Primetals Technologies has received the final acceptance report (FAC) for a wire rod mill modernization project at Kaptan Demir Çelik (Kaptan Iron & Steel, part of Kaptan Group) in Marmara Ereğlisi, Turkey. With an annual capacity of 650,000 tons, the plant will produce carbon steels, austenitic stainless steels and steels with cold heading grades.
The project expanded the Kaptans portfolio to include value-added products such as wound reinforcing steel, fine-grained reinforcing steel and welding wire for the construction and automotive industries in both domestic and export markets.
Standards for quality
The system ramped up quickly. It only took 21 days from the start of warm commissioning to the first salable product. This record-breaking implementation set a new industry standard and was made possible by an experienced project team and close and effective collaboration between Primetals Technologies and Kaptan Demir Çelik.
The technological advantages of the equipment as well as outstanding after-sales services ensured by Primetals Technologies' local presence in Turkey were two of the main factors that led Kaptan 2021 to select Primetals Technologies as a supplier.
Lower energy costs
The new wire rolling mill has increased Kaptan's overall production and manufacturing speed. The rolling mill processes up to 105 tons per hour at speeds of up to 110 meters per second. Kaptan can now offer quality carbon products in diameters ranging from 4.5 millimeters to 26 millimeters, as well as an expanded range of rebar from 6 to 20 millimeters. By installing the first Morgan Bar Reducing/Sizing Mill (RSM) in Turkey, Kaptan is able to roll seismic grade concrete steels with reduced alloying costs. The RSM can also meet the tight tolerances required for the high carbon tire wire market.
Kaptan's work also stands out because it is the only one to have the combination of an RSM and the new generation of the no-twist rolling mill (NTM) with individually driven stands (eDrive). This allows Kaptan to consistently deliver high quality finished products with reduced alloy and energy costs. Additional production advantages are provided by a metallurgical in-line heat treatment process using high-precision Morgan Water Boxes and Stelmor Controlled Cooling Conveyor.
Regulated processes
In addition to the mechanics, Primetals Technologies delivered the electrical equipment and plant automation, consisting of main and auxiliary drives, motors, a new state of the art level 1 automation system with plant and process visualization (HMI), a new level 2 process -Expert automation as well as the central and local operator stations.
The state-of-the-art standardized Level 1 automation solution (LRS) from Primetals Technologies made it possible to minimize the total downtime of the wire rolling mill and achieve a stable and rapid production ramp-up. By using the Moby Panel from Primetals Technologies - mobile control panel - on-site operators can safely control local system components during inspections and finishing operations. In addition, the concept meets the required shutdown requirement for mechanical work.
Scope of automation
The automation scope includes a cost-effective Level 2 process automation system. Long Rolling Process Expert developed by Primetals Technologies is a platform to support the production management process. The system has a clearly structured user interface for evaluating system performance and implementing optimization measures in the production process. The modular structure makes it easy to integrate additional functions to provide insights into material tracking and quality control based on actual production data. Together, these systems lay the foundation for greater networking and more effective system control
The scope of the project also includes spare parts, management devices, offline devices for scaffold preparation, media systems, project planning services for other system parts, consulting services for assembly, commissioning and training for the system personnel.
