SOLUTIONS FOR THE STEEL INDUSTRY

Table of Contents

About Us...... 1

Rolling Mill Equipment...... 7

Rolling Mill Automation...... 19

Roll Pass & Operations...... 35

Water Solutions...... 42 About Us

Background What we do Mission

Founded in 1988, Russula is a glob- Russula has implemented large scale Our objective is to develop solutions al engineering company serving the greenfield and modernization projects which increase productivity, improve largest steel producers in more than for over 100 long and flat steel plants product quality and reduce energy 30 countries. With its headquarters worldwide. Our areas of operations consumption. Because only the best and workshop located in A Coruña are: solutions guarantee the best results. province, Spain, the company has ma- • Rolling Mill Equipment jor offices in Brazil, India, Italy, Mexico, • Rolling Mill Automation Russia and the United States. • Roll Pass Design & Operations • Water Solutions

1 Major projects implemented for over 100 steel plants in 35 countries

Angola - Argentina - Brazil - Canada - Chile - China - Colombia - Czech Republic - France - Germany - Ghana - Greece Honduras - Hungary - India - Luxembourg - Macedonia - Malaysia - Mexico - Morocco - Nigeria - Paraguay - Poland - Portugal Romania - Russia - Serbia - Slovenia - South Korea - Spain - Taiwan - Thailand - Turkey - UK - USA

2 About Us - Key Projects

1989 2001 2013 2015

Global Steel Wire Celsa Atlantic SILAT Bar Mill Big River Steel

Russula implemented a Main engineering contractor Complete supply of a new Russula supplied the series of revamping proj- for two highly automated 600,000 tpy combined bar water solution to Big River ects on the two strand wire greenfield mills, one pro- and wire rod mill. The scope Steel’s Flex Mill™ which pro- rod mill, which increased ducing 8-32 mm rebar included mechanical equip- duces 3.3 MT of hot strip per production capacity from and the other 5.5-22 mm ment, electrics and automa- year. The water treatment 300,000 to 700,000 tpy. wire rod coils. In 2006, 105 tion, water treatment plant complex was divided into employees produced a and auxiliaries. two phases. Phase 1, award- combined two mill produc- ed in 2015, treats 35,000 m3/ tion of 900,000 tpy. hr (154,000 gpm). Phase 2, awarded in 2019, treats 21,000 m3/hr (92,000 gpm) of water.

3 2016 2017 2018 2019

Dojran Steel SILAT Wire Rod Mill Laminoirs de Landes Celsa France

Complete supply of a new Following the success- In a little over a year, Rus- Celsa Group chose Russula 350,000 tpy merchant bar ful completion of the bar sula delivered the electrical, to supply a new 600,000 tpy and section mill to Dojran mill, Russula supplied a automation and water treat- rolling mill that is currently Steel from Sidenor Group. high-speed wire rod mill ment supply, installation su- under construction in its The mill was commissioned that produces 5.5-16 mm pervision and startup sup- Boucau-Tarnos steelworks in 2017, fifteen months from wire rod and rebar in coil port for a 500,000 tpy heavy near the Bayonne area in the contract award date. to Silat. The mill features a plate mill at Laminoirs des Southern France. new patented laying head Landes. design that reduces mainte- nance downtime and power consumption.

4 About Us

STEEL INDUSTRY SOLUTIONS

Rolling Mills Roll Pass & Operations Water Solutions

The union between automation, Russula has a unique approach to Often times, water treatment plants process technology and mechanical successfully improving mill efficiency, can be an overlooked part of the steel equipment is at the heart of Russula’s which is based on customer collab- process, but you can’t roll without solutions for long product rolling mills. oration. Multi-disciplinary teams are water. Russula has developed its own With the successful implementation of formed to ensure a 360 degree view water treatment solutions specifically engineering projects in over 100 bar, of the mill problems from the process, designed for the steel industry to fulfill wire rod and section mill instalations mechanical and electrical points of the environmental requirements. around the world, Russula has the view. Russula will pull together the know-how and expertise to improve right mix of technical specialists to your rolling mill performance. jointly develop an action plan to solve your mill inefficiencies.

5 Rolling Mill Roll Pass & Equipment Operations

Rolling Mill Water Automation Solutions

6 Rolling Mill Equipment

BAR, SECTION & WIRE ROD MILLS

Russula supplies bar, section and wire Russula can supply the rolling mill on a • Bundling and stacking systems rod mills. All rolling mill equipment is turn-key basis or as part of a project re- • Wire tying machines manufactured in reputable European vamping as specified by the customer. • High speed finishing blocks workshops. Experienced craftsmen Our range of equipment include: • Water boxes and rolling mill process know-how • Pinch roll and laying heads guarantee that the equipment will • Housingless stands • Roller cooling conveyors have longer service life and reduced • Crop and divide shears • Coil forming stations downtime. • Uploopers • Vertical pallet/C-hook conveyors • Cooling beds • Coil compactors • Cold shears

