Significant capacity increase for hot strip mill
The Aliağa site of Habaş A.S, near Izmir, has completed a significant upgrade to its hot strip mill (HSM) in November 2023, executed by SMS group. This enhancement includes the addition of a new downcoiler and an upgrade to the roughing mill area. The new downcoiler mirrors the design of existing ones and is robust enough to handle a full range of hot strip grades and sizes, including pipe grades up to 25.4 mm thick. Additionally, the roughing mill upgrade involved installing a second roughing stand with an attached edger upstream of the existing mill. This configuration boosts the plant's production capabilities, enhancing capacity and operational flexibility for processing various strip dimensions.
Technological advancements
The project also includes a high-performance Camber Free Rolling (CFR) system to ensure camber-free rolling, producing perfectly straight transfer bars. This system relies on the effective interplay between heavy side guides and the X-Pact® Camber Free Rolling control system that keeps the rolls parallel and optimizes material flow.
The seamless integration of the new installations into the existing X-Pact® automation system was achieved through its modular and open structure. The Level 2 automation functions were expanded to include X-Pact® Plant Pacing, maximizing output and mill productivity. Additionally, the X-Pact® Vision HMI and visualization system was tailored to the new configuration of the mill.
The project's success was further underscored by an efficient digital commissioning process during the X-Pact® Plug & Work integration test. This process included the adaption of the existing 3D simulation of the hot strip mill to the new setup, which ensured a rapid ramp-up curve and smooth operation.
With the upgrade, Habaş has increased its mill capacity by 80%, reaching 4.5 million tons annually. The facility now supports a broader product range, including HSLA steels, pipe grades, and multi-phase steels, and can process slabs up to 225 mm thick. The modernization, managed by SMS group, minimized downtime and ensured a seamless integration of new equipment and systems.