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TECHNICAL PROPOSAL
FOR
200,000T/Y USED BAR ROLLING MILL
DANIELE (TAIWAN) OCT. 2008
Project No. 98001
30TON/HR ROLLING MILL PROJECT
-1-
CONTENTS
I. GENERAL .................................................................................. 1
II. DESIGN BASIS......................................................................... 4
III. ATTACHMENT...................................................................... 21
30TON/HR ROLLING MILL PROJECT
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I. GENERAL
1.1 PREFACE
This offer sheet covers the supply of the equipment and materials for a Bar
Mill Project capable of producing 200,000 tones per year of Deformed Bar
with product size of D10, D12, D16, D19, D22, D25&D32. and Rung Bar
with product size of ∮9.5mm~∮32mm
1.2 Plant description
The main features of the rolling process and equipment composing the
Plant are described in the following article.
The layout and Mill capacity of the Plant is shown in the attached
”General layout and calculation plan”
1.3 General features of the rolling Mill Process
This rolling mill is provided with necessary equipments for
rolling of bars. Capacity of the rolling mill is 200,000tons/y.
Production ratio of the different bar sizes can be selected freely,
according to distinct market demands.
40tons/hr, top fired, Pusher type Reheating Furnace, energy
saving technology and easy operation procedure are applied
Arrangement of mill stands is all tandem Horizontal type mill.
The Roughing Rolling Mill is driven by AC 1,500HP motors, and
Intermediate Mill is driven by AC 1,500HP motors, but the Finishing
Rolling Mill are driven by DC 1,200HP motors with Control SYS. Total
capacity of AC&DC motors is 3,100kw.
Low tension rolling is applied by Loop Control System in the Finishing
mill depending on the size of the products.
30TON/HR ROLLING MILL PROJECT
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CACULATION PLAN OF MILL CAPCITY ROLLING RATE (250,000T/Y)
Products Billet Annual Production
Size Area Unit-W Size Length WeightNo.
(mm) (mm2) (kg/m) (mm) (m) (kg)
Fin. RollingSpeed
(m/sec)
Pass Time
(sec)
Pause
(sec)
RollingCycle Time
(sec)
ProductYield
(%) (%) (T/Year)
Expected Rolling Hours
(hrs)
1 D10 78.5 0.617 120 4 450 10.8 61 10 71 96 20 30000 1200
2 D12 113.0 0.888 120 4 450 7.78 30 15 45 96 20 36000 1200
3 D16 176.7 1.387 120 4 450 5.8 25.88 15 40.88 96 10 35000 1000
4 D20 314.2 2.466 120 4 450 5.23 16.18 15 31.18 96 10 40000 1000
5 D22 380.1 2.984 120 4 450 5 15.6 15 30.6 96 10 18000 460
6 D25 490.90 3.853 120 4 450 3.29 14.1 15 29.1 96 10 18000 450
7 D32 804.25 5.313 120 4 450 3.29 14.1 15 29.1 96 10 18000 450
TOTAL 100 200000 5760
30TON/HR ROLLING MILL PROJECT
-4-
II. DESIGN BASIS 2.1 Product Mix and Rolling Rate
2.1.1 Product Mix
Product mix for annual production of 200,000 tons is described as the
table “Calculation Plan of Mill Capacity”.
2.1.2 Rolling Rate
With regard to rolling rate, please also refer to the table “Calculation
Plan of Mill Capacity”.
2.1.3 Others
Product length of bars: 12M or others
2.2 Billet
Billet: Continuously cast billets or hot rolled billets
Kind of steel: Low alloy steel for the manufacture of steel bars for
reinforcement, rolled steel for general structure.
Section 100~130 mm sq Length 4m ± 10 mm Weight 314~450kg
Camber (bow): Max.25mm in 4000mm length
Rhomboidity (right angularity): Less than 3%
Twist: Less than 1 degree per meter
Temperature of billet discharged: 1100℃ (Engineering basis)
Note: The billet above shall have the quality suitable for final products. In
order to attain high productivity, that is, improvement of rolling
efficiency and material yield, etc. which are resulted from high rolling
Rate and most suitable cutting of bar products , etc., it should be
essential to well control the billet tolerance and conditions.
30TON/HR ROLLING MILL PROJECT
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2.3 Rolling Capacity
2.3.1 Rolling Hours Required
Rolling Hours Requires=5760 Hrs/Year
With regard to rolling hours required, please refer to the table to
“Calculation Plan of Mill Capacity”.