7 8 Rolling Mill Equipment

CELSA FRANCE ROLLING MILL Boucau-Tarnos, France

Celsa France, part of the Celsa Group, of supply consists of a billet reheat Russula is responsible for the design contracted Russula to supply a new furnace, RCS Housingless stands for and the complete execution of the rolling mill that is currently under con- the continuous roughing and inter- project under a turn-key contract. The struction at its Boucau-Tarnos steel- mediate mills, and a pre-finishing mill commissioning of the new mill will take works, in Southern France. The rolling with 3 mini-blocks. The finishing mill place in 2021. mill has a design capacity of 600,000 is equipped with a 10 pass compact tpy, and will vertically integrate the ex- block, water-controlled cooling, and The new rolling mill features Russula’s isting meltshop production. Different a new generation laying head to form latest technological developments in European standard grades of steel will the coils onto a cooling conveyor. Once mechanical equipment design, auto- be produced. the coils are formed, they are further mation and process digitalization. cooled and transported by a system of Hot billets will be fed directly from vertical pallets and horizontal hooks to the casting area to the new mill, the compactor and tying area, ready which will optimize the energy costs of for storage and shipment. transformation. The equipment scope

9 10 Rolling Mill Equipment

SILAT BAR MILL Caucaia - Ceara, Brazil

Silat (Gerdau) contracted Russula to basic and detailed engineering for The rolling mill is based on proven de- supply a complete greenfield rebar civil works mechanical, electrical and sign concepts and is easy to operate and wire rod mill. Located 45 km from auxiliary installation, electrical and and maintain. Costs are reduced by Fortaleza, Brazil, the new bar mill rolls mechanical equipment supply, con- minimizing spare parts and mill down- 8-32 mm straight reinforcing bar with struction supervision and start-up time. a 4-slitting scheme and the rod outlet support. rolls 5.5-16 mm wire rod and rebar in coils for a total capacity of 600,000 tpy. The rolling mill is fed by a walking hearth reheat furnace. The plant lay- As the main engineering contractor out includes a 20 stand continuous bar Russula developed the original con- mill, quenching system, cooling bed, cept for the greenfield steel plant. cold shear and bundle and tying area. The scope of supply encompassed

11 12 Rolling Mill Equipment

SILAT WIRE ROD MILL Caucaia - Ceara, Brazil

The wire rod outlet features the latest Fed from the bar mill finishing stands, Russula’s compacting and handling Russula innovations for long product the rod outlet includes a 10-pass, system is designed for a fast, sophis- rolling technology. The laying head high-speed twist free finishing block, ticated process. Integrated sensors and design allows for more consistent coil controlled cooling line, coil forming advanced automation make for reliable formation and rolling stability. With station, pallet conveyor, hook convey- operation, easy troubleshooting and this innovative technology Silat is able or, coil compacting and tying machine, maintenance. to roll at 110 m/s sustained speeds. coil weighing and tagging station and unloading table. In its entirety, the coil handling system is designed for maxi- mum throughput and to compact the shortest coil possible for each product.

13 14 Rolling Mill Equipment

DOJRAN STEEL SECTION MILL Nikolic - F.Y.R. of Macedonia

Dojran Steel, a subsidiary of the Side- Russula supplied a total of 18 new RCS, Russula supplied 7 new loop formers, nor Group, selected Russula to supply housingless stands for the roughing, a dividing shear, a stands bypass roller a new bar and section mill. The new intermediate and finishing mills. The table, an accelerating roller table with mill is the first phase of a multi-phase modern merchant bar and section mill lifting aprons, a rake-type walking project that increased production ca- has enabled Dojran Steel to extend beam cooling bed, an automatic step- pacity from 50,000 to 350,000 tpy. As its market into rolling small and me- by-step chain transfer, a cut-to-length a result of this production expansion dium-sized merchant bars including cold shear and a runout roller table project, Dojran Steel can now produce 8-40 mm rounds, 16 x 4-140 x 20 mm fitted with a movable stopper. Existing the entire range of small to medium- flats, 8-40 mm square bars, 20 x 20 x trio and cold shear was refurbished sized merchant bars that command 2.5-120 x 120 x 12 equal angles, 30 x and adapted to the new rolling condi- greater value in the Balkan market. 20 x 3-120 x 80 x 10 unequal angles, tions to save project costs. UPN channels with a section height from 30 to 140 mm, IPE beams from 80 to 120 mm and T sections from 20 to 50 mm.

15 16 Rolling Mill Equipment References

Celsa Celsa Atlantic chose Russula to perform a mechanical upgrade that allows the plant to roll 180 mm size billets on both the bar and wire rod mills. The objective of the upgrade was to achieve greater flexibility and a higher tonnage output per billet. Included within the mechanical scope of supply were two roughing mill RCS stands, by-pass roller tables, pinch rolls, toggle shear and looper.

Erdemir After the successful upgrade of the automation system and drives of the two-line wire rod mill in 2015, Erdemir chose Russula to install two of the four water boxes of the same mill. Russula was responsible for the engineering, installation advisement, and commissioning support.

Gerdau Located in Texas, Gerdau Midlothian ordered a new loop former table for its mill which produces reinforcing bar #3 up to #11, and plain rounds 5/8” up to 3 1/4”. Russula supplied the engineering, mechanical equipment, installation supervision and commissioning support. The new looper was installed between stands # 16 and # 17 in the finishing end of the 340,000 tpy bar mill.

