Traditional long-product maker Scaw Metals is going to build a flat-steel complex on a brownfield site in Johannesburg and will revamp an existing steel meltshop with a new, state-of-the-art electric arc furnace. Both projects will be executed by Danieli.
With this major investment, the Barnes Group, since 2018 Scaw Metals’ controlling shareholder, intends to expand the company’s portfolio into the flat-steel market. So far, the Rolled Products division of Scaw Metals has operated an electric arc furnace to produce cast billets that are rolled into products, such as sections, low- and high-carbon wire rod, rebar, mining bar and rounds.
High-quality slabs for high-quality hot rolled coils (HRC)
As part of the flat-steel complex, Danieli will supply a vertical-curve, single-strand slab caster that will be designed to produce 650,000 t/year of high-quality quality slabs in various widths. The casting machine will come with latest Danieli technological packages for mould-level control, breakout prediction, online mould-width adjustment and solidification modelling.
The slab reheating furnace, bought from a third-party supplier, will be equipped with proven PHL firing logic patented by Danieli Centro Combustion to achieve maximum energy efficiency and reduce fuel consumption and emissions from furnace operation.
Hot strip down to 1.2 millimeter thickness
The narrow and medium-width hot rolled coil (HRC) will have final thicknesses ranging from 1.2 to 8.0 mm. The rougher and the first finishing stand will be equipped with edgers. All the finishing stands will feature hydraulic automatic gauge control (HAGC) as well as roll bending and shifting. The high-efficiency water treatment plants using Danieli-patented filters help reduce water and energy consumption in the rolling mill. Water from the laminar cooling system will be used to cool down the main mill stands.
Control of the entire line will be from a single pulpit arranged at the finishing mill. Danieli Automation will implement the Level 1 and Level 2 control, the medium-voltage system for the rolling stand drives and the descaling system.
New electric arc furnace to feed hot-strip mill
For the expansion of the existing meltshop, Danieli will supply a modern FastArc EAF which will be charged with a combination of steel scrap and DRI (direct reduced iron). It will be powered by an existing transformer of 100 MVA. The EAF will be equipped with a water leak detection system to provide maximum safety of operation.
The new HRC complex is scheduled to start production by March 2024.