Endless Bar Production: Linked Casting and Rolling

Direct Casting and Rolling of Steel Bar and Wire Rod

Endless Bar Production (EBP) merges a steel billet caster and high-speed bar mill, running continuously without reheating between casting and long rolling. Compared to conventional long-product casting and rolling methods, Endless Bar Production reduces energy consumption by 60% and CO₂ emissions by over 90% by combining processes. With minimal material losses, it achieves a remarkable 99% yield. Thanks to reduced infrastructure requirements and a compact design, conversion costs are, on average, 40% lower. Endless Bar Production (EBP), born from Arvedi Endless Strip Production technology, boasts top-tier performance, reliability, and eco-friendly production.

With Endless Bar Production (EBP), the cast strand is rolled as soon as it solidifies, making a conventional billet reheating furnace redundant. Removing the furnace in Endless Bar Production reduces the plant's energy consumption and environmental impact. For temperature control and replacing the conventional billet reheating furnace, the induction heater is activated by an automatic process control when needed and automatically switched off when unnecessary. All Endless Bar Production components are designed for long-rolling campaigns, from billets to bar and wire rods. With a small factory footprint, Endless Bar Production requires lower transformation costs, making it the most competitive solution for long products. Innovative design and process control enable Endless Bar Production to deliver superior-quality steel bars and steel wire rods. Its ability to flexibly operate in endless or semi-endless mode ensures production flexibility tailored to meet end-user demands.

Features of Endless Bar Production from Primetals Technologies

Billet caster with proven advancements for high-speed production
Rolling mill technology for high quality and productivity
Long-life components and quick-change parts to maximize plant availability
Advanced, multi-level automation systems
Smart sensors and mechatronic solutions linked to a centralized process control
Low consumption of energy, fluids, and consumables
Minimum direct emissions of CO₂
Compact footprint and reduced civil works
Flexible operation in endless or semi-endless mode when required

Endless Bar Production mill stands

Endless Bar Production inductive heater

Digitalization

Automation & Digital Solutions

Automation

Long Rolling Process Expert Automation System

Optimize long rolling mill operations with the Long Rolling Process Expert Automation System. Enhance production planning, material tracking, and product quality.

Long Rolling Wire Rod Expert

Optimize wire rod production with the LR WireRod Technology Expert. Achieve consistent quality, enhanced efficiency, and reduced downtime in the plant.

Energy Peak Optimizer

The Energy Peak Optimizer increases operational efficiency through intelligent predictive control, supports the transition towards greener production practices, and optimizes energy consumption by storing energy during low-demand times.

Digitalization

Central Operation Cockpit

Streamline steel plant operations with real-time monitoring, automated alerts, and advanced tools for safety, efficiency, and consistent quality.

ALEX: Asset Life Expert

Monitor condition, detect failures early, and optimize maintenance with Asset Life Expert (ALEX) for steel plants.

Coil Handling and Compacting Systems

Enhance productivity and coil consistency with advanced handling and compacting systems. Modular, efficient, and customizable for rolling mills.

Through-Process Quality Control

Ensure top-quality steel production with TPQC. Leverage real-time data, predictive analytics, and defect prevention for enhanced efficiency and precision.

MAT: Maintenance Asset Technology

Leverage advanced Maintenance Asset Technology (MAT) to optimize equipment performance, reduce downtime, and improve operational efficiency.

Electrification

Energy Management System

The energy management system enhances operational efficiency through predictive algorithms to optimize energy use at ironmaking plants, steel plants and rolling mills.

Medium-Voltage Power Supply

Medium-Voltage Power Supply, Substations, and Transformers

Digital Power Substation

Optimize energy use and reliability with the Digital Power Substation. Leverage real-time analytics, predictive maintenance, and scalable architecture for steel and aluminum plants.

Low-Voltage Drives and Motors

With various applications throughout the steel industry, low-voltage drives and motors enhance product quality and ensure optimal plant productivity.

Static Synchronous Compensator (STATCOM)

The static synchronous compensator (STATCOM) is a power quality and harmonics management system that enhances steel plant energy performance, reduces operational expenses, and ensures compliance with IEC and utility standards.

Services

Automation Migration for Rolling Mills

Upgrade rolling mill operations with advanced software migration solutions to enhance efficiency, reliability, scalability, and cybersecurity.

Automation System Maintenance & Optimization Service

Optimize rolling mill software with expert maintenance services. Enhance performance, reduce downtime, and save costs with tailored solutions.

Electrics & Automation Spares for Rolling Mills Webshop

Ensure uninterrupted rolling mill operations with our webshop. Access spare parts, transparent pricing, and tailored solutions for seamless production.

Automation Service Contracts for Steel Producers

Ensure seamless operations with tailored automation service contracts. Minimize downtime, optimize performance, and keep systems updated throughout your plant’s lifecycle.

Digitalization