Ironmaking and Steelmaking process
In April 1995, we replaced an existing blast furnace with new equipment featuring cutting-edge technologies, and introduced an iron making process that involves high-rate injection of powdered coal to achieve efficient operations. Leveraging the characteristics of our No. 1 and No. 2 steel plants, which have furnaces of different capacities, we dedicate the No. 1 plant for high-mix, low-volume production, chiefly special steel, and we have substantially reduced energy consumption through direct hot charge linking the No. 2 steel plant with the reheating furnaces of the hot strip mill. These plants are the source of NISSHIN STEEL's feedstock.
Our work roll single-cross finishing mill, the world's first, achieves precise control over product shape. The single hot-rolling line of the Kure Works enables us to process all our products—from ordinary and special steel to stainless steel, resulting in industry-leading rates of operation and unit rolling cost.
|Facility Name||Reference||Units||Annual Production Capacity(Ton/Year)||Principal Items Produced|
|Iron-making||No.1 blast furnace||Freestanding type
|1 standing||2,080,000||Pig iron|
|No.2 blast furnace||Freestanding type
|No.1 sintering machine||Dwight Lloyd type
|1 standing||3,290,000||Sintered ores|
|No.2 sintering machine||Dwight Lloyd type
|Steelmaking||Converter furnace||Tandem furnace bottom separation type 90T||2 standing||1,820,000||Slab|
|Furnace body converter type 185T||1 standing||2,381,000|
|Continuous casting||Continuous casting machine1||Vertical semi-underground type||1 standing||480,000|
|Continuous casting machine2||Vertical bending type||1 standing||1,992,000|
|Hot-rolling||No.2 hot rolling mill||Roughing mill, four-stage reversing type
Roughing mill, four-stage non-reversing type
Finishing mill, four-stage type
Finishing mill, six-stage type
|1 continuous||3,954,000||Ordinary steel
(Hot-rolled steel strip)
(Hot-rolled steel strip)
Surface treatment Process
Our fourth hot-dip coating line commenced operations in September 1990, which has several features including (1) an annealing furnace employing vertical indirect heating with the soaking area, which ensures good processability and high product quality; (2) our accumulated expertise maximized wih the YG gas wiping method and vibration control devices to achieve a high degree of evenness in coating weight; and (3) leading-edge roll-coating equipment installed in the post-treatment section. These characteristics enable us to offer zinc- and aluminum coated steel sheets of higher quality as compared with our conventional products.
Cold-rolling mill (for special steel production[1ZM])
Our state-of-the-art cold-rolling line for special steel came on stream in 2008. The operation of our 1ZM enables us to produce high-quality special steel—one of the Company's strengths with a consistent quality control process from the materials stage and to aim for an even higher degree of precision.
Electrolytic coating line (Electrolytic galvanizing equipment[EGL])
Over the years, we have amassed considerable experience in electrolytic copper plating and leading-edge technologies. For example, we use insoluble electrodes to achieve a superior degree of evenness on zinc coatings; we can produce coated sheet of up to five feet in width; the use of a highly fluidized horizontal cell ensures improved productivity with high current concentration for coating; and shortening the distance between electrodes helps to conserve electricity. We also comply with green purchasing requirements through post-treatment that employs chrome-free, phosphate and organic coatings, depending on the application.
|Facility Name||Reference||Units||Annual Production Capacity (Ton/Year)||Principal Items Produced|
|Cold-rolling||Cold rolling mill||Six-high, four-stand||1 continuous||1,209,000||Cold-rolled steel|
|20-stage reversing (sendzimir mill)||1 standing||249,000||Cold-rolled steel (Special steel)|
|Surface treatment||Aluminum coating line||Sendzimir method||1 continuous||164,400||Alstar|
|Galvanizing and aluminizing line||All radiant tube method||1 continuous||318,600||PAINTITE B
|Zinc coating line||Sendzimir method||1 continuous||183,000||PAINTITE B
|Electctrolytic copper plating line||Continuous||1 continuous||42,600||MOONSTAR Coppertite Copper Softain|
|Electrolytic galvanizing line||Continuous||1 continuous||222,000||MOONSTAR Zinc|
|Coating line||Continuous two-coat twice annealing||1 continuous||135,600||Moostar Color Tecstar|
RSPM line (Pickling, cold-rolling)
We were the first company in the industry to introduce a pre-rolling process that uses a mechanical descaler prior to the acid cleaning process.
The resulting increase in the removal of oxides from the steel surface significantly improves the efficiency of later cleaning with hydrochloric acid. At the same time, this process extends the life of the pickling tank, boosts operating speed and reduces energy by allowing the use of lower-temperature acid solutions.
