougang Iron & Steel, China 32

Taiyuan Iron & Steel, China 34

Wuhan Iron & Steel, China 36

ArcelorMittal Tubarão, Brazil 38

Further references 40

CONTENTS


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X-Roll® hot strip mills from the SMS group are all-round plants for the manufacture of hot strip. Theirproduct range extends from thin strips with a mini-mum 1.2 millimeters final gauge to high-strengthtube steels with a thickness of 25.4 millimeters,along with stainless steel grades. A large number ofhigh-powered technological features ensure excel-lent hot strip quality and guarantee high cost effi-ciency and availability.

As a leading plant-maker for the steel and non-fer-rous metals industry, SMS has executed 15 ordersworldwide for hot strip mills, with a total capacity ofover 60 million t per annum since the year 2000.The majority of the new plants have been built bythe SMS group in China, but investments have beenmade in modern hot strip mills also in Turkey, Indiaand North and South America.

Our X-Roll® hot strip mills are designed in accor-dance with our customers' requirements with theaid of comprehensive process simulations. Thedesign basis is the respective product range. Twofundamental variants have become standard here:

High-performance hot strip mills are designed foran annual capacity of up to 5.5 million t. They areusually equipped with a slab sizing press, tworeversing roughing stands, seven finishing standsand three coilers.Compact hot strip mills cater for capacitiesbetween 1.5 and 4 million t per annum. Their mainfeatures are the single-stand roughing mill and amandrelless coilbox between the roughing and fin-ishing stands.

SMS supplies the mills as integrated units withmutually coordinated systems comprising mechani-cal equipment, electrical & automation systems andprocess know-how.

The integrated solutions are based on the extensiveknowledge of our engineers concerning the possi-bilities of plant engineering, detailed process engi-neering knowledge and our know-how in the fieldsof design and manufacture of core components inour own workshops in Germany.

Our customers obtain major benefits from ourplants:

Powerful plant engineering with a secure futurefor the manufacture of modern steel grades intop-class product quality and within closest geo-metrical and metallurgical tolerances, high yieldand availability. High profitability thanks to Ecoplants compo-nents for reducing the energy consumption andfor high process stability. Handling of the entire project with just one part-ner, who is responsible for supplying all of theplants and services relevant to the process. Thismeans that there are no interfaces at all withother suppliers, such as for electrical andautomation systems.A steep run-up curve thanks to our own manu-facture of mechanical core components and tothe preliminary optimization of the Electrical &Automation package by means of Plug & Work.

X-ROLL® -HOT STRIP MILLS

X-Roll® designates the family of brands from our Flat-Product Rolling MillsDivision. It symbolizes plants and technical equipment for the economicaland flexible production of flat-steel products.

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POWERFUL COMPONENTS

Looper technology

Hot strip mills from the SMS group are universally equipped with equipment and tech-nologies which guarantee high productivity, a wide range of products and top productquality, all of which of course signify high profitability. Furthermore, Ecoplants compo-nents installed in the entire process chain contribute to environment-friendly productionthanks to their ability to reduce energy consumption and enhance the process stability.

Descaler

Slab sizing press

Camber-free rolling Crop shear

Mandrelless coilbox Finishing stands with CVC® plustechnology

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Descaler for excellent surface quality Slab sizing press for flexible adap-tation of the slab width* Camber-free rolling for eliminatingstrip cambers and high rolling stability* Mandrelless coilbox for compactlayout of the hot strip mill, storageof process heat and uniform striptemperatureCrop shear with cut optimizationfor low cropping losses*

Finishing stands in compact andmaintenance-friendly construction Work roll quick-change system CVC® plus, the actuator for stripprofile, contour and flatness* X-Roll® oil bearings for mountingthe backup rolls Gear unit with case-hardened bullgears and pinions Sieflex® HT spindles for safe transmission of extremely hightorques* Roll gap lubrication for reductionof the roll force* Looper technology for safe striprunning

Coiler technology

Pallet conveyor system

X-Pact® electrical and automation system

“Plug & Work“ testSieflex® HT spindles

Strip coolingDrive engineering

*Ecoplants-Komponente

Strip cooling with cooling conceptsstructured one above the other toachieve economic production of allsteel grades Universal coiler for straight-sided,closely wound coils UNI plus Coiler for the winding ofhigh-strength heavy-gauge strip Pallet conveyor system for flexible, gentle and safe coil transport X-Pact® electrical and automationpackage for controlling the entireproduction process Plug & Work for shortening thecommissioning

A SELECTION OF THE TECHNICAL HIGHLIGHTS:


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SMS GROUP AS A SYSTEM SUPPLIER

The SMS group supplies its plants asintegrated solutions with mutually coordi-nated systems comprising mechanicalequipment, electrical and automationpackages and the pertaining processknow-how. The supply scope of our X-Pact® electrical and automation sys-tems embraces all levels - from energysupply and distribution, drive engineeringand instrumentation, to measuring sys-tems and sensors, Level 1 and Level 2systems with the process models, thevisual display interface (HMI) and finallythe production planning system.

The process models make a decisivecontribution to the product quality, pro-ductivity and flexibility of the plant. Thepass schedule calculation (PSC), the pro-file, contour and flatness control (PCFC®)and the cooling section control (CSC)model are based on mathematical andphysical models and are used for settingthe various equipment items of therolling mill under consideration of thematerial properties.

Before delivery, we test the complete X-Pact® automation system with theunique "Plug & Work" procedure. Duringthis, the new automation system isinstalled in our test facilities beforehandand then tested and pre-optimized. Thisis possible thanks to a close-to-realityreal-time plant simulation in which thecustomer-specific plant, including all itsdynamic plant behavior parameters, isreproduced. It is proven that the Plug &Work concept speeds up the plant run-upand shortens the commissioning times.At the same time, during the integrationtest, the plant operators are preparedcomprehensively for their coming tasks.

The personnel learn the plant functionsand the handling of these under realisticoperating situations in virtual productiveoperation. In addition to the metallurgicalplant and equipment with the electricaland automation systems, the SMS groupportfolio also includes the foundation lay-outs, the utilities systems and ancillaryplants such as the water supply andtreatment system and the roll shop.Here, thanks to our many years of expe-rience, we offer solutions that are effi-cient and suitable for the requirements ofrolling mills.

