Kroman Çelik Sanayii AS, Turkey, has selected Danieli as supplier for a 20-stand superflexible mill for bars, rod and spooled bar-in-coil. The new mill will be installed at the company’s existing steel complex in Gebze, near Istanbul.

The 500,000 tonnes per year bar, rod and spooled bar-in-coil mill will be made up of ESS cantilever and SHS housingless stands arranged in continuous formation with quick-changing facilities, plus a 10-pass high-speed wire rod block. The mill will also include a wire rod controlled cooling line, spooler line for bar-in-coils and state-of-the-art finishing facilities for straight bars and coils production. Direct connection to a 6-strand Danieli conticaster that has been in operation since 2001 will enable direct hot charging of billets.

The new state-of-the-art mill, featuring some of the latest Danieli Morgårdshammar innovations in long product production technology, will be one of the most advanced plants in the area.

The plant will feature a spooler line, which will facilitate production of on-line heat-treated round and deformed bars, twist-free wound in ultra-compact, ultra-heavy coils. Spooled coils guarantee a cobble-free uncoiling that enables their direct feeding to downstream cold processing lines without any intermediate off-line treatment such as traditional uncoiling, stretching and cold recoiling. The Spooler line offers substantial savings in transformation costs.

The new line will also feature an HSS High Speed Shear for automatic on-line head and tail cropping of wire rod before the laying head, which will result in less manpower, higher material yield and higher coil quality.

The mill will be capable of finishing speeds up to 15 meters per second for multistrand-slit bars, up to 110 meters per second for wire rod, and up to 35 meters per second for spooled bars. The very high finishing speeds will facilitate high productivity for both straight and coiled products. Provision will be made for future production of sections.

The mill will produce 8- to 50-mm deformed bars, 16- to 75-mm quality plain bars, 5.5- to 20-mm smooth wire rod, 6- to 16-mm deformed wire rod in coils and 8- to 50-mm spooled plain bar (up to 32-mm deformed) in coils. Coil weight for wire rod and spooled bars is up to 3.4 ton. Steel grades will include low-, medium-, and high-carbon steels as well as alloy steel for various applications in construction and mechanical industry, including drawing, cold heading, spring, bearing and similar grades.

Danieli Automation will supply electricals and the automation system. Danieli Centro Combustion will supply the walking hearth reheat furnace, which will be rated 100 tonnes per hour and 120 tonnes per hour in cold and hot charge mode, respectively.

Plant startup is scheduled for spring 2006.