We have installed a four-stand cold-rolling UC mill, which uses computers to automatically control rolling conditions. As a result, we can adjust steel sheet profiles freely, regardless of material quality. This enables us to supply steel sheet featuring highly precise gauge and shape.
HCGL line Continuous (Hot-dip line)
The HCGL (hot-dip continuous galvanizing line) at the Toyo Works features combined vertical and horizontal annealing furnaces and four efficiently arranged zinc pots. The state-of-the-art technology on this line, which produces ZAM®, enables groundbreaking improvements in surface quality and productivity.
|Facility name||Reference||Units||Annual Production Capacity (Tons/Year)||Principal Items Produced|
|Pickling, Cold-rolling||Pre rolling type Pickling and cold rolling mill||Six-stage type(1 unit)+shallow bath type
|1 continuous||1,080,000||Cold-rolled steel sheet|
|Surface treatment||Zinc plating line||Vertial direct-fired reduction-type||1 continuous||480,000||PAINTITE
The Osaka Works is a specialized facility for manufacturing high-end cold-rolled steel sheet, which makes full use of its products, technologies and equipment. The works has a host of industry-leading equipment including one of the world's largest Sendzimir mills, automatic gauge control (AGC) to mass-produce high-quality cold rolled steel sheet according to required specifications, and a reverse mill to produce ultrathin high-quality sheet that serves the needs of the electronic sector. Here, we strive to meet increasingly diverse customer needs for automotive parts and materials for electronic components.
The Kanazaki plant of the Osaka Works delivers into the marketplace a host of household and industrial products, using a consistent quality control system that begins with raw materials.
A rolling mill employing computerized gauge monitoring equipment, as well as bainite processing equipment and slitters, enable the plant to meet industry's needs for small lots of highly diverse products. The plant has earned a strong reputation for quality, and is a Japanese leader in precision cold rolled steel strip both in terms of quality and quantity.
|Facility Name||Reference||Units||Annual Production Capacity (Tons/Year)||Principal Items Produced|
Cold rolling mill
|Four-stage reversing type||1 standing||157,000||Cold-rolled steel mill|
Cold rolling Mill
|Four-stage reversing type||2 continuous||85,900||Brushed steel strip|
Steelmaking process (Steelmaking facilities)
Depending on the targeted chemical composition, we use arc heat in an electric furnace to melt ferroalloys such as ferrochrome and ferronickel along with scrap to produce molten iron.
The molten iron passes through the converter furnace, vacuum degassing station and continuous casting to be made into slabs, which then go through hot-rolling process performed at the Kure Works.
Our cold-rolling mills are of four types: a cluster mill, a reverse Sendzimir mill, a four stand tandem Sendzimir mill and a tandem cold-rolling mill. Each of these mills is productive and delivers high-quality products.
|Facility Name||Reference||Units||Annual Production Capacity(Tons/Year)||Principal Items Produced|
|800,000||Stainless steel Slab|
|Converter furnace||Tandem furnace bottom converter type||80T||2standing|
|Continuous casting||Continuous casting line||Mannesmann bending type||1 standing||800,000|
|Vertical bending type||1 standing|
|Cold rolling||Cold-rolling mill||20-stage reversing
|4 standing||363,600||Stainless steel Cold-rolled steel sheet|
|20-stage continuous type
(Tandem Sendzimir mill)
Kinuura Works (Hot-rolling process)
The hot rolling plant, which was founded in 1996, boasts the state-of-the-art hot rolling facilities centered on the Steckel Mill. The plant has various high-performance machines and instruments as well as the computer system to comprehensively operate and control them, and processes slabs shipped from the Shunan Works into hot rolled coils and plates. In addition, having realized automated in-plant transportation of slabs and coils for example, this plant makes a significant contribution in improving key benchmarks including productivity, product quality and safety.
Kinuura Works (Cold-rolling process)
The plant processes hot rolled materials into cold rolled coils, hoops, etc. Such center pieces of the plant as the fie-foot-wide Sendzimir mill and the annealing & pickling line work to roll, heat-treat and pickle the feedstock, and make products excellent in surface gloss, shape and other attributes. Furthermore, the manufacturing line for ultra-light gauges turns out bright-annealed products with high gloss and hard products of improved flatness with their hardness and thicknesses fine-tuned.
|Facility Name||Reference||Units||Annual Production Capacity (Tons/Year)||Principal Itemes Produced|
|Hot-rolling||Hot rolling mill||Roughing mill, 4-stage reversing type||1 standing||1 continuous||450,000||Stainless steel hot-rolled steel strip|
|Finishing mill, 4-stage reversing type, steckel mill||1 standing|
|Cold-rolling||Cold rolling mill||20-stage reversing (Sendzimir mill)||2 standing||192,000||Stainless steel cold-rolled steel sheet|
|6-stage reversing||1 standing|