17 Rolling Mill Equipment References

Customer Year Project Cascade Steel 2020 Block guides, vertical loopers and wire rod outlet equipment Cascade Steel 2020 Roller guide optical alignment Erdemir 2020 Wire rod water boxes - Line B Cascade Steel 2019 Slitting guides and spares Gerdau Corsa Tlalnepantla 2018 Cold shear cut to length stopper Nucor Jackson 2018 Rougher crop and cobble shear Celsa Atlantic 2018 New rougher stands Gerdau Whitby 2018 New dividing shear AHMSA 2017 Strip Mill 2Hi stand refurbishing AHMSA 2017 Strip Mill F2 stand foundation reconstruction Erdemir 2017 Wire rod water boxes - Line A Gerdau Midlothian 2016 New Looper Table Gerdau Corsa Tlalnepantla 2016 New Cropping Shear CSN 2016 Approaching roller table and breaking slide equipment Dojran Steel 2016 Bar and section mill (350,000 tpy) SILAT 2015 Bar and wire rod mill plant ( 600,000 tpy) AHMSA 2015 Roller table supply for Universal Rolling Mill Votorantim Paz de Río 2013 Horizontal looper table Celsa Huta 2009 Engineering and mechanical equipment revamp Gerdau Cosigua 1999 New coil handling: Extension of pallet and horizontal C-Hook conveyor Antara Steel 1997 Revamp of mechanical and electrical equipment Celsa Global Steel Wire 1996 Cooling conveyor and coil handling Antara Steel 1991 Transfer, assembly and upgrade of a steel plant

18 Rolling Mill Automation

GUARANTEE PROCESS STABILITY

Russula supplies complete electrical knowledge to ensure our automation Reheat Furnace Control and automation solutions for bar, wire solutions increase mill productivity and rod and section mills, reheat furnaces, provide consistent production. Our approach is to automate by lev- steelmaking and strip processing lines. els and gradually improve the furnace All process and equipment control sys- Drives Upgrade performance. tems are implemented using the latest technology and best combination of AC and DC Drive upgrades are offered • Level 0: Field devices and instru- software and hardware available on independently and in conjunction mentation the market. with other electrical and mechanical • Level 1: Combustion and handling upgrades. We assist you in selecting system control Rolling Mill Control the optimal replacement drive with • Level 2: Heating optimization the correct features for your applica- includes heating strategies, The Russula team has a unique tion irregardless of the brand of your delay multiplier tables and combination of long product roll- current drives. mathematical model. ing process and electrical system

19 20 Rolling Mill Automation

REHEAT FURNACE CONTROL

Russula has developed a complete Combustion Control Material Handling control and optimization solution to better automate walking beam, Includes automatic temperature con- Controls charging, discharging and walking hearth and pusher furnaces trol, double cross control, air/fuel ratio auxiliary systems. for billets, blooms, beam blanks and control, automatic furnace pressure slabs. control and automatic combustion air Material Tracking pressure control. An important factor in controlling Charging and discharging queue com- reheat furnaces is optimizing the Combustion Optimization municates with MES/ERP systems. temperature control algorithm to en- sure a homogeneous material tem- Heating strategies that improve energy Production Delay Management perature to guarantee smooth rolling savings, exiting material temperature and provide premium product quality. feedback and a mathematical model Heating and cooling ramps for planned to predict stock temperature. and unplanned stops.

21 22 Rolling Mill Automation

ROLLING MILL CONTROL

Over the years, Russula has fine tuned reference, using the mill exit speed and Automatic Cobble Detection its rolling mill control solutions to each stand reduction. This parameter improve process stability, minimize directly relates to rolling fundamen- Once a cobble is detected, this system downtime and maintain a consistent, tals, simplifies the setup and operator will start to cut the remainder of the high quality product. control. billet immediately, far quicker than with manual control, so the operator Tension/Loop Control Shear Cut Control can resume production faster.

Russula’s tension and loop control The bar is tracked along the mill to Laying Head Control solution reduces tension along the determine the optimum point for mill, eliminating dimensional defects. cutting. Features like head, tail and Correct positioning of the laying head divide cut are implemented guaran- synchronized with the bar front end Cascade Control teeing high precision and reliability. ensures that it always enters at the Russula also offers cut optimization, correct position and eliminates snag- This control module uses R-Factor which optimizes the bar length using ging in the cooling conveyor. to calculate the mill cascade speed all available shears in the mill.

23 24 Rolling Mill Automation References

Nucor Steel Nucor Steel in Utah, USA upgraded the electrics and control of its mill #2 in a multi- phase project. The first phase consisted of upgrading the stacker, the second phase the finishing end and the third the rolling mill. A multi-phase revamp approach allowed Nucor Steel to upgrade obsolete control equipment and minimize downtime.

ArcelorMittal Acindar Russula supplied the complete control system software for the new bar mill, which has a capacity of 450,000 tpy, to ArcelorMittal Acindar in Villa Constitución, Argentina. The control scope included combustion and material handling for the 80 tph reheat furnace, mill control for an 18 stand in line mill including high speed flying shears and rotating channels, cooling bed and cold shear, bundling area, fluid systems and water treatment plant.

Laminoir des Landes In a little over a year, Russula delivered the electrical, automation and water treatment supply for a 500,000 tpy heavy plate mill in France, involving the supply, installation supervision and commissioning of all its respective equipment according to the project schedule.

