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Wally Heydendael

This document discusses recent technologies in cold rolling mills to improve product quality, as presented by SMS Demag AG. It describes Edge Drop Control systems that help achieve constant strip thickness across the width. It also details the T-roll® process technology package for simulating cold rolling processes. Furthermore, it presents a new lubrication and cleaning concept combining low-quantity lubrication with liquid nitrogen to improve strip surface quality. Online measuring systems are also discussed for documenting product quality parameters.

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COLD ROLLING MILLS and STRIP PROCESSING LINES Session 3 COLD ROLLING MILLS STRIP PROCESSING LINES SMS metallurgy Conference 2007
Most recent technologies in cold rolling to improve product quality Dr. Hartmut Pawelski General Manager Metal Forming and Surface Technology Dipl.-Ing. Christoph Schwarz Deputy General Manager Technical Sales Cold Rolling Mills Dipl.-Ing. Rüdiger Holz Execute Vice President Cold Rolling Mills Division Dr. Karl Hoen General Manager Plant Technology Hot/Cold Rolling Mills Division SMS Demag AG Düsseldorf/Hilchenbach, Germany
Most recent technologies in cold rolling to improve product quality Rüdiger Holz, Dr. Karl Hoen, Dr. Hartmut Pawelski, Christoph Schwarz In recent years, the steel industry world- wide achieved remarkable growth rates. It is not only growing in Asia, here espe- cially in China and India, but also in Europe and America. At the same time, its consolidation is going on and the steel markets become more and more global. In such an environment it is important for mill owners to meet highest quality re- quirements and at the same time curb the production costs. SMS Demag as system supplier for inte- grated solutions of rolling mill technology developed a large number of suitable systems for supporting mill owners in these efforts. Examples of effective solu- tions in cold rolling mills for achieving high quality requirements and highest economic efficiency are the following: ▬ Equipment for Edge Drop Control to achieve a constant strip thickness across the complete width, ▬ the T-roll® process technology, ▬ an alternative lubrication and clean- ing concept for an improved strip sur- face quality and ▬ online measuring systems for the documentation of product quality and meeting of narrower tolerances. Edge Drop Control (EDC® ) Edge Drop describes the undesired thickness drop in the edge zone of cold rolled strips. Reason for it is the chang- ing roll flattening in the transition from the loaded to the unloaded rolling sec- tion. Depending on the intended use of the strip, this area has to be removed. For this purpose, the strip is trimmed what will reduce the plant yield. For avoiding such losses, SMS Demag developed Edge Drop Control strategies for reversing cold mills and tandem cold mills. For compensating the thickness drop, the work roll diameter in the strip edge area has to be reduced. For this pur- pose, the work roll barrel is tapered by a special grind at one end. The principle of the control is now based on shifting the taper for so far into the strip edge zone until a specified edge drop value is set. The operating results of the CSC revers- ing mill in Taiwan illustrate the difference between using and not using an Edge Drop Control for non-grain-oriented silicon steel. Application of the Edge Drop Control was able to reduce the trimming losses by over 20 mm for each side. This increases the yield for the common strip width by more than 3 %.
The strategy for a continuously operating tandem mill is a combination of open- and closed-loop controls. The drop in thickness is measured after the first and the last stand (stand 5). The first mea- surement is used for controlling the edge drop in stand 1. At the same time, this signal is applied for a pilot control of mill stands 2, 3 and 4. The measurement after the last stand is introduced to cor- rect the control command of the pilot control in mill stands 2, 3 and 4 and that way the desired edge drop value after stand 5 is set. As the operating results show, this strat- egy is suitable to set a constantly low value for edge drop over the entire strip length and thus subsequent trimming losses are reduced. T-roll® process technology For optimizing the cold rolling process and for an improved product quality it is indispensable to understand the physical processes during cold rolling in a better way. Therefore SMS Demag developed T-roll® , a technology package including new and enhanced physical model ap- proaches for simulating the cold rolling process. Beside the complete mechani- cal and thermal description it is above all the detailed and realistic description of the tribological processes which open up new options for process optimization. The accuracy of the model approaches becomes apparent in the high coinci- dence between measurement and simu- lation. Examples are the accurate simu- lation of rolling force and strip lead as well as the transfer of the roll surface roughness onto the strip surface. As examples for the efficiency of T-roll® , the optimization of a single-stand revers- ing mill for the production of grain-orient- ed silicon steel shall be mentioned. In this project, the lubricant and the appli- cation of lubricant could be improved in a well-aimed way by the new way of con- sidering the tribology in the roll gap. This enabled a clearly higher rolling speed and thus a clear improvement of the plant's output capacity. A second example is the avoiding of form waves in cold rolling of brass in a two-stand tandem mill. It was only through the analysis of the problem by means of the T-roll® technological pack- age and a test setup in the laboratory based thereon that it was demonstrated that the form waves exclusively occur through insufficient lubrication condi- tions. By improving the lubricant and di- rect application of an additive in the first passes the form waves were avoided.
Lubrication and cleaning concept As a new lubrication and cleaning con- cept, SMS Demag developed a com- bination of least quantity lubrication and the utilization of liquid nitrogen. In skin- passing, this concept decisively im- proves the strip surfaces and at the same time curbs the operating costs. When using the least quantity lubrication in the skin-pass stand entry, the lubricant volume is precisely applied, which is re- quired for reducing the friction in the roll gap. This reduces the rolling force and improves flatness at simultaneously us- ing a minimum quantity of lubricant. The liquid nitrogen in the exit covers both the strip surface and the roll surface. This method has the following advantages: ▬ clean and dry strip surfaces and thus clearly lower susceptibility to rust, ▬ clearly reduced efforts in the down- stream cleaning steps for cleaning the strip surface and ▬ prolonged work roll service lives. For assessment of the strip surface qual- ity, the same material was skin-passed under different operating conditions. In the pass with emulsion, clear impres- sions of the lubricant could be found. They make the surfaces appear less bright. The roll abrasion in dry skin-pas- sing has a similar effect on the surface quality. Compared to that, the surfaces are clearly more uniform and thus brighter when using liquid nitrogen in the entry or in the entry and exit. Moreover the operating experience showed that the use of nitrogen more than doubled the work roll service lives. This and the lower refinishing effort on the strips led at our cooperation partner C. D. Wälzholz to cutting the process costs for skin-passing by ca. 20 %. The most recent reference for this con- cept is the new inline skin-pass mill stand for the continuous annealing line of ThyssenKrupp Steel in Dortmund, Germany. Online measuring systems Efficient production on a high quality lev- el today requires complete documenta- tion of the main quality parameters. Only that way it is possible to demonstrate quality towards the customer and at the same time efficiently track down causes for quality problems in the process line and to remedy them. Our new "Rotary Inspect" inline inspec- tion line sets the record here for safety and ergonomics in the manual assess- ment of strip top and bottom sides. Our patented roughness control system enables controlling the strip roughness over the entire length to a constant value and to perform the roll change only when it is really needed. For roughness mea- surement, the SORM 3 plus measuring system of our cooperation partner EMG is used.
The SMS Demag flatness measuring roll is the ideal solution for precise and reliable measurement of strip flatness. The closed surface of the roll avoids marks on the strip and can be coated specifically for each application. The roll allows simple installation of the sen- sors which can even be performed on site. The sensors can be arranged flexi- bly regarding their distances in accor- dance with the current and future re- quirements of the profile and flatness control system. Ten references within a short time demonstrate our customers' high acceptance of this measuring system.
1SMS metallurgy Conference 2007 Most recent technologies in cold rolling SMS Demag solutions for improved product quality Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Constant strip thickness up to the edge EDC Closer tolerances and better documentation Higher yield and improved product quality T-roll® process technology Lubrication and cleaning concepts Online measurement systems A new approach for perfect surface quality 2SMS metallurgy Conference 2007 Most recent technologies in cold rolling EDC® Edge Drop Control – constant strip thickness up to the edge Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems
3SMS metallurgy Conference 2007 Most recent technologies in cold rolling Principle of the Edge Drop Control Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Stripthickness Principle of work roll shifting for Edge Drop Control Strip width with EDC without EDC Reduced Edge Drop Influence of EDC on the strip edge transverse material flow 4SMS metallurgy Conference 2007 Results of Edge Drop Control in a single-stand reversing mill Most recent technologies in cold rolling Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Material: Non grain-oriented silicon steel 0 20 40 60 80 100 120 -2.5 -2 -1.5 -1 -0.5 0 0.5 Distance from strip edge Thicknessdeviation[%] Edge Drop measurement Hot strip After last pass with EDC without EDC Yield increased by approx. 3 % due to by reduced trimming losses►►
5SMS metallurgy Conference 2007 Most recent technologies in cold rolling Edge Drop Control strategy for a continuous tandem cold mill Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems AW Position AW Position AW Position S1 S2 S3 S4 S5 EDC Vorsteuerung EDC Regelung G2;G3;G4 AddRef AddRef Ref Ref Ref AW Position Ref AddRef EDC Regelung G1 Act AW Position WR shifting AW Position WR shifting AW Position WR shifting measured edge drop edge drop references EDC feed forward control EDC feedback control G2;G3;G4 AddRef AddRef Ref Ref RefRef Ref Ref AW Position WR shifting Ref AddRef EDC feedback control G1 Act Model parameter measured edge drop EDC feedback control for S1 EDC feed forward control and feedback control of S2, S3, S4 6SMS metallurgy Conference 2007 Most recent technologies in cold rolling Results of closed loop Edge Drop Control in a tandem cold mill Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems position(mm) Strip length [m] G1 G2 G3 G4 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 0 20 40 60 80 100 EDC-Position (measured) Strip length [m] 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 -10 0 20 40 60 80 Edge drop (measured) Edgedrop[μm] Edge drop measured EDC workroll shifting position Strip length [m] Edgedrop(μm) after G1 after G5 Reference value: after stand 1 20 μm after stand 5 10 μm with EDC Edge drop reduction constant over total strip length►►
7SMS metallurgy Conference 2007 Most recent technologies in cold rolling T-roll® process technology Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Technology package for the simulation of the cold rolling processes with advanced models for ▬ mechanical ▬ thermal and ▬ tribological processes Applications: ▬ thermal and tribological processes ▬ Analysis and optimization of lubrication and cooling conditions ▬ Selection of adequate lubricants ▬ Development of new rolling strategies ▬ Calculation of pass schedules for new steel grades ▬ Pre-calculation of strip surface roughness More profit due to higher yield and improved product quality►► 8SMS metallurgy Conference 2007 Most recent technologies in cold rolling T-roll® process technology Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems High capability of new approaches 0 0.5 1 1.5 2 2.5 3 0.0 0.5 1.0 1.5 2.0 2.5 Elongation in % Roughingofstrip,Rainμm Measured, top Measured, bottom Tribological model Tribologisches Modell Rolling Speed [m/min] Walzkraft [MN] Walzgeschwindigkeit [m/min] Tribologisches Modell Rolling Speed [m/min] Walzkraft [MN] Tribological model Rolling Speed [m/min] Roll force [MN] Roll speed [m/min] Rolling Speed [m/min] tribological model Voreilung [%] Tribologisches Modell Walzgeschwindigkeit [m/min] tribological model Rolling Speed [m/min] Tribologisches Modell Voreilung [%] Walzgeschwindigkeit [m/min]Rolling Speed [m/min] tribological model Voreilung [%] Tribologisches Modell Walzgeschwindigkeit [m/min] tribological model Rolling Speed [m/min] Tribological model forward slip [%] Roll speed [m/min] ▬ High forecast accuracy for • improved processing and • higher plant utilization
9SMS metallurgy Conference 2007 Most recent technologies in cold rolling Cold rolling of high-grain-oriented silicon steel Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems before modernization after modernization 900 m/min = max. motor speed 5 pass HGO Share of production approx. 30 % Max.rollingspeed [m/min] 900 600 300 0 pass 1 pass 2 pass 3 pass 4 pass 5 Increase of maximum speed by tribological optimization►► 10SMS metallurgy Conference 2007 Most recent technologies in cold rolling Cold rolling of brass on a tandem cold mill: elimination of waves Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems SMS Demag solutions: ▬ Optimization of lubricant ▬ Low quantity lubrication for first passes ►►
11SMS metallurgy Conference 2007 Most recent technologies in cold rolling Combination of low-quantity lubrication and liquid nitrogen Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Low quantity lubrication Liquid nitrogen ▬ Substantial reduction of lubrication quantities ▬ Reduction of friction in the roll gap • lower rolling force • improved strip flatness ▬ Improvement of strip surface quality ▬ Better cleaning effect on work rolls ▬ Longer service life of work rolls Benefits:In cooperation with: C.D. Wälzholz ►► 12SMS metallurgy Conference 2007 Most recent technologies in cold rolling Skin-pass rolling with liquid nitrogen Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Valuation of strip surface quality after skin-pass rolling Target: Ra = 1,0 – 1,8 μm; shining surface Liquid nitrogen, entry Liquid nitrogen, entry and exit Emulsion, entry (height profile: ± 0,8 μm) 100 μm lubricant impressed dry Abrasion of rolls Improved surface quality Considerably improved strip surface quality►►
13SMS metallurgy Conference 2007 Most recent technologies in cold rolling Skin-pass rolling with liquid nitrogen Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems after coil No. 1: 1.4 μm after coil No. 4: <1.0 μm Roughness of new work roll: 3 – 3.3 μm after coil No. 1: 1.7 μm after coil No. 10: 1.2 μm Coil No. Dry (2004-05-03) 3.0 10 1 2 3 4 5 0.0 0.5 1.0 1.5 2.0 2.5 3.0 Roughness of new work roll: 3 – 3.3 μm Coil No. 0.0 0.5 1.0 1.5 2.0 2.5 3.0 1 2 3 4 5 6 7 8 9 10 Liquid nitrogen (exit) Service life of work rolls increased by more than 100 % Skin-pass process costs reduced by 20 % ►► 14SMS metallurgy Conference 2007 Most recent technologies in cold rolling Recent reference: ThyssenKrupp Steel, Germany New inline skin-pass mill for continuous annealing line Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Main technical data: Strip thickness: 0.4 to 2.3 mm Strip width:: 600 to 1,720 mm Roll speed range: 0 to 412 m/min Annual capacity: 780,000 t Year of commissioning: 2007 Inline-skin pass Technical features: ▬ Newly developed low-quantity lubrication system and roll-strip cleaning with liquid nitrogen ▬ SMS Demag shapemeter roll ▬ X-Pact® – electric and automation systems
15SMS metallurgy Conference 2007 ►► Most recent technologies in cold rolling Online measurement systems to improve product quality and plant utilization Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems SMS Demag flatness measurement roll Inline inspection line „Rotary-Inspect“ SORM roughness measurement with control system Advantages: ▬ Continuous monitoring and documentation of quality parameters ▬ Close tolerances by means of integration in closed loops In cooperation with: 16SMS metallurgy Conference 2007 ►► Most recent technologies in cold rolling SMS Demag flatness measuring roll in new design Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Advantages: ▬ Easy sensor installation even at site ▬ Applicable at high temperatures e.g. production of Si-steel grades ▬ Individual arrangement of sensors ▬ Closed surface ▬ Application-based coating References in 18 months: 7 plants with a total of 10 shapemeter rolls
Modernization concept of the four-stand tandem cold rolling mill, BILSTEIN GmbH & Co. KG Dipl.-Ing. Detlef Böttner Deputy General Manager Sales Cold Rolling Mills Electrical and Automation Systems Dipl.-Ing. Falk Töpfer General Manager Technical Sales Cold Rolling Mills Dipl.-Ing. Arnulf Wurm Senior Project Manager Technical Sales Cold Rolling Mills SMS Demag AG Hilchenbach, Germany
Modernization concept of the four stand tandem cold mill, BILSTEIN GmbH & Co. KG Detlef Böttner, Falk Töpfer, Arnulf Wurm Ever increasing requirements on the cold strip qualities and the continuously grow- ing material and variant diversity more and more force rolling mill owners to keep their plants on the most recent technological level or to get them there. Due to the concurrently very high de- mand volume and thus the plant utiliza- tion in recent years, they had to face particular challenges. SMS Demag took up these customer problems and elaborated and constantly developed special concepts in recent years to cope with them. This is one of the reasons why the company BILSTEIN with their registered office in Hagen, Germany, tasked SMS Demag with the extensive modernization of their four- stand tandem cold mill. BILSTEIN is processing a diversified ma- terial and product mix starting from the standard grades over case-hardening and special grades up to micro-alloyed high-strength steels. The tandem mill is the central key plant for the complete production at BILSTEIN and in some cases also for their subsidiary com- panies. Therefore a consistent and reli- able modernization concept was even more significant for taking the decision to award the contract. The rolling mill was supplied in 1969 by SMS Demag and was during the years upgraded and modernized several times. This mill produces every year 400,000 t of cold strip of width from 320 to 670 mm and thicknesses from 7.5 to 0.3 mm. The input stock is produced by slitting hot strip normally into two to three stripes. Therefore the input stock has different wedge profiles what is a particular chal- lenge for the sequences in cold rolling. The modernization is related to a large number of objectives of which the follow- ing are the most important ones: ▬ Improvement of the plant availability ▬ Increase of the production volume by 60,000 t/year ▬ Improvement of the product quality ▬ Increase of the degree of automation A particular requirement which made the matter more complicated is that due to the above mentioned plant utilization the proper revamp times could only be taken during regular shutdowns. The total time available for this is three shutdown peri- ods of altogether five weeks. After each modification period, production has to be run up to the set point volume according to agreed run-up curves as fast as possi- ble. In the process, the comprehensive product mix of wedge-shaped hot strip
has to be considered and the currently applicable safety standards have to be observed. For various reasons, SMS Demag won the contract for this modernization. SMS Demag has wide experience in large and complex modernizations and was also in this case able to present a coherent overall concept. The "All from a single source" supply, i. e. the symbiosis of mechanics, hydraulics, electrics and automation as well as development and technology from one single supplier cre- ates the optimal conditions for modern- ization which were critical in terms of technology and time. Essential mechani- cal components as e. g. the hydraulic adjustment cylinders and valve stands are produced in the SMS Demag work- shop and carefully tested before deliv- ery. Moreover, the extensive actions ac- companying the order are performed for safeguarding the short modification phases. Among these are careful site in- vestigation, early setup of a "listening mode", a state-of-the-art integration test, the early operator training on the simu- lated plant up to a sophisticated change- over concept between the old and the new control system. For achieving the modernization objec- tives, many components are replaced by new and more recent ones or additional- ly integrated into the rolling mill. For increasing and stabilizing the strip back tension in the first stand, an addi- tional strip pinch roll unit will be installed in the entry guide. It is hydraulically approached, the additional strip tension is applied by means of electrically actu- ated rolls. That way it operates similar to a bridle roll unit but compared to that it bears the advantage that it can still be used for large entry thicknesses. All mill stands will be equipped with hy- draulic adjustment cylinders. That way it is not only possible to increase the rol- ling force by 30 % in each mill stand but for the first time it is possible to measure the precise positions of the cylinders. This is the prerequisite for converting the strip thickness control from the currently used roll gap control to a quick volume flow control. Moreover, the rolling speeds of all mill stands are increased and optimized with regard to one another. For this purpose, among other things new gearwheel sets will be installed. For minimizing the re- maining quantity of residual oil on the strip, the patented SMS Demag Dry Strip System (DSS) will be installed down- stream of the last mill stand. The coiling tension will in a similar way as on the entry side be separated by a new approachable bridle roll unit from the exit tension of the last stand. When the bottom roll of this unit is not ap- proached, it behaves like a "normal" de- flector roll, i. e. also this bridle roll unit can, as the strip pinch roll unit on the entry side, be started up step by step without any risk. Various other mechani-
cal extensions supplement the modern- ization. Among these are in particular: ▬ Various improvements for guiding and threading the strip ▬ Improvements for calibrating the roll assemblies ▬ Installation of work roll bending sys- tems at all stands ▬ New hydraulic valve stands for all mill stand functions ▬ Installation of devices for measuring strip position, strip tension and strip speed at different positions. The existing electrical and automation systems will to a large degree be re- placed by new systems. Interfaces are created with the remaining components and systems. All main drives will be re- placed. For the mill stands, advanced synchronous motors in medium voltage technology will be used. Compared to the asynchronous motors, they provide a higher operating efficiency at a simulta- neously smaller moment of inertia which leads to improved control dynamics. State-of-the-art multi-drive converters with a direct current intermediate circuit supply the medium-voltage motors of the mill stands as well as the low-voltage motors of the strip drives for the reels, pinch roll units and bridle rolls. This reac- tive power-free drive constellation both minimizes possible energy losses and negative effects on the feeding network. The plant will for the first time be operat- ed from a newly erected main control pulpit. Except new operator stations and an HMI system which can also be ac- cessed from all local stations, strip edge detection and camera systems will be in- stalled at different locations. The latter are provided for visual monitoring of the partly automated threading process by the operator. This is particularly required when threading the wedge-shape slit strip. The automation system will be complete- ly replaced. In the process, all Level 1 functions from the sequence processes up to the technological controls are all implemented on a uniform hardware and software platform. In particular for safeguarding the in- creased requirements on the automation system, faster coil sequence times and an improvement of the strip quality at the head-end, for the first time a Level 2 sys- tem will be used on this mill. Above the required interfaces and various report functions, this system makes available a model-based setup value calculation be- fore start of rolling. For this purpose, SMS Demag uses the complete imaging of the rolling processes through self- adapting physical models. For safeguarding the required run-up curves after the respective short modifi- cation phases, SMS Demag uses a con- cept of several parallel actions. First the current status is detected by means of detailed examinations and used as the basis of the following modifications. Among these are e. g. detection and localization of the mechanical and elec- trical components, functional and pro-
cess-technological aspects as well as the plant operation. By documentation of this site investiga- tion, the engineering could start. On site almost simultaneously the preparation of the interfaces is started for the systems required in the individual modification phases which are continued to be oper- ated. Moreover, a "listening mode" is es- tablished. For this purpose, so-called process IO servers are installed step by step which enable forwarding each sig- nal from or to the process to the existing control (maintaining the existing status) but also making available these signals in a global memory for the later new con- trol systems. That way the new system has knowledge of the current process events at a very early stage. This result- ing process data basis will be integrated in the engineering and the pre-commis- sioning of the new system. That way for example the mathematical models can already at that time automatically adapt to the material to be rolled and the exist- ing plant. In a next step, the complete new auto- mation system will be set up in the SMS Demag workshop. In parallel, the rolling mill will be simulated in every de- tail in real time. Here not only the rolling process itself is simulated but also all movements and all interfaces with the automation system. By means of this "integration test", already beforehand a pre-commissioning, complete functional and production tests are performed. This comprehensive simulation is also used for an intensive operator training. Only that way it is possible to achieve the short run-up phases. Now the previously installed listening mode is expanded in a modification phase and the following optimization phase to the effect that new functions or controls can be added in, tested and op- timized either completely or also partly. For this purpose the old and the new open- and closed-loop systems are oper- ated in parallel. That way the original condition can quickly be re-established by digital adding-in. It is only after all new functions were sufficiently verified and optimized that the "old" components will be dismantled and the final new en- hanced condition is established. This modernization concept provides both the plant operator company BILSTEIN and the contractor SMS Demag with the sufficient safety for a smooth sequence of the modification as well as the certainty that the modifica- tion objectives are really achieved within the defined time frame.
1SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill BILSTEIN GmbH & Co. KG, Hagen-Hohenlimburg employees: 600 dispatch volume: 400,000 t/year ▬ cold-rolled steel strip ▬ cold-rolled steel sheet ▬ construction steel ▬ case hardening steel ▬ electrical steel ▬ spring steel ▬ special purpose steel ▬ enameling steel strip The customer and their products Introduction Modernization objectives Modernization items Modernization concept 2SMS metallurgy Conference 2007 Four-stand tandem cold rolling mill of BILSTEIN GmbH & Co. KG, Germany Main mill data ▬ four-stand batch tandem cold mill ▬ Supplier: DEMAG, 1969 ▬ Rolling speed: max. 745 m/min ▬ Rolling force: max 6,000 kN per stand Modernization concept of the four-stand tandem cold mill Introduction Modernization objectives Modernization items Modernization concept
3SMS metallurgy Conference 2007 Four-stand tandem cold rolling mill of BILSTEIN GmbH & Co. KG, Germany Material data ▬ Strip width: 320 to 670 mm ▬ Strip thickness: 7.5 to 0.3 mm ▬ Annual production : 420,000 t Others ▬ Several modernizations over the years ▬ Four operators, all “on site” ▬ Low automation grade of mill sequences Modernization concept of the four-stand tandem cold mill Introduction Modernization objectives Modernization items Modernization concept 4SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Targets of the modernization General targets ▬ Increase of mill availability ▬ Increase of production rate by 60,000 t/y ▬ Improvement of product quality ▬ Higher degree of automation Special requirements ▬ Rolling and threading of wedge-type strips ▬ Extensive product-mix ▬ Change to operating with only three operators ▬ Only the regular mill downtimes can be used (in total five weeks) ▬ High priority in safe and steep run-up after each modernization step Introduction Modernization objectives Modernization items Modernization concept
5SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Reasons for placing the order with SMS Demag ▬ Experiences with comprehensive modernizations ▬ Convincing overall modernization concept ▬ Supply from one single source ▬ Manufacture at SMS Demag workshop ▬ Advanced integration test ▬ Operator training in advance ▬ Switch-over concept Introduction Modernization objectives Modernization items Modernization concept 6SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of mechanical equipment Entry-side pinch roll unit ▬ improve the strip tension behavior ▬ increase the strip tension Advantages ▬ independent of the strip thickness ▬ deflector roll mode possible
7SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of mechanical equipment Hydraulic screw down cylinders for all stands ▬ rolling force increase from 6,000 kN to 8,000 kN ▬ high resolution position measurement Advantages ▬ higher reduction ▬ change from roll gap to position control mode 8SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of mechanical equipment New gear sets respect. shifting gear sets between the stands ▬ increase the rolling speeds; from 745 to 1,000 m/min at last stand
9SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of mechanical equipment Dry Strip System after last stand ▬ increase the removal of the emulsion on the strip surface Advantages ▬ reduced noise level ▬ best dryness of the strip surface 10SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of mechanical equipment Exit-side swiveling bridle S-roll set ▬ improve the strip tension behavior ▬ increase the strip tension Advantages ▬ deflector roll mode possible
11SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill New synchronous motors for mill stands and tension reel ▬ increase the rolling speed of each stand Advantages ▬ high efficiency ▬ low inertia, i. e. high dynamic behavior Modernization of electrical equipment Introduction Modernization objectives Modernization items Modernization concept 12SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of electrical equipment New multi-drive converter systems ▬ IEGT converters for MV mill drives ▬ IGBT converters for LV drives Advantages ▬ low energy losses, low power feed-in ▬ high dynamic performance Introduction Modernization objectives Modernization items Modernization concept
13SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of electrical equipment New pulpit, operator panels and HMI system ▬ full HMI access at all operator panels ▬ industrial TV system and strip-edge monitoring systems Introduction Modernization objectives Modernization items Modernization concept 14SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of electrical equipment New Pulpit, Operator Panels and HMI-System full HMI access at all operator panels industrial TV system and strip edge monitoring systems Introduction Modernization objectives Modernization items Modernization concept New Level 1 automation system ▬ additional measurement devices for strip speed and tension ▬ position sensors of screw down cylinders, vibration monitoring Advantages ▬ switch-over from roll gap control to position control ▬ introducing fast volume control mode ▬ one uniform system platform G3 G2 G1 G0 HGC Decoupling Net Speed and Torque Control Speed Control Speed and Torque Control Speed Control Speed Control Speed Control Thickness Control HGCHGCHGC Tension Control Thickness Control Thickness Control Thickness Control Tension Control Tension Control Tension Control
15SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill High-accuracy Level-2 setup system ▬ physical-based models ▬ short-term and long-term self-adapting models Advantages ▬ reduction of off-gages/off-flatness length ▬ fast learning behavior ▬ flexible adaptation to new materials Introduction Modernization objectives Modernization items Modernization concept Modernization of electrical equipment Mill limits and configuration Rolling force model Flatness model Temperature model Tribological Model Material model 16SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill High accuracy of SMS Demag Level-2 process models (Example: Single-stand reversing mill for silicon steel) thickness deviation at head end [%] frequency[%] 1,514 strips force deviation at head end [relative, kN] frequency[%] 1,525 strips 0 5 10 15 20 25 30 20001,6001,2008004000-400-800-1,200-1,600 77 % within 0 % to + 3 % Introduction Modernization objectives Modernization items Modernization concept 0 5 10 15 20 25 30 35 40 45 1086420-2-4-6-8
17SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Overall modernization concept: Engineering, test and interfaces preparation in parallel Site investigation Preparation of interfaces/ listening mode Installation Switch- over Engineering Plug & Work test Stepwise time Introduction Modernization objectives Modernization items Modernization concept 18SMS metallurgy Conference 2007 Site investigation Preparation of interfaces/ listening mode Installation Switch- over Engineering Plug & Work test Stepwise Modernization concept of the four-stand tandem cold mill Site investigations ▬ hardware and layout piping, routing, locations, etc. ▬ functional technology signals, interfaces, etc. ▬ process sequences and mill operation standard operation procedure ▬ process technology pass schedules, emulsions, etc. Site investigation Introduction Modernization objectives Modernization items Modernization concept
21SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Hot run tests and “shadow mode” ▬ stepwise function and production test with mechanic and media systems ▬ test of sequences, test of dynamic behavior ▬ always possible to switch back to old controls (“shadow mode”) Old New ~ ~ M ~ PPS /L3 Process models /L2 Process control /L1 RIOs PIOS Process Models /L2 Process control /L1 PIOS (Process IO Server) = “electronic terminals” Installation Switch- over Introduction Modernization objectives Modernization items Modernization concept Site investigation Preparation of interfaces/ listening mode Installation Switch- over Engineering Plug & Work test Stepwise 22SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Typical run-up curve for a modernization with production increase 0 10 20 30 40 50 60 70 80 90 100 110 120 130 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Weeks Productionperweek[%] Downtime Introduction Modernization objectives Modernization items Modernization concept
Cold rolling of stainless steel using continuous high-perfor- mance tandem mills Dipl.-Ing. Rainer Effertz Deputy General Manager Filtration Systems/Roll Coolant Systems Dipl.-Ing. Rüdiger Holz Executive Vice President Cold Rolling Mills Division Dipl.-Ing. Ralf Matzka General Manager Technical Sales Cold Rolling Mills and Stainless Steel Lines Dipl.-Ing. Thorsten Bode Manager Metal Forming Technology SMS Demag AG Düsseldorf/Hilchenbach, Germany
Cold rolling of stainless steel using continuous high-performance tandem mills Ralf Matzka, Thorsten Bode, Rainer Effertz, Rüdiger Holz The market for cold-rolled stainless steel strip is characterized by continuous growth. The ever higher growth rates of cold rolled products require ever higher capacities of the process lines and rolling mills. Further the market requires reasonable prices for these products, with the optimization potential mainly be- ing the cost of production. As long ago as 1969, the Nisshin Steel company in Japan attempted to satisfy this market requirement by installing a then highly productive multi-stand tan- dem mill for the production of cold-rolled stainless steel. Another high-perfor- mance mill, supplied by SMS Demag, went in operation in 1999 at AK Steel in the United States, rolling both stainless steel and carbon steel grades. The new plant concept developed by SMS Demag for stainless-steel tandem mills consists of several rolling mills in a tandem ar- rangement, with extremely slender and therefore horizontally supported work rolls. Setting up a continuous rolling mill for the production of stainless steel strip is a cost-effective option where a cold-rolling stage with a capacity of more than 400,000 t/year is to be implemented. This plant concept requires the lowest cost of conversion due to the as com- pared to conventional stainless steel rolling on reversing rolling mills higher yield, less manpower and the lower specific investment cost. The new plant concept using rolling oil makes it pos- sible to produce surface finishes that bear comparison with cold rolled strip produced in 20-roll mills. As compared with the well-known fully integrated lines for the production of stainless steel strip (integrated rolling, annealing and pickling lines), the concept of a continuous tan- dem mill has a much higher flexibility. The differences between the continuous tandem mills set up so far for the produc- tion of cold-rolled stainless steel strip are as follows: The first mill in Japan was set up as a semi-continuous line and has no continuous exit. The mill stands are of 20-roll type and accordingly have long roll-changing times of the backing ele- ments and intermediate rolls. Another critical item in this mill stand design is the relatively poor accessibility in case of strip breaks. The continuous tandem mill at AK Steel was designed for the mass production of carbon steels and austenit- ic as well as ferritic stainless steels. The rolling mills are of four-high (mill stands 1 to 3) and six-high type (mill stands 4 and 5. The roll diameters were chosen to suit stability requirements and the torques needed to drive the work rolls,
they warrant a simple mill stand design with associated high service life and availability. Thanks to the application of a special cooling lubricant and the use of the required roll roughness it has also been possible to satisfy customers' sur- face finish demands. The new SMS Demag concept for a continuous rolling mill for stainless steel strip is based on the quality requirements of a specialized cold strip production using 20-roll mills. To achieve the necessary overall reduction, a very slender work roll was chosen which via laterally arranged intermediate rolls is supported on both sides by two rows of backup bearings. The mill stand design encompasses a six-roll mill with backup, intermediate and work rolls. The intermediate rolls are axially shifted and equipped with a roll bending facility. The tandem rolling mill is equipped for fully continuous oper- ation, i. e., on the entry side a welder and strip accumulator to bridge the non- productive entry time are arranged, whereas on the exit side coils are changed on the fly. The above requires the exit tension in the last mill stand to be maintained with the help of a pinch- roll mill stand and the continuous supply of paper through the use of carousel- type paper winders and automatic threading devices. In the production of cold-rolled stainless steel strip in continuous tandem mills, the following special technical items need to be considered: ▬ The large variety of the products to be rolled in terms of their dimenions and mechanical properties requires an adapted mill stand design. ▬ The benefit of the high yield can be achieved only in continuous opera- tion. ▬ The excellent surface finishes can be achieved only through the use of suitable cooling and lubrication sys- tems as well as an effective surface inspection. ▬ The benefit of the lower specific in- vestment cost becomes fully effective especially in a modular mill design. The mill stand design follows the require- ments of the rolling process. The neces- sary small work-roll diameter results from the strength of the material and the finish gauge to be achieved. Since the degree of slenderness in the necessary work-roll dimensions becomes too large, these rolls need to be supported horizon- tally. Lateral backup rolls, which are ad- ditionally guided by two rows of backing bearings, absorb the horizontal forces
and transmit them to the adjustable sup- port bridges. The benefits of this mill stand design mainly include the applica- tion of the CVC plus® technology for set- ting the roll-gap geometry, the use of the HS (horizontal stabilization) system for optimization of the horizontal forces and above all a quick work and intermediate roll change. Another important criterion for the design of a tandem rolling mill for cold-rolled stainless steel strip is the temperature control in the rolling process. The cooling lubricant used to attain the required sur- face finishes has a limited heat absorp- tion capacity and the deformation energy is predominantly transformed into heat, i. e., the temperature of the material rises. The compact design of the rolling mill further allows the limited installation of cooling sections. An exact prediction of the material temperature forms the basis for the production of excellent sur- face finishes with very good gloss and reflection properties. The already mentioned cooling and lubricant system of the rolling mill essen- tially has to satisfy two requirements: on the one hand it must support a high thickness reduction at relatively low rol- ling speeds while on the other hand it has to produce the gloss properties of the cold-rolled strip surface. The benefits of SMS Demag's cooling lubrication technology consist of the technological know-how of the cooling lubricant's pressure absorption capacity, lubrication effect, cooling efficiency, the filter tech- nology which for this rolling duty is based on the SUPAFINE® technology and the technological design of the coolant sys- tem with the additional possibility of setting different viscosity levels of the lubricant in the various mill stands. In SMS Demag's CVC® 18-HS rolling mills, the potential flatness position er- rors of the cold rolled strip are compen- sated by tried-and-tested quick-response actuators. Intermediate-roll bending and edge-oriented shifting of the intermediate rolls allow a very good correction of strip edge waves and center buckles. How- ever, the high degree of slenderness of the work roll as well as the absence of bending on the latter limit the potential for correction in the case of so-called quarter buckles. To be able to use this additional adjust- ment potential, SMS Demag has devel- oped a special CVC plus® grinding for the 18-HS rolling mills. In addition to the expanded control range of the roll-gap geometry, this CVC plus® grinding features an improved distribu- tion of rolling forces over the length of the roll barrel and thus across the entire strip width, thereby increasing the ser- vice life of the rolls in the mill stands. The HS system installed in SMS Demag's rolling mills allows the horizontal shifting of the work roll in the direction of rolling as a function of the predicted horizontal forces caused by the drive torque. This allows high thick-
ness reductions during each rolling pass, a longer service life of the lateral backing elements and, through the integration of the CVC plus® system in flatness control, an excellent strip quality. The HS system with its adjustable hori- zontal offset of the work rolls reduces the necessary supporting force which needs to be absorbed by the lateral backing elements. A more stable rolling process and lower maintenance cost are the es- sential benefits of this technology. As a competent partner, SMS Demag has a large number of reference installa- tions at its disposal. This basis warrants the efficient processing of projects as well as a quick start of production. The modular design of SMS Demag's rolling mills, which has been successfully em- ployed many times before, guarantees a high availability and low operating cost. SMS Demag offers rolling mill owners re- liable solutions and high-quality engi- neering at a cost-benefit ratio in line with the market.