With its X-Cellize® service, the SMSgroup is also the competent partner fordealing with all challenges relating toplant operation. SMS offers a wide rangeof maintenance and inspection services,spare parts supply and training and alsocontributes comprehensive processknow-how. Thanks to the worldwide ser-vice network, SMS experts are alwaysclose to the customer.

Perfectly harmonized systems are a precondition for excellent manufacturing results.

The Plug & Work test shortensthe commissioning time.

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The competence of the SMS group also extends to ancillary plants such asthe water supply and treatment system.

Closeness to the customer is a hallmarkof the SMS Service.


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PLANT LAYOUT, DESIGN AND MANUFACTURE GO HAND-IN-HAND

One of our success factors is the closeintermeshing of development, designand manufacture. All departments areunder a single roof at the Hilchenbachlocation, which means that continuousexchange is a matter of course. This kindof cooperation using the shortest possi-ble routes guarantees the continuousfully-integrated optimization of our prod-ucts. Of equal importance is the closecustomer contact throughout the entirelife-cycle of the plant.

All plants and components are designedand laid out individually by SMS accord-ing to the concrete operational require-ments. To determine the process require-ments, we make use of methods suchas FEM analyses (Finite ElementMethod) or dynamic simulations such asthose of deformation behavior. Fordesign work we use state-of-the-art 3DCAD systems to arrive at efficient andreliable results.

The core components of our hot stripmills, such as CVC® shifting systems,hydraulic roll-gap adjustment systems ordrive engineering are manufactured byus in our workshop of 40,000 m2,equipped with the most up-to-datemachines, in Hilchenbach.

The range of manufacturing in our work-shop extends from the production ofhigh-quality welded structures, machin-ing operations with a powerful pool ofmachine tools for innovative productionprocesses, and onwards to the assembly

and installation of heavy machinery. Weinstall all millstands, coilers and pipeworkand carry out function tests and trial runson special test facilities. We thus achievea high degree of efficiency and a longservice life of these components, whichare decisive for the product quality andthe profitability of the plants.

Components that are decisive for strip quality aremanufactured by SMS in its own workshops.

All plants are designed and laid outindividually.

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Portalfräsmaschine für Walzenständer.Gear unit manufacture is a core competenceof the Hilchenbach workshop.

Portalfräsmaschine für Walzenständer.Pre-assembly ensures trouble-free commissioning of theplants at the works.


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BAOSTEEL ZHANJIANGIRON & STEELZhanjiang, China

MAIN COMPONENTS

and FUNCTIONS

Slab sizing pressTwo-high reversing rougher with edgingstandFour-high reversing rougher with edgingstandThermal insulation elements - Crank cropshearSeven four-high finishing stands with Fully hydraulic roll gap adjustment (HGC) CVC® plus with work roll shifting and inte-grated work roll bendingInterstand cooling system, anti-peelingdevice, fume suppression system and rollcooling systems Roll-gap lubrication systemHydraulic loopers (F1 to F3) Differential-tension loopers (F4 to F6) Roll quick-change equipment Laminar strip coolingTwo hydraulic coilers with Automatic StepControl

HOT STRIP MILL WITH

"ECO" COMPONENTS

In June 2013 Baosteel Zhanjiang Iron &Steel awarded us an order for the supplyof a 2,250 mm hot strip mill. The rollingmill is being built at the new steel loca-tion in Zhanjiang in the south of Chinaand will go into operation at the end of2015.

The new hot strip mill for Baosteel Zhan-jiang Iron & Steel will set a new standardfor the efficient and environment-friendlyproduction of hot strip, since it isequipped with a large number of technol-ogy packages and Ecoplants compo-nents. Such components include thermalinsulation elements between the rough-ing and finishing mills, the CVC® plus sys-tem and hydraulic differential tensionloopers in the finishing mill.

As the first new plant worldwide, all fin-ishing stands are being equipped withSieflex®-HT toothed universal joint shafts(HT = High Torque). These shafts havethe same diameter as before but can reli-ably transmit considerably higher drivetorques. Above all in the front stands ofthe finishing mill, the high-performancejoint shafts allow the high rolling torquesthat are necessary for the production ofhigh-strength hot strip. The use of theSieflex®-HT toothed universal joint shaftsalso makes higher degrees of freedompossible when selecting the work rolldiameters.

With the new Sieflex®-HT toothed universal joint shaft, higher drive torques than before canbe reliably transmitted in finishing stands.

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"Eco" components in the hot strip mill atBaosteel Zhanjiang.

TECHNICAL DATA

Year of commissioning 2015

Annual production5,500,000 t

Steel gradesCarbon steels, tube grades, shipbuildingsteels, IF steel grades

SlabThickness 210, 230, 250 mmWidth 900 to 2,150 mm Length 4,500 to 11,000 mmWeight 38.0 t

Finished stripThickness 1.2 to 25.4 mmWidth 800 to 2,100 mm

CoilOutside diameter max. 2,150 mmSpec. coil weight max. 24.0 kg/mmTotal weight max. 38.0 t

01 Slab sizing press02 Camber-free rolling03 Thermal insulation elements 04 Optimized work roll cooling

05 Work roll conditioning06 Sieflex® HT shafts07 CVC® plus08 Intelligent utility systems

Thermal hoods between the roughing and finishing trainsprevent the transfer bar from cooling down too much.

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0504

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HABAşAliağa, Turkey

MAIN COMPONENTS

and FUNCTIONS

Four-high reversing roughing stand withedgerMandrelless coilboxDrum-type crop shearSeven four-high finishing stands with Fully hydraulic roll gap adjustment (HGC)CVC® plus with work roll shifting and inte-grated work roll bendingInterstand cooling system, anti-peelingdevice, fume suppression system and rollcooling systemsRoll-gap lubrication systemHydraulic loopers (F1 to F4)Differential-tension loopers (F5 and F6)Roll quick-change equipmentLaminar strip cooling systemTwo UNI plus coilers with Automatic StepControlPallet conveyor systemComplete X-Pact® electrical and automationpackage for the entire hot strip mill

The Turkish steelmaker Habaş enteredthe flat-steel market in 2014 with a com-pact hot strip mill from SMS. The mill isinitially designed for an annual capacity of 2.5 million tons, and can later beextended to 4.5 million tons.

