HOLZ RUEDIGER EXECUTIVE VICE PRESIDENT DANIELI WEAN UNITED COLD PRODUCTS 2° ROLLING & PROCESSING TECHNOLOGY DAY CHITTAGONG, BANGLADESH 22 NOVEMBER 2016
DANIELI COLD ROLLING MILL TECHNOLOGY LATEST REFERENCES AND INNOVATIVE SOLUTIONS
PRODUCT LINES AND RECENT REFERENCES
PRODUCT LINES
Cold Rolling Mills
> Tandem mills (3-, 4-, 5-, 6-stand, 4- high, 6high) semi continuous, fully continuous, coupled with pickling line. > Cold reversing mills (1-, 2-stand, 4-high, 6-high). > Combination cold reversing and temper mills. > Double cold reduction mills for tinplate. > Hot skin-pass mills. > Temper / Skin-pass mills.
Strip Processing Lines
> > > > > > > > > >
Pickling lines, continuous and push-pull. Annealing for tinplate, carbon and stainless. Electrolytic degreasing, in-line and stand-alone. Hot-dip metal coating lines. Electrolytic tinning/TFS lines. Color coating, in-line and stand-alone. Air knives and coating equipment. Recoiling and inspection lines. Surface finishing with shape and roughness. Precision roller leveling and cutting-to-length for special steel.
Solutions for Stainless Steel
> DaInox process. > Hot and cold annealing and pickling lines, combined lines. > Integrated rolling, annealing, and pickling lines. > Cold reversing mills and tandem mills (20-high and 6-high with SSR) > Coil preparation lines. > Skin-pass mills, in-line and stand-alone. > Coil grinding and polishing lines. > Slitting and cut-to-length lines.
PRODUCT LINES AND RECENT REFERENCES
18
COLD MILL COMPLEXES SCORECARD
COLD MILL COMPLEXES
JSW TARAPUR (INDIA)
TIN COMPLEX / MAIN PROCESS EQUIPMENT
RCL ETL CTL
DCR
Double cold rolling mill
250,000 tpy
Recoiling line
200,000 tpy
Electrolitic tinning line
200,000 tpy
Cut to length lines
2x 80,000 tpy
JSW TARAPUR (INDIA)
MAIN PLANT DATA / DOUBLE COLD ROLLING MILL
PRODUCTION OUTPUT
210,000 TPY
Incoming material
Annealed Coils
Strip width
650 - 1,250 mm
Entry Strip thick. SR
0.14 - 0.77 mm
Entry Strip thick. DR
0.14 - 0.30 mm
Exit Strip thick. SR
0.14 - 0.77 mm
Exit Strip thick. DR
0.14 - 0.30 mm
Max coil weight
25 tons entry/exit
Mill Type
4-Hi
JSW TARAPUR (INDIA)
MAIN PLANT DATA / ELECTROLYTIC TINNING LINE
PRODUCTION OUTPUT
200,000 TPY
Steel grades
SR: T1 - T5 DR: DR480, DR8, DR9,DR10
Strip width
650 - 1,250 mm
Strip thickness
0,14 - 0.6 mm
Line speeds
400 mpm process
Max coil weight
5 - 25 t exit
Chemical treatment
Sodium dichromate
311 type 5-12 mg/m²
Cr each side
300 type 5-12 mg/m²
Cr each side
HOA PHAT (VIETNAM)
COLD COMPLEX / MAIN PROCESS EQUIPMENT
Push Pull Pickling line
600,000 tpy
Cold Rolling mill No. 1
200,000 tpy
Cold Rolling mill No. 2
200,000 tpy
Hot Dip Galvanizing Line No.1
150,000 tpy
Hot Dip Galvanizing Line No.2
300,000 tpy
HOA PHAT (VIETNAM)
MAIN PLANT DATA / PUSH PULL PICKLING LINE
PRODUCTION OUTPUT
600,000 tpy
Steel grades
HR, LC, ASTM SAE
1006/1008/1010/JIS G 3131 Strip width
650 - 1,250 mm
Strip thickness
1.2 - 4.0 mm
Yield Strength
230 – 400N/mm²
Tensile Strength
550 N/mm²
Line speeds
170 mpm
Max coil weight
25 tons entry/exit
Pickle tanks
Four (4)
Surface Treatment
Oiled
HOA PHAT (VIETNAM)
MAIN PLANT DATA COLD REVERSING MILL N°1 / COLD REVERSIG MILL N°2
DATA PER EACH LINE: PRODUCTION OUTPUT
200,000 TPY
Incoming material
Pickled coils, low carbon Steel
Strip width
600 - 1,250 mm
Entry Strip thick.
1.6 - 4.0 mm
Exit Strip thick.