2.3.2 Annual Working Hours
8 hours/shift×3 shift/day×300 day/year=7200Hr
If operating rate is 80%
Operating Rate 0.8=Rolling hour required/Annual working hour
Rolling hour required=0.8×7200=5760Hr
This operating ratio is considered to be easily attained.
2.4 Steel Grades
The steel grades which are to be processed on the mill are as follows.
a. Deformed bar
D10~D32 Steel bars
Applicable standards:
JIS 20-2525&24-2536 “Rolled steel for general structure”
b. Rung bar
∮9.5mm~∮32mm Steel bars JIS G 3101&JIS G4051
2.5 Rolling Speed
Actual rolling speed: Max. 11 m/sec
2.6 Rolling Method
1. strand rolling
Deformed bars: D10, D12, D15, D20, D22, D25 &D32mm
Rung bars : ∮10, ∮12, ∮16, ∮ 20, ∮25 &∮32mm
30TON/HR ROLLING MILL PROJECT
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2.7 Site (Environmental) Conditions
1) Ambient temperature:
Max. 35 deg. C (more than 15℃)
Electrical control room and pulpits will be kept in 20~30℃
2) Relative humidity: Max. 98%
3) Altitude: Less than 1,000 m above sea level
2.8 Layout
Please refer to attached GENERAL LAYOUT.
1) Rolling Mill
The billet is charged on the Billet Charging Bed by the Billet Yard Crane, and
transferred to the Reheating Furnace by the Billet Charging Roller Table. And
the heated billets are discharged from Reheating Furnace and processed
through Roughing Mill Train, Intermediate Train, Finishing Mill Train.
The Cant Rolling Mill comprises a total of 11 stands(17 pass), divide in roughing
mill with 2 stands (8 pass), intermediate mill with 5 stands (5 pass), finishing
mill with 4 stands (4 pass).
The Roughing Rolling Mill and Intermediate is driven by AC motors, but the
Finishing Rolling Mill are driven by DC motors with vector inverter.
All stands are arranged in horizontal arrangement.
2) Cooling bed
On the Cooling Bed, products are cooled down to desired temperature, while
maintaining the straightness.
3) Cutting & Finishing System
a. For Deformed bar
Those products are then discharged from the Cooling Bed and further
processed by Cutting and Finishing System.
All products are cut to length by cold shear transferred to receiving conveyor.
At the end of the conveyor, a conveyed table is located which transfer the
products to AUTO bundling area then to shipping area.
2.9 Utilities Conditions
30TON/HR ROLLING MILL PROJECT
-7-
The utilities having characteristics or conditions as described hereunder will be
utilized for the plant operation and supplied by the Customer in sufficient
quantities at termination points described hereunder.
1) Electric power
Normal Electric power
- Power receiving: One (1) line
- Supplied power: AC3.3kv/3 phases /50HZ/3,000KVA and AC560V/3
phases /50HZ/1,500KVA
- Voltage fluctuation: Within ±5%
- Frequency fluctuation: Terminals of 3.3kv and AC560V receiving switch
and distributing panel in the electrical equipment
room of the plant.
2) Cooling water
a. Direct cooling water (350 T/hr)
- pH valve: 6.5 to 8.5
- Suspended solid: Max. 20 mg/lit
- M-alkalinity as Ca Co3: Max. 300 mg/lit
- Total dissolved solids: Max. 1,500 mg/lit
- Total hardness as Ca Co3: Max. 300 mg/lit
- Fe: Max. 3 mg/lit
- Cl: Max. 200 mg/lit
- So4: Max. 200 mg/lit
- SiO2: Max. 50 mg/lit
- Temperature: Max. 32℃
- Pressure: Max. 4 kgf/cm2
Design pressure: 3 kgf/ cm2 at the battery Limit of the building
30TON/HR ROLLING MILL PROJECT
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3. SCOPE OF SUPPLY SUPPLIER CUSTOMER REMARK
