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Badische Stahlwerke finds upgrade solutions for mill with Siemens VAI

Badische Stahlwerke GmbH, Kehl, Germany has selected Siemens VAI to undertake an extensive upgrade for its wire rod rolling line. The automation system of the two-strand wire rod mill will be thoroughly modernized, and two new rod outlets will be installed. The aim is to achieve greater efficiency and to adapt the mill to market requirements. The order value is in the medium double-digit million Euro range. The project will be carried out in three phases and will be finished in early 2014.

Wire rod mill of Badische Stahlwerke GmbH (BSW) in Kehl, Germany. The mill will be thoroughly modernized by Siemens (Photo: BSW).

Siemens VAI´s upgrade of the Badische Stahlwerke wire rod mill, which mainly produces base material for concrete reinforcing bar, will result in an increase in production capacity and a broader spectrum of qualities and sizes due to increased automation and the possibility of thermomechanical rolling.

To minimize downtime, the upgrade will be implemented in three phases from 2011 to 2014 during scheduled annual shutdowns. The first phase involves replacing the existing automation system of the 13 stands of the roughing and intermediate mill with the well-proven Siroll LR automation system, based on Siemens PCS7 software, to provide fully automatic control and easier maintenance.

In the second phase, Siemens VAI will erect the two new rod outlets, each with a six-stand and four-stand Morgan No-Twist mill, 10 Morgan Intelligent Pinch Rolls, high speed trimming shears, Morgan High Speed Laying Heads, Morgan Stelmor conveyors and a vertical coil handling system in preparation for the third phase, when the new equipment will be connected to the existing mill and commissioned in early 2014. The Siroll LR automation system, extended to the two new rod outlet control systems with mechatronical packages, will offer an integrated solution throughout the line.

Rod speed guarantees are up to 110 meters per second, and the coil handling system will produce a coil every 20 seconds, resulting in a production rate of up to 300 tons per hour. Siemens is responsible for all erection and commissioning of the mechanical and electrical equipment in a turn-key operation. The planning and execution of related infrastructure works and civil

engineering, as well as the installation of auxiliary facilities such as the water system, will be undertaken by BSW.

Founded in 1955, Badische Stahlwerke GmbH produces reinforcing bar and wire rod products for the European construction market. The company runs an EAF-based integrated production site in Kehl in the German state of Baden-Wuerttemberg. Final products are rolled in a bar mill and a wire rod mill, respectively.

No-Twist and Stelmor are registered trademarks of Siemens Industry, Inc. Siroll LR is a registered trademark of Siemens


The Siemens Industry Sector (Erlangen, Germany) is the worldwide leading supplier of environmentally friendly production, transportation and building technologies. With integrated automation technologies and comprehensive industry-specific solutions, Siemens increases the productivity, efficiency and flexibility of its customers in the fields of industry and infrastructure. In fiscal 2010, which ended on September 30, 2010, revenue from continuing operations of the Industry Sector (excluding Osram) totaled around €30.2 billion. At the end of September 2010, Siemens Industry Sector had around 164,000 employees worldwide without consideration of Osram. Further information is available on the Internet at:

The Siemens Industry Solutions Division (Erlangen, Germany) is one of the world's leading solution and service providers for industrial and infrastructure facilities comprising the business activities of Siemens VAI Metals Technologies, Water Technologies and Industrial Technologies. Activities include engineering and installation, operation and service for the entire life cycle. A wide-ranging portfolio of environmental solutions helps industrial companies to use energy, water and equipment efficiently, reduce emissions and comply with environmental guidelines. With around 29,000 employees worldwide (September 30), Siemens Industry Solutions posted sales of €6.0 billion in fiscal year 2010.

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