Uninterrupted production from liquid steel to completely finished product, including in-line heat treatment, surface finishing, and inspection procedures. The process leads to higher productivity, consistent product quality, and cost savings that average 40 Euro/ton in specialty steels, and 20 Euro/ton in commercial steel production.
The ECR process is based on the direct connection of the two-strand, high-speed caster with the rolling mill through an in-line equalizing roller-type tunnel furnace, making it possible for non-stop direct rolling of the bloom coming from the caster, for an uninterrupted production cycle.

Endless rolling by automatic continuous on-line welding of billets at the reheat furnace exit side, to perform uninterrupted production of straight bars, wire rod, and bar-in-coils in variable and customized coil weights. The EWR process means: no inter-billet time, no bar head and tail cropping during rolling, no short-bars/short-ends, no coil trimming in wire rod production, fewer cobbles, less maintenance, and fewer spares and consumables, resulting in an average production cost savings of 3.5-4.0 Euro/t. Heavy-weight coils obtained, even from low-weight billets.

Continuous and multi-bending radius configuration, FNC-Flying Nozzle Change / stopper rod practice, 1-m-long parabolic-tapered copper tube, retractable mechanical and hydraulic oscillator, dynamic spray-control system and the unique Mold Powder Measuring Device for continuous reading of mold slag thickness, for best product quality and productivity performances. Mold and final electromagnetic stirring in case of quality grades production. Curved mold to cast up to 700 mm round blooms.

90 tph per strand world-best performance in specialty steels casting. Progressive multibending
radius configuration, 3.0 to 6.0 mpm (for 160x200 mm cast size), T-shaped
30-t tundish, 1.2-m-long multi-tapered instrumented copper tube and mold/strand/final electromagnetic
stirring. Patented cartridge-type system allowing quick, automatic removal
of the casting segments (for ordinary/extraordinary maintenance) in less than 10 min without
the use of a service crane.

100% stainless steel production without grade limitation (austenitic, ferritic, duplex, and valve martensitic) up to 98.5% yield. Top surface and internal quality are assured by mold hydraulic oscillating table, tapered copper tube, mold and final (movable) EMS, air-mist secondary cooling. Reference performance: 20 tph per strand on a 10-m-radius four-strand machine, casting squares from 220 to 145 mm.

The cost-saving PSP process consists of a three-stand UFR reversing mill combined with a single-pass, independent finishing sizing stand. Enhancing product quality, productivity, and efficiency, the process finds ideal application in medium and heavy section mills to produce H-beams up to 1,100 mm (flange height of up to 400 mm), equal/unequal angles, special sections,
and rails. The SCC-Stand Core Concept stand, and the automatic quick program changing allow product size changes in just 20 minutes.

The superflexible structural mill at Nucor Berkeley, fitted with super-heavy duty SHS-U universal housingless stands, enables the production of 750,000 tpy of a very wide range of beams and shapes, including special ultra-light parallel-flange beams down to a web thickness of 2.3 mm (down to one-half of standard tolerance beams rolled upon request).

The Kocks/Danieli 3-roll RSB Reducing and Sizing Block provides stricter product tolerances, higher mill efficiency and opertional and market flexiblity, and lower operating costs in production of SBQ bars and wire rod. The HRS block is the
ideal solution for producing top quality square and flat bars. Based on the “Variable-Reduction” concept, the HRS block provides maximum operational flexibility coupled with precise product tolerances, leading to better product marketability, higher plant efficiency, and lower production costs.

Over 100 tph of 10-mm-dia bar/rebar production, fully exploiting reheating furnace capacity. This goal is achieved by the
Twin Channel system delivering one bar per notch (down to 6-mm bars) at speeds of up to 40 mps onto the cooling bed (following a rolling mill operating with Delta-type blocks), or through a multi-strand slit rolling system (2-3-4-strand slit-rolling of rebars), with a reduced number of rolling passes.

Thanks to a “zeroerror” bar counting system and a unique counted bar separation unit, finished bundles are made up of perfectly aligned bars (neither twisted nor entangled), assuring safer handling and unbundling operation. Its modular construction allows the station to be shipped in fully pre-assembled sections by container, and enables simpler / faster installation for “Plug-and-Run” startup (30% saving in civil works cost, 50% saving in installation time).

