A groundbreaking direct rolling innovation has achieved game-changing industrialization success, boasting broad adaptability for both new production lines and legacy system upgrades. This technological leap reflects a proactive response to global demands for new quality productive forces, fueling the iron and steel industry’s shift toward sustainability and efficiency.#SteelInnovation #GreenManufacturing #DigitalTransformation #IronAndSteelTech #SustainableIndustry #IndustrialEfficiency
I. Unmatched Versatility
Developed independently, this direct rolling technology offers flexible, scalable applications:
- Seamlessly integrates with new bar/wire production lines and existing facility renovations;
- Compatible with single or multiple rolling lines linked to steelmaking processes;
- Operates efficiently within a 500m steelmaking-rolling distance (extendable to 700m via third-generation ultra-high-speed heavy-duty roller tables);
- Adapts to terrain differences of up to 10m between steelmaking and rolling zones.
II. Industrialization Milestones
Launched at a flagship bar rolling line on December 12, 2022, the next-gen system has delivered extraordinary results: 1.7 million tons of annual direct rolling output, a 99.9% direct rolling rate, peak monthly output of 154,200 tons, and a daily high of 5,300 tons—proving its ability to meet the rigors of high-yield production environments.
(I) Setting the Bar with “Three Modernizations”
The flagship line redefines industry standards through high-quality engineering, digital intelligence, and intrinsic greenness:
1. Superior Quality & Compliance
- Maintains a temperature difference of ≤30℃ between billet/finished product heads and tails (across varying strands, casting speeds, discharge times, and fixed lengths)—no secondary heat sources or insulation needed;
- Pioneers the proprietary “center-edge ratio” theory, leveraging core-surface temperature differentials to drive significant alloy savings;
- Boosts weight deviation stability by 0.7% and covers full product portfolios (HPB300, HRB400E(F), HRB500E(F)) for high-speed wire rods, bar wires, and high-speed bars (154,300 tons of HRB500E grade 4 threaded steel produced in 2023);
- Aligns with upcoming production license regulations and global quality/safety risk management standards for hot-rolled ribbed steel bars.
2. Intrinsic Green Leadership
- Eliminates heating processes entirely (zero heat sources required), cutting 110,700 tons of carbon emissions and 33 tons of SO₂/NOₓ in 2023 alone;
- Recognized by the Chinese Society for Metals and included in the Recommended Catalog of Key Common Technologies for Cost Reduction & Efficiency Improvement in the Iron and Steel Industry (October 15, 2023).
3. Cutting-Edge Digital Intelligence
- Assigns a unique digital ID to every billet, enabling real-time online control of quality, temperature, and energy consumption;
- Features a highly integrated digital quality management system, ensuring consistent performance across all products;
- Integrates digital ultra-high-speed heavy-duty overpass roller tables—reducing the time from continuous casting/cutting to rolling to just 50 seconds (max billet speed: 8.5m/s);
- Achieves 99.80% fixed-length accuracy via dynamic length adjustment and slashes power consumption by 5-10% through intelligent mill torque distribution.
