Steel Dynamics Inc. (SDI), Fort Wayne, Indiana, USA, awarded the contract for an expansion of the merchant bar mill at its Roanoke Bar Division, Virginia operation to SMS group www.sms-group.com. The upgrade is to integrate a new reheating furnace and a completely new finishing area into the facility. With this investment, one of the largest steel producers in the United States strengthens its market position, enabling SDI Roanoke to increase its rolled capacity from the current 500,000 tons to over 600,000 tons per year.
The supply package is comprised of a pusher-type reheating furnace that is designed for high capacity to process 140 tons of billets per hour. These will be rolled into light sections and reinforcing bars from sizes 12.7 to 35.8 millimeters, as well as corresponding round bars.
The new reheating furnace aims not only to increase productivity but also to significantly improve energy efficiency, with the adoption of a smart combustion management system. The heating process will be optimized by the SMSPrometheus software and extra low NOx burners that are digitally controlled to reduce emissions. The furnace will be supplied complete with handling equipment to charge and discharge billets. A key factor in the selection of the full package from SMS is the lean design, which will allow a swift tie in with the existing mill machines in a one-week shutdown.
The new finishing package, specially designed for rebar with diameters from 12.7 to 35.8 millimeters, includes all equipment starting from the outlet of the dividing shear up to the finishing area. It comprises bar layer transfer devices, bar counter, lance-type bundler, electrical-type tying machines, bundle transfer and temporary storage devices. The lance-type bundler ensures high-quality bundle formation. The bundle length will vary from 6 to 18.3 meters and the weight can vary from one to five tons, maximizing the furnace capacity.
“One of the most important advantages of the SMS group concept is a favorable design that utilizes current floor space and minimizes construction and installation costs. Paired with the short delivery time, we will reach our goals within the shortest possible time,” says Tim Bradley, Project Manager of SDI Roanoke.
After its upgrade, the merchant bar mill will increase production of rebar to over 200,000 tons per year. Commissioning of the upgraded facility is scheduled for the end of 2017.