The product range of the hot strip millincludes not only carbon steels and multi-phase steels but also high-strengthtube grades. The two downcoilers aredesigned as UNI plus coilers for the coil-ing of tube steels in strength class X80up to a thickness of 25.4 millimeters.They are characterized by reinforcedmechanical components and an opti-mized coiling strategy for these mate-rials.

For the mill, SMS also supplied the entireelectrical and automation package withthe Level 1 and Level 2 systems, thetechnological measuring systems, instru-mentation, sensors, the HMI (HumanMachine Interface) and the drive engi-neering. The mill automation was testedbeforehand and pre-optimized in an inte-gration test. At the same time, duringthe Plug & Work tests, the Habaş operat-ing personnel were trained on the virtualmill in preparation for their future work.

The mandrelless coilbox improvesthe conditions for finish-rolling.

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TECHNICAL DATA

Commissioning July 2014

Annual production Initial stage 2,500,000 tExpansion stage 4,500,000 t

Steel gradesCarbon steels, HSLA steels, tube grades,DP steels, stainless grades

SlabThickness 200 to 225 mmWidth 1,000 to 2,100 mmLength 12,000 mmWeight max. 40.0 t



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Customer training during thePlug & Work test.

Mill layout.


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PANZHIHUA IRON & STEELXichang, China

MAIN COMPONENTS

and FUNCTIONS

Slab sizing pressSeven four-high finishing stands with - Fully hydraulic roll gap adjustment (HGC)- CVC® plus with work roll shifting and integrated work roll bending

- PCFC® (Profile, contour and flatness control)

- Interstand cooling system, anti-peeling device, fume suppression system and roll cooling systems

- Roll-gap lubrication system- Hydraulic loopers (F1 to F4)- Differential-tension loopers (F5 and F6)

The hot strip mill at Panzhihua Iron &Steel went into operation in December2011. The SMS group supplied theseven-stand finishing train for the mill,with the decisive components for stripquality.

The finishing stands have a roll force of50 (F1-F4) and 40 (F5-F7) MN respective-ly. For gauge control, all stands areequipped with hydraulic roll-gap adjust-ment systems. The setting of strip pro-file, contour and flatness is performed byusing the CVC® plus system with inte-grated work roll bending. On the basis of the process parameters for each strip,the PCFC® profile, contour and flatnesscontrol system calculates the correctshifting position for the work rolls, whichhave a special barrel finish, as well as thesetting values for the work roll bending.The roll gap is thus able to be ideallyadapted to the changing conditions foreach strip, allowing strips with close geometrical tolerances to be produced.

The finishing stands are characterized bytheir compact and low-maintenancedesign. Each hydraulic actuator, forexample, is controlled by its own mod-ule. The individual modules are groupedin compact columns on the millstand ser-vice platform, where they are well pro-tected and, at the same time, easilyaccessible.

In 2015 SMS is extending the roughingtrain by a slab sizing press, so thatPanzhihua Iron & Steel can flexibly adjustthe finished strip widths.

The finishing train.

Loopers ensure stable strip running.

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TECHNICAL DATA

Commissioning December 2011

Annual production3.7 million t

Steel gradesCarbon steels, tube grades

SlabThickness 230 and 250 mmWidth 900 to 1,930 mmLength max. 11,000 mmWeight 38.1 t



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Finishing stand with CVC® plus, work roll bending andhydraulic roll-gap adjustment systems.


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AM/NS CALVERT(formerly ThyssenKrupp Steel USA)Calvert, Alabama, USA

WORKS COMPLEX WITH

SMS GROUP TECHNOLOGY

In July 2010 the new high-performancehot strip mill, supplied by the SMSgroup, went into operation at Thyssen-Krupp Steel USA. Since 2014 it belongsto ArcelorMittal/Nippon Steel & Sumitomo(AM/NS) and is the core element of thenew works complex in Calvert (Alabama),for which SMS also supplied a combinedpickling line/tandem cold mill, a continu-ous pickling line, three continuous galva-nizing lines and an annealing line.

The high-performance hot strip mill hasan annual capacity of 5.3 million tons, ofwhich one million ton are represented bystainless grades. This makes it one ofthe world's most powerful mills. Besidesthe mechanical equipment, we also sup-plied the complete electrical and auto-mation package and the drives, thusenabling all systems to be harmonizedprecisely with each other. Moreover, thereheating furnaces, the coil conveyorsystem and the roll dressing shop areunder our responsibility.

The main components of the X-Roll® hotstrip mill are a slab sizing press, one two-high and one four-high roughing stand,each with an edging stand at the entryside, seven finishing stands, the laminarstrip-cooling section and three down-coilers.

The hot strip mill operates with theX-Pact®automation system.

MAIN COMPONENTS

and FUNCTIONS

Slab sizing pressTwo-high reversing roughing standwith edgerFour-high reversing roughing standwith edgerCrank crop shearSeven four-high finishing stands with - Fully hydraulic roll gap adjustment(HGC)

- CVC® plus with work roll shifting andintegrated work roll bending

- Interstand cooling system, anti-peeling device, fume suppressionand exhausting system, roll coolingsystems

- Roll gap lubrication- Hydraulic loopers- Differential-tension loopers- Roll quick-change equipment Laminar strip-cooling sectionThree hydraulic coilers with AutomaticStep Control Pallet conveyor system X-Pact® electrical and automationpackage for the entire hot strip mill

Layout of the hot strip mill.

