The mill is engineered with an environmentally conscious approach, eliminating reheating furnaces, reducing carbon emissions, and enhancing energy efficiency through induction heater technology. Scheduled for commissioning in Q3 2026, the new mill will increase production capacity and manufacture high-quality construction steel products.
With an annual production capacity of 500,000 metric tons, the new mill will enable Kalyani Ispat to effectively respond to the increasing demand for construction steel, such as rebar, in Asia’s rapidly expanding construction and infrastructure market. It will produce rebar in diameters of 8 to 40 millimeters and wire rods ranging from 5.5 to 20 millimeters, ensuring the company can effectively meet the growing needs of these sectors.
The order includes a comprehensive scope of supply, featuring a ten-pass finishing block, a new crop and dividing shear, and a high-speed delivery (HSD®) system. SMS’s HSD® technology is a proven, reliable system boasting over 108 reference installations worldwide since 1971, enabling customers to achieve higher production efficiency, reduced downtimes, and stable product quality. Designed to maximize yield and productivity, while achieving a consistent production speed of up to 45 meters per second in the rebar line. To enhance the production process, newly designed water boxes are integrated, allowing for efficient bar quenching. This innovation improves the mechanical properties of the bars while reducing the reliance on costly alloying elements in the melt shop. The high-speed wire rod line, capable of reaching speeds of 100 meters per second, is equipped with technologies such as pinch rolls, a laying head, and the loop cooling conveyor (LCC®) system. These features ensure precise mechanical properties and operational reliability. Additionally, an automated coil handling system will further enhance process efficiency. The mill incorporates an environmentally conscious design by directly utilizing 130-millimeter-square, 12-meter-long billets from existing casters through induction heaters, eliminating the need for reheating furnaces. This innovation significantly reduces carbon emissions while enhancing energy efficiency.
The mill will also be equipped with SMS’s advanced drive and automation technology. The advanced software architecture will enable sequential mill control from the entry area to the bar and coil finishing lines. Advanced diagnostics and digital analytical tools that optimize processes ensure fully automated rebar and coil production at high speeds.
“This partnership underscores the trust industry leaders place in SMS group’s advanced high-speed mill technology. Our mission extends beyond supplying equipment—we deliver a competitive edge through enhanced productivity, energy efficiency, and sustainability,” said Bernhard Steenken, CSO, APAC & MEA, SMS group.
