After decades of deep involvement in the steel industry, a landmark direct rolling technology transformation project for ribbed steel bars has been launched with substantial investment. Leveraging full-chain technological innovations, it addresses core industry pain points, achieving a triple breakthrough in green low-carbon development, efficiency improvement, and technological upgrading. This not only injects strong momentum into the high-quality development of the steel industry but also reshapes the industry’s production models and value orientation!
ð§ Core Technological Innovations: Addressing Industry Pain Points and Reshaping Production Logic
1. Full-Process Interconnection Innovation: Breaking Production Boundaries
Pioneering the “multi-caster + multi-rolling line” interconnected system, it breaks the rigid constraints of equipment compatibility in traditional production. Casters and rolling lines can be flexibly switched and combined according to production capacity needs and product specifications. Moreover, bar and wire production lines can quickly switch between different rolling modes, significantly enhancing the flexibility and adaptability of production organization.
Under the furnace-free mode, the daily output maintains stable output, equivalent to or even slightly higher than that of traditional heating furnace production. It completely changes the limitation that a single production line can only adapt to specific product specifications. It can not only meet the large-scale mass production of conventional products but also flexibly respond to customized and multi-batch production needs, providing greater space for production scheduling.
2. Temperature Drop Control Innovation: Solving Core Direct Rolling Challenges
Developing a patented “full-cycle heat preservation + high-speed conveying” system, it constructs a closed heat preservation system covering pre-shearing, post-shearing, and transportation waiting links. Equipped with customized high-speed heat preservation roller tables, it minimizes heat loss of billets during transportation by optimizing the slope and turning angle of the roller tables, greatly reducing the temperature drop range and ensuring the temperature conditions required for rolling.
Innovating the billet balanced cooling technology, it specifically addresses the industry pain point of excessive temperature difference between the head and tail of billets caused by uneven cooling time in the direct rolling process. By precisely regulating the cooling intensity and range, it significantly reduces the temperature fluctuation between the head and tail. Meanwhile, it optimizes the multi-strand splitting pass design and middle-line targeted cooling scheme, tackling from both equipment structure and process control dimensions. This effectively controls the fluctuation of product yield strength, completely eliminates undesirable metallographic structures such as WidmanstÀtten structure, and makes the uniformity of product mechanical properties reach the industry-leading level with greatly improved batch stability.
3. High-Strength Steel Process Breakthrough: Filling Technological Gaps
Pioneering the composite microalloying direct rolling scheme, through the scientific proportioning of microalloying elements, it gives full play to the synergistic strengthening effect between elements. It successfully overcomes the technical bottlenecks in the production of small-size high-strength seismic steel bars. The product’s yield ratio is better than the national standard requirements, the proportion of key metallographic structures is significantly increased, and the mechanical properties and safety performance are upgraded simultaneously.
Relying on the waste heat of billets to directly enter the rolling process, the direct rolling process eliminates the need for additional heating steps. Compared with the traditional heating rolling mode, it not only shortens the waiting time and reduces energy consumption but also avoids the oxidation loss and composition segregation that may occur during the heating process. While improving production efficiency and product yield, it provides an efficient and feasible path for the large-scale and low-cost production of high-strength steel bars.
ð Multidimensional Benefit Outbreak: Achieving Win-Win for Green Development and Value Creation
1. Significant Economic Benefit Improvement
Under the furnace-free mode, it greatly saves energy consumption such as blast furnace gas and reduces raw material waste caused by steel oxidation loss, achieving immediate cost reduction effects. Even in the flexible production mode with retained heating furnaces, considerable energy-saving and cost-reducing benefits can be achieved through process optimization, comprehensively enhancing the market competitiveness of products.
With stable quality performance and green low-carbon attributes, the related products are supplied in batches to multiple key projects, gaining wide recognition in infrastructure, high-end manufacturing and other fields. The market recognition and brand influence continue to rise, laying a solid foundation for expanding a broader market space.
2. Leading Environmental Benefits in the Industry
Both production modes can significantly save standard coal consumption, greatly reduce carbon dioxide emissions, and effectively reduce the total emissions of pollutants such as sulfur dioxide, nitrogen oxides, and dust. It reduces environmental pollution from the source, provides a feasible practice plan for the steel industry to implement the “dual carbon” goals, and helps the industry’s green transformation.
By eliminating the billet heating link, it not only reduces carbon emissions from energy consumption but also avoids pollutants generated during the operation of heating furnaces, realizing the environmental upgrading of the entire production process and setting a new benchmark for green production in the industry.
3. In-depth Empowerment of Industrial Value
Eliminating the billet heating link not only avoids the purchase and maintenance costs of heating furnaces but also reduces related energy consumption and labor input, greatly simplifying the production process, shortening the production cycle, reducing equipment failure rates, and significantly improving operation and maintenance efficiency and production continuity.
Covering the full range of high-strength seismic steel bars, from conventional specifications to customized products, it fully meets the strict requirements for steel performance in high-end projects and major infrastructure projects. It effectively broadens market application scenarios, promotes the upgrading of steel products from “basic building materials” to “high-end functional materials”, and empowers the high-quality development of downstream industries.
ð Long-Term Development: Establishing a New Paradigm for Industry Transformation
Upholding the spirit of “hard work and reform innovation”, it has built a closed loop of “process optimization – technological breakthrough – benefit upgrading”, offering a replicable green transformation sample for the steel industry.
In the future, it will deepen direct rolling technology iterationâtackling extreme-specification bottlenecks and exploring higher-strength steel production. It will integrate digital intelligence (intelligent sensing, digital twin) to build an efficient production system, advance low-carbon transformation (waste heat recovery, green power coupling), and extend industrial chain value. Committed to leading the industry toward “low energy consumption, low emission, high quality, and high added value”, it will support national infrastructure and modern industrial system construction.
