New Danieli Color Coating and Printing Line at Lysva, Perm Region, Russian Federation

The Color Coating and Printing Line was designed to produce 110,000 tpy of color-coated and printed coils for thin strip from 0.3 to 1.5 mm thick, in widths up to 1,500 mm. Since the line had to be installed in the existing building at the Lysva Plant, a customized layout and compact design was needed, so that the entire line could fit into a 160-m-long space.

The line has three coaters (prime, finish and clear) and one printing section with three printing heads. Convection ovens, supplied by Danieli Centro Combustion, are located after each coater; here the paint coats are cured by hot air.
The first coater (prime coater) applies the primer on both sides of the strip, while the second one (finish coater) applies the top finish coat and the backing coat. If printed products are required, the first coater applies the primer on both sides of the strip, while the second coater applies only a top coat called “base coating”. After the curing oven of the base coating, there is a printing section with three printing heads, which apply the ink to the painted strip using pattern rolls. After each printing section a hot air dryer is used to dry the ink applied on the strip surface. After the printing section, the third coater (clear coater) applies a transparent or “clear” paint on the strip surface to protect it and enhance its resistance against corrosion. In order to purify the solvent-containing air coming from the ovens and coating rooms, two purification systems were installed. A rotoconcentrator is installed downstream the coating rooms. This is an auto-regenerative zeolitic wheel that reduces the solvent concentration from 100 mg/Nm3 down to 20 mg/Nm3. The wheel directly adsorbs the solvents, which are regenerated with a hot air flow. A Regenerative Thermal Oxidizer (RTO) is installed downstream the ovens in order to oxidize the solvents. The concentrated flow coming from the wheel is also sent to the RTO. Oxidation reduces the solvent concentration from 8 g/Nm3 to 20 mg/Nm3. During normal operation, oxidation is performed without gas consumption.
The entire electric and automation system, including motors, drives, MCS, Level 1 and Level 2 process controls, were designed and supplied by Danieli Automation. Coating layer thickness control, accurate strip temperature control and efficient drive systems are the key technological components of Danieli Automation’s 3Q technological package.
Supervision to installation, start-up and commissioning is also supplied by Danieli to ensure a smooth and fast ramp-up curve.

Hot commissioning has already begun. The first coil was painted with both prime and finish coating on February 16th, 2016 (in the presence of the Minister of Industry of the Russian Federation), and the first strip was printed on March 2nd, 2016, reaching a surprising quality, right since the first day of the printing trials.
The inauguration ceremony for the LMZ Color Coating and Printing Line took place in Lysva on March 30th, 2016. The Russian Prime Minister Mr. Medvedev, connected to the event in videoconference, uttered words of praise for this result.
The satisfactory preliminary results of this line will enable LMZ to position itself as the only supplier in Europe of this specific high-value-added product.