Nucor Steel, based in Alabama, USA, is embarking on an ambitious project to modernize its Steckel mill at the Tuscaloosa site. This transformation, facilitated by a partnership with SMS group, aims to convert the existing mill into a state-of-the-art tandem Steckel mill. The primary objective is to enhance production capacity and improve the quality of high-strength thin strip products, positioning Nucor to meet the evolving demands of the steel industry.
The centerpiece of this modernization is the addition of a high-performance mill stand downstream of the existing setup. This tandem configuration allows for simultaneous rolling processes, effectively utilizing both stands for reversing roughing passes and finishing passes. Notably, the design accommodates special work rolls to produce various products, including base plates and checker plates, broadening Nucor's product offerings.
A significant aspect of the upgrade involves replacing the existing entry and exit-side Steckel furnaces with new, closed-type designs. These advanced furnaces are engineered for optimal temperature maintenance and efficiency, significantly reducing natural gas consumption. By minimizing heat radiation exposure to the roller tables, the new furnaces enhance operational safety and efficiency, ensuring that products maintain their quality throughout the rolling process.
To further improve the strip quality, both mill stands will incorporate CVC® plus technology. This innovative system allows for precise control of strip profile and flatness through the combination of bending and axial shifting of the work rolls. A looper placed between the stands aids in optimizing strip tension and supports speed control, enhancing the overall quality of the finished products.
In addition to the mechanical upgrades, SMS group is responsible for modernizing the electrical and automation systems within the Steckel mill. This includes the main drives, sensors, and measurement equipment, as well as the mill's basic and process automation. The modularized level 1 software architecture ensures quick responses to operational needs, promoting fault-free performance during production. The X-Pact® Centerline Control system enhances stability and guidance for the rolling process, utilizing intelligent cameras and advanced automation functions.
The new mill stand will feature a twin drive system, enabling independent operation of the top and bottom work rolls. SMS group’s Genius CM® system will monitor the drive unit's status continuously, facilitating condition-based maintenance. This proactive approach to equipment upkeep is expected to minimize downtime and maximize production efficiency.
Before the equipment is shipped, an integration test known as Plug & Work will be conducted to prepare the automation system for efficient commissioning. This ensures a smoother start-up process and allows the Nucor team to begin production quickly after the installation. Post-commissioning, SMS group will provide ongoing support via the X-Pact® service portal, ensuring that Nucor Steel can optimize its operations continuously.