25 Rolling Mill Automation References

Customer Year Project Nucor Birmingham 2020 Bundler HMI conversion to Wonderware Gerdau Corsa Tlalnepantla 2020 ABB DMI TT Electric Motors Celsa Celsa I 2020 High speed bar outlet electrical and automation upgrade Celsa Celsa UK 2020 Russula laser meters for two strand wire rod mill Nucor Nebraska 2020 Drives upgrade for the bar mill Nucor Nebraska 2020 Coilers and wire rod outlet upgrade Cascade Steel 2020 Control system upgrade Laminoirs des Landes 2020 New hot hydraulic shear automation Nucor Jewett 2019 Upgrade stand drives (ST1-ST12) Nucor Jewett 2019 Automation for new convertible stands Nucor Jewett 2019 Training and assistance Gerdau Cartersville 2019 Stands and stacker automation upgrade ArcelorMittal Acindar 2019 Automation and drives upgrade for mill #1 ArcelorMittal Acindar 2019 Electrical and automation upgrade for mill #2 Nucor Utah 2019 RM#1 shears upgrade and automation Nucor Utah 2019 Double buggies upgrade Gerdau Cartersville 2019 Bundling area roller table drives upgrade Nucor Kingman 2019 Pump house control upgrade Sidenor Vitoria 2019 Rod mill exit automation upgrade Nucor Longview 2019 Plate mill stand upgrade Gerdau Aza 2019 CPU AC800M PM891 & HMI upgrade CMC Texas 2019 Automation and drives upgrade Gerdau Charqueadas 2019 Automation and drives upgrade for rolling mill #2 Sidenor Thessaloniki 2019 Electrical and automation revamp Megasa Megasider Zaragoza 2019 Shear control upgrade CV60P Novelis Pindamonhangaba 2019 Hot finishing mill cleaning system automation Nucor Nebraska 2019 Kocks block upgrade (phase #2)

26 Rolling Mill Automation References

Customer Year Project Gerdau Charlotte 2019 Straightener and cold shear drives Gerdau Midlothian 2019 Rolling mill automation upgrade Celsa UK 2019 Stacker automation and drives revamp Laminoirs des Landes 2019 Hot straightener drives and control supply CMC Alabama 2019 Rougher electrics and automation Evraz 2018 Finishing block drive upgrade Novelis Pindamonhangaba 2018 Aluminum cold mill upgrade Cascade Steel 2018 Training program Nucor Kankakee 2018 Stacker upgrade Nucor Nebraska 2018 Electrics and automation upgrade phase #2 Nucor Utah 2018 Cold cut and stacker upgrade for mill #1 Celsa UK 2018 Revamping CCL Section Mill Nucor Jackson 2018 Rolling mill software and stand drives upgrade DCS800 Nucor Kankakee 2017 CCL control & drives Nucor Darlington 2017 Stand Drives mill # 1 and CCL Multidrive CIAFAL Divinopolis 2018 Iba expansion CSN Volta Redonda 2018 Iba system for bar and wire rod mill Nucor Jewett 2018 Technical assistance Nucor Jewett 2018 Drives upgrade for shears and stands Gerdau Petersburg 2017 Multidrive lineup for mill outlet Nucor Berkeley 2017 Pickling line drives upgrade Celsa Nervacero 2017 Control system upgrade for high speed bar mill Nucor Marion 2017 Rolling mill automation and drives for a new bar mill Nucor Kankakee 2017 AC & DC drives upgrade Novelis Pindamonhangaba 2017 Processing line electrical and control revamp Nucor Darlington 2017 Mill stands drives upgrade Laminoirs des Landes 2017 Plate mill control system and drives

27 Rolling Mill Automation References

Customer Year Project Vetorial Acepar 2017 Rolling mill automation upgrade Nucor Jewett 2017 Pendulum shear drives upgrade Nucor Jewett 2017 Pack annealing automation Nucor Utah 2017 Phase 3: Rolling mill #2 upgrade Nucor Kingman 2017 Bar and wire rod mill upgrade Evraz 2016 Rod mill outlet upgrade Sidenor Sovel 2016 Complete Iba system for rolling mill ICDAŞ 2016 Control upgrade for shears Gerdau Jacksonville 2016 Mill drives upgrade Nucor Kankakee 2016 Bar mill control upgrade Sidenor Dojran Steel 2016 Control system for the 350,000 tpy bar and section mill Nucor Utah 2016 Phase 2: Control and drives upgrade for the finishing end Aceros Alfa Aceros Alfa 2016 Electrical and automation system upgrade Gerdau Charlotte 2015 Rolling mill control and shears upgrade CSN Volta Redonda 2015 Control software upgrade SILAT (Gerdau) Fortaleza 2015 Complete control system for 600,000 tpy bar & wire rod mill Nucor Nebraska 2015 Drives upgrade for the rod block and laying head phase #1 Nucor Nebraska 2015 Electrical and control system engineering Gerdau Knoxville, TN 2015 Control and drives upgrade for shears and braking slide Nucor Birmingham, AL 2015 Bundler control upgrade ArcelorMittal Acindar 2015 Electrical and control system for 450,000 tpy high speed bar mill Celsa Global Steel Wire 2015 Vertical coil handling control system upgrade Gerdau Cartersville 2015 Rolling mill control system upgrade Erdemir Isdemir 2015 Control and drives upgrade (2nd gen) Sidenor Reinosa 2014 Drives and control Nucor Jewett 2014 Automation system and drives upgrade (Mill #2) Gerdau Barao de Cocais 2014 Rolling mill control system upgrade