1 SMS metallurgy Conference 2007 Applications Continuous tandem cold mills for stainless steel 1969 1999 2007 Nisshin Steel AK Steel SMS Demag continuous tandem mills combined stainless steel/carbon steel stainless steel 2 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel ▬ High productivity ⇒ capacity of more than 400,000 t/year ▬ Lowest conversion costs: • highest yield • less personnel • low specific investment costs ▬ Excellent quality ▬ High flexibility compared to fully integrated lines Advantages for stainless steel
3 SMS metallurgy Conference 2007 Nisshin Steel Continuous four-stand 20-high tandem mill Continuous tandem cold mills for stainless steel Main data material: stainless steel max. rolling speed: 600 mpm capacity: 220,000 t/year Existing plants 4 SMS metallurgy Conference 2007 AK Steel Continuous five-stand four-high/six-high tandem cold mill Continuous tandem cold mills for stainless steel Main data material: carbon steel stainless steel (austenitic, ferritic) max. rolling speed: 1,900 mpm capacity: 3,600,000 t/year Existing plants
5 SMS metallurgy Conference 2007 Four-stand CVC® 18-HS tandem cold mill Continuous tandem cold mills for stainless steel Main data material: stainless steel max. rolling speed: 400 mpm capacity: 720,000 t/year Advanced SMS Demag tandem mill 6 SMS metallurgy Conference 2007 Increase in output/yield Continuous rolling, two-high tension stand Top surface quality for subsequent processing SUPAFINE® filtration Quick and reliable strip surface control Inline inspection Low maintenance and operational costs Modular and robust mill design Wide range of products CVC® 18-HS technology Continuous tandem cold mills for stainless steel Tandem mill technology for stainless steel production
7 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel four-high Admissibleandrequiredlineload[kN/mm] Required line load for strip thickness of 0.2 0.4 0.8 1.6 mm Example: Tensile strength 1000 N/mm², reduction 40 %, strip width 1300 mm CVC plus® 18-HS Work roll diameter [mm] no horizontal stabilization required horizontal stabilization required Line concept for cold rolling of high-strength steels 8 SMS metallurgy Conference 2007 ▬ CVC plus® technology • improved roll gap setting and thus improved strip flatness • equal load distribution between the rolls and thus reduced roll wear ▬ HS system (Horizontal Stabilization) • reduced load of horizontal backing rolls • less wear of backing rolls ▬ Easy roll change • by installation of intermediate, work and backing rolls in change cassettes Benefits compared to the conventional 18-roll mill Continuous tandem cold mills for stainless steel CVC plus® 18-HS
9 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Simulation of strip temperature 10 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Requirements from the rolling process High reduction under low rolling speed Optimized roll coolant system in terms of cooling, lubrication and filtration High-performance rolling oil with excellent lubrication and cooling properties High surface quality demands 2B
11 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Advantages of SMS Demag coolant technology Design of the rolling oil system allows optimum adaptation to the rolling process in terms of heat removal and lubrication. Highest cleaning efficiency due to a SUPAFINE® filtration system and magnetic separator. Environmentally friendly concept as no filter aid is required. Viscosity can be adapted to each mill stand by means of inline coolers. 12 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Available flatness actuators of 18-roll mills flatness actuators ▬ IMR bending ▬ strip-edge-oriented IMR shifting flatness defects result ▬ small influence with IMR bending and conventional shifting ▬ insufficient influence of multi-zone cooling center buckles edge waves quarter buckles no significant improvement significant improvement CVC® 18-HS
13 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Principle of CVC® 18-HS Axially shiftable IMR with special CVC® shape of higher order ▬ Flatness control of higher order – defects possible (strip edge and quarter buckles) ▬ Due to special CVC® shape smooth load distribution between WR and IMR achievable 14 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Mill data: WR dia.: 140 mm IMR dia.: 355 mm BUR dia.: 1,350 mm Conventional 18-roll mill Strip width: 1,200 mm Spec. rolling force: 10 kN/mm IMR shifting IMRbending Comparison: Roll-gap adjusting field on conventional 18-roll and CVC® 18-HS mills CVC®18-HS mill
15 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel CVC® 18-HS mill with reduced work roll diameters Features Advantages Reduced work roll diameters High thickness reduction possible Horizontal Stabilization (HS) of Longer lifetime of side support work rolls (SMS Demag patent) clusters due to adjustable force Flatness control by proven IMR Excellent strip quality bending and axial shifting system (CVC plus® ) Horizontal Stabilization system (HS): Work rolls can be laterally shifted depending on strip data and rolling conditions. ▬ More than 15 references worldwide ▬ Ideal solution for stainless-steel tandem mills 16 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Principle of Horizontal Stabilization system (HS) With HS system: supporting force can be adjusted ▬ Stabilized rolling process ▬ Longer lifetime of side support inserts ▬ Less maintenance FTo FD FR without HSHS systemsystem required supporting force FT1 rolling direction FR rolling force FD tangential drive force FTo strip tension force entry FT1 strip tension force exit horizontal roling force component e (shift) with HS sHS systemystem FTo FD FR FT1 required supporting force = 0
17 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Benefits of SMS Demag technology ▬ SMS Demag is a competent partner in process technology ▬ Great number of reference plants with proven technology fast start-up and reliable operation ▬ Low operational cost and high availability due to modular design ▬ Excellent quality, high reliability, always on time ▬ Reasonable cost-benefit ratio
The new galvanizing line for SeAH Steel – Results and experiences Dipl.-Ing. Werner Haupt General Manager Preacquisition and Integrated Projects Dipl.-Ing. Joachim Kuhlmann General Manager Process Engineering Strip Processing Lines Division SMS Demag AG Hilden, Germany Y. J. Lee Director SeAH Steel Corp. Kunsan-City, Jeonbuk, Korea
The new galvanizing line for SeAH Steel – Results and experiences Y.J. Lee, Werner Haupt, Joachim Kuhlmann The new and also first hot-dip galvaniz- ing line of SeAH Steel Corporation is the heart of the new cold rolling mill complex built in Gunsan in the western part of South Korea. The following topics report on the construction of the facility by SMS Demag as well as on our first oper- ating results: ▬ General overview ▬ Market development ▬ Layout/technical data of the CGL ▬ Erection phase ▬ First coil ▬ Operation ▬ Results and experiences SeAH Steel Corporation specializes in the production of steel pipes, stainless steel pipes for gas and water plumbing installations in buildings as well as gal- vanized strip and pre-coated material. The annual production capacity is more than 1,200,000 t. Besides supplying the domestic market, high export rates to the USA and Japan are achieved. The subsidiaries of SeAH Steel include: ▬ Busan Pipe America Inc. (USA) ▬ State Pipe & Supply Corp. (USA) ▬ Vinapipe Corp. (Vietnam) ▬ Saigon Steel Pipe Corp. (Vietnam) ▬ SeAH Japan Co., Ltd. (Japan) The history of the company is as follows: 1960 Establishment of the company as “Busan Steel Industry” in Gammandong, Busan City. 1979 to 1982 – Acquisition of several specialist companies for the pro- duction of steel pipes. 1996 The company’s name was changed into “SeAH Steel Corporation”. 2005 Completion of the new cold rolling mill complex in Gunsan. As part of the new cold rolling mill in Gunsan, the agreement with SMS Demag for the supply of a hot- dip galvanizing line was signed on November 28, 2003.
With a market share of 660,000 t, SeAH Steel covers 22 % of the demand for steel pipes in the South Korean market and is South Korea’s biggest enterprise in this product sector. With 350,000 t of cold rolled steel, gal- vanized and pre-coated strip, SeAH holds just a small market share among the big players and has to compete with producers which, owing to the size of their companies, are able to produce high-grade products at favorable cost. The new galvanizing line has been de- signed for the production of hot-dip gal- vanized steel strip of the steel grades CQ, DQ, DDQ and FH (full hard). These products are used for white goods, in the electrical and building as well as the construction industries. Designed for an annual capacity of 300,000 t, the line galvanizes strip 0.23 to 1.8 mm thick and 600 to 1,300 mm wide. In the coating section, the strip runs at speeds of up to 200 m/min, while the entry and exit sections attain speeds of maximum 280 m/min. The line configuration is following the demand for hot-dip galvanized strip of highest surface quality. Pre-cleaning takes place in the entry section and full cleaning right upstream of the furnace. To facilitate installation, the vertical strip loopers feature a new modular design. They are completely balanced and equipped with a redundant drive system with amply dimensioned ropes to ensure reliable operation and a long service life. The radiant-tube-heated Drever furnace with a capacity of 73 t/h and the highly precise Duma air-knife system complete the process section. Downstream of the four-high skin-pass mill and the tension leveler unit, a ver- tical coater takes care of passivating the strip. The new galvanizing line of SeAH Steel was built by a consortium comprising SMS Demag AG, Germany, Drever International S.A., Belgium, and Duma GmbH, Germany. Picture 6 shows the steel structures of the two cleaning sections during erec- tion. Picture 7 on the left shows the area of the post-treatment section during instal- lation. The picture on the right reflects the line from the entry looper system, via the center cleaning section up to the vertical furnace. Erection started in November 2004 and was completed in June 2005. In total, more than 4,000 t of machines and steel structures were installed. As early as 21 months after contract signing, the first galvanized coil was produced.
Thanks to the excellent performance of all suppliers under the leadership of SMS Demag and the superb coopera- tion between the consortium and SeAH Steel, the first saleable strip was pro- duced four weeks before the scheduled contractual date. Picture 8 shows the festive celebration of production start, which is a very im- portant ceremony in the Korean self understanding and culture. As a result of this early and successful hot commissioning, the full production capacity was already achieved after 23 months and the Final Acceptance Certificate (FAC) was issued as soon as after 21 months. Picture 9 on the top shows the vertical post-treatment section in operation with roll coater, drying oven and air coolers. The right bottom picture reflects the op- eration of the line in the area between the pre-cleaning section and the vertical furnace. The picture provides a clear view of the entry-end vertical looper ar- ranged between the two cleaning sec- tions. The picture on the left is a top view of the Duma air-knife system. The remarkably steep run-up curve of the line is documented by the following production evaluations covering the ini- tial months after line startup. ▬ Run rate ▬ Production volume ▬ Yield ▬ Run-up curve ▬ Coating tolerances or accuracy Already in the first month, the line at- tained a relatively high availability of 74.5 %, and from the end of the third month on, the values stabilized around the target of 98 %. Picture 12 reflects the volumes pro- duced for direct sales and for processing in the own color-coating section. It is obvious also in this case that the line achieved its planned production after a short time. Picture 13 represents the ratio between input material and finished products. A high value means, for example, low scrap losses. As early as in the second month, the target value of 98 % was ex- ceeded. Values of over 100 % may re- sult owing to a weight increase due to coating.
The run-up curve is the best way to de- scribe the performance of the line as a combination of availability and yield. Just one month after commissioning, the value stabilized around the target of 96 %, and after eight months ideal val- ues of nearly 100 % were achieved. The coating accuracy is one of the most important factors for the product quality and, when zinc prices are high, decisive- ly impacts the operating costs. Thanks to the Duma air-knife system, coating uniformity is more than satis- factory. Currently, each 1 % in closer coating tolerances reduces operating costs by up to EUR 1 million per year.
1SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Contents General overview Market development Layout Erection phase First coil Operation Results and experiences ▬ General overview ▬ Market developments ▬ Layout/Technical data ▬ Erection phase ▬ First coil ▬ Operation ▬ Results and experiences 2SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Company profile SeAH Steel Corporation is specialized in the production of ▬ steel pipes, ▬ stainless steel pipes for plumbing and structures, ▬ galvanized steel and pre-coated metal Annual production capacity: 1,200,000 t of steel products Export of products to the USA and Japan Subsidiaries: ▬ Busan Pipe America Inc. (USA) ▬ State Pipe & Supply Corp. (USA) ▬ Vinapipe Corp. (Vietnam) ▬ Saigon Steel Pipe Corp. (Vietnam) ▬ SeAH Japan Co., Ltd. (Japan) General overview Market development Layout Erection phase First coil Operation Results and experiences
3SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Company history 1960 Establishment of the company as “Busan Steel Industry in Gammandong, Busan City 1979 - 82 Several acquisitions of specialized companies 1996 Change of company name into SeAH Steel Corp 2005 Completion of new CRM in Gunsan area 28.11.2003 Purchase agreement with SMS Demag for the new CGL General overview Market development Layout Erection phase First coil Operation Results and experiences 4SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Market shares 52.71,591Others 1003,019Total Husteel SeAH Steel Hysco 16.4495 21.9660 9.0273 Portion in % Market share 7.8932Union Steel 10.61,258Others 10011,910Total Dongbu Steel Posco Hysco 12.11,437 54.16446 15.41,837 Portion in % Market share General overview Market development Layout Erection phase First coil Operation Results and experiences Market share Cold rolled steel (in '000 t) Hysco Posco Dongbu Steel Union Steel Others Market share steel pipe (in '000 t) Hysco Seah Steel Husteel Others
5SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Technical Data: Products: GI / CQ, DQ, DDQ, FH (full hard) Application: White goods + construction Production capacity: 300,000 t/year Strip thickness: 0.23 to 1.6 mm Strip width: 600 to 1,300 mm Line speed: 200 m min (process section) General overview Market development Layout Erection phase Operation Results and Experiences Continuous galvanizing line – SeAH Steel, Korea 6SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Erection phase All main equipment by SMS group General overview Market development Layout Erection phase First coil Operation Results and experiences Continuous galvanizing line was built by a consortium between ▬ SMS Demag AG, Germany ▬ Drever International S. A., Belgium ▬ Duma GmbH Germany for air knife system
7SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Erection phase General overview Market development Layout Erection phase First coil Operation Results and experiences ▬ 21 months from purchase agreement to first coil ▬ erection period November 2004 until June 2005 ▬ total weight: 4,114 t 8SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel The first coil was produced in saleable quality four weeks before scheduled date General overview Market development Layout Erection phase First coil Operation Results and experiences
9SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Operation Cleaning section, entry looper and furnace Air knife Post treatment ▬ FAC after 21 months ▬ Full production after 23 months General overview Market development Layout Erection phase First coil Operation Results and experiences 10SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Results and experiences General overview Market development Layout Erection phase First coil Operation Results and experiences ▬ Run rate ▬ Production of main products ▬ Benefit (output/input) ▬ Startup curve ▬ Coating accuracy
11SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Run rate (prod. time/planned prod. time) 70 75 80 85 90 95 100 Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar. 06 Apr 06 May 06 Month Rate(%) Run rate target 98 % First month 273hrs 437.7hrs 306.7hrs 405hrs 576.9hrs 491.4hrs 602.6hrs 600.4hrs 588.6hrs hrs: Production hours Results and experiences General overview Market development Layout Erection phase First coil Operation Results and experiences 12SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Production - 5.000 10.000 15.000 20.000 25.000 Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar 06 Apr 06 May 06 Month tons/month GI FOR SALE MATERIAL FOR CCL TOTAL Results and experiences General overview Market development Layout Erection phase First coil Operation Results and experiences
13SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Benefit (output/input) 70 80 90 100 110 Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar 06 Apr 06 May 06 Month Rate(%) Benefit target 98% First month Results and experiences General overview Market development Layout Erection phase First coil Operation Results and experiences 14SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Startup curve 0 10 20 30 40 50 60 70 80 90 100 Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar 06 Apr 06 May 06 Month Rate(%) Target startup curve 96 % First month Results and experiences General overview Market development Layout Erection phase First coil Operation Results and experiences
15SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel SeAH is very satisfied with the achieved coating tolerances of the Duma air knife. Due to increased zinc costs each 1 % improvement of tolerances reduces our operation costs by approx. 1 million EUR per year. Coating tolerances General overview Market development Layout Erection phase First coil Operation Results and experiences
Economical solutions for high-quality processing lines Dipl.-Ing. Stefan Melster General Manager Technical Sales Strip Processing Lines Division Dr. Hans-Georg Hartung Executive Vice President Strip Processing Lines Division SMS Demag AG Hilden, Germany
Economical solutions for high-quality processing lines Stefan Melster, Dr. Hans-Georg Hartung While in the past many investment deci- sions were clearly made on the grounds of technical preferences, the majority of decisions nowadays is based on eco- nomic considerations or facts. The refer- ence figure today is the total cost, fig- ure 1. Costs such as the percentage of depreciation, overheads and the prices of raw materials cannot be influenced by plant builders. Investment cost or, in other words, the price of the line is a matter of technical requirements and so- lutions or, respectively, a matter of nego- tiation and by far not the most important factor. In the long run, it is the cost for maintenance, yield loss, staff and con- sumables that makes the difference be- tween standard lines and economically and profitably operating processing lines. For about ten years, our development of new equipment and the optimization of existing components have been follow- ing just one guideline – to improve the customer benefit and profit. This can on the one hand be achieved by technical improvements which have an economic impact, but also by cost-cutting with a subsequent price reduction which is based on a different design, but does not affect equipment performance. SMS Demag today offers the full range of high-quality strip processing lines with obviously significant economic advan- tages, figure 2, as demonstrated by the large number of recent references. Be- sides 13 continuous pickling lines and coupled pickling lines/tandem cold mills, six color coating lines, twelve continuous annealing lines and 14 galvanizing lines, SMS Demag has during the last six years received orders for more than 70 further strip processing lines. Among these are high-tech lines like silicon strip processing lines, processing lines for aluminum strip or acid regeneration plants. Figure 3 is a summary of our latest ma- jor worldwide references. Our guideline for achieving best total cost of ownership can be best explained by two recent ex- amples: the pickling line of the new coupled pickling line/tandem cold mill of Baosteel’s cold rolling mill No. 5 and the continuous galvanizing line No. 3 of US Steel Kosice in Slovakia. Figure 4 is a sectional view of Bao- steel’s new PLTCM, designed for an an- nual production capacity of 1.74 million t of steel, mostly high-quality grades for
the automotive industry. To explain the cost-saving potential of our technologies, three examples are provided of which more details will be shown: ▬ the turbulence pickling technology ▬ the horizontal loop accumulator ▬ the ASC side trimming shear Since the early 50s, SMS Demag has in- fluenced the design of all types of high- performance pickling lines all over the world. Meanwhile all components for pickling lines including mechanical and chemical equipment, even acid regener- ation plants and laser welding machines, can be supplied from one single source. This is a benefit to our customers as it involves a consistent process technology and minimizes potential interface prob- lems. The turbulence pickling method, fig- ure 5, developed by SMS Demag, is not only the most effective, but also the most economical pickling technology in terms of operating cost. The design of SMS Demag’s turbulence pickling line is characterized by shallow and horizontal pickling channels, the patented immer- sion covers and acid injection by spray headers on the entry and exit sides of each pickling tank. The straight, horizon- tal channel which is integrated into the main pickling tank, allows operation of the line at high strip tension for improved strip guiding. Its small height of about 150 mm not only ensures a high acid flow velocity and hence large turbu- lences, but also a much faster adjust- ment of the acid temperature, due to less acid circulation volumes. This improves process flexibility. The immersion cover seals off the pickling channel towards the top and thus prevents any free acid surface and acid evaporation in the pick- ling tank, which leads to significant ener- gy and operating cost savings. By injec- ting the acid at high pressure from the entry and exit sides into the pickling channel and onto the strip, the turbulent acid flow and the acid exchange on the strip surface are increased through the high input of kinetic spraying energy. During the pickling process the entire pickling channel is filled with acid, whereas the entry- and exit-side acid in- jection serves for hydrodynamic sealing of the pickling channel, figure 6. This ensures wetting of the full strip surface even at high strip speeds, as well as an improved acid separation between the pickling tanks. The high intensity of the turbulence pickling line allows a very compact design of this process section. Steam and power consumption as well as acid losses are significantly lower than in conventional pickling systems, due to the immersion covers. A much faster heat transfer from acid to strip and more intensive acid exchange at the strip surface can be achieved through the high kinetic spraying energy. This leads to a better acid utilization and an accel- erated pickling process. Due to the good controllability of the process, no pickling inhibitors are necessary. The rinse sec- tion has a second spray rinse circuit in order to avoid staining during line stops.
Therefore, no rinsing inhibitors are needed here either. For a pickling line with a production capacity of about 1.8 million t/year, annual savings may total 600,000 EUR just because of the above-mentioned features. The turbulence pickling process can be further optimized through the application of SMS Demag’s process model, fig- ure 7, which sets all essential pickling parameters to the relevant strip quality automatically and ten to 20 coils in ad- vance. The main objective is to prevent underpickling or overpickling and to set the lowest possible acid temperature. The lowest possible bath temperature means minimum energy and acid con- sumption, but also an increased lifetime of all equipment exposed to acid. A 5 °C drop in the bath temperature may result in a 50 % longer lifetime of plastic pipes. Part of this process model is the simula- tion of the pickling process for incoming coils. Based on all major pickling and strip parameters, the pickling result can be controlled by the correct setting of the acid pressure in consideration of the strip speed and the required bath tem- perature. The model controls the transi- tion from one strip to the next, so that the pickling process is adapted to the next strip without any visible change in the pickling results. In addition to the above- mentioned cost savings, the application of the SMS Demag process model may result in further savings of up to 300,000 EUR per year due to reduced power and fluids consumption. SMS Demag’s horizontal looper system, figure 8, is characterized by two main features: the retained looper car and the Maltese-cross looper gate design. The retained looper car means that the looper car is pulled on each side by ropes, whereas other systems use a rope for pulling on one side and the strip only for pulling on the other side. The ad- vantages of our system are lower ten- sion fluctuations and a more stable looper car operation. Constant strip ten- sion and thus untroubled operation of the coupled tandem mill is not the only bene- fit of the closed loop system. For mainte- nance purposes the looper car can be moved without strip in the line. Due to the Maltese-cross looper gate system, the looper gate arms can be opened and closed smoothly by the looper car without any shock even at high looper car speeds. The special me- chanism leads to a soft acceleration and deceleration of the looper arm without inertia-caused overloading of the me- chanical parts. Frequent consequential damage can thus be avoided. Each da- maged gate costs a total of approx. 90,000 EUR. These expenses for spares, maintenance work, production loss and fixed costs can be saved.