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TECHNICAL DATA

Commissioning July 2010

Annual production5.3 million t, of which 1 million t stainless steelgrades

Steel gradescarbon steels, thin sheet, IF steel, tubesteels, austenitic and ferritic stainless grades

SlabCarbon steels

Thickness 180 to 255 mmWidth 800 to 2,000 mmLength 4,200 to 11,500 mm

Stainless steelsThickness 180 to 240 mmWidth 800 to 1,870 mmLength 4,200 to 11,500 mmWeight max. 36.0 t

Finished stripCarbon steels

Thickness 1.5 to 25.4 mmWidth 800 to 1,870 mm

Stainless steelsThickness 2.0 to 10.0 mm Width 800 to 1,860 mm

CoilOutside diameter max. 2,150 mmSpec. coil weight max. 23.0 kg/mmTotal weight 36.0 t

Two-high roughing stand with edger.

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ÇOLAKOGLU METALURJIGebze, Turkey

MAIN COMPONENTS

and FUNCTIONS

Four-high reversing roughing stand withedgerMandrelless coilboxDrum-type crop shearSeven four-high finishing stands with - Seven four-high finishing stands with - Fully hydraulic roll-gap adjustment(HGC)


- Interstand cooling system, anti-peel-ing device, fume suppression systemand roll cooling systems

- Roll-gap lubrication system- Hydraulic loopers- Roll quick-change equipmentLaminar strip cooling systemTwo hydraulic coilers with AutomaticStep ControlPallet conveyor systemX-Pact® electrical and automation pack-age for the entire hot strip mill

ENTRY onto the market for

FLAT-STEEL PRODUCTS

The plant at Çolakoğlu Metalurji A.S. inTurkey was the first conventional X-Roll®

hot strip mill for which we supplied themechanical equipment and the completeelectrical and automation package. Thenew works was built in Gebze, a port onthe Sea of Marmara about 30 kilometersaway from Istanbul. There, ÇolakoğluMetalurji also operates an electric steel-making plant with rolling facilities for longproducts.

Thanks to the supply of the completeplant engineering from a single source, allsystems were optimally coordinated withone another. We tested the completeautomation system prior to commission-ing by using the Plug & Work method.

By means of pre-optimization and pre-commissioning, the hot strip mill attainedstable production within a very short time.Also with regard to the strip quality, thebenefits of a full-line supply by the SMSgroup became evident right from thestart. Already after three weeks, 99 % ofall strips produced were within the agreedtolerances for strip gauge and width, aswell as strip profile and flatness.

Automatic work roll changing in theseven-stand finishing mill.


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TECHNICAL DATA

Commissioning June 2010

Annual production

3,000,000 t

Steel grades

Carbon steels, HSLA steels, tube grades,DP steels, TRIP grades

Slab

Thickness 180 to 250 mmWidth 800 to 1,650 mmLength max. 12,000 mmWeight max. 39.0 t

Finished strip


Coil

Outside diameter max. 2,200 mmSpec. coil weight max. 24.0 kg/mmTotal weight 39.0 t

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BHUSHAN STEELMeramandali, India

MAIN COMPONENTS

and FUNCTIONS

Two-high reversing roughing standwith edgerFour-high reversing roughing standwith edgerMandrelless coilboxDrum-type crop shearSeven four-high finishing stands with - Fully hydraulic roll gap adjustment(HGC)


- PCFC® (Profile, contour and flatnesscontrol)

- Automatic pass-line adjustment (F5and F6)

- Interstand cooling system, anti-peeling device, fume suppressionsystem and roll cooling systems

- Roll-gap lubrication system- Hydraulic loopers- Roll quick-change equipmentLaminar strip cooling systemThree coilers with Automatic StepControlPallet conveyor system

INDIA - A GROWTH MARKET

Bhushan Steel Ltd. erected an integratediron and steel plant in the Indian federalstate of Orissa. For the new works com-plex, we supplied the CONARC®-basedsteelworks, two continuous slab castersand an X-Roll® hot strip mill.

In the first construction stage, the com-pact hot strip mill includes a four-highreversing roughing stand, a mandrellesscoilbox, a six-stand finishing mill and twocoilers. It is thus designed for an annualproduction of 3.0 million tons. BhushanSteel also entrusted SMS with the millexpansion, i.e. the increasing of capacityto 4.5 million tons per annum. It compris-es an additional two-high roughing stand,a seventh finishing stand, the extensionof the laminar cooling by two coolinggroups and a third coiler.

The production range of the hot strip mill not only includes input stock for thegroup's own cold rolling mills but also a range of high-quality products, withHSLA steels, tube steels and stainlesssteel grades.


Roughing mill with edger.

TECHNICAL DATA

Commissioning March 2010

Annual production

1st construction stage 3,000,000 t2nd construction stage approx. 4,500,000 t

Steel grades

Carbon steels (low, medium and high carbon), tube steels, stainless steels

Slab

Thickness 200 to 250 mmWidth 800 to 1,680 mmLength 6,000 to 12,000 mmWeight 37.0 t

Finished strip


Coil


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Pre-assembly of the coiler inthe SMS workshop.


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SHOUGANG JINGTANG UNITEDIRON & STEEL, Caofeidian, China

MAIN COMPONENTS and

FUNCTIONS of the rolling mill

Slab sizing pressTwo-high reversing roughing stand withedgerFour-high reversing roughing standwith edgerCrank crop shearSeven four-high finishing stands with - Fully hydraulic roll gap adjustment(HGC)



- Automatic pass-line adjustment, inter-stand cooling system, anti-peelingdevice, fume suppression system androll cooling systems

- Roll-gap lubrication system- Hydraulic loopers (F1 to F3) - Differential-tension loopers (F4 to F6) - Roll quick-change equipment Laminar strip coolingThree hydraulic coilers with AutomaticStep ControlPallet conveyor system

HOT STRIP MILL

in a new industrial complex

The high-capacity hot strip mill atShougang Jingtang United Iron & Steelproduced its first strip in December 2008. The mill is located on the island of Caofeidian on the coast of Hebeiprovince, where the Chinese steelmakerShougang Iron & Steel has erected acomplete iron and steel plant. For theplant complex we are also supplying acombined pickling line / tandem cold milland several strip processing lines.

