- New laying head significantly reduces heavy vibrations, ensuring no more costly unexpected shutdowns
- Increases Stahl Gerlafingen’s production utilization by improving yield through reduced conveyor stops and maintenance downtime
- Tension monitoring system improves front-end orientation for more uniform coil packages
Primetals Technologies recently received the final acceptance certificate (FAC) for an upgrade to AFV Beltrame Stahl Gerlafingen’s wire rod mill in Gerlafingen, a city in the canton of Solothurn, located in the north-western part of Switzerland. The upgrade included an intelligent pinch roll and laying head utilizing electrical motors and drives, as well as an automation system. The mill’s wire rod outlet will produce 600,000 tons per year of 6 – 20 millimeter quenched rebar and 5.5 – 20 millimeter low carbon wire rod.
An Updated Laying Head
The new laying head technology incorporates an integral segmented deflector plate for front- and tail-end control, as well as a rugged gearbox with roller bearings. This new generation’s one-piece fabrication design reduces manufacturing time and second harmonics. The improved pipe path and optimized center of gravity (CG) position reduce vibrations and extend pipe path lifetime.
The new laying head also includes a tension monitoring system that uses laser speed gauges to measure product movement and position. The new solution immediately improved front-end orientation once installed and running. This effectively eliminated vibrations, significantly reduced unplanned mill stops, and increased production.
Christiane Hess, Technical Project Manager for Stahl Gerlafingen, commented: “Thanks to the new screw technology, both the start and end of the coil are now placed significantly more precisely and stably in the coil formation area. Additionally, the new equipment allows for higher production speeds and a more powerful drive mechanism, improving overall process stability and product quality.”
Real-Time Product Monitoring
The tension monitoring control system measures how fast the product moves through the laying head, and its position. Integrated with the mill’s human-machine interface (HMI), it allows operators a unique opportunity to monitor production in real-time and make informed, data-driven decisions.
Producing an average of over 700,000 tons of low-CO2 steel, Stahl Gerlafingen is the largest producer of recycled steel in Switzerland. Founded over 200 years ago in 1823, the company supplies steel bars and beams and is part of the AFV Beltrame Group.
8-millimeter wire rod exiting laying head onto cooling conveyor at Stahl Gerlafingen’s new wire rod mill from Primetals Technologies.
A close up of 8-millimeter wire rod exiting laying head onto cooling conveyor at Stahl Gerlafingen’s new wire rod mill from Primetals Technologies.
Primetals Technologies, Limited, headquartered in London, United Kingdom, is a pioneer and world leader in the fields of engineering, plant building, and the provision of lifecycle services for the metals industry. The company offers a complete technology, product, and services portfolio that includes integrated electrics and automation, digitalization, and environmental solutions. This covers every step of the iron and steel production chain—from the raw materials to the finished product—and includes the latest rolling solutions for the nonferrous metals sector. Primetals Technologies is a Group Company of Mitsubishi Heavy Industries, with around 7,000 employees worldwide. To learn more about Primetals Technologies, visit the company website www.primetals.com.
