Amid the global steel industry’s transformation toward intelligence, low carbonization, and large-scale production, high-performance bar rolling lines have become a key pillar for enterprises to enhance core competitiveness. Drawing on decades of experience in metallurgical equipment R&D, engineering design, and project implementation, we are proud to launch our 300,000 tons per year single high-speed bar rolling line turnkey solution—a fully integrated system tailored for the large-scale production of high-quality ribbed steel bars. Covering specifications from Φ8~Φ40mm, the solution is compatible with carbon structural steel (Q235), high-quality carbon steel (20#, 45#), and low-alloy steel (HRB400E/500E/600E) processing. Adhering strictly to GB/T 1499.2-2024, GB/T 700-2006, and other national and international standards, we maintain full control from process design and equipment manufacturing to operation and maintenance services, helping steel enterprises achieve seamless connectivity, cost optimization, and high-precision production goals.
Core Production Capacity & Product Advantages
Production Scale & Operational Efficiency
- Capacity Benchmark: With an annual designed output of 300,000 tons, the line operates on a three-shift continuous working system (330 working days per year, 7,200 rated operating hours for rolling mills). Boasting a calendar operating rate of 82.19% and an effective operating rate of 55.8%, it ensures stable mass production even during peak demand through intelligent fault early warning and rapid response mechanisms, minimizing unplanned downtime.
- Raw Material Configuration: Utilizes 150×150×12000mm continuous casting billets (single billet weight ~2.065t) that strictly comply with YB/T 2011-2014 standards, with no cracks, folds, or other defects on the billet surface. The annual billet requirement is 306,748 tons, achieving a metal yield rate of 97.8%—with only 0.7% oxidation loss and 1.5% loss from head/tail cutting and scrap, far below the industry average and representing leading raw material utilization efficiency.
- Energy Efficiency & Cost Performance: The comprehensive energy consumption per ton of steel is 120kWh, with a circulating water consumption of 35m³/ton and fresh water supplement of only 0.7m³/ton, resulting in a water circulation rate of ≥98%. Per ton of steel consumes 0.16kg of rolls, 0.01kg of tungsten carbide roll rings, and 0.2kg of hydraulic lubrication materials. Precise consumable management further reduces production costs, fully aligning with green manufacturing trends.
Product Range & Quality Assurance
- Specification Coverage: Output distribution is tailored to market demand, accurately matching diverse application scenarios: Φ8~12mm: 120,000 tons/year (40% of total output), produced via slitting rolling technology—one billet can be rolled into two finished products, doubling capacity while ensuring uniform quality. Φ14~18mm: 90,000 tons/year (30% of total output), a mainstream specification in the construction industry, suitable for reinforced concrete structure construction. Φ20~25mm: 30,000 tons/year (10% of total output), ideal for mechanical processing and engineering structural component manufacturing. Φ28~40mm: 60,000 tons/year (20% of total output), meeting the high-strength requirements of heavy machinery, bridges, wind power, and other applications.
- Quality Control Standards: Dimensional Precision: Complies with GB/T 702-2017, with a diameter tolerance of ≤±0.5mm and a fixed-length delivery tolerance of +50mm, featuring flat and burr-free cutting edges. Surface & Mechanical Properties: A 20MPa 3D high-pressure descaling system (efficiency ≥98%) thoroughly removes oxide scale and cracks formed during heating, avoiding indentation defects. Closed-loop controlled rolling and cooling (TMCP) technology optimizes the microstructure into uniform pearlite + ferrite by precisely adjusting the cooling rate (10~30℃/s), ensuring the yield strength of rebars meets HRB400E/500E/600E grades without adding additional alloy elements—reducing costs while guaranteeing performance. The core-surface hardness difference is ≤40HV, with no red rust or pitting on the surface.
- Delivery Specifications: Delivered as bundled straight bars (2~3 tons per bundle), with 4 bundling passes for 6~9m fixed lengths and 5 passes for 10~12m fixed lengths. The bundles are tightly bound to prevent loosening, facilitating storage and long-distance transportation. Each bundle is accompanied by a clear quality traceability label indicating specification, steel grade, weight, production batch, execution standard, and other information, enabling full traceability from billet to finished product.
