Russula  

Fiskdale,  MA 
United States
  • Booth: 2465


Stop by our booth to talk with out rolling mill specialists.

Russula is a global engineering company serving the largest steel producers in more than 35 countries. With its headquarters and workshop located in A Coruña, Spain, the company has major offices in Brazil, India, Italy, Mexico, Russia and Sturbridge, MA. Russula has implemented over 200 electrical and mechanical upgrades and greenfield water treatment plants in the United States and Canada.

Russula collaborates with steel producers to help them become high-performance businesses by developing innovative technology for meltshops, bar, wire rod and section mills, flat mills and water treatment plants. Our strategy builds on our technical expertise to develop engineering solutions to help steel producers around the world increase productivity and improve operational efficiencies.

Brands: MILL PULSE: A user-friendly, mobile, flexible, goal-oriented, integrated and customizable Manufacturing Execution System. LAYING HEAD TECHNOLOGY: Our patented laying head design solves real-world performance problems, reducing maintenance downtime, noise and power consumption.


 Videos

RUSSULA_AISTECH

 Press Releases

  • Following the successful upgrade of the 700,000 tpy merchant bar mill and the cold cut area, Nucor Steel Kankakee is modernizing the stacker area.

    Located in Bourbonnais, Illinois, USA, the mill produces merchant bar and rebar, including rounds, flats, and angles. The goal of the upgrade is to replace the automation system and AC/DC drives, which will improve performance, troubleshooting, facilitate training and spare parts availability.  

    All equipment from the entry chains after the cutting area to the bundle discharge area are included within the electrical and automation upgrade scope. The existing stacker controllers will be replaced with more powerful ControlLogix CPUs that incorporate safety features. All the racks, power supply, and IO boards will be reused. The existing stacker HMI will be replaced with Wonderware and integrated with the recently upgraded mill and CCL HMI, bringing all functionality into one, common application and removing the necessity to develop interfaces. New main operator desks featuring Elo® touchscreens will be custom designed for this project.   

    New ABB DCS800 drives will replace the existing drives with the latest in digital control. The Rockwell PowerFlex 755 drive series will replace the existing AC drives. All drive units will be pre-built in cabinets and supplied with Ethernet IP boards connected to the new ControlLogix hardware.  

    The startup is scheduled for the beginning of November 2019. This project counts as the 7th stacker and bundler upgrade that Russula has implemented within Nucor Steel. Plants in Utah, Texas, Arizona and Alabama have effectively modernized the stacker and bundle discharge area with the latest advances in drives and controller technology.

  • Gerdau Long Steel North America, located in Whitby, Ontario, Canada has placed an order for a new combined dividing shear. The Gerdau Whitby mill produces angles, channels, rounds, square reinforcing and flat bars.

    Within the project scope, Russula will supply a new pinch roll, a divide shear, servo actuated diverter and a chopping shear. The mechanical and electrical equipment including the motion controller, drives, servos and new motors is also included within the scope of supply. Russula is responsible for the engineering, installation supervision, commissioning and production support.

    The new 40-ton combined shear is multi-functional with both crank and flying modes. The shear is movable. In order to switch between the crank and flying mode the complete shear assembly can be moved hydraulically. This feature reduces the switching time to a few seconds and avoids the laborious task of coupling and uncoupling the shear cutting arms.

    The new combined dividing shear is scheduled to be in full operation by the summer of 2019. Taking advantage of our extensive knowledge of the steel process and experience in mill revamping, Russula specialists are equipped to develop equipment that will improve productivity and mill performance.

    Russula has a long-standing relationship with the Gerdau Whitby plant over the past thirteen years. In 2004, Russula upgraded the bar mill. The upgraded resulted in an 8% production output increase.

    Recently, Russula supplied all the electrical equipment and control software necessary to upgrade the 120 tons/hr reheat furnace, such that the mill complied with international safety standards and improved plant safety and reliability.

  • Nucor Corporation contracted Russula to upgrade the drives and automation of the finishing end of its bar mill #1 in Plymouth, Utah. Russula successfully completed a similar upgrade for bar mill #2 in September 2016.

    The main objective of the upgrade was to replace the obsolete automation and AC/DC drive equipment with a new modern first line control and HMI system. The new automation system improved operational performance, troubleshooting failures, spare parts availability as well as facilitate training.  

    The scope of this upgrade included all the equipment from the aligning rollers at the cooling bed to the removal rolls, including layer forming, straightening and cold shear cutting, layer forming, bundle forming, tying stations and bundle exit. The existing AC and DC drives were part of the Reliance Electric drive series, which had become antiquated and had limited replacement parts and support. All of the AC and DC drives were replaced with ABB ACS880 and ABB DCS880 drives respectively. The drives were supplied pre-installed in a new lineup up of cabinets to match the existing power distribution and to reuse the existing power cables whenever possible. The existing Automax automation system and Reliance RIO hardware were replaced with new hardware based on Allen Bradley ControlLogix and Point IO series and Factory Talk HMI.   

    Russula was also responsible for the installation advisement, commissioning and training. The electrical and automation equipment was assembled in the Russula workshop at the end of last year and underwent a factory acceptance test in January 2019. Technical specialists from Nucor Steel – Utah and Russula were present during the test to ensure that the new automation and drives functioned correctly and according to specification. Commissioning occurred in March, 2019. The switchover was implemented in a fast and sequenced manner in order to least disturb production.  