28 Rolling Mill Automation References

Customer Year Project SILAT (Gerdau) Fortaleza 2014 Technical consulting and feasibility study Celsa UK 2014 Multi-phase drives revamp for the mill stands (phase III) Nucor Utah 2014 Phase 1: Control and drives upgrade for the stacker Gerdau Riograndense 2014 New high speed data acquisition system (IBA) ArcelorMittal Acindar Fenicsa 2014 Drive and control system for dividing shear Gerdau Corsa Tultitlan 2014 Drives upgrade phase 2 Gerdau Corsa Tlalnepantla 2014 Control and drives upgrade Celsa Atlantic Laracha 2014 Finishing end control upgrade ICH (SIMEC) Republic Lackawanna 2014 Wireless Remote IO system for strapper units Nucor Birmingham 2014 Complete mill drives and control supplied in E-houses AHMSA 2014 Electrical revamping for cold rolling mill Sidenor 2014 Drives and control upgrade for duo blooming mill Gerdau Cartersville 2014 Rolling mill drives upgrade Gerdau Cosigua 2014 New DC drives for roughing mill Evraz 2015 Control system upgrade for 500,000 tpy wire rod mill Celsa Atlantic Laracha 2014 Development and implementation of a Manufacturing Execution System Cascade Steel 2014 Control upgrade for shears Nucor Jackson 2013 Cut to length optimization Nucor Jewett 2013 Automation system and drives upgrade (Mill #1) Celsa UK 2013 Multi-phase drives revamp for the mill stands (phase II) ArcelorMittal Acindar Fenicsa 2013 Drives for motor stands ArcelorMittal Acindar Navarro 2013 Drive for dividing shear ArcelorMittal Vinton 2013 Control system and drives upgrade Special Metals Huntington 2013 Automation system and drives upgrade for SBQ bar mill Gerdau Corsa Tultitlan 2013 Drives for cooling bed area CMC Alabama 2013 Control system and drives upgrade Gerdau Açominas 2013 Control system upgrade

29 Rolling Mill Automation References

Customer Year Project Gerdau Cosigua 2013 Drive upgrade for finishing blocks ArcelorMittal João Monlevade 2013 New drives for finishing blocks Votorantim Paz de Río 2014 Drives and control system upgrade for two strands rolling mill Sidenor Vitoria 2013 Multiphase revamping for wire rod mill Nucor Jackson 2012 New tension control system Nucor Jackson 2012 High speed data acquisition system (IBA) ArcelorMittal Juiz de Fora 2013 High speed data acquisition system (IBA) Gerdau Corsa Tultitlan 2012 Drives upgrade phase 1 Gerdau Pindamonhangaba 2013 High speed data acquisition system with cameras (IBA) Gerdau Knoxville, TN 2012 Control and HMI system upgrade Gerdau Cartersville 2012 Rougher drives replacement Gerdau Beaumont 2012 Automation system for two strand wire rod mill Sidenor Vitoria 2011 Automation and drives for 15 stand wire rod mill Votorantim Barra Mansa 2011 Drives upgrade Gerdau Cosigua 2011 High speed data acquisition system with cameras (IBA) Gerdau Cambridge 2011 Control system and drives upgrade Celsa Celsa Atlantic Laracha 2010 Electrical and control system for 500,000 ton/yr bar mill Nucor Seattle 2010 High speed data acquisition system (iba) Gerdau Manitoba 2010 Cooling bed rake control and drive upgrade Gerdau Manitoba 2010 Drives upgrade for the straightener Gerdau Divinopolis 2010 High speed data acquisition system (IBA) Gerdau Calvert City 2010 Finishing end control and drives upgrade ICH (SIMEC) Pindamonhangaba 2010 High speed data acquisition system (IBA) Celsa Global Steel Wire 2010 Horizontal coil handling control system upgrade Gerdau Cartersville 2010 Straightener motors and drives upgrade Gerdau Divinopolis 2010 Rolling mill executive training Gerdau Cosigua 2010 Product tracking system

30 Rolling Mill Automation References

Customer Year Project Store Steel 2009 Electrical and automation system for SBQ bar mill Celsa UK 2009 Multi-phase drives revamp for the mill stands (phase I) ArcelorMittal Vinton 2009 Dividing shear control system Nucor Seattle 2009 Shears control upgrade Sinobrás 2009 Process consulting Gerdau Cosigua 2009 Control system revamp Gerdau Charlotte 2008 Finishing end control system Gerdau Aza 2008 Control and HMI system upgrade (2nd gen) Gerdau Knoxville 2008 Increasing finishing stand power/speed for slit rolling ICH (SIMEC) Republic Lackawanna 2008 Electrical and automation system for Kocks Block ArcelorMittal Acindar 2007 Electrical and automation system for a new SBQ Bar and Wire Rod Mill Gerdau St. Paul 2007 Electrical system for start/stop crop shear ICH (SIMEC) Republic Lackawanna 2007 Control and HMI system for finishing area Nucor Seattle 2007 Stands DC drives upgrade Ternium Chrubusco (APM) 2007 Roller table AC motors & drives Gerdau Beaumont 2007 Stands and rod block drives upgrade Votorantim ArcelorMittal Barra Mansa 2007 Electrical & automation system for 500,000 tpy wire rod mill Megasa Megasider Zaragoza 2006 Electrical and automation system for the Mill #2 Megasa Megasider Zaragoza 2006 Electrical and automation system for the Mill #1 Nucor Jackson 2006 AC and DC drives upgrade Celsa Celsa III 2006 Asea Tyrak stand drives upgrade ArcelorMittal Acindar 2006 Control system and drives upgrade Gerdau Knoxville 2006 Control system for new cold shear and bundling area Gerdau Wilton 2006 Control and drives upgrade Shiu Wing Steel 2006 Control system upgrade for 750000 ton/yr bar mill Gerdau Tamco 2006 Control system upgrade ArcelorMittal Acindar 2006 NTMs block drives upgrade