Advanced Process Layout: 24-Stand Continuous Rolling System
The production line adopts a semi-continuous layout with 24 high-rigidity rolling mills, divided into four key sections—rough rolling, intermediate rolling, pre-finishing rolling, and finishing rolling—creating a seamless production flow from cold billet to finished product:
Cold Billet Storage → Furnace Feeding Roller Conveyor → Pusher-Type Heating Furnace → High-Pressure Water Descaling → Rough Rolling (6 stands) → No.1 Flying Shear → Intermediate Rolling (6 stands) → No.2 Flying Shear → Pre-Finishing Rolling (6 stands) → Pre-Water Cooling Device → No.3 Flying Shear → Finishing Rolling (6 stands) → Post-Finishing Water Cooling → No.4/5 Flying Shears → Hub-Type Steel Feeding Device → Step Rack Cooling Bed → Aligning Roller Conveyor → 650t Cold Shear → Counting & Separating → Bundling → Weighing → Warehousing & Shipping
Key Process Highlights & Technical Advantages
- Heating & Descaling: Foundational Guarantee for High-Quality Rolling
- Multi-Stage Rolling: Precision Forming & Efficiency Enhancement
- Controlled Cooling & Precision Shearing: Guarantee for Performance & Fixed-Length Cutting
- Cooling & Finishing: Standardization & Traceable Closed-Loop
High-Specification Equipment & Intelligent Control System
Core Equipment Configuration
- Rolling Mill Equipment: All rolling mills in the production line adopt a short-stress-line design. The frame is made of high-quality alloy structural steel, strengthened through overall heat treatment, featuring high rigidity and excellent fatigue resistance. Gears are made of high-quality 20CrNi2MoA alloy steel, with a tooth surface hardness of HRC58~62 after carburizing and quenching, and a gear precision of Grade 6, achieving a transmission efficiency of ≥98%. Bearings are imported SKF/FAG brands, with high rotational precision, low wear, and long service life. The rolling mills are equipped with hydraulic roll gap adjustment and elastic damper balance devices, eliminating bearing and thread clearance, and improving rolling stability and dimensional accuracy.
- Key Auxiliary Equipment: Hub-Type Steel Feeding Device (adaptable speed 16~45m/s) adopts an independent water cooling system and oil-gas lubrication, enabling stable transportation of high-speed rolled bars to the cooling bed without impact damage, with a steel feeding accuracy of ≥99.5%. Step Rack Cooling Bed: Racks are made of Q345B steel, treated for high-temperature oxidation resistance, ensuring a long service life. The cooling bed drive uses frequency conversion speed regulation, allowing flexible adjustment of stepping speed according to rolling rhythm. 3 Sets of Hydraulic Automatic Bundling Machines: Support single-strand/double-strand bundling modes, with a bundling cycle of ≤15 seconds per bundle, achieving high efficiency and stable bundling quality, suitable for 2~3-ton per bundle packaging needs.
- Utility Systems: Hydraulic System: 5 independent hydraulic stations (for heating furnace/rolling mill area/high-speed area/cold bed finishing area/machine repair workshop) with oil cleanliness reaching NAS 7~8 grades. Equipped with high-precision filtering devices and real-time monitoring systems for oil temperature, oil level, and pressure, ensuring stable operation of the hydraulic system with a response speed of ≤0.5 seconds. Lubrication System: Adopts a multi-mode lubrication scheme combining centralized thin oil lubrication (for reducers and bearings), oil-gas lubrication (for rolling mill roll necks), and dry oil lubrication (for conveyors and hinges), achieving precise lubrication with low consumption, effectively reducing equipment wear and extending the equipment maintenance cycle.
Intelligent Automation & Power Supply Guarantee
- Control System: Adopts a dual-PLC architecture (Siemens S7-400 series) + HMI touch screen, integrating various detection elements such as encoders, temperature sensors, pressure transmitters, and infrared thermometers. It real-time collects key parameters including rolling speed, roll gap size, cooling water flow, and billet temperature, and automatically adjusts equipment operating status through closed-loop control algorithms. Manual intervention is reduced by 80%, and product dimensional accuracy fluctuation is ≤±0.2mm.
