"New Achievements in EWR Endless Rolling Process, Thanks to Billet K-Welding Technology "

by "Sandro Orlando "

Publisher - "Danieli Morgårdshammar, Danieli & C. Officine Meccaniche S.p.A., Via Nazionale 41, 33042 Buttrio (UD), Italy "

Category - Engineering & IT

"Since more than two decades Danieli is front running the development of EWR (Endless Welding Rolling) Technology, which consists in continuous welding of billets between the re-heating furnace and the rolling mill in order to establish a continuous rolling process. This technology brings a wide array of benefits, especially in due course of modernization of the rebar industry. The elimination of the inter-billet gap allows to eliminate head and tail cropping and provide much higher stability in the rolling in both slit and single strand modes.Furthermore, in case of production of rebar on cooling bed, the EWR eliminates the short bars and, in case of shifting the production from bar to coil, the K-Welding technology is the key to feed and allow hot rolled coil spooler to produce tailor made weight compact coils up to 8 Ton. Depending of the mill configuration and its initial capacity, the implementation of an EWR process can drive to increase of production from 8% to 12% and yield improvement up to 1,5%. Study and development on this Technological Package can allow nowadays to operate in EWR mode also for output requirements far over 200 Ton/h covering a wide array of steel grades and production segments. The areas of last development are including and not limited to Automation and process control, spark/spatter containment thanks to new “spark killer” solution, amongst the others, and brought substantial improvement in a technology that – even well known since many years – has now reached a proven level of consistency in productivity and operational reliability. Worldwide markets, and particularly Far East markets, are moving to a challenging phase of process modernization which ultimately target to quality improvement, expanding in new products while reducing operational and production costs in effective manner. "

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