The combined ASC side trimmer and chopper unit is one of the most impres- sive cost savers in our lines, figure 9. On each side of the line two trimming shears with associated scrap choppers are mounted on a turntable platform in a 180-degree arrangement. This arrange- ment allows the safe maintenance of the standby trimmer/scrap chopper unit also during production, with the other unit in operation. All settings of the knife gap and knife overlap are performed automatically by eccentrics. In comparison, linear shifting devices with bushes tend to wear and are always a matter of maintenance. In contrast, ec- centrics are backlash- and almost main- tenance-free. Due to the automatic knife- gap and knife-overlap setting, an ex- tended lifetime of the blades and im- proved cutting qualities can be achieved. The knife blades are face-ground and mounted against mechanical stops, therefore no calibration is required after a blade change. The side-trimmings chute between the trimmer and chopper is undivided with- out any gaps. Gaps in the side-trimmings chute are usually the cause of scrap cobbles and each cobble can take approximately one to two hours to be removed. During a width change, the complete side trimmer and chopper unit will be re- adjusted within seconds without produc- ing any extra scrap. Our design avoids the above-mentioned typical operational problems, i. e. unscheduled downtimes for troubleshooting like scrap jam remov- al. Even in the unlikely case of trouble or in case of normal maintenance, the whole system together with its problem is simply turned out of the line and re- placed by fully operative equipment with- in 60 seconds. The problem can then be fixed in the safe 180-degree position while the line is running. With one trouble per week, this ASC side trimming system can save up to 1 million EUR per year in high-performance pickling lines. The combined ASC side trimmer unit is not only used in our pickling line, but al- so in most of our other strip processing lines. Another good example for economical processing-line solutions is the new gal- vanizing line No. 3 of US Steel Kosice, figure 10. This is a typical line for the production of exposed automotive mate- rial with GI and GA coatings. Highly so- phisticated structural steel grades are al- so part of the product mix.
The total-cost-of-ownership guideline is explained by the following examples: ▬ Coil transport system ▬ Cleaning section ▬ Air knife ▬ Post-treatment/coating section Our coil cars, figure 11, are of extremely compact and flat design and do not need any deep, expensive and eventually also dangerous foundation pits. Still they are as sturdy as necessary for metallurgical works. As opposed to other scissors- type coil cars, the cylinder force acts in the load direction and not in transverse direction. The scissors just have a guid- ing function, but do not transmit any load. Besides safety and maintenance aspects, the cost reduction for the foun- dations of three coil cars is about 70,000 EUR. Our strip cleaning sections, figure 12, are characterized by three main fea- tures. First, sealed modules with lower required fume exhaust volumes at the connection points of the modules reduce energy losses significantly. Second, the changing of rolls is fairly easy and can be done during operation with no addi- tional downtimes or maintenance work required. Finally, special tongue-shaped spray nozzles guarantee a clog-free op- eration. No clogging means no surface stripes, no subsequent downgrading and no prematurely damaged brush rolls. Based on European cost basis, up to 600,000 EUR can be saved per year. SMS Demag can provide two prime- quality air knife systems: Fontaine and Duma, figure 13. Both air-knife systems are technically excellent. Both can be equipped with width-adjustment actua- tors without any negative influence on the surface quality produced. Depending on the product mix, such a blow-off width adjustment can save up to 30 % of com- pressed air or, respectively, nitrogen. In the production of automotive strip such nitrogen savings can add up to 1 million EUR a year in case the nitrogen has to be purchased. The high precision of our air knife systems results in closer coating tolerances than in other systems. A mere 1 % more precise coating can save zinc worth up to 1 million EUR per year in a typical hot-dip galvanizing line producing approx. 400,000 t/year and approx. 190 million m² strip surface. In modern lines that conform to the latest health and safety standards, the heart of the post-treatment section is the roll coater, figure 14. Using two separate circuits, our coaters can be used for chromating as well as anti-fingerprint coating. Due to the use of coated pans and the automated cleaning and rinsing system, a change in coating agent is not very time-consuming. Alternatively, a two-coater or shuttle coater system can be provided. The rolls can be changed without any major maintenance effort. But the most impressive property is no doubt the outstanding accuracy of the coating. With this system, a coating ac- curacy of plus/minus a quarter of a mi- cron can be achieved. In comparison
with other coating systems with ac- curacies of plus/minus 1 micron, this means, in addition to other benefits, sav- ings of up to 500,000 EUR per year for the post-treatment system of hot-dip gal- vanizing lines. In color-coating lines, three times this amount can easily be saved due to the particularly high cost of chemicals and paints. All the above-mentioned examples are the result of a continuous improvement process, figure 15. All developments must follow the total-cost-of-ownership guideline. This means that improve- ments must pay off to our customers in terms of reduced operating cost, less energy consumption, less maintenance, less downgrading, higher yield or a mar- ketable better product quality. All these economical solutions for high-quality pro- cessing lines are incorporated in our lat- est reference list and have been suc- cessfully commissioned. As a conse- quence, a steep ramp-up curve is part of our customer benefit.
1SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines Introduction Introduction Strip processing lines Pickling line technology Summary No cost influence by SMS Demag Cost influence by SMS Demag Investment cost Overheads Depreciations Total cost of ownership Staff costYield loss Consumables & media Maintenance Raw material Hot-dip galvanizing line technology 2SMS metallurgy Conference 2007 Strip processing lines – Major references since 2000 Economical solutions for high-quality processing lines Carbon steel … in total more than 50 new processing lines since 2000 … incl. seven lines for silicon strip … incl. seven lines for aluminum strip … … plus approx. 60 service lines … … plus 13 new ARPs 13 CPL/PLTCMs 14 CGLs 12 CALs 6 CCLs 1 ETL Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology
3SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines Strip processing lines – Major references since 2003 Customers and type of lines Introduction Strip processing lines Pickling line technology Summary Tokyo Steel CPL + ARP Shougang Jing-Tang CAL Nucor CGL ILVA Taranto and Cornigliano 2 CGLs Baosteel 4 Si-lines Tiantie PLTCM Salzgitter CPL SeverCorr CGL + PLTCM Baosteel CAL + PLTCM Shougang CAL + PLTCM US Steel Kosice CGL Jinan CPL WISCO 3 CGLs + CAL + PLTCM Anshan CAL Seah CGL Rasselstein ETL Baosteel CAL + PLTCM US Steel Kosice CGL Hot-dip galvanizing line technology 4SMS metallurgy Conference 2007 Introduction Pickling line technology Summary Products: Strip thickness Strip width: Pickling speed: Production capacity: CQ, DQ, DDQ, EDDQ, SEDDQ, DP, Trip 1.8 to 6.0 mm 700 to 1,650 mm 270 m/min 1,740,000 t/year Technical data Economical solutions for high-quality processing lines Pickling line/tandem cold mill Baosteel, Baoshan/China Hot-dip galvanizing line technology
5SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines Turbulence pickling technology Turbulence pickling channel Immersion cover Outer cover Pickling tank ▬ Flat and horizontal pickling channel ▬ Immersion covers – less acid evaporation ▬ Hydrodynamic sealing Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology 6SMS metallurgy Conference 2007 ▬ Better controllability due to less acid volumes in circulation ▬ Less steam, acid and energy consumption due to immersion covers ▬ No pickling and rinsing inhibitors ▬ Lower possible acid temperature – less energy, longer lifetime Economical solutions for high-quality processing lines Turbulence pickling technology Turbulence pickling tank with circulation system Total potential on cost savings: up to 600,000 EUR/year Draining chamber with spray bars and squeegee roll unit (hydrodynamic sealing) Acid supply piping Cascade piping Pump Heat exchanger Steam Condensate Waste acid Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology
7SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines Turbulence pickling technology ▬ Minimized overpickling: less material loss less energy higher yield ▬ Automatic setting and control of process actuators ▬ Minimized bath temperature less energy longer lifetime less maintenance Total potential on cost savings: up to 300,000 EUR/year SMS Demag process model for turbulence pickling Turbulence Temperature Desired bath temp.Strip speed Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology 8SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines High-speed looper concept – Technical advantages Steering Curve Tension Rope Retaining Rope Each damaged gate costs EUR 90,000 Introduction Strip processing lines Pickling line technology Summary Maltese-cross looper gates ▬ impact-free opening and closing ▬ less damages ▬ longer lifetime ▬ less maintenance Hot-dip galvanizing line technology Closed loop system (two-side rope pulling) ▬ less tension fluctuation ▬ better maintainability
9SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines ASC trimming shear Features: ▬ No line stop during knife change ▬ Easy and safe maintenance access ▬ No extra scrap during width change ▬ No calibration of knives after change Potential cost savings up to 1 million EUR/year due to less downtime Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology 10SMS metallurgy Conference 2007 Products: Strip thickness Strip width: Process speed: Production capacity: CQ, DQ, DDQ, EDDQ, SEDDQ, HSS-CQ, HSS-DQ, HSS-DDQ, BH, DP 0.3 – 2.0 mm 800 – 1,850 mm 180 m/min 410,000 t/a Technical data: Economical solutions for high-quality processing lines Continuous galvanizing line US Steel Kosice, Slovak Republic
11 Coil transport systems Economical solutions for high-quality processing lines SMS Demag technology ▬ Coil cars with extremely flat design and rigid design for metallurgical works ▬ Guiding scissors are load- free ▬ No expensive and dangerous foundation pits ▬ Good maintainability Reduction of foundation cost up to 70,000 EUR Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology 12SMS metallurgy Conference 2007 Potential cost savings: up to 600,000 EUR/year Economical solutions for high-quality processing lines SMS Demag technology ▬ Sealed modules – less energy ▬ Easy roll changes – less maintenance ▬ No clogging – no brush roll damages, no stripes, no downgrading Strip cleaning section Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology
13SMS metallurgy Conference 2007 SMS Demag technology ▬ Width adjustable ▬ Outstanding coating accuracy ▬ Minimized over-coating Possible reduction of production costs per year: up to EUR 1,000,000 nitrogen savings for customers without oxygen plants 1 % better coating accuracy = approx. 1,000,000 EUR cost savings for zinc Air knife Economical solutions for high-quality processing lines Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology 14SMS metallurgy Conference 2007 SMS Demag technology ▬ Outstanding coating accuracy ▬ Simple roll change ▬ Automated cleaning of rolls, pans and media systems ▬ Minimized over-coatings due to higher coating accuracy Post-treatment Economical solutions for high-quality processing lines A coater accuracy of ± 0.25 μm instead of ± 1.0 μm can save up to 500,000 EUR/year for post-treatment Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology
15SMS metallurgy Conference 2007 Summary ▬ Cost savings resulting from … • less operating materials and energy consumption • less maintenance and longer service life • less downgrading of product quality • less downtimes and higher yield ▬ Better product quality ▬ Higher flexibility and faster start-up curves The essentials of economical solutions are … Economical solutions for high-quality processing lines Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology
The SMS Demag laser welding machine Dipl.-Ing. Lutz Kümmel Senior Project Manager Strip Processing Lines Division Dr. Hans-Georg Hartung Executive Vice President Strip Processing Lines Division Dipl.-Ing. M.B.M. Markus Jaenecke Senior Project Manager Project Planning Strip Processing Lines Division SMS Demag AG Hilden, Germany
The SMS Demag laser welding machine Dr. Hans-Georg Hartung, Markus Jaenecke, Lutz Kümmel Some three years ago, SMS Demag and Oxytechnik, a German welder manufac- turer, agreed to jointly develop a laser welder for strip processing lines. Tech- nology and design are the results of many years of experience in designing high-performance strip processing lines and equipment as well as welding ma- chines including laser welders for special applications. Nowadays, laser welding machines are the first choice for continuous pickling lines. These welders are meanwhile cheaper than flash butt welders and easier to commission, especially if new materials or material combinations are to be welded. In addition, these welding machines are able to weld thinner strip and strip with higher amounts of alloying elements. Based on the experiences gained from many projects, we devel- oped a new laser welder design. Thanks to the closed-frame concept, the ma- chine is more compact than C-frame- type machines and can usually be trans- ported on trucks. The laser resonator is fixed on a sepa- rate foundation. No resonator vibrations will influence the welding accuracy. For maintenance purposes, access to the machine as well as to the resonator is excellent. Another remarkable feature is the posi- tioning system that aligns the head end of the new strip with the tail end of the previous strip. That means that it is the center line of the leaving strip that de- fines the correct alignment, and not the center line of the machine. After joining, the two strips will have one common center line and definitely no so-called dog-leg shape. One of the biggest ad- vantages is that the strip edges will not be damaged. The clamping of the strip will not be interrupted until welding is finished. The integrated shear is not a notcher- type shear with more or less no gap be- tween top and bottom knives. Such a de- sign leads to huge perpendicular forces acting on the knives and subsequently to high wear and less accuracy. The laser welder consists of a robust, mill-type-de- sign dividing shear with automatically ad- justable knife gaps separately for the outgoing and ingoing strip ends. The knife crossbeam is supported at several positions across the width and doesn’t allow any relevant breathing. The blade lifetime is at least three times as long as for other laser welders and, due to the cassette design, the blades can be changed easily by an electro-hydraulical- ly changing device. The top knife can be used twice, the bottom knives four times before regrinding. The precise cut has
the potential to allow using lasers with less power in the future because the de- focusing of the beam can be reduced. This leads to less laser power and con- sequently to a longer laser lifetime. For the same reason we expect that more and more Neodymium-YAG lasers will be used in the near future instead of high-power CO2 laser sources. One ma- jor advantage is the possibility to feed the beam via fiber-optic cable to the weld spot – subsequently no mirrors can be contaminated. The shear remains in the machine during welding. Therefore, we could avoid the either heavy or flimsy C-frame design. Scrap can be discharged directly into a pit or be removed by a conveyor belt. In case of different strip thicknesses, the joint can be made centrically, top side or bottom side orientated. Real zero-gap welding is possible due to the shifting function of the strip clamping device. As an option for special applications a wire feeder can be provided. Mixed gas or helium is used as inert gas. Along with the design work plenty of laboratory tests were conducted. The test results were very promising, even for hard-to-weld steel grades like C60 with a carbon content of 0.67 %. The cross-sections of the welds were excel- lent and so were the microstructures of the heat influence zone and of the weld itself. The main components of the mi- crostructure of this high-carbon steel are ferrite and perlite. Post-annealing and particularly preheating and post-anneal- ing led to a highly uniform hardness dis- tribution in the vicinity of the weld as compared to the results without anneal- ing. In order to ensure the best possible heat treatment of the weld, new inductive pre- and post-heaters were developed together with our sister company SMS Elotherm. The main features are fast heating during preheating and post- annealing with retarded cooling. Early in 2006, we received an order from Salzgitter Flachstahl GmbH, Germany, for a heavy-duty laser welding machine. This laser welder for 800 up to 1,900- mm-wide strip will be installed in a 2.5- million-t/year continuous pickling line that will also be supplied by SMS Demag. The strip thickness ranges between 1.5 and 6 mm and the yield stress may ex- ceed 1,100 N/mm². Some of the steel grades are extremely difficult to weld such as C60. The laser welder for Salz- gitter is currently being tested in our workshop. In April 2007 Tokyo Steel, Japan, placed a further order for a laser welder with us.
1SMS metallurgy Conference 2007 The SMS Demag laser welding machine Development of SMS Demag laser welding machine ▬ In 2004, a cooperation between SMS Demag and was established in order to develop a laser welding machine for strip processing lines Introduction Main features Laboratory test Laser welding machine for Salzgitter 2SMS metallurgy Conference 2007 The SMS Demag laser welding machine Laser beam source CO2 laser resonator Introduction Main features ▬ The laser resonator is fixed beside the machine on a separate foundation ▬ No vibrations, no influence on the welding accuracy ▬ Easy access for maintenance Laboratory test Laser welding machine for Salzgitter
3SMS metallurgy Conference 2007 The SMS Demag laser welding machine Strip alignment Introduction ▬ Incoming strip head is aligned with the tail end of the previous strip ▬ Center line of the leaving strip defines the right alignment ▬ No pushers – no strip edge can be damaged Laboratory test Laser welding machine for Salzgitter Main features 4SMS metallurgy Conference 2007 The SMS Demag laser welding machine Shear design ▬ Robust, mill-type design dividing shear with automatically adjustable knife gaps separately for outgoing and ingoing strip Introduction Laboratory test Laser welding machine for Salzgitter Main features
5SMS metallurgy Conference 2007 The SMS Demag laser welding machine Shear design details Introduction ▬ Knife lifetime triples ▬ Quick knife changes ▬ Precise cuts = precise weld Multiple support of knife crossbeam Knife changing device Laboratory test Laser welding machine for Salzgitter Main features 6SMS metallurgy Conference 2007 The SMS Demag laser welding machine Welding process Introduction ▬ The joint can be made centrically, top side or bottom side oriented ▬ For special steel grades a wire feeder can be installed ▬ For shielding, mixed gas or helium is used Laboratory test Laser welding machine for Salzgitter Main features
7SMS metallurgy Conference 2007 The SMS Demag laser welding machine Results of laboratory test Introduction Main features ▬ Cross-sections of the welds as well as the microstructure of the heat influence zone and of the weld itself were excellent. ▬ Hard-to-weld steel grades like C60 with a carbon content of 0.67 % were welded successfully Laboratory test Laser welding machine for Salzgitter 8SMS metallurgy Conference 2007 The SMS Demag laser welding machine Influence on weld seam hardness by heat treatment Preheating and post- annealing of coils Introduction Main features ▬ Fast preheating and soft post- annealing with retarded cooling 200 300 400 500 600 700 800 900 1000 -5,0 -4,0 -3,0 -2,0 -1,0 0,0 1,0 2,0 Position [mm] HV1 Probe 10.2 Probe 8.2 Probe 5.1 Pr. 5.1, Grundwerkstoff C60, Anlieferung Laboratory test Laser welding machine for Salzgitter
9SMS metallurgy Conference 2007 The SMS Demag laser welding machine The new laser welding machine will be installed in the new 2.5-million-t/year continuous pickling line of Salzgitter Flachstahl GmbH Introduction Main features ▬ The order was placed in March 2006 ▬ Carbon content up to 0.67 % ▬ Strip width between 800 and 1,900 mm ▬ Strip thickness between 1.5 and 6 mm ▬ Yield stress up to 1,100 N/mm² ▬ Pre-commissioning underway in our Hilchenbach workshop Laboratory test Laser welding machine for Salzgitter
Innovative and flexible: the Automatic Coil Transporter (A.C.T.®) developed by SIEMAG Dipl.-Ing. Bernd Klein CEO Dipl.-Ing. Volker Schneider Project Manager Sales Dr. rer. nat. Horst Thorn Head of Sales Department SIEMAG GmbH Netphen, Germany
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Wally s3 e cold_rolling_mills_strip_processing_lines

  • 1. COLD ROLLING MILLS and STRIP PROCESSING LINES Session 3 COLD ROLLING MILLS STRIP PROCESSING LINES SMS metallurgy Conference 2007
  • 2.
  • 3. Most recent technologies in cold rolling to improve product quality Dr. Hartmut Pawelski General Manager Metal Forming and Surface Technology Dipl.-Ing. Christoph Schwarz Deputy General Manager Technical Sales Cold Rolling Mills Dipl.-Ing. Rüdiger Holz Execute Vice President Cold Rolling Mills Division Dr. Karl Hoen General Manager Plant Technology Hot/Cold Rolling Mills Division SMS Demag AG Düsseldorf/Hilchenbach, Germany
  • 4.