Country of origin ITEM NO. EQUIPMENT NAME Q’TY Supply
Country Remarks Supply
M1 REHEATING FURNACE (FN.) TAIWAN Type:40Ton/hr M101 -01 Charging Roller Way 1set TAIWAN -02 Hyd. Unit 1set TAIWAN -03 Main Pusher 1set TAIWAN -04 Furnace (Case) And Alloy Rail 1set TAIWAN -05 Waste Chimney 1 p TAIWAN -06 Blower 40HP AC Motor 2 s TAIWAN -07 Heavy Oil Burner 8 p TAIWAN -08 Temperature control for Furnace 1 s TAIWAN -09 Heater for Heavy Oil Tank 1 s -10 Refractory Bricks/Blocks 1Lot ---- -11 Duct 1 s TAIWAN M2 MILL MECHANCAL SECTION M201 ROUGHING MILL TRAIN (RM.) 2 s M201 -01 Horizontal 3HI-Mill Stand With Base Plates 2 s DANIELI 1#~8#Pass -02 Roll (∮455x1500L) 6 p TAIWAN -03 Chock 12 p DANIELI -04 Fiber Bearing (Bakelite) 12 p TAIWAN -05 Reducer Gear Box 1 s DANIELI -06 Flying Wheel With Bearing 1 p DANIELI -07 Gear Coupling (Motor-Reducer-P. Stand ) 2 s DANIELI
30TON/HR ROLLING MILL PROJECT
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SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
-08 Joint Shaft (Pinion Stand-Mill Stand) 6 s DANIELI -09 Cant Table (Guide In & Out) 1 s TAIWAN -10 Approach Roller Table (FN→RM) 12M 1 s TAIWAN -11 Oil Lubrication System 1 s DANIELI -12 Repeater 2 s TAIWAN M202 INTERMEDIATE MILL TRAIN (IM.)2 HI M202 -01 Roller Bearing Mill Stand With Base Plates 5 s DANIELI 9#~13#Pass -02 Roller Bearing Roll (∮350 x 800L x 6pass) 10 s DANIELI -03 Roller Bearing Chock 20 p DANIELI -04 Roller Bearing 20 p DANIELI -05 Reducer Gear Box (With Pinion Stand) 1 s DANIELI -06 Flying Wheel With Bearing 1 p DANIELI -07 Gear Coupling (Motor-Reducer) 2 s DANIELI -08 Joint Shaft (Reducer-Mill Stand) 10 s DANIELI -09 Joint Shaft Coupling For Reducer 4 p DANIELI -10 Joint Shaft Coupling For Stand 4 p DANIELI -11 Approach Roller Table (RM→IM) 36M 1 s TAIWAN -12 Oil Lubrication System 1 s DANIELI -13 Repeater 4 s TAIWAN M203 FINISHING MILL TRAIN (FM) M203 -01 Horizontal Mill Stand With Base Plates 4 s DANIELI 14#~17#Pass
30TON/HR ROLLING MILL PROJECT
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SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
-02 Roller Bearing Roll (∮300 x 600L x 4pass) 8 p DANIELI -03 Roller Bearing Chock 16 p DANIELI -04 Roller Bearing 16 p DANIELI -05 Reducer Gear Box (With Pinion Stand) 4 s DANIELI -06 Cardon Shaft 8 p DANIELI -07 Gear Coupling (Motor to Reducer) 8 s DANIELI -08 Oil Lubrication System 1 s DANIELI M204 GUIDING DEVICE M204 -01 Delivery guide for Rough Mill 4 s DANIELI -02 Guide Through for Rough Mill 4 s DANIELI -03 Entry & Delivery Guide for IM & FM 9 s DANIELI -04 Guide Through for IM & FM 9 s DANIELI M205 SHEAR MACHINE M205 -01 Flying Shear 1 s DANIELI -02 Dividing Shear 1 s DANIELI M3 COOLING AND CUTTING SECTION M301 RUN IN GUIDING EQUIPMENT 54M M301 -01 Run In Guiding Through (54M) 1 s DANIELI -02 Pinch Roller 1 s DANIELI
30TON/HR ROLLING MILL PROJECT
-11-
SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
M302 COOLING BED 42M/9M M302 -01 Cooling Bed 42M 1 s DANIELI -02 Cooling Bed Drive Unit 25HP 1 s DANIELI -03 Bar Collecting Device 1 s DANIELI -04 Bar Traversing Devise 1 s DANIELI -05 Run Out Roller Table 42M 1 s DANIELI M303 COLD SHEAR M303 -01 Cold Shear (power-300ton) 1 s DANIELI M4 BAR FINISHING SECTION M401 TRAVERSING FACILITIES FOR BAR M401 -01 Cold Shear Run Out Table 1 s DANIELI -02 Traverser 1 s DANIELI -03 Product Transfer 1 s DANIELI -04 Shipping Table 1 s DANIELI -05 Auto Bundling 1 s DANIELI M5 SIMPLE PARTS M501 FOUNDATIOM BOLTS AND GAUGE
