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.
TIMELINE
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.
April 2021
Work begins with the first civil works which officially kick off construction of the new facilities.
June 2021
Completed first plinths, on which will rests facilities which will house the new rolling plant.
April 2022
Facilities are almost ready to host machinery that will make up the rolling train.
June 2022
First materials begin to arrive from SMS Group, construction site proceeds and systems take shape.
June 2023
The assembly of the rolling machinery is completed and the first operational test begin.
July 2023
Assembly of the machinery ended, start first real hot rolling tests with the new technology.
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
