As a pillar of the national economy, the steel industry’s technological iteration and efficiency improvement directly impact the development quality of downstream sectors like infrastructure and manufacturing. Our 300,000 tons/year single high-bar steel rolling production line integrates three core advantages—precision manufacturing, intelligent control, and green low-carbon operations—covering the production of ribbed steel bars in full specifications from Φ8mm to Φ40mm. It achieves end-to-end optimization from raw material processing to finished product delivery, providing steel enterprises with a high-quality, high-capacity, and cost-effective solution that sets a benchmark for industry transformation and upgrading.
I. Core Technology: End-to-End Precision Control for Superior Quality
1. Equipment Configuration: Professional-Grade Gear Ensures Stable Capacity
The production line boasts a robust core equipment lineup, with 24 rolling mills divided into four functional units (roughing, intermediate, pre-finishing, and finishing) for specialized tasks:
- Roughing Mills: Φ550/Φ450 short-stress-line rolling mills offer high rigidity and quick roll change, boosting operational efficiency.
- Finishing Mills: 2 sets of double-stand Φ250 modular mills arranged at 45° top intersection enable torsion-free rolling, with a maximum rolling speed of 45m/s to meet high-speed production of small-sized products.
Key auxiliary equipment is equally refined:
- Hydraulic billet pushers and extractors ensure smooth billet transportation.
- 5 flying shears precisely cut heads, tails, and emergency breaks, handling a maximum shear section of Φ40mm.
- Hub-type steel feeding devices adapt to high-speed workpieces (16~45m/s) for stable cooling bed entry.
All equipment adopts high-quality materials and precision manufacturing to guarantee stable output of the rated 300,000 tons/year capacity.
2. Process Innovation: Controlled Rolling/Cooling + Intelligent Linkage
- Closed-Loop Controlled Rolling & Cooling: Water cooling devices after pre-finishing and finishing mills rapidly cool workpieces to the phase transformation zone, controlling grain growth and avoiding martensite formation. The final product features balanced strength and toughness, no red rust on the surface, and a core-surface hardness difference ≤40HV, fully complying with GB/T1499.2-2024 and other national standards.
- Intelligent Integration: The entire process is controlled by Siemens S7-1500 series PLC, enabling real-time coordination of billet tracking, loop height adjustment, and micro-tension control. The counting and separation device achieves an error ≤±0.1‰, and fixed-length cutting precision reaches ±10mm, eliminating inefficiencies and errors from manual intervention.
3. Quality Control: Full-Chain Inspection
- Raw Material Check: Uses 150mm×150mm×12000mm qualified continuous casting billets (complying with YB/T2011-2014).
- In-Process Monitoring: Temperature and position detection at key points (e.g., 1H mill inlet, finishing mill in/outlet) tracks workpiece status in real time.
- Finished Product Testing: Equipped with electronic universal testing machines, bending testers, and abrasive cutters to conduct tensile, bending, and weight deviation tests, ensuring compliance with high-end application requirements (construction, bridges, rail transit).
II. Green & Low-Carbon: Balancing Cost Efficiency & Environmental Compliance
1. Energy Conservation: Resource Optimization
- Waste Heat Recovery: Natural gas-fired heating furnaces paired with combined tubular air heat exchangers preheat air to 450℃, minimizing gas consumption to ≤33Nm³/ton of steel and controlling oxidation loss ≤1.0%.
- Water Saving: Vaporization cooling systems replace traditional water cooling for furnace bottom pipes, achieving a production water recycling rate of 97.5% and only 0.7m³ makeup water/ton of steel.
- Low Consumption: Optimized process and equipment reduce electricity consumption to 120kWh/ton, roll consumption to 0.16kg/ton, and tungsten carbide ring consumption to 0.01kg/ton—all at industry-leading levels.
2. Environmental Compliance
- Low-Emission Design: Heating furnaces adopt low-NOₓ combustion technology and efficient exhaust systems to meet emission standards.
- Wastewater Recycling: Turbid circulating water systems use high-efficiency purification devices for sedimentation and filtration, enabling water reuse and avoiding pollution.
- Waste Reutilization: Collected iron oxide scale is recycled, reducing solid waste generation.
III. Flexible Capacity: Adapting to Full-Scenario Applications
1. Product Portfolio
The line produces three steel categories with diverse grades (Q235, 45#, HRB400(E), HRB500(E), HRB600(E)) and specifications:
Specification RangeProduction RatioAnnual Output (10,000 tons)Φ8~12mm40%12Φ14~18mm30%9Φ20~25mm10%3Φ28~40mm20%6
Products are delivered in straight bundles (2000~3000kg/bundle) with a fixed-length deviation of +50mm, facilitating storage, transportation, and construction.
2. Production Efficiency
- Operates on a 3-shift 2-rotation continuous system (no shutdowns on holidays) with a rated annual working time of 7,200 hours.
- Calendar availability rate: 82.19%; Effective availability rate: 55.8%.
- Quick roll change and intelligent fault early warning minimize non-production time, ensuring rapid order response for large-scale infrastructure projects.
IV. Whole-Chain Empowerment: One-Stop Turnkey Solution
1. EPC Services
We offer end-to-end EPC services, including:
- Customized Design: Optimized process layout based on site conditions (main plant axis area: 22,320㎡).
- Equipment Supply: Core equipment from top-tier suppliers (mechanical, fluid, automation systems).
- Installation & Commissioning: On-site guidance by professional teams for fast commissioning.
2. Operation & Maintenance Support
- On-Site Maintenance: Equipped with roll lathes, CNC roller ring lathes, and bearing cleaning machines for on-site processing and repair.
- After-Sales Service: Long-term support including maintenance training, spare parts supply, and technical upgrades.
Conclusion: Driving High-Quality Industry Development Through Innovation
This 300,000 tons/year production line is more than a manufacturing tool—it is a core engine for steel enterprises to achieve “quality improvement, cost reduction, efficiency enhancement, and green transformation.” With precision manufacturing, intelligent control, green technology, and flexible capacity, it injects strong momentum into the high-quality development of the steel industry.
We are committed to technological innovation and customer-centricity, continuously deepening R&D and application of steel rolling technology. We look forward to partnering with steel enterprises and infrastructure partners to support national economic construction and industry upgrading through high-quality equipment and professional services.
Contact Us
For inquiries, collaboration, or detailed technical specifications, feel free to reach out:
📱 WhatsApp: +86 13613814286
📧 Email: hengyuan6@hotmail.com