    The cooperation between Russula and the Nucor Steel – Utah mill began in 2014 with the upgrade of mill #2 stacker. This is the fourth consecutive revamp project that has occurred over that time. 

    Nucor Corporation is the largest steel producer in the United States, and is North America’s largest recycler. Nucor Steel – Utah is one of Nucor’s 13 bar mills strategically located across the United States, which produce a wide usage of bar product for the agricultural, automotive, construction, energy, furniture, machinery, metal building, railroad, recreational equipment, shipbuilding, heavy truck and trailer market segments. The capacity of Nucor’s bar mills is approximately 8,830,000 tons per year.

  • Celsa Group has selected Russula to supply a new rolling mill that will be installed in its Celsa France Boucau-Tarnos steelworks near the Bayonne area in Southern France. The new rolling mill will feature Russula’s latest technological developments in mechanical equipment design, automation and process digitalization.

    The rolling mill has a design capacity of 600,000 tpy, and will serve to vertically integrate the existing meltshop production at the Celsa France steelworks. The mill will produce different steel grades according to European standards.

    The new mill will be fed with hot billets directly from the casting, which will optimize the energy costs of transformation. It will be outfitted with a walking beam reheat furnace, RCS Housingless stands in the continuous roughing and intermediate mills, and a pre-finishing mill with 3 mini-blocks. The finishing mill will be equipped with a 10 pass compact block, water-controlled cooling, a new generation laying head to form the coils onto a cooling conveyor. Once the coil is formed, it will be further cooled and transported by a system of vertical pallets and horizontal hooks to the compactor and tying area, where it will be ready for storage and shipment.

    Russula will apply all of its experience and technology to provide Celsa with a wire rod mill that is at the forefront of process digitalization, automation, production management and the standards and tools of Industry 4.0. The new rolling mill will have all the latest advances developed by Russula focused on maximizing production and reducing processing costs.

    Russula is responsible for the design and the complete execution of the project under a turn-key contract. The commissioning of the new mill will take place within a 20 month time frame. Within the Russula scope of supply is the general design of the plant, warehouses, main and auxiliary technological equipment, civil construction, assembly and commissioning support.

    With the addition of the new wire rod mill, the Boucau-Tarnos steelworks will become a fully integrated steel complex, the largest of its kind in Southern France. Once the mill is fully operational, Celsa Group will be able to offer a full range of finished steel products to customers in the France and Benelux markets.

    About Celsa Group

    Celsa Group is the leading Spanish and second largest long steel producer in Europe. Currently, the Group recycles eight million tons of ferrous scrap per year. The company employees more than 9,400 employees worldwide in industrial facilities in Denmark, Spain, Finland, France, Norway, Poland, Sweden and the United Kingdom.

  • In October 2018, Nucor Steel – Nebraska located in Norfork, NE, commissioned Russula to implement phase two of the electrical and automation upgrade of its bar and wire rod mill.

    Russula previously  implemented phase one in 2015, which consisted of a drives upgrade for the rod block and laying head, and the electrical and control system engineering for the roughing and intermediate mills.  

    Phase two consisted of the drives upgrade for the roughing mill, pinch roll and shear #1. The pinch roll motor drive was converted from DC to AC. The electrical and services scope of supply includes:              

    • ABB DC drives for the roughing stands and shear
    • Arc flash protection for the DC drives
    • Motor replacement for the pinch roll
    • AC drive for the pinch roll
    • Safety Remote IO
    • Local control stations
    • Sensors
    • Network equipment
    • Installation supervision
    • Commissioning support
    • Production support
    • Training

    The switch-over to the new drives and commissioning tests were performed by Russula during the phase two implementation in October. The electrical upgrade will help Nucor leverage the latest control technology to produce excellent quality bars and tightly wound, straight-sided coils. 

    Nucor Steel – Nebraska is one of Nucor’s 13 bar mills strategically located across the United States, and is one of Nucor’s four bar mills that has a significant focus on manufacturing engineered special bar quality (“SBQ”) and wire rod products. Nucor Corporation is the largest steel producer in the United States, and is North America’s largest recycler.


 Products

  • Rolling Mills
    Equipment designed for the long run and built to last....

  • With over thirty-one years experience in the steel industry, Russula combines its long product process, automation and mechanical design expertise to create bar mills, wire rod mills and section mills that are reliable, easy to maintain and efficient. We design new plants and modernizations, all custom made solutions to fit the way you roll today.
  • Digitalization
    Process digitalization and Industry 4.0...

  • Computer Vision
    An artificial eye on your process can provide data you have never seen before

    Mill Pulse
    Track Key Plant Performance Indicators with Russula’s Manufacturing Execution System 

  • Water Solutions
    Our water technologies help steel producers meet environmental regulations and reduce costs....

  • Founded on years of experience from working in the steel industry, Russula develops water treatment plants for meltshops, flat mills, long mills and processing lines. Engineering designs are made according to the requirements of your steel plant. Complying with local legislation and your environmental protection plan is first and foremost. There are currently 22 Russula water treatment plants in 9 countries operating in the world today.
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