  • 5. Most recent technologies in cold rolling to improve product quality Rüdiger Holz, Dr. Karl Hoen, Dr. Hartmut Pawelski, Christoph Schwarz In recent years, the steel industry world- wide achieved remarkable growth rates. It is not only growing in Asia, here espe- cially in China and India, but also in Europe and America. At the same time, its consolidation is going on and the steel markets become more and more global. In such an environment it is important for mill owners to meet highest quality re- quirements and at the same time curb the production costs. SMS Demag as system supplier for inte- grated solutions of rolling mill technology developed a large number of suitable systems for supporting mill owners in these efforts. Examples of effective solu- tions in cold rolling mills for achieving high quality requirements and highest economic efficiency are the following: ▬ Equipment for Edge Drop Control to achieve a constant strip thickness across the complete width, ▬ the T-roll® process technology, ▬ an alternative lubrication and clean- ing concept for an improved strip sur- face quality and ▬ online measuring systems for the documentation of product quality and meeting of narrower tolerances. Edge Drop Control (EDC® ) Edge Drop describes the undesired thickness drop in the edge zone of cold rolled strips. Reason for it is the chang- ing roll flattening in the transition from the loaded to the unloaded rolling sec- tion. Depending on the intended use of the strip, this area has to be removed. For this purpose, the strip is trimmed what will reduce the plant yield. For avoiding such losses, SMS Demag developed Edge Drop Control strategies for reversing cold mills and tandem cold mills. For compensating the thickness drop, the work roll diameter in the strip edge area has to be reduced. For this pur- pose, the work roll barrel is tapered by a special grind at one end. The principle of the control is now based on shifting the taper for so far into the strip edge zone until a specified edge drop value is set. The operating results of the CSC revers- ing mill in Taiwan illustrate the difference between using and not using an Edge Drop Control for non-grain-oriented silicon steel. Application of the Edge Drop Control was able to reduce the trimming losses by over 20 mm for each side. This increases the yield for the common strip width by more than 3 %.
  • 6. The strategy for a continuously operating tandem mill is a combination of open- and closed-loop controls. The drop in thickness is measured after the first and the last stand (stand 5). The first mea- surement is used for controlling the edge drop in stand 1. At the same time, this signal is applied for a pilot control of mill stands 2, 3 and 4. The measurement after the last stand is introduced to cor- rect the control command of the pilot control in mill stands 2, 3 and 4 and that way the desired edge drop value after stand 5 is set. As the operating results show, this strat- egy is suitable to set a constantly low value for edge drop over the entire strip length and thus subsequent trimming losses are reduced. T-roll® process technology For optimizing the cold rolling process and for an improved product quality it is indispensable to understand the physical processes during cold rolling in a better way. Therefore SMS Demag developed T-roll® , a technology package including new and enhanced physical model ap- proaches for simulating the cold rolling process. Beside the complete mechani- cal and thermal description it is above all the detailed and realistic description of the tribological processes which open up new options for process optimization. The accuracy of the model approaches becomes apparent in the high coinci- dence between measurement and simu- lation. Examples are the accurate simu- lation of rolling force and strip lead as well as the transfer of the roll surface roughness onto the strip surface. As examples for the efficiency of T-roll® , the optimization of a single-stand revers- ing mill for the production of grain-orient- ed silicon steel shall be mentioned. In this project, the lubricant and the appli- cation of lubricant could be improved in a well-aimed way by the new way of con- sidering the tribology in the roll gap. This enabled a clearly higher rolling speed and thus a clear improvement of the plant's output capacity. A second example is the avoiding of form waves in cold rolling of brass in a two-stand tandem mill. It was only through the analysis of the problem by means of the T-roll® technological pack- age and a test setup in the laboratory based thereon that it was demonstrated that the form waves exclusively occur through insufficient lubrication condi- tions. By improving the lubricant and di- rect application of an additive in the first passes the form waves were avoided.
  • 7. Lubrication and cleaning concept As a new lubrication and cleaning con- cept, SMS Demag developed a com- bination of least quantity lubrication and the utilization of liquid nitrogen. In skin- passing, this concept decisively im- proves the strip surfaces and at the same time curbs the operating costs. When using the least quantity lubrication in the skin-pass stand entry, the lubricant volume is precisely applied, which is re- quired for reducing the friction in the roll gap. This reduces the rolling force and improves flatness at simultaneously us- ing a minimum quantity of lubricant. The liquid nitrogen in the exit covers both the strip surface and the roll surface. This method has the following advantages: ▬ clean and dry strip surfaces and thus clearly lower susceptibility to rust, ▬ clearly reduced efforts in the down- stream cleaning steps for cleaning the strip surface and ▬ prolonged work roll service lives. For assessment of the strip surface qual- ity, the same material was skin-passed under different operating conditions. In the pass with emulsion, clear impres- sions of the lubricant could be found. They make the surfaces appear less bright. The roll abrasion in dry skin-pas- sing has a similar effect on the surface quality. Compared to that, the surfaces are clearly more uniform and thus brighter when using liquid nitrogen in the entry or in the entry and exit. Moreover the operating experience showed that the use of nitrogen more than doubled the work roll service lives. This and the lower refinishing effort on the strips led at our cooperation partner C. D. Wälzholz to cutting the process costs for skin-passing by ca. 20 %. The most recent reference for this con- cept is the new inline skin-pass mill stand for the continuous annealing line of ThyssenKrupp Steel in Dortmund, Germany. Online measuring systems Efficient production on a high quality lev- el today requires complete documenta- tion of the main quality parameters. Only that way it is possible to demonstrate quality towards the customer and at the same time efficiently track down causes for quality problems in the process line and to remedy them. Our new "Rotary Inspect" inline inspec- tion line sets the record here for safety and ergonomics in the manual assess- ment of strip top and bottom sides. Our patented roughness control system enables controlling the strip roughness over the entire length to a constant value and to perform the roll change only when it is really needed. For roughness mea- surement, the SORM 3 plus measuring system of our cooperation partner EMG is used.
  • 8. The SMS Demag flatness measuring roll is the ideal solution for precise and reliable measurement of strip flatness. The closed surface of the roll avoids marks on the strip and can be coated specifically for each application. The roll allows simple installation of the sen- sors which can even be performed on site. The sensors can be arranged flexi- bly regarding their distances in accor- dance with the current and future re- quirements of the profile and flatness control system. Ten references within a short time demonstrate our customers' high acceptance of this measuring system.
  • 9. 1SMS metallurgy Conference 2007 Most recent technologies in cold rolling SMS Demag solutions for improved product quality Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Constant strip thickness up to the edge EDC Closer tolerances and better documentation Higher yield and improved product quality T-roll® process technology Lubrication and cleaning concepts Online measurement systems A new approach for perfect surface quality 2SMS metallurgy Conference 2007 Most recent technologies in cold rolling EDC® Edge Drop Control – constant strip thickness up to the edge Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems
  • 10. 3SMS metallurgy Conference 2007 Most recent technologies in cold rolling Principle of the Edge Drop Control Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Stripthickness Principle of work roll shifting for Edge Drop Control Strip width with EDC without EDC Reduced Edge Drop Influence of EDC on the strip edge transverse material flow 4SMS metallurgy Conference 2007 Results of Edge Drop Control in a single-stand reversing mill Most recent technologies in cold rolling Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Material: Non grain-oriented silicon steel 0 20 40 60 80 100 120 -2.5 -2 -1.5 -1 -0.5 0 0.5 Distance from strip edge Thicknessdeviation[%] Edge Drop measurement Hot strip After last pass with EDC without EDC Yield increased by approx. 3 % due to by reduced trimming losses►►
  • 11. 5SMS metallurgy Conference 2007 Most recent technologies in cold rolling Edge Drop Control strategy for a continuous tandem cold mill Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems AW Position AW Position AW Position S1 S2 S3 S4 S5 EDC Vorsteuerung EDC Regelung G2;G3;G4 AddRef AddRef Ref Ref Ref AW Position Ref AddRef EDC Regelung G1 Act AW Position WR shifting AW Position WR shifting AW Position WR shifting measured edge drop edge drop references EDC feed forward control EDC feedback control G2;G3;G4 AddRef AddRef Ref Ref RefRef Ref Ref AW Position WR shifting Ref AddRef EDC feedback control G1 Act Model parameter measured edge drop EDC feedback control for S1 EDC feed forward control and feedback control of S2, S3, S4 6SMS metallurgy Conference 2007 Most recent technologies in cold rolling Results of closed loop Edge Drop Control in a tandem cold mill Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems position(mm) Strip length [m] G1 G2 G3 G4 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 0 20 40 60 80 100 EDC-Position (measured) Strip length [m] 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 -10 0 20 40 60 80 Edge drop (measured) Edgedrop[μm] Edge drop measured EDC workroll shifting position Strip length [m] Edgedrop(μm) after G1 after G5 Reference value: after stand 1 20 μm after stand 5 10 μm with EDC Edge drop reduction constant over total strip length►►
  • 12. 7SMS metallurgy Conference 2007 Most recent technologies in cold rolling T-roll® process technology Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Technology package for the simulation of the cold rolling processes with advanced models for ▬ mechanical ▬ thermal and ▬ tribological processes Applications: ▬ thermal and tribological processes ▬ Analysis and optimization of lubrication and cooling conditions ▬ Selection of adequate lubricants ▬ Development of new rolling strategies ▬ Calculation of pass schedules for new steel grades ▬ Pre-calculation of strip surface roughness More profit due to higher yield and improved product quality►► 8SMS metallurgy Conference 2007 Most recent technologies in cold rolling T-roll® process technology Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems High capability of new approaches 0 0.5 1 1.5 2 2.5 3 0.0 0.5 1.0 1.5 2.0 2.5 Elongation in % Roughingofstrip,Rainμm Measured, top Measured, bottom Tribological model Tribologisches Modell Rolling Speed [m/min] Walzkraft [MN] Walzgeschwindigkeit [m/min] Tribologisches Modell Rolling Speed [m/min] Walzkraft [MN] Tribological model Rolling Speed [m/min] Roll force [MN] Roll speed [m/min] Rolling Speed [m/min] tribological model Voreilung [%] Tribologisches Modell Walzgeschwindigkeit [m/min] tribological model Rolling Speed [m/min] Tribologisches Modell Voreilung [%] Walzgeschwindigkeit [m/min]Rolling Speed [m/min] tribological model Voreilung [%] Tribologisches Modell Walzgeschwindigkeit [m/min] tribological model Rolling Speed [m/min] Tribological model forward slip [%] Roll speed [m/min] ▬ High forecast accuracy for • improved processing and • higher plant utilization
  • 13. 9SMS metallurgy Conference 2007 Most recent technologies in cold rolling Cold rolling of high-grain-oriented silicon steel Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems before modernization after modernization 900 m/min = max. motor speed 5 pass HGO Share of production approx. 30 % Max.rollingspeed [m/min] 900 600 300 0 pass 1 pass 2 pass 3 pass 4 pass 5 Increase of maximum speed by tribological optimization►► 10SMS metallurgy Conference 2007 Most recent technologies in cold rolling Cold rolling of brass on a tandem cold mill: elimination of waves Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems SMS Demag solutions: ▬ Optimization of lubricant ▬ Low quantity lubrication for first passes ►►
  • 14. 11SMS metallurgy Conference 2007 Most recent technologies in cold rolling Combination of low-quantity lubrication and liquid nitrogen Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Low quantity lubrication Liquid nitrogen ▬ Substantial reduction of lubrication quantities ▬ Reduction of friction in the roll gap • lower rolling force • improved strip flatness ▬ Improvement of strip surface quality ▬ Better cleaning effect on work rolls ▬ Longer service life of work rolls Benefits:In cooperation with: C.D. Wälzholz ►► 12SMS metallurgy Conference 2007 Most recent technologies in cold rolling Skin-pass rolling with liquid nitrogen Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Valuation of strip surface quality after skin-pass rolling Target: Ra = 1,0 – 1,8 μm; shining surface Liquid nitrogen, entry Liquid nitrogen, entry and exit Emulsion, entry (height profile: ± 0,8 μm) 100 μm lubricant impressed dry Abrasion of rolls Improved surface quality Considerably improved strip surface quality►►
  • 15. 13SMS metallurgy Conference 2007 Most recent technologies in cold rolling Skin-pass rolling with liquid nitrogen Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems after coil No. 1: 1.4 μm after coil No. 4: <1.0 μm Roughness of new work roll: 3 – 3.3 μm after coil No. 1: 1.7 μm after coil No. 10: 1.2 μm Coil No. Dry (2004-05-03) 3.0 10 1 2 3 4 5 0.0 0.5 1.0 1.5 2.0 2.5 3.0 Roughness of new work roll: 3 – 3.3 μm Coil No. 0.0 0.5 1.0 1.5 2.0 2.5 3.0 1 2 3 4 5 6 7 8 9 10 Liquid nitrogen (exit) Service life of work rolls increased by more than 100 % Skin-pass process costs reduced by 20 % ►► 14SMS metallurgy Conference 2007 Most recent technologies in cold rolling Recent reference: ThyssenKrupp Steel, Germany New inline skin-pass mill for continuous annealing line Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Main technical data: Strip thickness: 0.4 to 2.3 mm Strip width:: 600 to 1,720 mm Roll speed range: 0 to 412 m/min Annual capacity: 780,000 t Year of commissioning: 2007 Inline-skin pass Technical features: ▬ Newly developed low-quantity lubrication system and roll-strip cleaning with liquid nitrogen ▬ SMS Demag shapemeter roll ▬ X-Pact® – electric and automation systems
  • 16. 15SMS metallurgy Conference 2007 ►► Most recent technologies in cold rolling Online measurement systems to improve product quality and plant utilization Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems SMS Demag flatness measurement roll Inline inspection line „Rotary-Inspect“ SORM roughness measurement with control system Advantages: ▬ Continuous monitoring and documentation of quality parameters ▬ Close tolerances by means of integration in closed loops In cooperation with: 16SMS metallurgy Conference 2007 ►► Most recent technologies in cold rolling SMS Demag flatness measuring roll in new design Edge Drop Control T-roll® process technology Lubrication and cleaning concepts Online measure- ment systems Advantages: ▬ Easy sensor installation even at site ▬ Applicable at high temperatures e.g. production of Si-steel grades ▬ Individual arrangement of sensors ▬ Closed surface ▬ Application-based coating References in 18 months: 7 plants with a total of 10 shapemeter rolls
  • 17. Modernization concept of the four-stand tandem cold rolling mill, BILSTEIN GmbH & Co. KG Dipl.-Ing. Detlef Böttner Deputy General Manager Sales Cold Rolling Mills Electrical and Automation Systems Dipl.-Ing. Falk Töpfer General Manager Technical Sales Cold Rolling Mills Dipl.-Ing. Arnulf Wurm Senior Project Manager Technical Sales Cold Rolling Mills SMS Demag AG Hilchenbach, Germany
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  • 19. Modernization concept of the four stand tandem cold mill, BILSTEIN GmbH & Co. KG Detlef Böttner, Falk Töpfer, Arnulf Wurm Ever increasing requirements on the cold strip qualities and the continuously grow- ing material and variant diversity more and more force rolling mill owners to keep their plants on the most recent technological level or to get them there. Due to the concurrently very high de- mand volume and thus the plant utiliza- tion in recent years, they had to face particular challenges. SMS Demag took up these customer problems and elaborated and constantly developed special concepts in recent years to cope with them. This is one of the reasons why the company BILSTEIN with their registered office in Hagen, Germany, tasked SMS Demag with the extensive modernization of their four- stand tandem cold mill. BILSTEIN is processing a diversified ma- terial and product mix starting from the standard grades over case-hardening and special grades up to micro-alloyed high-strength steels. The tandem mill is the central key plant for the complete production at BILSTEIN and in some cases also for their subsidiary com- panies. Therefore a consistent and reli- able modernization concept was even more significant for taking the decision to award the contract. The rolling mill was supplied in 1969 by SMS Demag and was during the years upgraded and modernized several times. This mill produces every year 400,000 t of cold strip of width from 320 to 670 mm and thicknesses from 7.5 to 0.3 mm. The input stock is produced by slitting hot strip normally into two to three stripes. Therefore the input stock has different wedge profiles what is a particular chal- lenge for the sequences in cold rolling. The modernization is related to a large number of objectives of which the follow- ing are the most important ones: ▬ Improvement of the plant availability ▬ Increase of the production volume by 60,000 t/year ▬ Improvement of the product quality ▬ Increase of the degree of automation A particular requirement which made the matter more complicated is that due to the above mentioned plant utilization the proper revamp times could only be taken during regular shutdowns. The total time available for this is three shutdown peri- ods of altogether five weeks. After each modification period, production has to be run up to the set point volume according to agreed run-up curves as fast as possi- ble. In the process, the comprehensive product mix of wedge-shaped hot strip
  • 20. has to be considered and the currently applicable safety standards have to be observed. For various reasons, SMS Demag won the contract for this modernization. SMS Demag has wide experience in large and complex modernizations and was also in this case able to present a coherent overall concept. The "All from a single source" supply, i. e. the symbiosis of mechanics, hydraulics, electrics and automation as well as development and technology from one single supplier cre- ates the optimal conditions for modern- ization which were critical in terms of technology and time. Essential mechani- cal components as e. g. the hydraulic adjustment cylinders and valve stands are produced in the SMS Demag work- shop and carefully tested before deliv- ery. Moreover, the extensive actions ac- companying the order are performed for safeguarding the short modification phases. Among these are careful site in- vestigation, early setup of a "listening mode", a state-of-the-art integration test, the early operator training on the simu- lated plant up to a sophisticated change- over concept between the old and the new control system. For achieving the modernization objec- tives, many components are replaced by new and more recent ones or additional- ly integrated into the rolling mill. For increasing and stabilizing the strip back tension in the first stand, an addi- tional strip pinch roll unit will be installed in the entry guide. It is hydraulically approached, the additional strip tension is applied by means of electrically actu- ated rolls. That way it operates similar to a bridle roll unit but compared to that it bears the advantage that it can still be used for large entry thicknesses. All mill stands will be equipped with hy- draulic adjustment cylinders. That way it is not only possible to increase the rol- ling force by 30 % in each mill stand but for the first time it is possible to measure the precise positions of the cylinders. This is the prerequisite for converting the strip thickness control from the currently used roll gap control to a quick volume flow control. Moreover, the rolling speeds of all mill stands are increased and optimized with regard to one another. For this purpose, among other things new gearwheel sets will be installed. For minimizing the re- maining quantity of residual oil on the strip, the patented SMS Demag Dry Strip System (DSS) will be installed down- stream of the last mill stand. The coiling tension will in a similar way as on the entry side be separated by a new approachable bridle roll unit from the exit tension of the last stand. When the bottom roll of this unit is not ap- proached, it behaves like a "normal" de- flector roll, i. e. also this bridle roll unit can, as the strip pinch roll unit on the entry side, be started up step by step without any risk. Various other mechani-
  • 21. cal extensions supplement the modern- ization. Among these are in particular: ▬ Various improvements for guiding and threading the strip ▬ Improvements for calibrating the roll assemblies ▬ Installation of work roll bending sys- tems at all stands ▬ New hydraulic valve stands for all mill stand functions ▬ Installation of devices for measuring strip position, strip tension and strip speed at different positions. The existing electrical and automation systems will to a large degree be re- placed by new systems. Interfaces are created with the remaining components and systems. All main drives will be re- placed. For the mill stands, advanced synchronous motors in medium voltage technology will be used. Compared to the asynchronous motors, they provide a higher operating efficiency at a simulta- neously smaller moment of inertia which leads to improved control dynamics. State-of-the-art multi-drive converters with a direct current intermediate circuit supply the medium-voltage motors of the mill stands as well as the low-voltage motors of the strip drives for the reels, pinch roll units and bridle rolls. This reac- tive power-free drive constellation both minimizes possible energy losses and negative effects on the feeding network. The plant will for the first time be operat- ed from a newly erected main control pulpit. Except new operator stations and an HMI system which can also be ac- cessed from all local stations, strip edge detection and camera systems will be in- stalled at different locations. The latter are provided for visual monitoring of the partly automated threading process by the operator. This is particularly required when threading the wedge-shape slit strip. The automation system will be complete- ly replaced. In the process, all Level 1 functions from the sequence processes up to the technological controls are all implemented on a uniform hardware and software platform. In particular for safeguarding the in- creased requirements on the automation system, faster coil sequence times and an improvement of the strip quality at the head-end, for the first time a Level 2 sys- tem will be used on this mill. Above the required interfaces and various report functions, this system makes available a model-based setup value calculation be- fore start of rolling. For this purpose, SMS Demag uses the complete imaging of the rolling processes through self- adapting physical models. For safeguarding the required run-up curves after the respective short modifi- cation phases, SMS Demag uses a con- cept of several parallel actions. First the current status is detected by means of detailed examinations and used as the basis of the following modifications. Among these are e. g. detection and localization of the mechanical and elec- trical components, functional and pro-
  • 22. cess-technological aspects as well as the plant operation. By documentation of this site investiga- tion, the engineering could start. On site almost simultaneously the preparation of the interfaces is started for the systems required in the individual modification phases which are continued to be oper- ated. Moreover, a "listening mode" is es- tablished. For this purpose, so-called process IO servers are installed step by step which enable forwarding each sig- nal from or to the process to the existing control (maintaining the existing status) but also making available these signals in a global memory for the later new con- trol systems. That way the new system has knowledge of the current process events at a very early stage. This result- ing process data basis will be integrated in the engineering and the pre-commis- sioning of the new system. That way for example the mathematical models can already at that time automatically adapt to the material to be rolled and the exist- ing plant. In a next step, the complete new auto- mation system will be set up in the SMS Demag workshop. In parallel, the rolling mill will be simulated in every de- tail in real time. Here not only the rolling process itself is simulated but also all movements and all interfaces with the automation system. By means of this "integration test", already beforehand a pre-commissioning, complete functional and production tests are performed. This comprehensive simulation is also used for an intensive operator training. Only that way it is possible to achieve the short run-up phases. Now the previously installed listening mode is expanded in a modification phase and the following optimization phase to the effect that new functions or controls can be added in, tested and op- timized either completely or also partly. For this purpose the old and the new open- and closed-loop systems are oper- ated in parallel. That way the original condition can quickly be re-established by digital adding-in. It is only after all new functions were sufficiently verified and optimized that the "old" components will be dismantled and the final new en- hanced condition is established. This modernization concept provides both the plant operator company BILSTEIN and the contractor SMS Demag with the sufficient safety for a smooth sequence of the modification as well as the certainty that the modifica- tion objectives are really achieved within the defined time frame.
