- Both projects are part of EMSTEEL’s Asset Enhancement Programme, aimed at expanding production capabilities to include higher-quality products
- Advanced equipment, including the eDrive Morgan No-Twist Mill, Morgan Reducing/Sizing Mill, and Morgan Stelmor conveyor will enhance product tolerances, product quality and optimize operational costs
- New wire rod outlet line will be constructed offline, ensuring existing bar mill production is unaffected while reducing downtime for faster commissioning
EMSTEEL, one of the largest publicly traded steel and building materials manufacturers in the region, recently selected Primetals Technologies as a technology partner for the implementation of a new wire rod outlet at Rebar Mill No. 05 and upgrades to an existing wire rod mill at RM No. 03 in Abu Dhabi, UAE. These projects are key components of the EMSTEEL Asset Enhancement Programme, which focuses on enhancing production capabilities and incorporating advanced solutions to meet growing market demands. This will enable EMSTEEL to enter higher quality markets, supporting international tire cord, seismic rebar, pre-stressed concrete (PC) strand, alloyed cold heading, and welding wire product lines.
New State-of-the-Art Wire Rod Outlet to Enable Thermomechanical Rolling
The new wire rod outlet will be part of the existing RM No. 05, expanding EMSTEEL’s product portfolio to include plain wire rod in coil from 5.5 to 24 mm and rebar in coil from 8 to 16 mm. In addition to the expansion, Primetals Technologies has redrafted the existing mill to optimize tolerance and reduce wear on existing passes, as well as loading on mill stands.
The new wire rod outlet will include state-of-the-art equipment, including an 8-stand eDrive Morgan No-Twist Mill, Morgan Reducing/Sizing Mill, Intelligent Pinch Roll and Morgan Laying Head, a Morgan Stelmor Controlled Cooling Conveyor, in-line heat treatment via Morgan Waterboxes, as well as a vertical pallet and horizontal C-hook coil conveyor system. Also included is a Level 1 basic automation system, and a complete Level 2 Long Rolling Process Expert system to support the production management process and offer operators advanced insights into the production process.
The mill is designed for thermomechanical rolling and fine grain rebar to reduce operating expenditures. The equipment will be constructed prior to installation, reducing downtime and enabling faster commissioning.
Advanced Cooling Upgrades for Higher Quality Finished Products
The upgrade to EMSTEEL’s wire rod mill at RM No.03 will include a new Morgan Stelmor Controlled Cooling Conveyor, utilizing the mill’s existing support structure. The cooling conveyor will improve overall cooling capabilities and as-rolled wire rod properties, allowing EMSTEEL to meet strict requirements for high-quality pre-stressed concrete (PC) strand grades.
The addition of new roller modules with blowers will seemlessly integrate into the mill’s existing coil handling system, while the patented Optimesh air distribution will enhance tensile uniformity for small diameter products. The upgrade also includes new drives, a new motor, and a fully integrated automation system.
EMSTEEL is a public joint stock company (ADX: EMSTEEL) and the UAE’s largest steel and building materials manufacturer. The Group leverages cutting-edge technologies to supply both the local market and over 70 international markets with high-quality finished products, creating a one-stop shop for the manufacturing and construction sectors.
Hot wire rod coil exiting Morgan High-Speed Laying Head and cooling as it moves down the Morgan Stelmor Cooling Conveyor
Primetals Technologies, Limited, headquartered in London, United Kingdom, is a pioneer and world leader in the fields of engineering, plant building, and the provision of lifecycle services for the metals industry. The company offers a complete technology, product, and services portfolio that includes integrated electrics and automation, digitalization, and environmental solutions. This covers every step of the iron and steel production chain—from the raw materials to the finished product—and includes the latest rolling solutions for the nonferrous metals sector. Primetals Technologies is a Group Company of Mitsubishi Heavy Industries, with around 7,000 employees worldwide. To learn more about Primetals Technologies, visit the company website www.primetals.com.