The X-Roll® hot strip mill is designed foran annual capacity of 5.5 million tons. The roughing mill consists of a slab sizingpress, a two-high and a four-high revers-ing stand. Hydraulic roll gap adjustmentsystems, CVC® plus and work roll bendingin all finishing stands as well as hydraulicloopers (F1 to F3) and differential-tensionloopers (F4 to F6) guarantee close geo-metrical tolerances and stable production.

It was decided that we should receive theorder not only because of our highlydeveloped, tried-and-tested componentsbut also because of the positive experi-ence that Shougang Iron & Steel hadmade when working with us. Besides theX-Roll® hot strip mill at the Qian’an loca-tion, we had supplied the company with aheavy plate mill, a combined pickling line /tandem cold mill and several facilities forstrip processing.

Automatic work roll changing in theseven-stand finishing mill.


Drive engineering from the SMS group.

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TECHNICAL DATA


Annual production

Initial stage 5,500,000 t

Steel grades

bon steels (low, medium and high carbon),tube steels, steels for automotive structuralcomponents

Slab

Thickness 230 mmWidth 900 to 2,150 mmLength 4,500 to 11,000 mmWeight 40.0 t

Finished strip


Coil


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BENXI IRON & STEEL Benxi, China

MAIN COMPONENTS and


Slab sizing press Two-high reversing roughing stand withedgerFour-high reversing roughing standwith edgerCrank crop shearSeven four-high finishing stands with - Fully hydraulic roll gap adjustment (HGC)


- Automatic pass-line adjustment- Interstand cooling system, anti-peeling device, fume suppression system and roll cooling systems

- Roll gap lubrication- Hydraulic loopers (F1 to F3) - Differential-tension loopers (F4 to F6) - Roll quick-change equipment Laminar strip cooling with double-rein-forced cooling groups Compact coolingThree hydraulic coilers with AutomaticStep ControlPallet conveyor system

MODERN COOLING

TECHNOLOGIES

The high-capacity hot strip mill at BenxiIron & Steel went into operation inNovember 2008. The new mill hasenabled the company to increase its hot strip capacity by 5.15 million tons,and it is now able to open up new mar-kets through its wide range of products,including strips made of carbon andstainless steels.

The main components of the X-Roll® hotstrip mill are a slab sizing press, one two-high and one four-high reversing rough-ing stand, a crop shear, the seven-standfinishing train, the cooling section withlaminar and compact cooling, and threefully hydraulic downcoilers.

The combination of laminar and compactcooling provides Benxi Iron & Steel witha wide range of cooling strategies formodern steel grades. The compact cool-ing system at the end of the coolingprocess allows the application of veryhigh water flow rates and therefore veryhigh cooling rates. For additional flexibili-ty, in the laminar cooling system, SMSreplaced the first five of the total of 20cooling groups with double-reinforcedunits.

The two-stand roughing train; inthe background: the finishing train.


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TECHNICAL DATA

Commissioning November 2008

Annual production

5,150,000 t

Steel grades

Stainless steel grades, carbon steels, high-strength low-alloy steels, shipbuilding steels,tube steels, DP, MP and TRIP steel grades

Slab (carbon steels)

Thickness 230 and 250 mmWidth 1,000 to 2,200 mmLength 4,500 to 11,000 mm

Slab (stainless steels)

Thickness 180 and 200 mmWidth 1,000 to 2,150 mmLength 4,500 to 11,000 mm

Finished strip (carbon steels)

Thickness 1.2 to 25.4 mmWidth 1,000 to 2,150 mm

Finished strip (stainless steels)

Thickness 2.0 to 20.0 mmWidth 1,000 to 2,150 mm

Coil


Compact coolingsystem.

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HANDAN IRON & STEELHandan, China

MAIN COMPONENTS and


Slab sizing pressTwo four-high reversing roughingstands with edgerCrank crop shearSeven four-high finishing stands with - Fully hydraulic roll gap adjustment(HGC)

- CVC® plus with work roll shifting and integrated work roll bending


- Automatic pass-line adjustment- Interstand cooling system, anti-peeling device, fume suppression andexhausting system and roll cooling systems

- Roll-gap lubrication system- Hydraulic loopers (F1 to F3)- Differential-tension loopers (F4 to F6)- Roll quick-change equipmentLaminar strip cooling systemThree hydraulic coilers with Automatic Step ControlPinch roll polishing devices Pallet conveyor system

HOT STRIP MILL

for 4.5 million t

The X-Roll® hot strip mill from HandanIron & Steel went into operation inAugust 2008. Besides the mechanicalequipment, we supplied the profile andflatness model for this mill and, as theconsortium leader, coordinated the com-panies participating in the project.

The mill is designed as a high-capacityhot strip mill and possesses a slab sizingpress, two four-high reversing roughingstands, a seven-stand finishing train andthree fully hydraulic coilers. The tworeversing roughing stands in four-highconstruction provide the mill with a par-ticularly high degree of flexibility in thedrafting pattern for the roughing mill.

Automatic Step Control in the coiler unitmakes possible the gentle winding of thestrips. Special polishing devices regularlyclean the pinch rolls and thereby preventpick-ups which may cause damage to thestrip surface.

In establishing its flat-steel production,Handan Iron & Steel has placed its trustin plants from the SMS group. The firm'ssuccessful entry into this market wasaccomplished in 1999 with a CSP® facili-ty. For the further processing of the prod-ucts we supplied two combined picklinglines / tandem cold mills in 2005 and2010.


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TECHNICAL DATA

Commissioning August 2008

Annual production


Steel grades

HSLA steel, carbon steel grades (low, medi-um und high carbon), steels for automotivestructural components, tube steels, IF, DP,MP, TRIP steel grades

Slab

Thickness 230 to 250 mmWidth 900 to 2,150 mmLength 4,800 to 11,000 mmWeight 40.0 t

Finished strip


Coil


The hydraulic control systems are accommodated in protectivehousings in the utility platforms on the millstands.

Laminar cooling systemwith edge masking.

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30

MAANSHAN IRON & STEELMaanshan, China

The first line with a PALLET

CONVEYOR SYSTEM

Within a few years, Maanshan Iron & Steel(Masteel) has become one of China's mostimportant hot strip producers, thanks toplants from the SMS group. First of all, in2004, the CSP® plant went into operation, fol-lowed three years later by the new X-Roll®

hot strip mill.