  • 23. 1SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill BILSTEIN GmbH & Co. KG, Hagen-Hohenlimburg employees: 600 dispatch volume: 400,000 t/year ▬ cold-rolled steel strip ▬ cold-rolled steel sheet ▬ construction steel ▬ case hardening steel ▬ electrical steel ▬ spring steel ▬ special purpose steel ▬ enameling steel strip The customer and their products Introduction Modernization objectives Modernization items Modernization concept 2SMS metallurgy Conference 2007 Four-stand tandem cold rolling mill of BILSTEIN GmbH & Co. KG, Germany Main mill data ▬ four-stand batch tandem cold mill ▬ Supplier: DEMAG, 1969 ▬ Rolling speed: max. 745 m/min ▬ Rolling force: max 6,000 kN per stand Modernization concept of the four-stand tandem cold mill Introduction Modernization objectives Modernization items Modernization concept
  • 24. 3SMS metallurgy Conference 2007 Four-stand tandem cold rolling mill of BILSTEIN GmbH & Co. KG, Germany Material data ▬ Strip width: 320 to 670 mm ▬ Strip thickness: 7.5 to 0.3 mm ▬ Annual production : 420,000 t Others ▬ Several modernizations over the years ▬ Four operators, all “on site” ▬ Low automation grade of mill sequences Modernization concept of the four-stand tandem cold mill Introduction Modernization objectives Modernization items Modernization concept 4SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Targets of the modernization General targets ▬ Increase of mill availability ▬ Increase of production rate by 60,000 t/y ▬ Improvement of product quality ▬ Higher degree of automation Special requirements ▬ Rolling and threading of wedge-type strips ▬ Extensive product-mix ▬ Change to operating with only three operators ▬ Only the regular mill downtimes can be used (in total five weeks) ▬ High priority in safe and steep run-up after each modernization step Introduction Modernization objectives Modernization items Modernization concept
  • 25. 5SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Reasons for placing the order with SMS Demag ▬ Experiences with comprehensive modernizations ▬ Convincing overall modernization concept ▬ Supply from one single source ▬ Manufacture at SMS Demag workshop ▬ Advanced integration test ▬ Operator training in advance ▬ Switch-over concept Introduction Modernization objectives Modernization items Modernization concept 6SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of mechanical equipment Entry-side pinch roll unit ▬ improve the strip tension behavior ▬ increase the strip tension Advantages ▬ independent of the strip thickness ▬ deflector roll mode possible
  • 26. 7SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of mechanical equipment Hydraulic screw down cylinders for all stands ▬ rolling force increase from 6,000 kN to 8,000 kN ▬ high resolution position measurement Advantages ▬ higher reduction ▬ change from roll gap to position control mode 8SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of mechanical equipment New gear sets respect. shifting gear sets between the stands ▬ increase the rolling speeds; from 745 to 1,000 m/min at last stand
  • 27. 9SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of mechanical equipment Dry Strip System after last stand ▬ increase the removal of the emulsion on the strip surface Advantages ▬ reduced noise level ▬ best dryness of the strip surface 10SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of mechanical equipment Exit-side swiveling bridle S-roll set ▬ improve the strip tension behavior ▬ increase the strip tension Advantages ▬ deflector roll mode possible
  • 28. 11SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill New synchronous motors for mill stands and tension reel ▬ increase the rolling speed of each stand Advantages ▬ high efficiency ▬ low inertia, i. e. high dynamic behavior Modernization of electrical equipment Introduction Modernization objectives Modernization items Modernization concept 12SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of electrical equipment New multi-drive converter systems ▬ IEGT converters for MV mill drives ▬ IGBT converters for LV drives Advantages ▬ low energy losses, low power feed-in ▬ high dynamic performance Introduction Modernization objectives Modernization items Modernization concept
  • 29. 13SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of electrical equipment New pulpit, operator panels and HMI system ▬ full HMI access at all operator panels ▬ industrial TV system and strip-edge monitoring systems Introduction Modernization objectives Modernization items Modernization concept 14SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Modernization of electrical equipment New Pulpit, Operator Panels and HMI-System full HMI access at all operator panels industrial TV system and strip edge monitoring systems Introduction Modernization objectives Modernization items Modernization concept New Level 1 automation system ▬ additional measurement devices for strip speed and tension ▬ position sensors of screw down cylinders, vibration monitoring Advantages ▬ switch-over from roll gap control to position control ▬ introducing fast volume control mode ▬ one uniform system platform G3 G2 G1 G0 HGC Decoupling Net Speed and Torque Control Speed Control Speed and Torque Control Speed Control Speed Control Speed Control Thickness Control HGCHGCHGC Tension Control Thickness Control Thickness Control Thickness Control Tension Control Tension Control Tension Control
  • 30. 15SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill High-accuracy Level-2 setup system ▬ physical-based models ▬ short-term and long-term self-adapting models Advantages ▬ reduction of off-gages/off-flatness length ▬ fast learning behavior ▬ flexible adaptation to new materials Introduction Modernization objectives Modernization items Modernization concept Modernization of electrical equipment Mill limits and configuration Rolling force model Flatness model Temperature model Tribological Model Material model 16SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill High accuracy of SMS Demag Level-2 process models (Example: Single-stand reversing mill for silicon steel) thickness deviation at head end [%] frequency[%] 1,514 strips force deviation at head end [relative, kN] frequency[%] 1,525 strips 0 5 10 15 20 25 30 20001,6001,2008004000-400-800-1,200-1,600 77 % within 0 % to + 3 % Introduction Modernization objectives Modernization items Modernization concept 0 5 10 15 20 25 30 35 40 45 1086420-2-4-6-8
  • 31. 17SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Overall modernization concept: Engineering, test and interfaces preparation in parallel Site investigation Preparation of interfaces/ listening mode Installation Switch- over Engineering Plug & Work test Stepwise time Introduction Modernization objectives Modernization items Modernization concept 18SMS metallurgy Conference 2007 Site investigation Preparation of interfaces/ listening mode Installation Switch- over Engineering Plug & Work test Stepwise Modernization concept of the four-stand tandem cold mill Site investigations ▬ hardware and layout piping, routing, locations, etc. ▬ functional technology signals, interfaces, etc. ▬ process sequences and mill operation standard operation procedure ▬ process technology pass schedules, emulsions, etc. Site investigation Introduction Modernization objectives Modernization items Modernization concept
  • 32.
  • 33. 21SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Hot run tests and “shadow mode” ▬ stepwise function and production test with mechanic and media systems ▬ test of sequences, test of dynamic behavior ▬ always possible to switch back to old controls (“shadow mode”) Old New ~ ~ M ~ PPS /L3 Process models /L2 Process control /L1 RIOs PIOS Process Models /L2 Process control /L1 PIOS (Process IO Server) = “electronic terminals” Installation Switch- over Introduction Modernization objectives Modernization items Modernization concept Site investigation Preparation of interfaces/ listening mode Installation Switch- over Engineering Plug & Work test Stepwise 22SMS metallurgy Conference 2007 Modernization concept of the four-stand tandem cold mill Typical run-up curve for a modernization with production increase 0 10 20 30 40 50 60 70 80 90 100 110 120 130 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Weeks Productionperweek[%] Downtime Introduction Modernization objectives Modernization items Modernization concept
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  • 35. Cold rolling of stainless steel using continuous high-perfor- mance tandem mills Dipl.-Ing. Rainer Effertz Deputy General Manager Filtration Systems/Roll Coolant Systems Dipl.-Ing. Rüdiger Holz Executive Vice President Cold Rolling Mills Division Dipl.-Ing. Ralf Matzka General Manager Technical Sales Cold Rolling Mills and Stainless Steel Lines Dipl.-Ing. Thorsten Bode Manager Metal Forming Technology SMS Demag AG Düsseldorf/Hilchenbach, Germany
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  • 37. Cold rolling of stainless steel using continuous high-performance tandem mills Ralf Matzka, Thorsten Bode, Rainer Effertz, Rüdiger Holz The market for cold-rolled stainless steel strip is characterized by continuous growth. The ever higher growth rates of cold rolled products require ever higher capacities of the process lines and rolling mills. Further the market requires reasonable prices for these products, with the optimization potential mainly be- ing the cost of production. As long ago as 1969, the Nisshin Steel company in Japan attempted to satisfy this market requirement by installing a then highly productive multi-stand tan- dem mill for the production of cold-rolled stainless steel. Another high-perfor- mance mill, supplied by SMS Demag, went in operation in 1999 at AK Steel in the United States, rolling both stainless steel and carbon steel grades. The new plant concept developed by SMS Demag for stainless-steel tandem mills consists of several rolling mills in a tandem ar- rangement, with extremely slender and therefore horizontally supported work rolls. Setting up a continuous rolling mill for the production of stainless steel strip is a cost-effective option where a cold-rolling stage with a capacity of more than 400,000 t/year is to be implemented. This plant concept requires the lowest cost of conversion due to the as com- pared to conventional stainless steel rolling on reversing rolling mills higher yield, less manpower and the lower specific investment cost. The new plant concept using rolling oil makes it pos- sible to produce surface finishes that bear comparison with cold rolled strip produced in 20-roll mills. As compared with the well-known fully integrated lines for the production of stainless steel strip (integrated rolling, annealing and pickling lines), the concept of a continuous tan- dem mill has a much higher flexibility. The differences between the continuous tandem mills set up so far for the produc- tion of cold-rolled stainless steel strip are as follows: The first mill in Japan was set up as a semi-continuous line and has no continuous exit. The mill stands are of 20-roll type and accordingly have long roll-changing times of the backing ele- ments and intermediate rolls. Another critical item in this mill stand design is the relatively poor accessibility in case of strip breaks. The continuous tandem mill at AK Steel was designed for the mass production of carbon steels and austenit- ic as well as ferritic stainless steels. The rolling mills are of four-high (mill stands 1 to 3) and six-high type (mill stands 4 and 5. The roll diameters were chosen to suit stability requirements and the torques needed to drive the work rolls,
  • 38. they warrant a simple mill stand design with associated high service life and availability. Thanks to the application of a special cooling lubricant and the use of the required roll roughness it has also been possible to satisfy customers' sur- face finish demands. The new SMS Demag concept for a continuous rolling mill for stainless steel strip is based on the quality requirements of a specialized cold strip production using 20-roll mills. To achieve the necessary overall reduction, a very slender work roll was chosen which via laterally arranged intermediate rolls is supported on both sides by two rows of backup bearings. The mill stand design encompasses a six-roll mill with backup, intermediate and work rolls. The intermediate rolls are axially shifted and equipped with a roll bending facility. The tandem rolling mill is equipped for fully continuous oper- ation, i. e., on the entry side a welder and strip accumulator to bridge the non- productive entry time are arranged, whereas on the exit side coils are changed on the fly. The above requires the exit tension in the last mill stand to be maintained with the help of a pinch- roll mill stand and the continuous supply of paper through the use of carousel- type paper winders and automatic threading devices. In the production of cold-rolled stainless steel strip in continuous tandem mills, the following special technical items need to be considered: ▬ The large variety of the products to be rolled in terms of their dimenions and mechanical properties requires an adapted mill stand design. ▬ The benefit of the high yield can be achieved only in continuous opera- tion. ▬ The excellent surface finishes can be achieved only through the use of suitable cooling and lubrication sys- tems as well as an effective surface inspection. ▬ The benefit of the lower specific in- vestment cost becomes fully effective especially in a modular mill design. The mill stand design follows the require- ments of the rolling process. The neces- sary small work-roll diameter results from the strength of the material and the finish gauge to be achieved. Since the degree of slenderness in the necessary work-roll dimensions becomes too large, these rolls need to be supported horizon- tally. Lateral backup rolls, which are ad- ditionally guided by two rows of backing bearings, absorb the horizontal forces
  • 39. and transmit them to the adjustable sup- port bridges. The benefits of this mill stand design mainly include the applica- tion of the CVC plus® technology for set- ting the roll-gap geometry, the use of the HS (horizontal stabilization) system for optimization of the horizontal forces and above all a quick work and intermediate roll change. Another important criterion for the design of a tandem rolling mill for cold-rolled stainless steel strip is the temperature control in the rolling process. The cooling lubricant used to attain the required sur- face finishes has a limited heat absorp- tion capacity and the deformation energy is predominantly transformed into heat, i. e., the temperature of the material rises. The compact design of the rolling mill further allows the limited installation of cooling sections. An exact prediction of the material temperature forms the basis for the production of excellent sur- face finishes with very good gloss and reflection properties. The already mentioned cooling and lubricant system of the rolling mill essen- tially has to satisfy two requirements: on the one hand it must support a high thickness reduction at relatively low rol- ling speeds while on the other hand it has to produce the gloss properties of the cold-rolled strip surface. The benefits of SMS Demag's cooling lubrication technology consist of the technological know-how of the cooling lubricant's pressure absorption capacity, lubrication effect, cooling efficiency, the filter tech- nology which for this rolling duty is based on the SUPAFINE® technology and the technological design of the coolant sys- tem with the additional possibility of setting different viscosity levels of the lubricant in the various mill stands. In SMS Demag's CVC® 18-HS rolling mills, the potential flatness position er- rors of the cold rolled strip are compen- sated by tried-and-tested quick-response actuators. Intermediate-roll bending and edge-oriented shifting of the intermediate rolls allow a very good correction of strip edge waves and center buckles. How- ever, the high degree of slenderness of the work roll as well as the absence of bending on the latter limit the potential for correction in the case of so-called quarter buckles. To be able to use this additional adjust- ment potential, SMS Demag has devel- oped a special CVC plus® grinding for the 18-HS rolling mills. In addition to the expanded control range of the roll-gap geometry, this CVC plus® grinding features an improved distribu- tion of rolling forces over the length of the roll barrel and thus across the entire strip width, thereby increasing the ser- vice life of the rolls in the mill stands. The HS system installed in SMS Demag's rolling mills allows the horizontal shifting of the work roll in the direction of rolling as a function of the predicted horizontal forces caused by the drive torque. This allows high thick-
  • 40. ness reductions during each rolling pass, a longer service life of the lateral backing elements and, through the integration of the CVC plus® system in flatness control, an excellent strip quality. The HS system with its adjustable hori- zontal offset of the work rolls reduces the necessary supporting force which needs to be absorbed by the lateral backing elements. A more stable rolling process and lower maintenance cost are the es- sential benefits of this technology. As a competent partner, SMS Demag has a large number of reference installa- tions at its disposal. This basis warrants the efficient processing of projects as well as a quick start of production. The modular design of SMS Demag's rolling mills, which has been successfully em- ployed many times before, guarantees a high availability and low operating cost. SMS Demag offers rolling mill owners re- liable solutions and high-quality engi- neering at a cost-benefit ratio in line with the market.
