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Pig iron is produced in two blast-furnaces with increased top pressure. The blast-furnace charge is composed of iron containing pellet and sinter, as well as flux, and coke is added to it. Sinter is produced in the Ore Preparing and Agglomerating Plant. Pellet is imported. The heat produced during the burning of coke melts the ore charge. Developing gases, as well as carbon of coke reduce iron-oxides into iron. Products arising from pig iron manufacturing: pig iron, liquid slag and blast-furnace gas. Pig iron produced in the Blast-furnace Plant is transported to the Steelworks, discharged into a hot-metal ladle. |
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The next production unit after the Blast-furnace Plant is the Steelworks. Hot steel is produced during the steel-making process from pig iron and scrap adding fluxes, refining materials, deoxidants and alloying additions. Phases of steel-making process: charge production, ladle metallurgical treatment and steel casting. Steel is produced in two LD basic oxygen furnaces with the capacity of 135 tons each.
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| Hot Rolling Mill |
The Hot Rolling Mill is the only plant in Hungary that is able to produce hot rolled steel strip with the thicknesses of 1.2 – 18.0 mm and with the widths of 840-1540 mm. The mill was commissioned in 1960. In the last period, the technical and production process was continuously modernized until it reached its present level suitable for the requirements of the demanding market.
Transport of hot rolled products – according to the customers’ demands – can be arranged in the form of wide or slit coil, as well as sheet. The place of production of sheets is the modern uncoiling-cutting line. Cut sheets are delivered packed in bundles and bound. The production process is controlled by computers. Hot rolled-pickled products are produced with the thickness of 1.0-6.0 mm and the width of 800-1520 mm. Significant quality improvement could be realized, as well as the product range could be expanded by the modern pickling equipment using muriatic acid installed in 2008 and by the new reversing roll stand with the skirt width of 1760 mm. |
| Cold Rolling Mill |
500 thousand tons of cold rolled products are produced on annual basis. Cold rolled products can be manufactured with the thickness of 0.3-3.0 mm, the width of 19-1500 mm depending on the requirements. |
| Profiling Works |
Cold bent steel sections are produced by continuous roll bending from downcoiled slit strips, by shaped roll pairs assembled into the stands installed behind each other. During the production of hollow steel sections the two edges of the round-bent strip is joined by high-frequency induction welding, the external welding bead is burred and then make the section to the required shape and size. The section is cut to the precise length by disc-type flying saw. The products are designed and manufactured by qualified specialists having experience of several decades. The production capacity exceeds the value of 200 thousand tons on annual basis. The choice of hollow sections ranges from 16 to 133 mm in the case of round steel sections with the thickness of 1-4.6 mm, as well as from 15x15 mm to 150x60 mm in the case of square steel sections. Open steel sections include L, U, C, Z and other special steel sections with the thickness of 1-6 mm. Aligning with European norms the quality of products and related services are continuously developed. Products are designed, manufactured and sold in certified quality and environment management systems. The company has the certificates of conformity for products bound to CE-mark used for construction industrial applications. |
Hot-dip Galvanizing and Metalworks |
The base material of hot-dip galvanization is cold rolled wide strip. Hot-dip galvanizing is carried out by Sendzimir process. The quality of galvanized wide strips and sheets complies with the technical requirements of the standard for low-carbon, as well as structural steel strip. Constructional industrial elements are produced from galvanized or organic-coated galvanized base material by cold forming. The products comply with the requirements of the standard Eurocad 3 and have ÉME classification. |
| Transport Plant |
The basic activity of the Transport Plant is the transport of base materials arriving to the blast furnaces, of materials, products and semi-finished products arriving to the individual production plants, as well as of the manufactured products by rail to individual customers. The Transport Plant moves 11 million tons of material on a yearly basis. We have 96 km of railway tracks, 25 Diesel engines, 413 railway wagons, high-capacity forklifts, loading machines and other transport and loading devices to perform the above tasks. The maintenance and repair of transport and loading devices are performed in our own repair shop. |
Lőrinci Rolling Mill |
ISD DUNAFERR Lőrinci Hot Rolling Mill has been serving plate users since 1950. in the thickness of 8- 100 mm are produced by production technology controlled in quality management system certified according to the standard ISO 9001:2000 and transported to the purchaser by rail or truck in bundles in case of need up to the sheet size of 1500x3000 mm, otherwise in stacks of 3-5 tons separated from each other by timber skids.
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The Blast-furnace Plant operates as the first technological phase within DUNAFERR Co. Ltd. The Production profile of the plant is pig iron production over 1.3 mT/year in 1999.
Steel is treated by ladle metallurgical process by homogenizing steel, decreasing its gas and gas cavity content in order to meet the increasing demands for steel quality. Steel treated on ladle metallurgical station goes to the continuous casting plant. The next phase of production is computer controlled continuous casting. Hot steel is cast to a crystallized and solidificated strand by water-cooling. Steel slabs are produced by cutting these into pieces of determined sizes.
Slabs produced in the Steelworks are transported to the Hot Rolling Mill.
Almost 1.35 million tons of hot rolled products are produced on a yearly basis.
The Cold Rolling Mill is the only facility in Hungary performing cold rolling of wide steel strips. Normal operation was started in June 1965 after successful test run. Hot rolled pickled and cold rolled products are included in the product range in the form of wide coils, slit coils and sheets. Beside those for general purpose, the products meet the demands of hot-dip galvanizing, radiator producing, enamelling, construction industrial, electrical engineering and automobile industrial producing companies.
DUNAFERR Profiling Works is the steel sheet processing plant of ISD DUNAFERR Zrt. that was originally established in 1964 for the production of metallurgical second and third products.
It is the first and only production plant in Hungary producing continuous hot-dip galvanized steel coils. A 100% self-owned member company of DUNAFERR Co. Ltd. had performed the activity from 1998 to 2004. Hot-dip Galvanizing and Metalworks of DUNAFERR Co. Ltd. has performed this task since 1st January 2004. Our galvanized steel coil and sheet production exceeds 100,000 tpy. and our production of galvanized and organic-coated constructional industrial products exceeds the quantity of 250,000 m2/y. We are the suppliers of domestic and European constructional industry companies as well as companies producing household appliances, light constructional buildings and profiles.
The Transport Plant provides railway transport for the Company Group, as well as road transport between the production plants of DUNAFERR Co. Ltd. The plant was established in 1952 and its organization has been changing continuously together with the company.