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Danieli to Construct New Flat Products Complex for MMK-Atakas
10/22/2007 - Danieli will be the sole supplier of technological equipment for a new flat products complex MMK-Atakaş is planning for Iskenderun, Turkey, including EAF-based meltshop and caster, high-capacity hot rolling mill, continuous pickling line, cold rolling mill, hot dip galvanizing, and coil coating facilities.
MMK-Atakaş, a joint venture between Russian Magnitogorsk Iron & Steel works and Turkish Atakaş, has awarded Danieli as the sole supplier of technological equipment for a new complex for flat products to be installed in Iskenderun, Turkey. In addition to the new complex, Danieli will also install a new facility for the production of coated flat products at a separate site near to Istanbul.
The facility’s meltshop will feature a jumbo-size (250-tonne) electric arc furnace and high-power (275-MVa) transformer capacity to satisfy the facility’s production requirement of 300 tonnes/hour. Additional equipment will include twin ladle furnace, twin vacuum system, and an effective fume de-dusting plant, featuring two parallel filters to ensure the necessary environmental protection.
The first part of the plant’s new casting and rolling facility will feature one Danieli twin-strand thin-slab caster with the capacity to produce from 50- to 80-mm thick slabs (after dynamic soft reduction) that are 800- to 1570-mm wide. With a product mix including low and medium carbon grades and HSLA, the new caster is also designed for casting extra low carbon, interstitial-free and high carbon grades.
The second part of the casting and rolling facility begins with two strands of roller hearth furnaces that were designed and supplied by Danieli Centro Combustion. The furnaces—one following each casting line—guarantee proper temperature and buffer time between casters and mill.
The new hot strip mill (HSM) will feature the following equipment, installed within a compact, 137-meter footprint. The HSM begins with a vertical edger (E1); primary descaler (D1); two roughing stands (R1 and R2); a drum crop shear cutting on the flight; and a secondary descaler (D2). Four 4-high finishing stands (F1 to F4) are followed by twenty-one water wall(tm) laminar cooling benches and two down coilers with entry pinch rolls. The line is completed by a coil handing system including coil circumferential and radial strapping machines, coil weighing scale, coil marking unit, and a coil visual inspection station.
The cold rolling and coating facility at Iskenderun will include a Turboflow® continuous pickling line that is designed to produce in excess of 1.2-milion tonne/year. Entry loading and processing will be made through two robust uncoilers, opener, flattening, and anti-coilbreaking units designed for high reliability and "any coil feed" concept, in order to ensure no production losses due to coil preparation and joining. Coil joining will be made with a state-of-the-art laser welding machine incorporating the best technology available in terms of joint over-thickness and strength. The pickling section’s three tanks and five-stage rinse tank is based on Danieli’s patented Turboflow technology, an advanced turbulent-channel concept that facilitates the highest possible energy savings and pickling condition flexibility to provide uniform pickling quality regardless of strip grade and speed.
The two-stand cold reversing mill will be produce approximately 0.75M tonne/year of low carbon, CQ, DQ, DDQ, IF and HSLA steels. The mill will be equipped with all mechanical devices to ensure a flexible production program, including an uncoiling device with flattener unit, two tension reels and coil handling equipment to allow for a flexible quantity of passes, and an automatic work-roll-changing device. The four-roll type mill stands are provided with the latest actuators for thickness and flatness control.
The continuous hot dip galvanizing line is designed to produce 0.45-million tonne/year of finished coils. Designed to serve high-quality paint applications, the line is equipped with a double entry end with electrical mashed seam welder, degreasing section (located ahead of the entry accumulator), and a horizontal annealing furnace from Danieli Centro Combustion. The annealing furnace includes a recuperative room, direct-fired section, gas-fired radiant tubes and a jet coolers section. The final zinc thickness will be tightly controlled by the Danieli Kohler wiping system. After being cooled, the strip will be skinpassed for final roughness control, tension-leveled and passivated. At the exit of the line, strip edges will be cut to the nominal desired width by the Danieli carousel-type side trimmer and scrap chopper, prior to being oiled and rewound.
The color coating line will have nominal production capacity of approximately 0.2-million tonne/year, for white goods, construction, and general commerce applications. The line will be equipped with a double entry end with hydraulic stitcher, degreasing sections (located before and after the entry accumulator), pre-treatment section, prime and finish coaters, and horizontal catenary ovens and water-quench equipment. At the exit of finish oven, strip is directed to the exit accumulator, prior to being inspected and than rewound.
The coating facility at Istanbul includes one hot dip galvanizing line and a color coating line with the same characteristics of Iskenderun site.
Danieli Automation will design and supply all electrical equipment and the control systems for the complete plant, providing an integrated and optimized system configuration. The single-source automation system will help the facility improve plant efficiency thanks to common interfaces and design concepts, as well as a smoother project execution, quicker and more efficient start-up, easier know-how transfer.
Located on the sea side, the new plant will have a dedicated harbor, with consequent advantages in terms of logistical material flow from ships to and from the plant. The new plants will come into operation gradually during 2009 and 2010 starting with the coating facilities and ending with meltshop and hot rolling facility. The Istanbul installation includes a 0.45-million tonne/year hot dip galvanizing line facility and a 0.2-million tonne/year color coating line.