- Hierarchical Operation & Safety Guarantee: 3 main operation consoles (rough rolling area/intermediate & finishing rolling area/finishing area) + 8 on-site operation boxes support both centralized management and on-site debugging modes. The operation interface is intuitive and easy to understand, allowing operators to get on the job after simple training. The system is equipped with comprehensive safety interlock functions—when abnormalities such as over-temperature, over-pressure, or steel jamming occur, it can automatically shut down and alarm, avoiding equipment damage and personal safety risks.
- Power Supply System: 33kV high-voltage power supply (installed capacity 25,000kW) is configured with an SVG+FC reactive power compensation system (power factor ≥0.95) and harmonic filtering devices, stabilizing grid voltage and reducing power loss. Low-voltage power distribution uses drawer-type switchgear with an IP54 protection level, dustproof and moisture-proof, adapting to the harsh workshop environment and ensuring reliable power supply.
Core Competitive Advantages
✅ Ultra-High Production Efficiency: Maximum rolling speed of 45m/s; slitting rolling technology doubles the capacity of Φ8~12mm bars. With an annual capacity of 300,000 tons and a maximum hourly output of 61.3 tons, the operating rate is ≥85%, far exceeding the industry average.
✅ Superior Precision & Quality: Short-stress-line rolling mills + closed-loop controlled rolling and cooling technology ensure a product dimensional tolerance of ≤±0.5mm and a 100% mechanical property compliance rate. Meeting national and international standards, it can directly meet high-end customer demands.
✅ Flexible Production Capacity: Quick roll change in ≤30 minutes, adapting to the production of multiple specifications (Φ8~Φ40mm) and multiple steel grades (Q235~HRB600E). Supports small-batch, multi-batch orders, enabling rapid response to market demands.
✅ Full-Process Turnkey Service: Comprehensive coverage from project planning and customized design to equipment R&D and manufacturing, on-site installation and commissioning, personnel training, and 24/7 after-sales service. A professional technical team provides on-site guidance to ensure the project is put into production on schedule and meets standards.
✅ Cost Optimization & Sustainability: Water circulation rate of ≥98%, oxide scale recycling rate of ≥95%, and no additional alloy investment reduce the comprehensive cost per ton of steel by 10~15%, delivering a high return on investment.
✅ Stable & Durable Equipment: High-specification components (SKF/FAG bearings, 20CrNi2MoA gears) + systematic lubrication and maintenance schemes result in an equipment mean time between failures (MTBF) of ≥800 hours, reducing downtime losses and lowering operation and maintenance costs.
Join Hands to Create a New Future of Intelligent Steel Manufacturing
As practitioners deeply rooted in the metallurgical equipment field, we have always focused on the R&D, design, and implementation of rolling production lines, accumulating rich practical experience from numerous domestic and international projects. Our technical team consists of senior industry engineers who personally oversee every step from process planning to equipment commissioning, enabling accurate alignment with customers’ actual needs—whether it is the adaptation of production capacity and product specifications, the constraints of site conditions, or the considerations of budget scope. We communicate meticulously and optimize repeatedly to create personalized solutions that truly fit customers’ production scenarios.
This 300,000 TPY single high-speed bar rolling line solution is a mature product iteratively upgraded based on past project experience, integrating proven process technology, high-reliability equipment configuration, user-friendly intelligent control systems, and energy-saving and emission-reducing green concepts. Whether you plan to build a new factory, expand existing capacity, or upgrade old production lines, we will take “stable commissioning, compliance with standards, and efficiency improvement” as our core goals, following up the entire process from preliminary communication to later implementation to help the project land smoothly and operate efficiently.
Regarding follow-up services, we adhere to the principle of “long-term companionship and practical guarantee”: After the project is put into production, we will conduct on-site visits if needed, assisting in optimizing process parameters based on actual production data and operator feedback. We have established a dedicated spare parts supply channel to ensure sufficient inventory of key wearing parts, shortening equipment maintenance waiting time. We provide free technical training and guidance for customers—whether it is new employees learning to operate or old employees improving their skills, we will fully cooperate to help the team quickly master the operation and maintenance key points of the production line, ensuring a smooth production process.
