INNOVATION

NEW ROLLING MILL

INNOVATION

NEW ROLLING MILL

The Smart Beam manufacturing (SBM) is the new rolling mill that will allow to verticalize the production of the plant in San Zeno Naviglio, Brescia.

We inaugurated in the fall of 2023 thanks to the experience of the Duferco technicians and to the strong collaboration with SMS Group, technology partner and supplier for the project.

A new integrated rolling mill, downstream of the San Zeno steel mill, to allow for optimal verticalization of the steel production, with the goal of becoming the best cost producer of steel beams in Europe.

Length

m2 New Rolling Mill Area

m2 Finished Products Wharehouse Area

m3 Volume of Concrete for the Fondations

THE NEW ROLLING MILL

Italian steel industry heads toward the future. The new rolling mill is integrated with the steel mill, through innovative and sustainable technologies.

An ambitious project looking to the future. A strong investment that confirms the attitude of Duferco Group to innovation. Integrated with San Zeno Naviglio steel mill, the new SBM rolling mill (Smart Beam Manufacturing) has endowed Duferco Travi e Profilati of an extremely efficient system at the heart of the Italian and European steel market, allowing to verticalize the steel production. The rolling mill has a potential production capacity of 700,000 tons per year and artificial intelligence for its management.

The total investment is around 250 million euros and has created 150 new job positions and many opportunities for the local satellite activities.

million euros invested

new hires

CIRCULAR ECONOMY

The new SBM rolling mill for the steel beam production has been conceived as a system integrated with the steel mill and is the perfect example of circular economy.

It is a sustainable model, based on the reuse of resources: from the recycling of ferrous scrap, which is the main raw material used in production, to its transformation in a semi-product and the further rolling to obtain finished product for the construction field.

TECHNOLOGY

The project was created with the most innovative and modern technologies available. It is fully interconnected with other plant machinery and involves the most advanced technological tools, developed by the company’s teams in collaboration with Universities and Research Institutes, as already done for other projects in the plant.

The system is highly integrated: every single machine is digitally interconnected to other digital platforms; information and data has been gathered in database organized to be processed through optimization and simulation software based on predictive algorithms.

CIRCULAR ECONOMY

The new SBM rolling mill for the steel beam production has been conceived as a system integrated with the steel mill and is the perfect example of circular economy.

It is a sustainable model, based on the reuse of resources: from the recycling of ferrous scrap, which is the main raw material used in production, to its transformation in a semi-product and the further rolling to obtain finished product for the construction field.

OUR GOALS:

integrating the new production flow at the San Zeno site

defining and implementing state-of-the-art security systems with automation system

optimizing our production process, reducing time and costs

developing a digital infrastructure to collect and process information on cloud-based databases

reducing our carbon footprint and the demand fo energy, with energy recovery systems for heating and rolling, minimizing emissions

expanding the range of products offered by our group

PRODUCT RANGE OF THE NEW SYSTEM:

  • HE beams from 100 to 600
  • HE-M beams from 100 to 400
  • I profiles from 140 to 750
  • U profiles rom 140 to 400
  • H-Pile from 8×29 to 12×74
  • American profiles
  • English profiles

SUSTAINABILITY

The rolling mill was designed to be at the forefront of sustainability, technology, and innovation.
The supply of energy from renewable sources was ensured through two PPAs (power purchase agreements),

Through two purchase power agreement (PPA) with renewable energy, the entire San Zeno Naviglio site will be supplied with 60 million kWh, leading to an indirect CO2 reduction of 28 thousand tons per year.

 

Furthermore, Duferco Travi e Profilati has also concluded a project, in collaboration with BM Group, for a photovoltaic system made up of 19,400 photovoltaic modules for a total peak power of more than 9 MWp.

Reduction of gas consumption by 20% compared to comparable systems.

10% reduction in electricity consumption compared to existing systems.

Reduction of a further 10% of gas consumption thanks to the hot loading application.

Reduction of water consumption below 1 m3/t.

TIMELINE

Timeline new SBM rolling mill - DufercoTP

November 2020

Duferco signs supply contract for San Zeno Naviglio rolling plant with SMS Group: a model plant in trms of competitiveness and reduction of environmental impact.

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April 2021

Work begins with the first civil works which officially kick off construction of the new facilities.

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June 2021

Completed first plinths, on which will rests facilities which will house the new rolling plant.

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April 2022

Facilities are almost ready to host machinery that will make up the rolling train.

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June 2022

First materials begin to arrive from SMS Group, construction site proceeds and systems take shape.

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June 2023

The assembly of the rolling machinery is completed and the first operational test begin.

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July 2023

Assembly of the machinery ended, start first real hot rolling tests with the new technology.

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August 2023

Start production of beams at the new rolling mill powered by SBM green energy.

The SMS machineries

The Smart Beam Manufacturing is part of an industrial model that preserves the value of raw material and resources and aims at high standards in terms of:

Environmental Sustainability

Development of innovative models of circular economy

Optimization of energy and resources consumption

Reduction of carbon footprint

Economic Competitiveness

Research of max efficiency

Optimization of production processes

Integration of processes and material flows

Development of digital system for decision-making process

Social Sustainability

Positive employment impact

Product innovation

Support systems for operators

Evento inaugurazione – 16 Ottobre 2023