PLATE
M501 -01 Foundation Bolts (Steel Bar) 15 t -02 Installation Liner (Steel Plate) 5 t
30TON/HR ROLLING MILL PROJECT
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SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
M502 SAFETY COVER M502 -01 Safety Cover (5 tons Steel Plate&5 tons Angle
And Channel ) 10 t
M503 WORKING DECK M503 -01 Working Deck (Steel Plate) 5 t M504 PIT AND DUCT COVER M504 -01 Pit And Duct Cover (5 tons Steel Plate&5 tons
Angle And Channel ) 10 t
M506 CROP CHUTE AND BAG M506 -01 Crop Chute 1 s -02 Crop Bag 1 s M507 MISCLLANIOUS ITEMS M507 -01 Supporting For Detectors 1 s -02 Scrap Box 1 s -03 Dust Box 1 s -04 Tool For Election 1 s -05 Tool For Operation And Maintenance 1 s -06 Coiler For Mis-Rolled Material 1 s
30TON/HR ROLLING MILL PROJECT
-13-
SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
M6 PIPING M601 OUTDOOR PIPING M601 -01 Outdoor Piping For Utilities
(Air 200M,Oil 100M,Water 300M) 15 t
-02 Indoor Piping For All Utilities (Air 800M,Oil 300M,Water 500M)
25 t
-03 Valve And Piping Accessories 1 s E2 POWER RECEIVING & DISTRIBUTION
SYSTEM
E201 -01 3.3 KV Power Receiving Switch And Distributing Panel
3 s TAIWAN
-02 Power Factor Compensation Equipment 1 s TAIWAN -03 Main AC Motor 1,500HP/60HZ/3,300V/10P 2 s TAIWAN -04 Main DC Motors 1,200HP/600V 1 s TAIWAN 600rpm~1,200rpm -05 Main AC 1500HP On/Off Panel 2 s TAIWAN -06 Vector Inverter (For RM &IM AC) 2 s TAIWAN -07 Converter For DC Motor 1200HP 1 s TAIWAN -08 Transformers for AC(1,500KVA/3,300v) 2 s TAIWAN -09 Transformers for AC(1,500KVA/560v) 1 s TAIWAN -10 Transformers for AC(500KVA/220v/440v) 1 s TAIWAN E3 MILL LINE DRIVE CONTROL SYSTEM
30TON/HR ROLLING MILL PROJECT
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SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
E301 -01 Operation Desk 2 s TAIWAN -02 PLC Control For Mill Line 1 s DANIELI -03 Sensor Control-Photocell 12 s DANIELI E4 CABLING, WIRING, BUS, DUCT &
PIPING
E401 -01 Power Cable And Accessories 1 s -02 Control Cable And Accessories 1 s -03 Instrument Pipe And Fitting 1 s -04 Cable Duct, Tray, Conduit Tube And Fitting 1 s -05 HV & LV Cable 1 s -06 Cabling Material & Accessories 1 s -07 Piping Material & Accessories 1 s E4 LIGHTING AND SOCKET OUT SYS. E502 -01 Lighting Transformer & Distribution Board 1 s -02 Socket Outlet Switch 1 s E6 COMMUNICATION SYSTEM E601 -01 Paging System 1 s -02 Closed Circuit T.V. System 1 s -03 Mil Status Indication Lamp 1 s -04 Clocks 1 s -05 Telephone System 1 s
30TON/HR ROLLING MILL PROJECT
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SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
-06 Loud Speaker System 1 s E7 MAINTENANCE TOOL AND
INSTRUMENT
E701 -01 Tools And Instrument For Election 1 s -02 Tools And Instrument For Maintenance 1 s E8 FIRE DETECTION AND FIGHTING
SYSTEM
E801 -01 Fire Detection System 1 s -02 Fire Fighting System 1 s E9 AUXILIARY SYSTEM FOR BUILDING E901 -01 Air Conditioning System 1 s -02 Ventilation System 1 s -03 Lighting Protection System 1 s S OTHER SUPPORTING FACILTIES S1 ROLL SHOP S101 ROLL SHOP EQUIPMENT S101 -01 Roll Turning Lathe 4 s -02 Guide Roller Lathe 1 s -03 Universal Tool Gridding Machine 1 s
30TON/HR ROLLING MILL PROJECT
-16-
SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