The high-capacity hot strip mill is part of anew works complex, for which we have alsosupplied two continuous casters. These arearranged in such a way that a large propor-tion of the slabs can be fed into the rollingmill by hot charging. The slab sizing press isthe ideal link between the continuous casterand the hot strip mill, since it allows widthreductions of up to 350 millimeters and thusa high degree of flexibility as regards castingand strip widths. The roughing train has twopowerful four-high reversing stands. Thesegive Masteel a large amount of flexibility inthe drafting pattern.

At Masteel, an innovatory pallet conveyorsystem has been installed for the first time ina hot strip mill. In this system, the hot coilsare deposited on transport pallets and con-veyed safely into the coil storage yard. Thesimple and modular structure of the systemenables investment, maintenance and operat-ing costs to be kept lower than for conven-tional systems and, at the same time, thelayout can be organized in a flexible manner.

Layout of thehot strip mill.

MAIN COMPONENTS and


Slab sizing pressTwo four-high reversing roughingstands with edgerCrank crop shearSeven four-high finishing stands with - Fully hydraulic roll gap adjustment(HGC)



- Automatic pass-line adjustment- Interstand cooling system, anti-peel-ing device, fume suppression andexhausting system and roll coolingsystems

- Roll-gap lubrication system- Hydraulic loopers (F1 to F3)- Differential-tension loopers (F4 to F6)- Roll quick-change equipmentLaminar strip cooling systemThree hydraulic coilers with - Automatic Step Control- Pinch roll polishing devices Pallet conveyor system

Roughing train with twofour-high reversing stands.

31

Pallet conveyor system.

TECHNICAL DATA

Commissioning February 2007

Annual production


Steel gradesHSLA steel, carbon steel grades (low, medi-um und high carbon), steels for automotivestructural components, tube steels, steel forpressure purposes

Slab Thickness 230 and 250 mmWidth 800 to 2,130 mmLength 4,800 to 12,000 mmWeight max. 45.0 t

Finished strip


Coil


Cold charging Hot charging

❱


32

SHOUGANG IRON & STEELQian’an, China

MAIN COMPONENTS and

FUNCTIONS of the hot strip mill

Slab sizing press Two-high reversing roughing stand Four-high reversing roughing standwith edger Mandrelless coilbox Crank crop shear Six four-high finishing stands with - fully hydraulic roll-gap adjustment (HGC)


- interstand cooling, anti-peeling device, fume suppression system and roll cooling systems

- roll gap lubrication - hydraulic loopers - quick roll-change equipment Laminar strip cooling systemThree hydraulic coilers with AutomaticStep Control

INTENDED EXTENSIONS

One walking-beam furnace One vertical edger on the two-highroughing standOne finishing stand

COMPACT LINE thanks to

COILBOX

The X-Roll® hot strip mill from ShougangIron & Steel went into operation inDecember 2006. A mere twelve monthslater, the line reached its nominal capac -ity of 330,000 tons/month.

The powerful roughing train at ShougangIron & Steel consists of a slab sizingpress, a two-high and a four-high revers-ing roughing stand. The line thus has thepotential for a future production increase.

The mandrelless coilbox enabled the distance between the roughing and finishing trains to be shortened and acompact plant layout was thus achieved.Furthermore, the homogeneous transferbar temperature and the smaller thick-ness of the transfer bar make it possibleto reduce the required forming capacity,which means that only six stands arenecessary in the finishing train.

On the line, Shougang produces not only strips for processing in the coldrolling mill supplied by the SMS groupbut also multiphase steel grades andhigh-strength tube steels. Already duringthe hot commissioning, Shougang Iron &Steel received the commercial certifica-tion for a tube steel in strength classX80. To enable strips in these grades tobe coiled more reliably and in high quali-ty, the SMS group supplied ShougangIron & Steel with a new coiler intendedspecially for high-strength, thick-gaugestrips.

Six-stand finishing train with CVC® plus technology.

Exit side of the slab sizing press.

33

TECHNICAL DATA


Annual production


Steel grades

Carbon steels (low, medium and high car-bon), high-strength low-alloy steels, steelsfor pressure and high-pressure purposes,tube steels, multiphase steels

Slab

Thickness 230 (250) mmWidth 900 to 2,150 mmLength 4,000 to 10,500 mmWeight max. 38.5 t

Finished strip


Coil



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34

TAIYUAN IRON & STEEL Taiyuan, China

China's largest STAINLESS

STEEL PRODUCER

With the commissioning of the X-Roll®

compact hot strip mill in the summer of2006, Taiyuan Iron & Steel assumed itsplace as one of the world's largest stain-less steel producers. The total productionof the mill is around four million tons/year,comprising stainless steel strips and carbonsteel strips in equal proportions.

A mandrelless coilbox is installed betweenthe roughing and finishing trains at TaiyuanIron & Steel. The intermediate storage ofthe rolling stock in the coilbox results in ahomogeneous temperature over the entiretransfer bar length and thus assures con-stant conditions during finish rolling. Thisenables Taiyuan Iron & Steel to producestainless steel strip with a minimum gaugeof 2.0 millimeters.

In order to extend the product range for high-strength steels, SMS modernized the laminarcooling and supplied a UNI plus coiler in2012. In the strip cooling system, the entirelaminar cooling system was dismantled andreplaced by reinforced cooling groups with aview to increasing the water volumes andthus the cooling rates. Each row of coolingtubes can be switched separately, thusallowing great flexibility in implementing avery wide variety of cooling strategies.

The UNI plus coiler is one of the world’smost powerful coilers and is designed forthe coiling of tube grades in strength classesX100 and X120 and for high-strength dual-phase steels. To ensure reliable dischargeand safe processing of the coils, the coilerincludes a coil transfer car of advanceddesign, a patented coil hold-down device andan optimized coil banding machine.