  • 41. 1 SMS metallurgy Conference 2007 Applications Continuous tandem cold mills for stainless steel 1969 1999 2007 Nisshin Steel AK Steel SMS Demag continuous tandem mills combined stainless steel/carbon steel stainless steel 2 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel ▬ High productivity ⇒ capacity of more than 400,000 t/year ▬ Lowest conversion costs: • highest yield • less personnel • low specific investment costs ▬ Excellent quality ▬ High flexibility compared to fully integrated lines Advantages for stainless steel
  • 42. 3 SMS metallurgy Conference 2007 Nisshin Steel Continuous four-stand 20-high tandem mill Continuous tandem cold mills for stainless steel Main data material: stainless steel max. rolling speed: 600 mpm capacity: 220,000 t/year Existing plants 4 SMS metallurgy Conference 2007 AK Steel Continuous five-stand four-high/six-high tandem cold mill Continuous tandem cold mills for stainless steel Main data material: carbon steel stainless steel (austenitic, ferritic) max. rolling speed: 1,900 mpm capacity: 3,600,000 t/year Existing plants
  • 43. 5 SMS metallurgy Conference 2007 Four-stand CVC® 18-HS tandem cold mill Continuous tandem cold mills for stainless steel Main data material: stainless steel max. rolling speed: 400 mpm capacity: 720,000 t/year Advanced SMS Demag tandem mill 6 SMS metallurgy Conference 2007 Increase in output/yield Continuous rolling, two-high tension stand Top surface quality for subsequent processing SUPAFINE® filtration Quick and reliable strip surface control Inline inspection Low maintenance and operational costs Modular and robust mill design Wide range of products CVC® 18-HS technology Continuous tandem cold mills for stainless steel Tandem mill technology for stainless steel production
  • 44. 7 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel four-high Admissibleandrequiredlineload[kN/mm] Required line load for strip thickness of 0.2 0.4 0.8 1.6 mm Example: Tensile strength 1000 N/mm², reduction 40 %, strip width 1300 mm CVC plus® 18-HS Work roll diameter [mm] no horizontal stabilization required horizontal stabilization required Line concept for cold rolling of high-strength steels 8 SMS metallurgy Conference 2007 ▬ CVC plus® technology • improved roll gap setting and thus improved strip flatness • equal load distribution between the rolls and thus reduced roll wear ▬ HS system (Horizontal Stabilization) • reduced load of horizontal backing rolls • less wear of backing rolls ▬ Easy roll change • by installation of intermediate, work and backing rolls in change cassettes Benefits compared to the conventional 18-roll mill Continuous tandem cold mills for stainless steel CVC plus® 18-HS
  • 45. 9 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Simulation of strip temperature 10 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Requirements from the rolling process High reduction under low rolling speed Optimized roll coolant system in terms of cooling, lubrication and filtration High-performance rolling oil with excellent lubrication and cooling properties High surface quality demands 2B
  • 46. 11 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Advantages of SMS Demag coolant technology Design of the rolling oil system allows optimum adaptation to the rolling process in terms of heat removal and lubrication. Highest cleaning efficiency due to a SUPAFINE® filtration system and magnetic separator. Environmentally friendly concept as no filter aid is required. Viscosity can be adapted to each mill stand by means of inline coolers. 12 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Available flatness actuators of 18-roll mills flatness actuators ▬ IMR bending ▬ strip-edge-oriented IMR shifting flatness defects result ▬ small influence with IMR bending and conventional shifting ▬ insufficient influence of multi-zone cooling center buckles edge waves quarter buckles no significant improvement significant improvement CVC® 18-HS
  • 47. 13 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Principle of CVC® 18-HS Axially shiftable IMR with special CVC® shape of higher order ▬ Flatness control of higher order – defects possible (strip edge and quarter buckles) ▬ Due to special CVC® shape smooth load distribution between WR and IMR achievable 14 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Mill data: WR dia.: 140 mm IMR dia.: 355 mm BUR dia.: 1,350 mm Conventional 18-roll mill Strip width: 1,200 mm Spec. rolling force: 10 kN/mm IMR shifting IMRbending Comparison: Roll-gap adjusting field on conventional 18-roll and CVC® 18-HS mills CVC®18-HS mill
  • 48. 15 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel CVC® 18-HS mill with reduced work roll diameters Features Advantages Reduced work roll diameters High thickness reduction possible Horizontal Stabilization (HS) of Longer lifetime of side support work rolls (SMS Demag patent) clusters due to adjustable force Flatness control by proven IMR Excellent strip quality bending and axial shifting system (CVC plus® ) Horizontal Stabilization system (HS): Work rolls can be laterally shifted depending on strip data and rolling conditions. ▬ More than 15 references worldwide ▬ Ideal solution for stainless-steel tandem mills 16 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Principle of Horizontal Stabilization system (HS) With HS system: supporting force can be adjusted ▬ Stabilized rolling process ▬ Longer lifetime of side support inserts ▬ Less maintenance FTo FD FR without HSHS systemsystem required supporting force FT1 rolling direction FR rolling force FD tangential drive force FTo strip tension force entry FT1 strip tension force exit horizontal roling force component e (shift) with HS sHS systemystem FTo FD FR FT1 required supporting force = 0
  • 49. 17 SMS metallurgy Conference 2007 Continuous tandem cold mills for stainless steel Benefits of SMS Demag technology ▬ SMS Demag is a competent partner in process technology ▬ Great number of reference plants with proven technology fast start-up and reliable operation ▬ Low operational cost and high availability due to modular design ▬ Excellent quality, high reliability, always on time ▬ Reasonable cost-benefit ratio
  • 50.
  • 51. The new galvanizing line for SeAH Steel – Results and experiences Dipl.-Ing. Werner Haupt General Manager Preacquisition and Integrated Projects Dipl.-Ing. Joachim Kuhlmann General Manager Process Engineering Strip Processing Lines Division SMS Demag AG Hilden, Germany Y. J. Lee Director SeAH Steel Corp. Kunsan-City, Jeonbuk, Korea
  • 52.
  • 53. The new galvanizing line for SeAH Steel – Results and experiences Y.J. Lee, Werner Haupt, Joachim Kuhlmann The new and also first hot-dip galvaniz- ing line of SeAH Steel Corporation is the heart of the new cold rolling mill complex built in Gunsan in the western part of South Korea. The following topics report on the construction of the facility by SMS Demag as well as on our first oper- ating results: ▬ General overview ▬ Market development ▬ Layout/technical data of the CGL ▬ Erection phase ▬ First coil ▬ Operation ▬ Results and experiences SeAH Steel Corporation specializes in the production of steel pipes, stainless steel pipes for gas and water plumbing installations in buildings as well as gal- vanized strip and pre-coated material. The annual production capacity is more than 1,200,000 t. Besides supplying the domestic market, high export rates to the USA and Japan are achieved. The subsidiaries of SeAH Steel include: ▬ Busan Pipe America Inc. (USA) ▬ State Pipe & Supply Corp. (USA) ▬ Vinapipe Corp. (Vietnam) ▬ Saigon Steel Pipe Corp. (Vietnam) ▬ SeAH Japan Co., Ltd. (Japan) The history of the company is as follows: 1960 Establishment of the company as “Busan Steel Industry” in Gammandong, Busan City. 1979 to 1982 – Acquisition of several specialist companies for the pro- duction of steel pipes. 1996 The company’s name was changed into “SeAH Steel Corporation”. 2005 Completion of the new cold rolling mill complex in Gunsan. As part of the new cold rolling mill in Gunsan, the agreement with SMS Demag for the supply of a hot- dip galvanizing line was signed on November 28, 2003.
  • 54. With a market share of 660,000 t, SeAH Steel covers 22 % of the demand for steel pipes in the South Korean market and is South Korea’s biggest enterprise in this product sector. With 350,000 t of cold rolled steel, gal- vanized and pre-coated strip, SeAH holds just a small market share among the big players and has to compete with producers which, owing to the size of their companies, are able to produce high-grade products at favorable cost. The new galvanizing line has been de- signed for the production of hot-dip gal- vanized steel strip of the steel grades CQ, DQ, DDQ and FH (full hard). These products are used for white goods, in the electrical and building as well as the construction industries. Designed for an annual capacity of 300,000 t, the line galvanizes strip 0.23 to 1.8 mm thick and 600 to 1,300 mm wide. In the coating section, the strip runs at speeds of up to 200 m/min, while the entry and exit sections attain speeds of maximum 280 m/min. The line configuration is following the demand for hot-dip galvanized strip of highest surface quality. Pre-cleaning takes place in the entry section and full cleaning right upstream of the furnace. To facilitate installation, the vertical strip loopers feature a new modular design. They are completely balanced and equipped with a redundant drive system with amply dimensioned ropes to ensure reliable operation and a long service life. The radiant-tube-heated Drever furnace with a capacity of 73 t/h and the highly precise Duma air-knife system complete the process section. Downstream of the four-high skin-pass mill and the tension leveler unit, a ver- tical coater takes care of passivating the strip. The new galvanizing line of SeAH Steel was built by a consortium comprising SMS Demag AG, Germany, Drever International S.A., Belgium, and Duma GmbH, Germany. Picture 6 shows the steel structures of the two cleaning sections during erec- tion. Picture 7 on the left shows the area of the post-treatment section during instal- lation. The picture on the right reflects the line from the entry looper system, via the center cleaning section up to the vertical furnace. Erection started in November 2004 and was completed in June 2005. In total, more than 4,000 t of machines and steel structures were installed. As early as 21 months after contract signing, the first galvanized coil was produced.
  • 55. Thanks to the excellent performance of all suppliers under the leadership of SMS Demag and the superb coopera- tion between the consortium and SeAH Steel, the first saleable strip was pro- duced four weeks before the scheduled contractual date. Picture 8 shows the festive celebration of production start, which is a very im- portant ceremony in the Korean self understanding and culture. As a result of this early and successful hot commissioning, the full production capacity was already achieved after 23 months and the Final Acceptance Certificate (FAC) was issued as soon as after 21 months. Picture 9 on the top shows the vertical post-treatment section in operation with roll coater, drying oven and air coolers. The right bottom picture reflects the op- eration of the line in the area between the pre-cleaning section and the vertical furnace. The picture provides a clear view of the entry-end vertical looper ar- ranged between the two cleaning sec- tions. The picture on the left is a top view of the Duma air-knife system. The remarkably steep run-up curve of the line is documented by the following production evaluations covering the ini- tial months after line startup. ▬ Run rate ▬ Production volume ▬ Yield ▬ Run-up curve ▬ Coating tolerances or accuracy Already in the first month, the line at- tained a relatively high availability of 74.5 %, and from the end of the third month on, the values stabilized around the target of 98 %. Picture 12 reflects the volumes pro- duced for direct sales and for processing in the own color-coating section. It is obvious also in this case that the line achieved its planned production after a short time. Picture 13 represents the ratio between input material and finished products. A high value means, for example, low scrap losses. As early as in the second month, the target value of 98 % was ex- ceeded. Values of over 100 % may re- sult owing to a weight increase due to coating.
  • 56. The run-up curve is the best way to de- scribe the performance of the line as a combination of availability and yield. Just one month after commissioning, the value stabilized around the target of 96 %, and after eight months ideal val- ues of nearly 100 % were achieved. The coating accuracy is one of the most important factors for the product quality and, when zinc prices are high, decisive- ly impacts the operating costs. Thanks to the Duma air-knife system, coating uniformity is more than satis- factory. Currently, each 1 % in closer coating tolerances reduces operating costs by up to EUR 1 million per year.
  • 57. 1SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Contents General overview Market development Layout Erection phase First coil Operation Results and experiences ▬ General overview ▬ Market developments ▬ Layout/Technical data ▬ Erection phase ▬ First coil ▬ Operation ▬ Results and experiences 2SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Company profile SeAH Steel Corporation is specialized in the production of ▬ steel pipes, ▬ stainless steel pipes for plumbing and structures, ▬ galvanized steel and pre-coated metal Annual production capacity: 1,200,000 t of steel products Export of products to the USA and Japan Subsidiaries: ▬ Busan Pipe America Inc. (USA) ▬ State Pipe & Supply Corp. (USA) ▬ Vinapipe Corp. (Vietnam) ▬ Saigon Steel Pipe Corp. (Vietnam) ▬ SeAH Japan Co., Ltd. (Japan) General overview Market development Layout Erection phase First coil Operation Results and experiences
  • 58. 3SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Company history 1960 Establishment of the company as “Busan Steel Industry in Gammandong, Busan City 1979 - 82 Several acquisitions of specialized companies 1996 Change of company name into SeAH Steel Corp 2005 Completion of new CRM in Gunsan area 28.11.2003 Purchase agreement with SMS Demag for the new CGL General overview Market development Layout Erection phase First coil Operation Results and experiences 4SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Market shares 52.71,591Others 1003,019Total Husteel SeAH Steel Hysco 16.4495 21.9660 9.0273 Portion in % Market share 7.8932Union Steel 10.61,258Others 10011,910Total Dongbu Steel Posco Hysco 12.11,437 54.16446 15.41,837 Portion in % Market share General overview Market development Layout Erection phase First coil Operation Results and experiences Market share Cold rolled steel (in '000 t) Hysco Posco Dongbu Steel Union Steel Others Market share steel pipe (in '000 t) Hysco Seah Steel Husteel Others
  • 59. 5SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Technical Data: Products: GI / CQ, DQ, DDQ, FH (full hard) Application: White goods + construction Production capacity: 300,000 t/year Strip thickness: 0.23 to 1.6 mm Strip width: 600 to 1,300 mm Line speed: 200 m min (process section) General overview Market development Layout Erection phase Operation Results and Experiences Continuous galvanizing line – SeAH Steel, Korea 6SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Erection phase All main equipment by SMS group General overview Market development Layout Erection phase First coil Operation Results and experiences Continuous galvanizing line was built by a consortium between ▬ SMS Demag AG, Germany ▬ Drever International S. A., Belgium ▬ Duma GmbH Germany for air knife system
  • 60. 7SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Erection phase General overview Market development Layout Erection phase First coil Operation Results and experiences ▬ 21 months from purchase agreement to first coil ▬ erection period November 2004 until June 2005 ▬ total weight: 4,114 t 8SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel The first coil was produced in saleable quality four weeks before scheduled date General overview Market development Layout Erection phase First coil Operation Results and experiences
  • 61. 9SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Operation Cleaning section, entry looper and furnace Air knife Post treatment ▬ FAC after 21 months ▬ Full production after 23 months General overview Market development Layout Erection phase First coil Operation Results and experiences 10SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Results and experiences General overview Market development Layout Erection phase First coil Operation Results and experiences ▬ Run rate ▬ Production of main products ▬ Benefit (output/input) ▬ Startup curve ▬ Coating accuracy
  • 62. 11SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Run rate (prod. time/planned prod. time) 70 75 80 85 90 95 100 Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar. 06 Apr 06 May 06 Month Rate(%) Run rate target 98 % First month 273hrs 437.7hrs 306.7hrs 405hrs 576.9hrs 491.4hrs 602.6hrs 600.4hrs 588.6hrs hrs: Production hours Results and experiences General overview Market development Layout Erection phase First coil Operation Results and experiences 12SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Production - 5.000 10.000 15.000 20.000 25.000 Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar 06 Apr 06 May 06 Month tons/month GI FOR SALE MATERIAL FOR CCL TOTAL Results and experiences General overview Market development Layout Erection phase First coil Operation Results and experiences
  • 63. 13SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Benefit (output/input) 70 80 90 100 110 Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar 06 Apr 06 May 06 Month Rate(%) Benefit target 98% First month Results and experiences General overview Market development Layout Erection phase First coil Operation Results and experiences 14SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel Startup curve 0 10 20 30 40 50 60 70 80 90 100 Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar 06 Apr 06 May 06 Month Rate(%) Target startup curve 96 % First month Results and experiences General overview Market development Layout Erection phase First coil Operation Results and experiences
  • 64. 15SMS metallurgy Conference 2007 The new galvanizing line for SeAH Steel SeAH is very satisfied with the achieved coating tolerances of the Duma air knife. Due to increased zinc costs each 1 % improvement of tolerances reduces our operation costs by approx. 1 million EUR per year. Coating tolerances General overview Market development Layout Erection phase First coil Operation Results and experiences
  • 65. Economical solutions for high-quality processing lines Dipl.-Ing. Stefan Melster General Manager Technical Sales Strip Processing Lines Division Dr. Hans-Georg Hartung Executive Vice President Strip Processing Lines Division SMS Demag AG Hilden, Germany
  • 66.
  • 67. Economical solutions for high-quality processing lines Stefan Melster, Dr. Hans-Georg Hartung While in the past many investment deci- sions were clearly made on the grounds of technical preferences, the majority of decisions nowadays is based on eco- nomic considerations or facts. The refer- ence figure today is the total cost, fig- ure 1. Costs such as the percentage of depreciation, overheads and the prices of raw materials cannot be influenced by plant builders. Investment cost or, in other words, the price of the line is a matter of technical requirements and so- lutions or, respectively, a matter of nego- tiation and by far not the most important factor. In the long run, it is the cost for maintenance, yield loss, staff and con- sumables that makes the difference be- tween standard lines and economically and profitably operating processing lines. For about ten years, our development of new equipment and the optimization of existing components have been follow- ing just one guideline – to improve the customer benefit and profit. This can on the one hand be achieved by technical improvements which have an economic impact, but also by cost-cutting with a subsequent price reduction which is based on a different design, but does not affect equipment performance. SMS Demag today offers the full range of high-quality strip processing lines with obviously significant economic advan- tages, figure 2, as demonstrated by the large number of recent references. Be- sides 13 continuous pickling lines and coupled pickling lines/tandem cold mills, six color coating lines, twelve continuous annealing lines and 14 galvanizing lines, SMS Demag has during the last six years received orders for more than 70 further strip processing lines. Among these are high-tech lines like silicon strip processing lines, processing lines for aluminum strip or acid regeneration plants. Figure 3 is a summary of our latest ma- jor worldwide references. Our guideline for achieving best total cost of ownership can be best explained by two recent ex- amples: the pickling line of the new coupled pickling line/tandem cold mill of Baosteel’s cold rolling mill No. 5 and the continuous galvanizing line No. 3 of US Steel Kosice in Slovakia. Figure 4 is a sectional view of Bao- steel’s new PLTCM, designed for an an- nual production capacity of 1.74 million t of steel, mostly high-quality grades for
  • 68. the automotive industry. To explain the cost-saving potential of our technologies, three examples are provided of which more details will be shown: ▬ the turbulence pickling technology ▬ the horizontal loop accumulator ▬ the ASC side trimming shear Since the early 50s, SMS Demag has in- fluenced the design of all types of high- performance pickling lines all over the world. Meanwhile all components for pickling lines including mechanical and chemical equipment, even acid regener- ation plants and laser welding machines, can be supplied from one single source. This is a benefit to our customers as it involves a consistent process technology and minimizes potential interface prob- lems. The turbulence pickling method, fig- ure 5, developed by SMS Demag, is not only the most effective, but also the most economical pickling technology in terms of operating cost. The design of SMS Demag’s turbulence pickling line is characterized by shallow and horizontal pickling channels, the patented immer- sion covers and acid injection by spray headers on the entry and exit sides of each pickling tank. The straight, horizon- tal channel which is integrated into the main pickling tank, allows operation of the line at high strip tension for improved strip guiding. Its small height of about 150 mm not only ensures a high acid flow velocity and hence large turbu- lences, but also a much faster adjust- ment of the acid temperature, due to less acid circulation volumes. This improves process flexibility. The immersion cover seals off the pickling channel towards the top and thus prevents any free acid surface and acid evaporation in the pick- ling tank, which leads to significant ener- gy and operating cost savings. By injec- ting the acid at high pressure from the entry and exit sides into the pickling channel and onto the strip, the turbulent acid flow and the acid exchange on the strip surface are increased through the high input of kinetic spraying energy. During the pickling process the entire pickling channel is filled with acid, whereas the entry- and exit-side acid in- jection serves for hydrodynamic sealing of the pickling channel, figure 6. This ensures wetting of the full strip surface even at high strip speeds, as well as an improved acid separation between the pickling tanks. The high intensity of the turbulence pickling line allows a very compact design of this process section. Steam and power consumption as well as acid losses are significantly lower than in conventional pickling systems, due to the immersion covers. A much faster heat transfer from acid to strip and more intensive acid exchange at the strip surface can be achieved through the high kinetic spraying energy. This leads to a better acid utilization and an accel- erated pickling process. Due to the good controllability of the process, no pickling inhibitors are necessary. The rinse sec- tion has a second spray rinse circuit in order to avoid staining during line stops.
  • 69. Therefore, no rinsing inhibitors are needed here either. For a pickling line with a production capacity of about 1.8 million t/year, annual savings may total 600,000 EUR just because of the above-mentioned features. The turbulence pickling process can be further optimized through the application of SMS Demag’s process model, fig- ure 7, which sets all essential pickling parameters to the relevant strip quality automatically and ten to 20 coils in ad- vance. The main objective is to prevent underpickling or overpickling and to set the lowest possible acid temperature. The lowest possible bath temperature means minimum energy and acid con- sumption, but also an increased lifetime of all equipment exposed to acid. A 5 °C drop in the bath temperature may result in a 50 % longer lifetime of plastic pipes. Part of this process model is the simula- tion of the pickling process for incoming coils. Based on all major pickling and strip parameters, the pickling result can be controlled by the correct setting of the acid pressure in consideration of the strip speed and the required bath tem- perature. The model controls the transi- tion from one strip to the next, so that the pickling process is adapted to the next strip without any visible change in the pickling results. In addition to the above- mentioned cost savings, the application of the SMS Demag process model may result in further savings of up to 300,000 EUR per year due to reduced power and fluids consumption. SMS Demag’s horizontal looper system, figure 8, is characterized by two main features: the retained looper car and the Maltese-cross looper gate design. The retained looper car means that the looper car is pulled on each side by ropes, whereas other systems use a rope for pulling on one side and the strip only for pulling on the other side. The ad- vantages of our system are lower ten- sion fluctuations and a more stable looper car operation. Constant strip ten- sion and thus untroubled operation of the coupled tandem mill is not the only bene- fit of the closed loop system. For mainte- nance purposes the looper car can be moved without strip in the line. Due to the Maltese-cross looper gate system, the looper gate arms can be opened and closed smoothly by the looper car without any shock even at high looper car speeds. The special me- chanism leads to a soft acceleration and deceleration of the looper arm without inertia-caused overloading of the me- chanical parts. Frequent consequential damage can thus be avoided. Each da- maged gate costs a total of approx. 90,000 EUR. These expenses for spares, maintenance work, production loss and fixed costs can be saved.
