In late December 2020, Italian steel producer Ferriera Valsabbia SpA issued the Final Acceptance Certificate to Primetals Technologies for the supply ERT-EBROS of endless rolling technology for the company's existing bar rolling mill in Odolo, Brescia province. The aim was to boost plant output and utilization levels. The system welds together billets intended for rolling, thus enabling a continuous rolling process with a consistently high product quality. The new ERT-EBROS plant is the first system of its kind installed in Italy. Primetals Technologies was responsible for the project engineering as well as for assembly and commissioning supervision of the new equipment, and supplied the ERT-EBROS billet welding system, including a deburring station, extraction system and complementary equipment such as pinch roll, shear and roller table. The ERT-EBROS system is designed for an annual production capacity of 900,000 tonnes. The scope of supply also included the fluid systems, the electrical equipment and automation system and also technology packages for controlling the welding. An induction furnace was installed before the rolling train to make up for temperature losses.
Some innovative solutions were implemented by Primetals Technologies, so to comply with Ferriera Valsabbia's requirements about both metallurgy and mechanical features along the entire length of the bar. A specifically-engineered interactive software suite analyses the operation results and produces an array of statistics about system productivity, number of joints and duration of welding sequences.
Established in 1954, Ferriera Valsabbia operates an EAF-based minimill with a production capacity of some 900,000 metric tons per year of billets and bars for concrete reinforcement. It is one of the largest privately owned rebar producers in Italy. The bar rolling mill was realized by Primetals Technologies in 2007/2008. This included the installation of a hot-charging system for billets as well as a system for single-bar high-speed delivery that allows rolling speeds of up to 29 meters per second. The mill is designed to process low-carbon steel billets with a square cross-section of 150 x 150 (160 x 160 in the future) millimeters and length of 9 meters. This results in rebars with diameters of between 8 and 40 millimeters. In two-slit rolling mode, the bar diameters from 8 to 20 millimeters can be realized.