-04 Drilling Machine 1 s -05 Double Ended Gridding Machine 1 s -06 Rid Cutting Machine 1 s -07 Tools 1 s S2 MACHINE SHOP & LABORATORY S201 -01 MACHINE SHOP EQUIPMENT 1 s S202 -01 MECHANICAL LABORATORY Tension & Compression Load Tester 1 s S3 TRANSPORTATION EQUIP MENT S301 TRANSFER CAR S301 -01 Transfer Car For Roll Shop 1 s -02 Transfer Car For Shipping Yard 1 s S4 CRANE AND HOIST S401 -01 OHT Crane For Billet Yard With Lifting
Magnet 10t 1 s
-02 OHT Crane For Mill Yard 10t 1 s -03 OHT Crane For Bar Product Yard 10t 2 s -04 Crane Trolley Wire 1 s
30TON/HR ROLLING MILL PROJECT
-17-
SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
S5 PULPIT S501 -01 Furnace Control Room 1 s -02 Main Control Room 1 s -03 Cold Shear Control Room 1 s -04 Bar Finishing Control Room 1 s S6 COMPRESSED AIR SUPPLY FACILTIES S601 -01 Compressed Air Station 12M3/min 3 s -02 Receiver Tank 10 s A SPARE PARTS & CONSUMABLES A1 SPARE PARTS -01 Roller For Rough Mill 455∮ 24 s TAIWAN -02 Roller For Intermediate Mill 350∮ 40 s TAIWAN -03 Roller For Finishing Mill 300∮ 36 s TAIWAN -04 Roller Bearing Chock For Intermediate Mill 40 s DANIELI -05 Roller Bearing Chock For Finishing Mill 36 s DANIELI -06 Roller Bearing For Intermediate Mill 40 s SKF -07 Roller Bearing For Finishing Mill 36 s SKF -08 Fiber Bearing (Bakelite) 40 p TAIWAN -09 Cardon Shaft For Finishing Mill 10 p DANIELI -10 Joint Shaft For Rough Mil 6 p TAIWAN
30TON/HR ROLLING MILL PROJECT
-18-
SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
-11 Joint Shaft For Intermediate Mill 10 p TAIWAN -12 Guide Plate 60 p TAIWAN -13 Reducer Gear For Intermediate Mill 1 p DANIELI A2 SUPPLY OF UTILITIES -01 Cooling water DCW, ICW -02 Lubrication Oil -03 Grease -04 Hydraulic Oil -05 Fuel Oil -06 Electric Power -07 Gases A3 MATERIALS -01 Erection Material A4 ITEMS EXCLUDED FROM SUPPLIER’S
SCOPE
-01 Civil Work & Building -02 Equipment Foundation -03 Erection Work -04 Wiring Work -05 Piping Work
30TON/HR ROLLING MILL PROJECT
-19-
SUPPLIER CUSTOMER REMARK Country of origin ITEM NO. EQUIPMENT NAME Q’TY
Supply Country Remarks
Supply
-06 Water Treatment Facility -07 Drainage Pump -08 Fire Fighting Facilities -09 Lighting -10 Communication System -11 Simple Structure -12 Crane / Transportation Equipment -13 Air Conditioning & Ventilation -14 ITV -15 Roll Shop Equipment -16 Maintenance Equipment -17 Laboratory -18 Sewage Facility -19 Template -20 Consumables -21 Tools -22 Grounding Material 1 s
30TON/HR ROLLING MILL PROJECT
-20-
CT-001:BILLET CHAGE BED CT-002:40T/H HEATING FURNACE
CT-004:40T/H FURNACE MAIN PUSHER CT-003:40T/H FURNACE MAIN PUSHER HYD,UNIT
30TON/HR ROLLING MILL PROJECT
-21-
CT-005:40T/H HEATING FURNACE
CT-008:40T/H HEATING FURNACE SIDE PUSHER
CT-007:40T/H HEATING FURNACE
CT-011:3 HI ROUGH MILL REDUCER GEAR
30TON/HR ROLLING MILL PROJECT
-22-
CT-009:40T/H FURNACE BLOWER
CT-010:3 HI ROUGH MILL REDUCER GEAR
CT-012:3 HI ROUGH MILL REDUCER GEAR
30TON/HR ROLLING MILL PROJECT
-23-
CT-013:3 HI ROUGH MILL STAND
CT-015:3 HI ROUGH MILL STAND
CT-014:3 HI ROUGH MILL STAND
CT-016:3 HI ROUGH MILL STAND
30TON/HR ROLLING MILL PROJECT
-24-
CT-017:3 HI ROUGH MILL STAND
CT-019:3 HI ROUGH MILL STAND
CT-018:3 HI ROUGH MILL STAND
30TON/HR ROLLING MILL PROJECT
-26-
CT-024:3 HI ROUGH MILL STAND
CT-026:PINCH ROLLER
CT-025:FLYING SHEAR
CT-027:1 IN→2 OUT INTERMEDIATE REDUCER GEAR
30TON/HR ROLLING MILL PROJECT
-27-
CT-028:1 IN→2 OUT INTERMEDIATE REDUCER GEAR CT-029:1 IN→2 OUT INTERMEDIATE REDUCER GEAR
CT-030:2 HI INTERMEDIATE MILL STAND CT-031:2 HI INTERMEDIATE MILL STAND