31 Rolling Mill Automation References

Customer Year Project ArcelorMittal Zumarraga 2006 Replacing existing ABB rolling mill control with Siemens S7 Celsa Global Steel Wire 2006 High speed data acquisition system (IBA) ArcelorMittal João Monlevade 2006 Electrical and control system for a two strands wire rod mill ArcelorMittal Warsaw 2005 Technical consulting Celsa UK 2005 Control system and drives upgrade for two strand wire mill ArcelorMittal Acindar 2005 Electrical equipment consultancy Gerdau Wilton 2005 Control system and drives for a new dividing shear Gerdau Knoxville 2005 Drive and control system for dividing shear Celsa UK 2005 Medium section mill shears upgrade Celsa Global Steel Wire 2005 Drives and control supply for two new coilers outlet Celsa Global Steel Wire 2005 Drives and control upgrade for increasing the mill production rate Celsa Atlantic Laracha 2005 Feasibility study and technical consultancy ArcelorMittal Celaya (SIBASA) 2005 Electrical and control system for wire rod outlet Cascade Steel 2005 Asea Tyrak stand drives upgrade POSCOChangwon 2005 Electrical and control for new RSM, pinch roll & laying head rod outlet ArcelorMittal Ares 2004 Technical consulting ArcelorMittal Ares 2004 Control and drives for a 350,000 tpy bar mill Nucor Seattle 2004 Auxiliary AC drives upgrade Steel Dynamics Roanoke Electric Steel 2004 Shears and finishing end control upgrade CMC Steel Sayreville 2004 Diverter and braking slide control and drives upgrade Celsa UK 2004 Medium section mill drives and control system upgrade Acerinox Roldan 2004 Roughing mill electrical revamp Gerdau Whitby 2004 Control system and drives upgrade ArcelorMittal Zumarraga 2004 Electrical equipment for new intermediate pinch rolls Gerdau Perth Amboy 2004 Control system and drives upgrade Celsa Atlantic Laracha 2004 Electrical and control equipment for new wire rod mill Gerdau Riograndense 2004 HMI system upgrade including the material tracking, fault and signal analysis

32 Rolling Mill Automation References

Customer Year Project Gerdau Charlotte 2003 Drives and control upgrade for 350,000 bar mill ArcelorMittal Acindar 2003 Bar mill control and drives upgrade Gerdau Riograndense 2003 Control system and drives upgrade Gerdau Whitby 2003 Control system and drives upgrade Gerdau Knoxville 2003 Drives and control upgrade for 500,000 bar mill Erdemir Isdemir 2003 Control and drives upgrade (1st gen) Gerdau Cosigua 2003 HMI system and material tracking Celsa Global Steel Wire 2003 Level 2 and material tracking system CBA CBA 2002 Finishing end control upgrade Celsa III Barcelona 2002 Control and drive system for stacker ArcelorMittal Acindar Bonelli 2002 Control system upgrade Gerdau Divinopolis 2002 Control system and drives upgrade Gerdau Riograndense 2002 Electrical equipment for the cold cut area Celsa IV Barcelona 2002 Control and drives system for fourth stacker (phase 2) Gerdau Riograndense 2002 Automation supply for three new stands Gerdau Barao de Cocais 2001 New looper tables and tracking system control Gerdau Riograndense 2001 Bar tracking, fault analysis and signal recording system Acerinox Roldan 2001 Intermediate and finishing end upgrade Celsa Global Steel Wire 2001 Drives and control upgrade Celsa II Barcelona 2001 Electrical & control system for stelmor & coil handling system Gerdau Riograndense 2001 Control system for new stands and water cooling boxes Celsa III Barcelona 2000 HMI upgrade for cold cut and stacker area Celsa III Barcelona 2000 Digitalize seven analog Siade Klein existing converter for mini flat bar mill Celsa Atlantic Laracha 2000 Electrical and control equipment for new bar mill Gerdau Aza 2000 Control system and drives upgrade (1st gen) Celsa Atlantic Laracha 2000 Technical consulting Gerdau Riograndense 2000 Electrical equipment for a new looper table