MAIN COMPONENTS and


Four-high reversing roughing standwith edgerMandrelless coilboxCrank crop shearSeven four-high finishing stands with - Fully hydraulic roll gap adjustment(HGC)


- Interstand cooling system, anti-peel-ing device, fume suppression andexhausting system and roll coolingsystems

- Roll-gap lubrication - Hydraulic loopers (F1 to F3)- Differential-tension loopers (F4 to F6)- Roll quick-change equipmentLaminar strip cooling system with rein-forced cooling groupsTwo hydraulic coilers with - Automatic Step Control- Pinch roll polishing devices UNI plus coiler

Finishing stands with newly developed fume exhaust system.

Coiler unit.

35

TECHNICAL DATA

Commissioning June 2006

Annual production

4,000,000 t of which stainless steels 2,000,000 t

Steel grades

Austenitic and ferritic stainless steel grades(AISI 200, 300, 400 series), carbon steelgrades (low and medium carbon), tube steelsup to X120

Slab

Carbon steels Thickness 230 to 250 mmWidth 1,000 to 2,130 mmLength 4,800 to 12,000 mm

Stainless steels Thickness 180 to 200 mmWidth 1,000 to 2,100 mmLength 4,800 to 12,000 mmWeight max. 40.0 t

Finished strip

Carbon steels Thickness 1.2 to 25.4 mmWidth 1,000 to 2,130 mm

Stainless steelsThickness 2.0 to 20.0 mmWidth 1,000 to 2,100 mm

Coil

Outside diameter max. 2,150 mm Spec. coil weight max. 23.0 kg/mmTotal weight 40.0 t


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36

WUHAN IRON & STEELWuhan, China

Finishing train.

CHINA'S FIRST HOT STRIP

MILLwith a strip width of over

2,000 mm

Wuhan Iron & Steel (Wisco) has beenproducing high-grade hot strip since 2003with the X-Roll® hot strip mill supplied by us and an X-Pro® dividing shear. Themill was initially designed for an annualproduction of 3,5 million tons. Already inthe year of commissioning, Wisco decid-ed to implement the second stage of construction, representing a capacityincrease to 4.5 million tons. Actually,Wisco today attains an annual productionof more than 5 million tons.

Wisco's hot strip mill was the first facilityin China for strips with widths greaterthan 2,000 millimeters. One of the cus-tomer markets for strips in this width isamang others the automotive industry.

The Wisco facility was the first hot stripmill in China to be equipped with a slabsizing press and thus to have the possi-bility of flexible coordination of the cast-ing widths and strip widths. The four-highreversing roughing stand and the finish-ing stands are fitted with hydraulic roll-gap adjustment systems for controllingthe strip gauge. The strip profile and flat-ness are set in the finishing train usingCVC® plus to close tolerances.

At the beginning of 2009 the CSP® facili-ty built by us commenced operations atWuhan Iron & Steel. This line is usedabove all to produce high-quality gradessuch as multiphase steels and magneticsteel strip. The transfer of these prod-ucts to the CSP® line allows the conven-tional hot strip mill to utilize its strengthsto the full as regards productivity.


MAIN COMPONENTS and

FUNCTIONS of the hot strip

mill in the first stage of con-

struction

Slab sizing pressFour-high reversing roughing standwith edgerCrank crop shearSeven four-high finishing stands with - Fully hydraulic roll gap adjustment (HGC)


- PCFC® (Profile, contour and flatness control)

- Automatic pass-line adjustment- Interstand cooling systems, anti-peeling devices, fume suppression system and roll cooling systems

- Hydraulic loopers- Roll quick-change equipmentLaminar strip cooling systemTwo hydraulic coilers with Automatic Step Control

MAIN COMPONENTS in the

second stage of construction

One two-high roughing stand One hydraulic coiler with AutomaticStep Control

37

TECHNICAL DATA

Commissioning March 2003

Annual production

First stage of construction 3,500,000 tSecond stage of construction (2004) 4,500,000 t

Steel grades

Carbon steels (low, medium and high car-bon), IF steels, multiphase steels, tubesteels up to X80

Slab

Thickness 230 to 250 mmWidth 800 to 2,150 mmLength 4,500 to 11,000mmWeight 38.5 t

Finished strip


Coil

Outside diameter 2,150 mmSpec. coil weight 24.0 kg/mmTotal weight 38.5 t

Cold charging Hot charging Direct charging for the future

Roughingstand.

❱


38

ARCELOR-MITTAL TUBARÃO Vitória, Brazil

Layout of the hot strip mill with connec-tion to the continuous casters.

Finishing train.

TURNKEY FACILITY

Since 2002 ArcelorMittal Tubarão (for-merly CST) has been operating a com-pact hot strip mill supplied by us on a turnkey basis. The mill has enabledArcelorMittal Tubarão to extend its goodreputation as a manufacturer of top-quality slabs also to the hot strip field.

The annual capacity of the mill was 2.0 million tons at the time of commis-sioning. Meanwhile, the capacity hasbeen increased to around 4.0 milliontons/year by installing an additional walking-beam furnace.

The slabs for the hot strip mill are pro-duced by two continuous casters sup-plied by us. These are arranged in such a way that the slabs can be inserted intothe hot strip mill by hot charging.

The mandrelless coilbox and the finishingstands, which are equipped with all up-to-date actuators, allow the production ofhot strip with very close geometrical andmetallurgical tolerances. A special thin-strip technology package makes possibleminimum strip gauges of only 1.0 mil-limeters. This package also includes thehigh-speed gauge control system (AGC)and the tensiometer looper behind F4and F5. The strip tension distributionsmeasured by the tensiometer loopersserve as incoming information for thestrip-flow control system and the profile,contour and flatness control system,which form part of the automation pack-age supplied by us.

MAIN COMPONENTS and


Four-high reversing roughing standwith edgerMandrelless coilboxCrank crop shearSeven four-high finishing stands with - Fully hydraulic roll gap adjustment (HGC)- CVC® plus with work roll shifting and integrated work roll bending- Interstand cooling system, anti-peeling device and roll cooling systems- Roll-gap lubrication - Hydraulic loopers (F1 to F5)- Roll quick-change equipmentLaminar strip cooling system Two hydraulic coilers with AutomaticStep ControlX-Pact® automation system - PCFC® (profile, contour and flatnesscontrol system)- CSC (process model for laminar stripcooling)- TCS (technological control systems for the finishing train and coilers)

INTENDED EXTENSIONS

One walking-beam furnace One four-high reversing roughing stand

39

Laminar strip cooling. Mandrelless coilbox.