  • 70. The combined ASC side trimmer and chopper unit is one of the most impres- sive cost savers in our lines, figure 9. On each side of the line two trimming shears with associated scrap choppers are mounted on a turntable platform in a 180-degree arrangement. This arrange- ment allows the safe maintenance of the standby trimmer/scrap chopper unit also during production, with the other unit in operation. All settings of the knife gap and knife overlap are performed automatically by eccentrics. In comparison, linear shifting devices with bushes tend to wear and are always a matter of maintenance. In contrast, ec- centrics are backlash- and almost main- tenance-free. Due to the automatic knife- gap and knife-overlap setting, an ex- tended lifetime of the blades and im- proved cutting qualities can be achieved. The knife blades are face-ground and mounted against mechanical stops, therefore no calibration is required after a blade change. The side-trimmings chute between the trimmer and chopper is undivided with- out any gaps. Gaps in the side-trimmings chute are usually the cause of scrap cobbles and each cobble can take approximately one to two hours to be removed. During a width change, the complete side trimmer and chopper unit will be re- adjusted within seconds without produc- ing any extra scrap. Our design avoids the above-mentioned typical operational problems, i. e. unscheduled downtimes for troubleshooting like scrap jam remov- al. Even in the unlikely case of trouble or in case of normal maintenance, the whole system together with its problem is simply turned out of the line and re- placed by fully operative equipment with- in 60 seconds. The problem can then be fixed in the safe 180-degree position while the line is running. With one trouble per week, this ASC side trimming system can save up to 1 million EUR per year in high-performance pickling lines. The combined ASC side trimmer unit is not only used in our pickling line, but al- so in most of our other strip processing lines. Another good example for economical processing-line solutions is the new gal- vanizing line No. 3 of US Steel Kosice, figure 10. This is a typical line for the production of exposed automotive mate- rial with GI and GA coatings. Highly so- phisticated structural steel grades are al- so part of the product mix.
  • 71. The total-cost-of-ownership guideline is explained by the following examples: ▬ Coil transport system ▬ Cleaning section ▬ Air knife ▬ Post-treatment/coating section Our coil cars, figure 11, are of extremely compact and flat design and do not need any deep, expensive and eventually also dangerous foundation pits. Still they are as sturdy as necessary for metallurgical works. As opposed to other scissors- type coil cars, the cylinder force acts in the load direction and not in transverse direction. The scissors just have a guid- ing function, but do not transmit any load. Besides safety and maintenance aspects, the cost reduction for the foun- dations of three coil cars is about 70,000 EUR. Our strip cleaning sections, figure 12, are characterized by three main fea- tures. First, sealed modules with lower required fume exhaust volumes at the connection points of the modules reduce energy losses significantly. Second, the changing of rolls is fairly easy and can be done during operation with no addi- tional downtimes or maintenance work required. Finally, special tongue-shaped spray nozzles guarantee a clog-free op- eration. No clogging means no surface stripes, no subsequent downgrading and no prematurely damaged brush rolls. Based on European cost basis, up to 600,000 EUR can be saved per year. SMS Demag can provide two prime- quality air knife systems: Fontaine and Duma, figure 13. Both air-knife systems are technically excellent. Both can be equipped with width-adjustment actua- tors without any negative influence on the surface quality produced. Depending on the product mix, such a blow-off width adjustment can save up to 30 % of com- pressed air or, respectively, nitrogen. In the production of automotive strip such nitrogen savings can add up to 1 million EUR a year in case the nitrogen has to be purchased. The high precision of our air knife systems results in closer coating tolerances than in other systems. A mere 1 % more precise coating can save zinc worth up to 1 million EUR per year in a typical hot-dip galvanizing line producing approx. 400,000 t/year and approx. 190 million m² strip surface. In modern lines that conform to the latest health and safety standards, the heart of the post-treatment section is the roll coater, figure 14. Using two separate circuits, our coaters can be used for chromating as well as anti-fingerprint coating. Due to the use of coated pans and the automated cleaning and rinsing system, a change in coating agent is not very time-consuming. Alternatively, a two-coater or shuttle coater system can be provided. The rolls can be changed without any major maintenance effort. But the most impressive property is no doubt the outstanding accuracy of the coating. With this system, a coating ac- curacy of plus/minus a quarter of a mi- cron can be achieved. In comparison
  • 72. with other coating systems with ac- curacies of plus/minus 1 micron, this means, in addition to other benefits, sav- ings of up to 500,000 EUR per year for the post-treatment system of hot-dip gal- vanizing lines. In color-coating lines, three times this amount can easily be saved due to the particularly high cost of chemicals and paints. All the above-mentioned examples are the result of a continuous improvement process, figure 15. All developments must follow the total-cost-of-ownership guideline. This means that improve- ments must pay off to our customers in terms of reduced operating cost, less energy consumption, less maintenance, less downgrading, higher yield or a mar- ketable better product quality. All these economical solutions for high-quality pro- cessing lines are incorporated in our lat- est reference list and have been suc- cessfully commissioned. As a conse- quence, a steep ramp-up curve is part of our customer benefit.
  • 73. 1SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines Introduction Introduction Strip processing lines Pickling line technology Summary No cost influence by SMS Demag Cost influence by SMS Demag Investment cost Overheads Depreciations Total cost of ownership Staff costYield loss Consumables & media Maintenance Raw material Hot-dip galvanizing line technology 2SMS metallurgy Conference 2007 Strip processing lines – Major references since 2000 Economical solutions for high-quality processing lines Carbon steel … in total more than 50 new processing lines since 2000 … incl. seven lines for silicon strip … incl. seven lines for aluminum strip … … plus approx. 60 service lines … … plus 13 new ARPs 13 CPL/PLTCMs 14 CGLs 12 CALs 6 CCLs 1 ETL Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology
  • 74. 3SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines Strip processing lines – Major references since 2003 Customers and type of lines Introduction Strip processing lines Pickling line technology Summary Tokyo Steel CPL + ARP Shougang Jing-Tang CAL Nucor CGL ILVA Taranto and Cornigliano 2 CGLs Baosteel 4 Si-lines Tiantie PLTCM Salzgitter CPL SeverCorr CGL + PLTCM Baosteel CAL + PLTCM Shougang CAL + PLTCM US Steel Kosice CGL Jinan CPL WISCO 3 CGLs + CAL + PLTCM Anshan CAL Seah CGL Rasselstein ETL Baosteel CAL + PLTCM US Steel Kosice CGL Hot-dip galvanizing line technology 4SMS metallurgy Conference 2007 Introduction Pickling line technology Summary Products: Strip thickness Strip width: Pickling speed: Production capacity: CQ, DQ, DDQ, EDDQ, SEDDQ, DP, Trip 1.8 to 6.0 mm 700 to 1,650 mm 270 m/min 1,740,000 t/year Technical data Economical solutions for high-quality processing lines Pickling line/tandem cold mill Baosteel, Baoshan/China Hot-dip galvanizing line technology
  • 75. 5SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines Turbulence pickling technology Turbulence pickling channel Immersion cover Outer cover Pickling tank ▬ Flat and horizontal pickling channel ▬ Immersion covers – less acid evaporation ▬ Hydrodynamic sealing Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology 6SMS metallurgy Conference 2007 ▬ Better controllability due to less acid volumes in circulation ▬ Less steam, acid and energy consumption due to immersion covers ▬ No pickling and rinsing inhibitors ▬ Lower possible acid temperature – less energy, longer lifetime Economical solutions for high-quality processing lines Turbulence pickling technology Turbulence pickling tank with circulation system Total potential on cost savings: up to 600,000 EUR/year Draining chamber with spray bars and squeegee roll unit (hydrodynamic sealing) Acid supply piping Cascade piping Pump Heat exchanger Steam Condensate Waste acid Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology
  • 76. 7SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines Turbulence pickling technology ▬ Minimized overpickling: less material loss less energy higher yield ▬ Automatic setting and control of process actuators ▬ Minimized bath temperature less energy longer lifetime less maintenance Total potential on cost savings: up to 300,000 EUR/year SMS Demag process model for turbulence pickling Turbulence Temperature Desired bath temp.Strip speed Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology 8SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines High-speed looper concept – Technical advantages Steering Curve Tension Rope Retaining Rope Each damaged gate costs EUR 90,000 Introduction Strip processing lines Pickling line technology Summary Maltese-cross looper gates ▬ impact-free opening and closing ▬ less damages ▬ longer lifetime ▬ less maintenance Hot-dip galvanizing line technology Closed loop system (two-side rope pulling) ▬ less tension fluctuation ▬ better maintainability
  • 77. 9SMS metallurgy Conference 2007 Economical solutions for high-quality processing lines ASC trimming shear Features: ▬ No line stop during knife change ▬ Easy and safe maintenance access ▬ No extra scrap during width change ▬ No calibration of knives after change Potential cost savings up to 1 million EUR/year due to less downtime Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology 10SMS metallurgy Conference 2007 Products: Strip thickness Strip width: Process speed: Production capacity: CQ, DQ, DDQ, EDDQ, SEDDQ, HSS-CQ, HSS-DQ, HSS-DDQ, BH, DP 0.3 – 2.0 mm 800 – 1,850 mm 180 m/min 410,000 t/a Technical data: Economical solutions for high-quality processing lines Continuous galvanizing line US Steel Kosice, Slovak Republic
  • 78. 11 Coil transport systems Economical solutions for high-quality processing lines SMS Demag technology ▬ Coil cars with extremely flat design and rigid design for metallurgical works ▬ Guiding scissors are load- free ▬ No expensive and dangerous foundation pits ▬ Good maintainability Reduction of foundation cost up to 70,000 EUR Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology 12SMS metallurgy Conference 2007 Potential cost savings: up to 600,000 EUR/year Economical solutions for high-quality processing lines SMS Demag technology ▬ Sealed modules – less energy ▬ Easy roll changes – less maintenance ▬ No clogging – no brush roll damages, no stripes, no downgrading Strip cleaning section Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology
  • 79. 13SMS metallurgy Conference 2007 SMS Demag technology ▬ Width adjustable ▬ Outstanding coating accuracy ▬ Minimized over-coating Possible reduction of production costs per year: up to EUR 1,000,000 nitrogen savings for customers without oxygen plants 1 % better coating accuracy = approx. 1,000,000 EUR cost savings for zinc Air knife Economical solutions for high-quality processing lines Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology 14SMS metallurgy Conference 2007 SMS Demag technology ▬ Outstanding coating accuracy ▬ Simple roll change ▬ Automated cleaning of rolls, pans and media systems ▬ Minimized over-coatings due to higher coating accuracy Post-treatment Economical solutions for high-quality processing lines A coater accuracy of ± 0.25 μm instead of ± 1.0 μm can save up to 500,000 EUR/year for post-treatment Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology
  • 80. 15SMS metallurgy Conference 2007 Summary ▬ Cost savings resulting from … • less operating materials and energy consumption • less maintenance and longer service life • less downgrading of product quality • less downtimes and higher yield ▬ Better product quality ▬ Higher flexibility and faster start-up curves The essentials of economical solutions are … Economical solutions for high-quality processing lines Introduction Strip processing lines Pickling line technology Summary Hot-dip galvanizing line technology
  • 81. The SMS Demag laser welding machine Dipl.-Ing. Lutz Kümmel Senior Project Manager Strip Processing Lines Division Dr. Hans-Georg Hartung Executive Vice President Strip Processing Lines Division Dipl.-Ing. M.B.M. Markus Jaenecke Senior Project Manager Project Planning Strip Processing Lines Division SMS Demag AG Hilden, Germany
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  • 83. The SMS Demag laser welding machine Dr. Hans-Georg Hartung, Markus Jaenecke, Lutz Kümmel Some three years ago, SMS Demag and Oxytechnik, a German welder manufac- turer, agreed to jointly develop a laser welder for strip processing lines. Tech- nology and design are the results of many years of experience in designing high-performance strip processing lines and equipment as well as welding ma- chines including laser welders for special applications. Nowadays, laser welding machines are the first choice for continuous pickling lines. These welders are meanwhile cheaper than flash butt welders and easier to commission, especially if new materials or material combinations are to be welded. In addition, these welding machines are able to weld thinner strip and strip with higher amounts of alloying elements. Based on the experiences gained from many projects, we devel- oped a new laser welder design. Thanks to the closed-frame concept, the ma- chine is more compact than C-frame- type machines and can usually be trans- ported on trucks. The laser resonator is fixed on a sepa- rate foundation. No resonator vibrations will influence the welding accuracy. For maintenance purposes, access to the machine as well as to the resonator is excellent. Another remarkable feature is the posi- tioning system that aligns the head end of the new strip with the tail end of the previous strip. That means that it is the center line of the leaving strip that de- fines the correct alignment, and not the center line of the machine. After joining, the two strips will have one common center line and definitely no so-called dog-leg shape. One of the biggest ad- vantages is that the strip edges will not be damaged. The clamping of the strip will not be interrupted until welding is finished. The integrated shear is not a notcher- type shear with more or less no gap be- tween top and bottom knives. Such a de- sign leads to huge perpendicular forces acting on the knives and subsequently to high wear and less accuracy. The laser welder consists of a robust, mill-type-de- sign dividing shear with automatically ad- justable knife gaps separately for the outgoing and ingoing strip ends. The knife crossbeam is supported at several positions across the width and doesn’t allow any relevant breathing. The blade lifetime is at least three times as long as for other laser welders and, due to the cassette design, the blades can be changed easily by an electro-hydraulical- ly changing device. The top knife can be used twice, the bottom knives four times before regrinding. The precise cut has
  • 84. the potential to allow using lasers with less power in the future because the de- focusing of the beam can be reduced. This leads to less laser power and con- sequently to a longer laser lifetime. For the same reason we expect that more and more Neodymium-YAG lasers will be used in the near future instead of high-power CO2 laser sources. One ma- jor advantage is the possibility to feed the beam via fiber-optic cable to the weld spot – subsequently no mirrors can be contaminated. The shear remains in the machine during welding. Therefore, we could avoid the either heavy or flimsy C-frame design. Scrap can be discharged directly into a pit or be removed by a conveyor belt. In case of different strip thicknesses, the joint can be made centrically, top side or bottom side orientated. Real zero-gap welding is possible due to the shifting function of the strip clamping device. As an option for special applications a wire feeder can be provided. Mixed gas or helium is used as inert gas. Along with the design work plenty of laboratory tests were conducted. The test results were very promising, even for hard-to-weld steel grades like C60 with a carbon content of 0.67 %. The cross-sections of the welds were excel- lent and so were the microstructures of the heat influence zone and of the weld itself. The main components of the mi- crostructure of this high-carbon steel are ferrite and perlite. Post-annealing and particularly preheating and post-anneal- ing led to a highly uniform hardness dis- tribution in the vicinity of the weld as compared to the results without anneal- ing. In order to ensure the best possible heat treatment of the weld, new inductive pre- and post-heaters were developed together with our sister company SMS Elotherm. The main features are fast heating during preheating and post- annealing with retarded cooling. Early in 2006, we received an order from Salzgitter Flachstahl GmbH, Germany, for a heavy-duty laser welding machine. This laser welder for 800 up to 1,900- mm-wide strip will be installed in a 2.5- million-t/year continuous pickling line that will also be supplied by SMS Demag. The strip thickness ranges between 1.5 and 6 mm and the yield stress may ex- ceed 1,100 N/mm². Some of the steel grades are extremely difficult to weld such as C60. The laser welder for Salz- gitter is currently being tested in our workshop. In April 2007 Tokyo Steel, Japan, placed a further order for a laser welder with us.
  • 85. 1SMS metallurgy Conference 2007 The SMS Demag laser welding machine Development of SMS Demag laser welding machine ▬ In 2004, a cooperation between SMS Demag and was established in order to develop a laser welding machine for strip processing lines Introduction Main features Laboratory test Laser welding machine for Salzgitter 2SMS metallurgy Conference 2007 The SMS Demag laser welding machine Laser beam source CO2 laser resonator Introduction Main features ▬ The laser resonator is fixed beside the machine on a separate foundation ▬ No vibrations, no influence on the welding accuracy ▬ Easy access for maintenance Laboratory test Laser welding machine for Salzgitter
  • 86. 3SMS metallurgy Conference 2007 The SMS Demag laser welding machine Strip alignment Introduction ▬ Incoming strip head is aligned with the tail end of the previous strip ▬ Center line of the leaving strip defines the right alignment ▬ No pushers – no strip edge can be damaged Laboratory test Laser welding machine for Salzgitter Main features 4SMS metallurgy Conference 2007 The SMS Demag laser welding machine Shear design ▬ Robust, mill-type design dividing shear with automatically adjustable knife gaps separately for outgoing and ingoing strip Introduction Laboratory test Laser welding machine for Salzgitter Main features
  • 87. 5SMS metallurgy Conference 2007 The SMS Demag laser welding machine Shear design details Introduction ▬ Knife lifetime triples ▬ Quick knife changes ▬ Precise cuts = precise weld Multiple support of knife crossbeam Knife changing device Laboratory test Laser welding machine for Salzgitter Main features 6SMS metallurgy Conference 2007 The SMS Demag laser welding machine Welding process Introduction ▬ The joint can be made centrically, top side or bottom side oriented ▬ For special steel grades a wire feeder can be installed ▬ For shielding, mixed gas or helium is used Laboratory test Laser welding machine for Salzgitter Main features
  • 88. 7SMS metallurgy Conference 2007 The SMS Demag laser welding machine Results of laboratory test Introduction Main features ▬ Cross-sections of the welds as well as the microstructure of the heat influence zone and of the weld itself were excellent. ▬ Hard-to-weld steel grades like C60 with a carbon content of 0.67 % were welded successfully Laboratory test Laser welding machine for Salzgitter 8SMS metallurgy Conference 2007 The SMS Demag laser welding machine Influence on weld seam hardness by heat treatment Preheating and post- annealing of coils Introduction Main features ▬ Fast preheating and soft post- annealing with retarded cooling 200 300 400 500 600 700 800 900 1000 -5,0 -4,0 -3,0 -2,0 -1,0 0,0 1,0 2,0 Position [mm] HV1 Probe 10.2 Probe 8.2 Probe 5.1 Pr. 5.1, Grundwerkstoff C60, Anlieferung Laboratory test Laser welding machine for Salzgitter
  • 89. 9SMS metallurgy Conference 2007 The SMS Demag laser welding machine The new laser welding machine will be installed in the new 2.5-million-t/year continuous pickling line of Salzgitter Flachstahl GmbH Introduction Main features ▬ The order was placed in March 2006 ▬ Carbon content up to 0.67 % ▬ Strip width between 800 and 1,900 mm ▬ Strip thickness between 1.5 and 6 mm ▬ Yield stress up to 1,100 N/mm² ▬ Pre-commissioning underway in our Hilchenbach workshop Laboratory test Laser welding machine for Salzgitter
  • 90.
  • 91. Innovative and flexible: the Automatic Coil Transporter (A.C.T.®) developed by SIEMAG Dipl.-Ing. Bernd Klein CEO Dipl.-Ing. Volker Schneider Project Manager Sales Dr. rer. nat. Horst Thorn Head of Sales Department SIEMAG GmbH Netphen, Germany