33 Rolling Mill Automation References

Customer Year Project Celsa Global Steel Wire 2000 Electrical equipment and control system for Reducing Sizing Mill (RSM) Celsa Celsa III 1999 Electrical equipment for VRM (Variable Reduction Mill) Gerdau Barao de Cocais 1999 Control system upgrade for bar and profile mill Gerdau Divinopolis 1999 Electrical and control system upgrade Celsa IV Barcelona 1999 Control and drives system for three stackers (phase 1) Acerinox Roldan 1999 Drives and control upgrade for wire rod mill Sidenor Vitoria 1998 Flat bar mill electrical and control system upgrade Celsa Celsa Atlantic Victoria 1998 Electrical and control equipment upgrade Acerinox Roldan 1997 Section mill drives and control upgrade ArcelorMittal Acindar 1997 Upgrade control system for roughing mill Antara Steel Antara Steel 1996 Electrical and control system upgrade Celsa Celsa IV 1996 Electrical equipment and control system Celsa Global Steel Wire 1996 Electrical equipment & control system for cooling conveyor & coil handling Sidenor Vitoria 1996 Electrical and control upgrade for single strand wire rod mill Tata Steel Tarapur 1995 AC motors, drives and control system Celsa III Barcelona 1993 Drives and control system ArcelorMittal Zumarraga 1993 Drives and control system Celsa Global Steel Wire 1989 Drives and control system for two strand wire rod mill

34 Roll Pass & Operations

360 DEGREE PROCESS VIEW

Russula has built a technical team The basis for a strong trouble shoot- • Operational training , hands on with a 100% focus on delivering ing team is a thorough understanding courses mill floor, directly with operational support, efficiency and of all aspects of the core rolling mill operators quality improvements for long product disciplines. The Russula team offers: • Production assistance rolling mills. Different from other • Troubleshooting suppliers, which fold customer service • Roll pass design into the area of revamping existing • Process optimization The key to effectively improving rolling plant equipment, this team is solely • Modern methods of process mill efficiency is to bring together the dedicated to making mills operate analysis right mix of technical disciplines. It is more efficiently. • Custom equipment design not enough to understand how the • Customized solutions electrical configuration affects produc- Multi-disciplinary teams are formed to • On site process reviews tion, but how the process impacts all ensure a 360 degree view of the mill aspects of rolling. problems from the process, mechan- ical and electrical points of view.

35 36 Roll Pass & Operations

CUSTOM SOLUTIONS

No two rolling mills have the same Mill operations and maintenance Russula has the technical know-how operational challenges, which is teams know what is really going on in to work jointly with the mill personnel why custom solutions and customer the plant and their input is critical to to propose what solution will work for collaboration are crucially important driving effective solutions. Russula each unique customer and applica- to the Russula Approach. The Russula aims to work closely with all personnel tion. Close customer collaboration and Approach uses a strong team of experi- inside the customer’s plant to identify a joint decision-making process are enced production and automation en- and resolve operational deficiencies. essential for improving operational gineers who visit the mill and discuss Teams are purposefully kept small to efficiencies in rolling mills. what problems the mill has with the give a more personalized, flexible, ser- production and management teams. vice to the customer. Gathering the right mix of people, depending on the issue at hand, is at the core of the Rus- sula Approach.

37 38 Roll Pass & Operation References

Customer Year Project Nucor Jackson 2020 3D Simulation Cascade Steel 2020 Pomini block pass design | Feasibility study | Gearing analysis Cascade Steel 2020 Extended process support CMC Arkansas 2020 3D Simulation CMC Texas 2019 Roll pass design CMC Texas 2019 IBA operations training and roll pass analysis Sidenor (Dojran Steel) 2019 Roll pass design | UPN channels Liberty Georgetown 2019 Roll pass design for roughing mill CMC Alabama 2019 Roll pass design | Finishing end productivity study Nucor Jackson 2019 Rolling mill training Nucor Jackson 2019 Slitting pass design revamp Special Metals 2019 Roll pass design for blooming mill | Operational support Special Metals 2019 Annual customer support Cascade Steel 2019 Operational support #3 bar Cascade Steel 2019 Operational assistance | Shear 12 engineering design Sidenor (Dojran Steel) 2019 Pass design | Operational training Keystone Steel & Wire 2018 Pass design and guide study Carpenter Technology Corporation 2018 Roll pass design & roughing mill pass design Evraz 2018 Pass design | Operational assistance Gerdau Monroe 2018 Engineering audit Gerdau Ouro Branco 2018 Operational support Gerdau Charlotte 2018 Operational assistance | Roll pass design Keystone Steel & Wire 2018 NTM A, B & C cycle pass designs Cascade Steel 2018 Operational assistance | Finishing grooves | Training Nucor Utah 2017 Operational assitance Nucor Jackson 2017 Operational assistance Cascade Steel 2018 Rebar study

39 Roll Pass & Operation References

Customer Year Project Sidenor Sovel 2017 Roll pass review Special Metals 2018 Operational assistance|Roll pass design for finishing mill Celsa Nervacero 2018 Pass design Kroman Celik 2018 Operational assistance Keystone Steel & Wire 2017 NTM Pass design and guide study Gerdau Midlothian 2017 Operational assistance |Slitting pass design Nucor Jackson 2017 Roll pass design review and operational assistance ArcelorMittal Villa Constitución 2017 Pass design and operational assistance Evraz 2017 Roll pass design Sidenor Stomana 2017 Operational improvement technical consultancy Sidenor (Dojran Steel) 2017 Operational improvement technical consultancy Special Metals 2016 General rolling assistance ArcelorMittal Acindar 2016 Slitting pass design revamp ArcelorMittal Acindar 2016 Rolling mill operational assistance Sidenor Volos 2016 Operational improvement technical consultancy Kyoei Steel 2015 Roll pass design, guide study and startup support Cascade Steel 2015 Operational assistance |Pass design |Guide study CSN 2015 Bar mill cooling bed audit Nucor Jewett 2015 Operational assistance Sidenor Thessaloniki 2015 Operational assistance for equipment Special Metals 2015 Operational improvement technical consultancy CMC Sterling Steel 2015 Equipment design project Yücel Boru 2014 Operational assistance |Full mill pass design Ugitech 2014 Operational assistance