TECHNICAL DATA

Commissioning August 2002

Annual production

First stage of construction 2,000,000 tSecond stage of construction (2008) 4,000,000 t

Steel grades

Structural steels, ULC steels, IF steels, high-carbon steels, high-strength low-alloy steels,tube steels

Slab

Thickness 200 to 250 mmWidth 750 to 1,955 mmLength 4,500 to 11,500 mmWeight max. 40.0 t

Finished strip

Thickness 1.2 to 16.0 mmWidth 700 o 1,880 mm

Coil

Outside diameter 2,100 mmSpec. coil weight max. 22.5 kg/mmTotal weight 40.0 t

Cold charging Hot charging

❱


40

FURTHER REFERENCES prior to 2000

TATA STEELJamshedpur, India


Main components- Four-high roughing stand with edger- Coilbox- Six-stand finishing mill with CVC® plus- Laminar strip cooling- 2 coilers

Annual production 3,550,000 t

Steel gradescarbon steels (low and medium carbon), HSLAsteels, tube steels, micro-alloyed steels, struc-tural steels


SAHAVIRIYA STEEL INDUSTRIESBang Saphan, Thailand


Main components- Four-high roughing stand with two edgers- Coilbox- Seven-stand finishing mill with CVC® plus- Laminar strip cooling- 3 coilers


Steel gradesCarbon steels, micro-alloyed steels, ferritic andaustenitic stainless grades


BAOSHAN IRON & STEELShanghai, China


Main components- Two-high reversing roughing stand with edger- Four-high reversing roughing stand with edger- Two four-high non-reversible roughing standswith edger

- Seven-stand finishing mill with CVC®

technology- Laminar strip cooling- 3 coilers


Steel gradesSteel grades: Carbon steels, tube grades


Special features- For the first time, CVC® technology in all fin-ishing stands

- Production greatly in excess of 100 milliontons of hot strip since 1989

41

SAUDI IRON & STEEL COMPANYAl-Jubail, Saudi-Arabia




Steel gradesStructural steels, steels for welded pipes, tubesteels up to X60, HSLA grades


CHINA STEEL CORP.Kaohsiung, Taiwan


Main components- Two-high roughing stand with edger - Four-high roughing stand with edger - Seven-stand finishing mill - Laminar strip cooling- 2 coilers

Annual production 2,700,000 t, of which 160,000 t stainless grades

Steel gradesCarbon steels (low and medium carbon), siliconsteels, stainless steels, tube steels


ESSAR STEELHazira, India




Steel gradesKohlenstoffstähle (low and medium carbon),Baustähle, Rohrstähle, mikrolegierte Stähle


ARCELOR-MITTAL EISENHÜTTENSTADTGermany


Main components- Four-high roughing stand with edger- Mandrelless coilbox- Five-stand finishing mill with CVC® plus- Laminar strip cooling- 1 coiler


Steel gradesLow-carbon steels, IF steel grades, structuralsteels (with improved atmospheric corrosionresistance), high-strength and micro-alloyedsteels, non-grain-oriented silicon steels



42

OVERVIEW OF REFERENCES

Customer Country Commissioning

Baosteel Zhanjiang Iron & Steel China 2015

Habaş Turkey 2014

Panzhihua Iron & Steel China 2011

ArcelorMittal/Nippon Steel & Sumitomo USA 2010

Çolakoglu Metalurji Turkey 2010

Bhushan Steel India 2010

Shougang Jingtang United Iron & Steel China 2008

Benxi Iron & Steel China 2008

Handan Iron & Steel China 2008

Maanshan Iron & Steel China 2007

Shougang Iron & Steel China 2006

Taiyuan Iron & Steel China 2006

Wuhan Iron & Steel China 2003

ArcelorMittal Tubarão Brazil 2002

Saudi Iron & Steel Saudi Arabia 1999

ArcelorMittal Eisenhüttenstadt Germany 1997

China Steel Corporation Taiwan 1997

Essar Steel India 1996

Sahaviriya Steel Industries Thailand 1994

Tata Steel India 1993

Baoshan Iron & Steel China 1989

43

Design capacity Strip thickness Strip width[Million t per annum] [mm] [mm]

5.5 1.2 – 25.4 800 – 2,100

2.5 / 4.5 1.2 – 25.4 700 – 2,100

3.7 1.2 – 25.4 900 – 1,900

5.3 1.5 – 25.4 800 – 1,870

3.0 1.2 – 25.4 800 – 1,650

4.5 1.4 – 25.4 800 – 1,680

5.5 1.2 – 25.4 830 – 2,130

5.15 1.2 – 25.4 1,000 – 2,150

4.5 1.2 – 25.4 800 – 2,130

5.5 1.2 – 25.4 800 – 2,130

4.0 1.5 – 19.0 750 – 2,130

4.0 1.2 – 25.4 1,000 – 2,130

4.5 1.2 – 25.4 700 – 2,130

4.0 1.2 – 16.0 700 – 1,880

2.0 1.2 – 16.0 900 – 1,650

1.5 1.5 – 13.0 600 – 1,640

2.7 1.2 – 12.7 914 – 1,880

3.0 1.6 – 20.0 740 – 2,000

2.4 1.0 – 19.0 750 – 1,550

3.55 1.2 – 12.0 650 – 1,550

4.2 1.2 – 25.4 600 – 1,900

SMS group

Flat Rolling Plants Division

Wiesenstrasse 3057271 Hilchenbach, Germany

Phone: +49 2733 29-1616Telefax: +49 2733 29-2832

E-mail: [email protected]: www.sms-group.com/hot-rolling-mills

“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 thesecharacteristics 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 willnot have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.”

W4-303E

© SMS group · Published on 15.05.2015 · C

irculation 1000 · Printed in Germany · K

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