This document provides information about the wire rod mill and bar mill at a steel plant, including: - The wire rod mill has a capacity of 550,000 tons per year and can produce wire rod sizes from 5.5 to 22 mm. It is equipped with a 150 ton per hour walking beam reheat furnace. - The bar mill has a capacity of 900,000 tons per year and can produce bar sizes from 8 to 50 mm. It is equipped with a 160 ton per hour walking beam reheat furnace. - Both mills have multi-stand blocks for rolling, laying heads to form coils, and cooling beds. The document includes layout diagrams and details of the key equipment for each mill

1. 1
P.K.SINHA
DGM I/C (WIRE ROD & BAR MILL)

2. WIRE ROD MILL

3. 3
WIRE ROD MILL & BAR MILL
Technology Provider – Danieli, Italy.
Automation & Electrics – Danieli Automation.
Equipment Erection – SEPC.
Cranes – WMI Pvt Ltd..

4. RHF
WTP
MILL
AREA
Cooling
Conveyor
C-Hook
Area

5. WALKING BEAM REHEATING FURNACE

6. RE-HEATING FURNACE OF WRM
 Consortium leader :M/s Bricmont Inc. USA
( Technology ,Design Engg, Supply of Main Eqpt, supervision)
 Consortium Partner: M/s Gillanders Arbuthnot &
Co.Ltd. ( MICCO), INDIA
(Design Engg of Auxiliary Eqpt, Supply,Erection,Supervision)
 Consultant : M/S MECON Ltd.
(Project Management)
6

7. DESCRIPTION
 TYPE- WALKING BEAM WITH IN FURNACE
ROLLS SIDE CHARGING AND SIDE
DISCHARGING TYPE.
 CAPACITY- 150TPH (Cold charge)/180 TPH
(Hot charge)
 SIZE – L-19.5M X W-12.9M X H-14.6 M
 MIXED GAS FIRED WITH INPUT BILLETS OF
150 mmx150 mmx12 mtr.
 DEDICATED W.T.P WITH EMERGENCY O/H
TANK.
 LEVEL 2 AUTOMATION WITH LEVEL 3
INTERFACE.
7

8. 8
CHARGING SIDE OF WRM –
FCE
IS
P

9. 9
DISCHARGING SIDE OF WRM
FCE
IS
P

10. 10LIFTING FRAME
TRAVERSE
FRAME
FIXED SKID POSTS AND
PIPES
MOVING SKID POSTS AND
PIPES
REFRACTORY
LINING
IS
P

11. Air
In
Air Out
Chimney
RECUPERATOR
200
C
6100C
Flue
Gas(850oC)
Waste
gas(450oC)

12. Main Valve
N2 purge
CO
gas
Main Header 1000 DN
Heat Zone Preheat
Zone
SoakZone
Charging
Door
Dischargin
g Door
Gas Pipelines & Burner position
600DN
550DN
400DN
350DN
250DN
200DN

13. Industria
l Water
T.O.P
Make
Up
Water
Tank
Soft water
Tank
ColdWaterChannel
Heat
Exchanger
Back Wash
Tank
Industrial
water Tank
Softening
Plant
RO
E.O.T.
SSF
FURNACE
Dosing
NRV
ASCF
WATER SYSTEM
Dosing
Cooling
Towers
Overflo
w
Buffer Tank
ASCF

14. WIRE ROD MILL-LAYOUT

15. Wire Rod Mill
Type of Mill Single strand continuous, +5 m mill floor level
Capacity of the Mill 550000 t/year
Wire rod sizes 5.5 mm to 22 mm in 0.5 mm increments 6.0
mm rebar
Re heating furnace 150 t/hr walking beam type
Input billet size 150X150 mm, 12 M long
Maxm. Delivery speed 115 m/sec
Grades of steel Carbon steel, spring steel, Electrode quality,
Cold heading, low alloy steel, forging quality,
Rebar
Operating days 300
Working days 6 days (3 shifts per day)
Hot rolling hours 5500
Coil weight 2T
Coil size (mm) 850 ID/ 1250 OD
Yield 97 %
Mill Utilization 74.8
15

16. Wire Rod Mill
Billet Cold/hot
charging & Weighing
Re-heating Furnace
Billet discharging
& descaling
Roughing Mill
Crop & Cob.Shear #1
Intermediate Mill
Crop & cob. shear #2
Pre finishing Mill (vertical
loopers & carpet roll charging
Pinch roll, crop shear#3
Horizontal looper
2 stand pre-finishing block
Water box
Pinch roll & crop shear/snap shear
Horizontal looper
8 stand No twist block
Water box
High speed crop & cob. shear
RSM
Water box
Pinch roll & laying head
Coil conveyor & forming chamber
Coil conveyor, compacting,tying,
Weighing, trimming station
16

17. 17

18. 18

19. 19

20. 20
2 HI STAND

21. 21
8 PASS FAST FINISHING BLOCK

22. 22

23. 23

24. 24
SPEED CONTROL PULPIT

25. 25
LAYING HEAD

26. Location:
The laying forming head is
located between the Wire
rod Block and the cooling
conveyor
Purpose:
The purpose of the laying
head is to form the wire rod
turns and discharge them
onto the cooling conveyor.
LAYING HEAD AND COIL FORMING ROLLER TABLE

27. 27
COIL FORMATION

28. 28
COIL HANDLING AREA

29. 29
COIL COMPACTOR

30. 30
BAR MILL LAYOUT

31. Parameters Bar Mill
1. Type Single strand continuous 2 Hi, H-V
housing less stands
2. Supplier Danieli, Italy
3. Capacity 900,000 MT/Year
4. Bar sizes 8 to 50 mm
(TMT up to 40.0 mm)
5. Reheating
furnace
160 T/hr walking beam furnace
6. Input Billet
size
150 mm square, 12 mt. long
7. Max. delivery
speed
38.0 m/sec
31
BAR MILL

32. Parameters New Mill
8. Grades of product Carbon steel, low alloy steel &
Rebar
9. Operating days 300
10. Working days
per week
6 days (3 shifts per day)
11. Hot rolling hours 5500
12. Bundle weight 2-5 T
13. Commercial length 6,9,12 M
14. Yield 97 %
15. Mill utilization 71.3 %
32

33. • Endless Welding
Rolling
• Bar Slit Technology

34. MILL PROPER AREA
34

35. DIVIDING SHEAR AREA
35

36. SLIT ROLLING AREA
36

37. BAR MILL COOLING BED
37

38. 38
TWIN CHANNEL

39. THANK YOU