40 41 Water Solutions

DESIGNED FOR SUSTAINABILITY

Based on over 30 years experience pro- Russula can supply the water treat- Russula has the in-house capabilities viding engineering solutions, Russula ment plant as a turn-key solution to manage all aspects of the project. has designed a water treatment plant specifically designed according to your Cost savings are incurred due to a fast exclusively for the steel industry. The specifications. The equipment selec- and accurate project execution and company believes the solution to be tion represents the latest in proven a modular approach. Prefabricated space efficient, low cost, low mainte- water treatment technology. The inno- piping reduces welding during the nance and most importantly provides vative configuration is based on a twin water treatment plant construction, high water quality to the rolling mill decanting concept, complete with ring installation time and costs. To date, process. The closed loop recirculating filtration and modular cooling towers. Russula has supplied the water treat- water system meets stringent quality ment plant to 20 steel plants world- and discharge requirements. wide.

42 43 Water Solutions

BIG RIVER STEEL Osceola, AR, USA

As Big River Steel’s 3.3 MT per year Due to the enormous size of the fa- The implementation of the water treat- Flex Mill™ is the first of its kind in the cility, operational efficiency was a ment complex was divided into two world, so is its water treatment solu- key priority for Big River Steel. Rus- phases. Phase 1 treats 35,000 m3/hr tion. Russula supplied the entire water sula focused on three design aspects, (154,000 gpm) of water. Phase 2 was treatment complex, which treats and lowering energy consumption, mini- part of the BRS expansion project to cools water required by the steelmak- mizing chemical dosing and providing doubled its initial capacity and treats ing, RH Degasser, Gas Cleaning Plant, an easy to operate and maintain water 21,000 m3/hr (92,000 gpm) of water. Casters, Tunnel Furnaces, CSP Mill, treatment plant. In order to minimize Pickling Line/Tandem Cold Mill, Skin the environmental impact of the steel Pass Mill, Continuous Galvanizing Line, production process, the water treat- and Batch Annealing processes. ment plant was designed to comply with strict local legislation and reuse Russula’s main design objective was as much of the water as possible be- to build a water treatment complex fore discharging it permanently to the that was both efficient and ecological. Mississippi River.

44 45 Water Solution References

Gerdau Sayreville Russula has redesigned Gerdau Sayreville’s water treatment facility. In the redesign, the plant reused sections of the existing equipment configuration to treat process water coming from the contact cooling circuit of the 800,000 tpy mill. Apart from improving the water quality, the modernization provided greater operating flexibil- ity, reduced maintenance costs and fully-automated operations, which significantly reduced energy costs and chemical additives.

Severstal Russula enabled Severstal, located in Balacovo the Saratov Region of Russia, to run a state of the art water treatment facility that operates in extreme weather condi- tions. The water facility treats 9675 m3/hr (42,598 gpm) of water critical to the steel production process providing Severstal’s 1 MT new generation steel plant with clean, cooled process water.

AHMSA Russula supplied a turn-key water for AHMSA’s 1 MT Steckel plate mill located in Monclova, Mexico. The new water treatment plant has a capacity of 7,400 m3/hr (32,657 gpm) contact water and 4,600 m3/hr (20,300 gpm) non-contact water circuits. The entire water treatment plant was constructed in 1 year from breaking ground to final installation.

46 Water Solution References

Customer Year Project North Star BlueScope 2020 Water treatment plant for meltshop expansion OMK Steel 2020 Water treatment plant for meltshop, section and merchant bar mill Nucor 2020 New scale pit for water treatment plant Big River Steel 2019 Water treatment plant phase 2: meltshop, hot strip and cold mill Celsa 2019 Water treatment plant in conjunction with wire rod mill supply Nucor Kankakee 2019 WTP for section mill Nucor Marion 2018 WTP for bar mill PROTEC Coating Company 2017 WTP for galvanizing line Laminoirs des Landes 2017 WTP for plate mill Big River Steel 2015 WTP for meltshop, hot strip and cold mill Ferroeste Gusa Nordeste 2015 WTP for the meltshop, combined bar and wire rod mill GV do Brasil 2015 WTP for the meltshop, combined bar and wire rod mill SILAT (Gerdau) 2014 WTP for combined bar and wire rod mill Severstal Balakovo 2013 WTP for the meltshop, bar and wire rod mill AHMSA 2013 WTP for the plate Steckel mill Gerdau Sayreville 2013 WTP for existing bar mill Gerdau Cosigua 2011 WTP for the two strand wire rod mill Celsa Huta 2009 WTP for the profile, bar and wire rod mill Celsa UK 2008 WTP revamp for Temcore system Nucor Connecticut 2007 WTP revamp for existing wire rod mill Votorantim Barra Mansa 2007 WTP for meltshop and wire rod mill ArcelorMittal Acindar VC 2007 Compact WTP for greenfield caster and wire rod mill Celsa Atlantic 2005 WTP for the combined bar and wire rod mill Ferroatlantica 2003 WTP revamp in collaboration with ABT Celsa Global Steel Wire 2003 WTP revamp for wire rod mill

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