Specialty steel SBQ bar finishing stations grant optimized-shape stacks ideally formed in relation to product type, granting absolute bar stability within the stack. Hexagon- or square-shaped stacks are obtained for round, square, and hexagon bars through regular and gentle deposit of subsequent bar layers into the stack-forming cradles, by means of a lance-type piling device. Bar layers are made up of predetermined number of bars in relation to product type.

Over 125-mps regular production speed of down to 4.5-mm dia (and up to 25 mm) special and commercial steel wire rod, with strict size tolerances, in high-quality coils of up to 3 tons.The entire product mix is finished at the 4-pass TMB block (suitable for low-temperature rolling) positioned after the 8-pass Delta-type prefinishing block. A highspeed shear ensures on-line trimming of wire rod heads and tails directly in front of the oil-film bearing laying head, or before the TMB block. At the end of the controlled cooling conveyor is the combined RRT-Rotary Reforming Tube and Easy-Down system.

HSS performs automatic on-line trimming of wire rod heads and tails directly in front of the Laying Head or before the TMB block (depending on line configuration), granting lower transformation costs, mainly due to manpower reduction (at least two operators per shift). Product range is 5 to 25-mm-dia wire rod at speeds of up to 120 mps.

The latest-generation Laying Head features a unique, patented Oil-Film Bearing for rotor support to provide absolute stability. This leads to regular loop formation, lower wear, and extended laying pipe life, as well as to minimized maintenance. High stiffness and high damping capability result in vibration-free operation for the full range of speeds, even in highly unbalanced conditions. This innovative technology is available with all new Danieli laying heads, and can be applied easily for modification and upgrading of existing units.

At the end of the roller conveyor, the combined RRT-Rotary Reforming Tube and Easy-Down system provides regular and
homogeneous coil formation thanks to eccentric wire rod loop deposit and gradual coil lowering during formation, resulting in superior final product quality. When installed in a mill operating in endless rolling mode, the pit is fitted with a shearing unit for coil weight selection.

The latest innovation in bar-in-coil production, enabling twist-free winding of high-quality bars into ultra-compact coils up to 4 tons (filling factor 0.7). Thanks to a cobble-free uncoiling capability, spooled coils are directly supplied “as-rolled” for feeding to downstream cold processing lines, avoiding traditional off-line cold decoiling, stretching, and rewinding with substantial savings
of up to 18 Euro/ton in production costs. Product range is 8 to 32-mm-dia water-quenched (or V-alloyed) rebars, 8 to 52-mm-dia plain bars. Operating speed is up to 35 mps.

We have opened a new era in high-speed drawing of tubular and full cross sections materials with the development of a new generation of chain track combined drawing machine (patented) for a continuous and smooth drawing process. This technology has made it possible to achieve operating speeds of up to 200 mpm for full cross-sections materials and pulling jaws replacement in less than 10 minutes. Low specific pressure applied by the pulling jaws thanks to an electronically controlled hydraulic pressure closing system is also provided in a sturdy machine design, available in sizes from 1 up to 26 tons of pull power.

High efficiency and superior product quality are obtained thanks to CDM-series combined and CDT-series drawing machines
featuring high drawing speed and quick program changing capability to the innovative “Recipe” system, particularly suitable for the production of small-lots. Operating speeds are up to 400 mpm.

Highly efficient and defect-free surface peeling obtained thanks to the high-speed CTM centerless turning machine, featuring constant laser monitoring and dimensional control, self-adjusting system, and quick changing of the cutting tool set (with off-line pre-setting system). Down to ISO h8 achievable tolerances and surface roughness equal to Ra 0.6 μm (or down to 0.3 μm after bar straightening/polishing).

FQM (Fine Quality Mill) is a retained mandrel mill that uses the state-of-the-art process for seamless tube rolling, featuring 3-roll stands. Rolls are radially adjusted using hydraulic capsules. The mill produces tubes of the highest quality up to 18” in a wider range of sizes and steel grades, as compared with the traditional two-roll process. The mill is based on a compact and simplified design, with a high degree of component standardization, and allows easy and quick roll changes.