Emirates Steel Industry has contracted Danieli for the completion of Phase 2 expansion of the minimill complex currently in operation in the Mussaffah Industrial Area, Abu Dhabi with the installation of a new Heavy Section Mill with a capacity of 1 million tonne per year of large size sections, beams, columns and sheet piles.
The new mill will be integrated with the 1.4 million tonne per year 2 Steel melt shop and the associated DRI plant currently under construction and due for start operation in autumn 2010. This is the latest step completion of the Mussaffah integrated mini mill plant, completely supplied by Danieli on a complete turn key basis that also includes Phase-1 made up of the 1.4 million tonne per year 1 Steel melt shop, the associated DRI plant, a 480,000 tonne per year high speed wire rod mill and 620,000 tonne per year high speed bar mill that started operation in October 2007 and January 2008. The new Heavy Section Mill, planned to start production by the end of year 2011, will produce parallel flange beams, columns and bearing piles with up to 1,030-mm flange with and 419 web depth, up to 430 mm parallel flange channels, 250 mm angles, 750 mm U-sheet piles and 630 mm Z sheet piles using 350 x220 mm conti cast blooms and up to 1050x435x120 mm beam blanks as starting material.
The new plant, based on the PSP Profile Sizing Process, will be fed by 250 TPH Danieli Centro Combustion walking beam reheating furnace, directly connected to the Beam Blank Conti caster for hot charging operation. The hot rolling area will composed of a single reversing stand BDM Break Down Mill and the UFR Ultra Flexible Reversing pre finishing or finishing sizing mill, made up of three stands arranged in “U” universal, “E” edging and “UF” universal or sizing configuration.
After the finishing stand, a Hi profile gauge unit will enable in line product size measurement and control. The mill's finishing end includes 96 meters long, 40 meters wide cooling bed, on line jumbo size straightened, cutting to length, automatic stacking, gagging, repairing, piling and collecting facilities. All electrical and the advanced automation system will be supplied by Danieli Automation. Completion of ESI phase 2 expansion projects will make this Steel Complex the most technologically advanced and one of largest plants of this type ever built in the whole Gulf Region and in the neighboring Countries.
