Dojran Steel installs new bar and section mill

3 June 2016

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Merchant bar and section mill in full operation at Dojran Steel

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Dojran Steel section mill

In January 2016, Dojran Steel signed a contract with Russula to do a major overhaul on its plant. Russula will supply a new 350,000 tpy bar and section mill that includes mechanical equipment, an automation system and all the technical support necessary for Dojran Steel to expand its current product range and improve its finished product quality.

Bar and Section Mill | 350,000 tpy

In the first project phase, the existing 20 tph reheat furnace will be used in conjunction with the existing three high open type roughing mill, crop shears, quenching system and a cold cutting shear. In the second project phase, production capacity will increase to 350,000 tpy when the existing 20 tph furnace is replaced with a new 60 tph reheat furnace. Furthermore, the existing three high open type roughing mill will be replaced with four new roughing mill stands for continuous production.

For the first project phase, Russula will supply a total of 18 new RCS, housingless stands for the roughing, intermediate and finishing mills. All the stands are housingless type and can be installed in a horizontal or vertical arrangement, without any further modifications necessary. Each stand is completed with on board systems, arranged in such a way to minimize piping and simplify adjustments.

The new stands will be pre-assembled in the workshop with all their interconnecting piping already assembled and connected, which will considerably reduce on-site assembly and start-up time. All components are designed for high durability and maximum uptime.

Moreover Russula will supply 7 new loop formers, a dividing shear, stands bypass roller table, accelerating roller table with lifting aprons, a rake-type walking beam cooling bed, a step-by-step chain transfer and layer extraction trolleys are foreseen at the cooling bed exit side. Also a new wheeled stopper for cut to length and chain transfers are foreseen.

Existing rolling mill equipment will be adapted to the new rolling conditions. Two crop shears, a quenching system and a cold shear will be upgraded and reutilized reducing the total capital expenditure of the expansion project.

Roughing Mill

The existing three–high open type roughing mill will be complemented with two new housingless stands in H and V configuration. A conveying chute will be engineered for the existing start stop crank shear.

Intermediate Mill

The intermediate mill is made up of 8 housingless stands in H, V and existing H/U (Universal) arrangements. Existing cartridges for the universal stands and an existing start-stop double arm rotary shear will be adapted to the new rolling mill.

Finishing Mill

The finishing mill consists of 8 cartridge type stands in H, V and H/U configurations. Seven new loop formers will be supplied for one strand rolling located betwee each pair of finishing stands. Also, five bypass roller tables will be supplied to replace of stands when they are not required by the production schedule.

Cooling Bed Area

After cooling in the quenching system, the material is fed into a start-stop dividing shear that divides the bars into multiple lengths. The straight bars will then accelerate down a 72 m long roller table with lifting aprons to be positioned correctly before discharging onto the cooling bed. The bar and section mill will feature a 42 m x 12 m raketype walking beam cooling bed fitted with a movable frame, an automatic step-by-step chain transfer, a cut-to-length cold shear, plus a run-out roller table fitted with a movable stopper. The layers of bars are fed to 6+6 m chain transfers and then to existing tying and collecting facilities.

Rolling Mill Start-up March, 2017

Russula is also responsible for the basic civil engineering, detailed mechanical and electrical engineering, start-up supervision and training. The mechanical and electrical equipment delivery is scheduled for November 2016. Cold and hot testing are scheduled for March 2017, fourteen months after the award date. Signed in January 2016, this contract represents the 3rd major mechanical project for Russula in the last three years.