0.14 - 1.8 mm
Max coil weight
25 tons entry/exit
Rolling speed
1,400 mpm max
Mill Type
4-HI Single stand
HOA PHAT (VIETNAM)
MAIN PLANT DATA / HOT DIP GALVANIZING LINE N°1
PRODUCTION OUTPUT
105,000 tpy
Steel grades
Cold rolled, Low carbon Steel, JIS G33141-2009
Strip width
750 - 1,250 mm
Strip thickness
0.14 – 1.0 mm
Line speeds process
150 mpm
Line speeds Entry
180 mpm
Line speeds Exit
200 mpm
Max coil weight
5 - 25 tons entry/exit
Coating weight
40 -200 g/m2
Surface Treatment
500 tons force
HOA PHAT (VIETNAM)
MAIN PLANT DATA / HOT DIP GALVANIZING LINE N°2
PRODUCTION OUTPUT
300,000 tpy
Steel grades
Cold rolled, Low carbon Steel, JIS G33141-2009
Strip width
750 - 1,250 mm
Strip thickness
0.25 – 1.5 mm GI coating
Strip thickness
0.25 – 3.0 mm Al-Zn Coating
Line speed process
200 mpm
Line speeds Entry
270 mpm
Line speeds Entry
30 mpm
Max coil weight
5 - 25 tons exit
YILDIZLAR ENTEGRE (TURKEY)
TECHNOLOGICAL PLANTS / THE COLD COMPLEX
Supplied by Danieli > > > >
One (1) One (1) One (1) One (1)
Continuous Pickling Line combined with five stand 6Hi OSRT Tandem Mill up to 1,500,000 t/y Hot Dip Galvanizing up to 400,000 t/y Set of Bell Annealing Furnaces up to 250,000 t/y Temper Mill Single Stand up to 400,000 t/y
YILDIZ ENTEGRE
COLD MILL COMPLEX
Pickling Line coupled with Tandem Mill (PLTCM)
PRODUCTION OUTPUT
1,500,000 tpy
Steel grades
HR strip, CQ, DQ, IF, HSLA, DP600, DP1000
Strip width
700 - 1,600 mm entry 700 - 1,570 mm exit
Strip thickness
1.2 - 5 mm entry
0.20 – 2.0 mm exit Line speeds
220 mpm process 1400 mpm tandem
Max coil weight
30 tons entry/exit
YILDIZ ENTEGRE
COLD MILL COMPLEX
Hot Dip Galvanizing Line for structural high-strength steels PRODUCTION OUTPUT
400,000 tpy
Steel grades
CR, HR, Low Carbon Steel,
CQ, DQ, DDQ, EDDQ (with YS > 200 MPa), HSS Strip width
700 - 1,300 mm entry
Strip thickness
0.2 - 3 mm
Lines speeds
280 mpm entry/exit 200 mpm process
Max coil weight
30 tons entry/exit
Coating weight
60 - 600 g/m2 total
Products
GI
DWU COLD ROLLING AND PROCESSING
DANIELI PICKLING LINE
Danieli INNOVACTION: Danieli TurboFlo® Tank > > >
BENEFIT:
> Tank profile: flat (no catenary) > Strip support: Granite Sliding Blocks Turbolence type: high kinetic thanks to spray jets + cover design
10% decrease of steam consumption For heating of the acid (lower opex)
DWU COLD ROLLING AND PROCESSING
INNOVACTION 6HI COLD ROLLING MILL
Shifting
Top HAGC
Cylinders According to International standards
6-High Configuration
Bottom wedge plus stepper plates Hammer Head Cylinders
Cassette Design Blocks
Thickness Tolerance
Approx. 2%
Flatness Tolerance
20 I-Units
Present Market Requirements
Projected Market Requirements
1.0 %
< 0.8 %
8 I-Units
< 6 I-Units
> WR and IR bending (both positive and negative) > WR and IR shifting > IR shifting 250 mm with the DANIELI&C OSRT technology (Optimized Shaped Roll Technology) > High response HAGC system > Ultra low friction HAGC system > The new HAGC allow new control to eliminate not only BUR eccentricity disturbances but also the one produced by work rolls
DWU COLD ROLLING AND PROCESSING
Principle
THE DANIELI 6-HI OSRT MILL TECHNOLOGY
> OSRT - OPTIMIZED SHAPED ROLL TECHNOLOGY >
>
>
Control range for shifting position (mm)
>
Small work roll diameters are reducing roll kissing and thus reduce creating of wavy edges Effective work roll bending releases the strip edges und thus reduces strip edge drop High mill structural stiffness -> precondition for high performance thickness control at thin gauge OSRT crown provided by special contoured intermediate rolls
250
60 0 700
870 1250 Strip width (mm)
> DESIGNED FOR PRODUCING HIGHEST QUALITY ALSO IN THIN GAUGE RANGE
DWU COLD ROLLING AND PROCESSING
PRINCIPLE OF COLD ROLLING MILLS DANIELI INNOVACTION / CONFINED JET DRYER ®
>
Definite answer to “Solution Stain”
>
Contact-less solution to eliminate excess of rolling fluid that deposits after the last rolling stand creating localized patches of oxidation.
>
A wiping system removes the rolling solution from top and bottom strip surfaces simultaneously. Extremely high values of pressure and shear force of the fluid are applied on the strip
DWU COLD ROLLING AND PROCESSING
LATEST ORDERS / YILDIZLAR (TURKEY) / MAIN DATA
Mill stand
6-Hi OSRT technology
Strip width
700 - 1,600 mm exit
Production output
1,200,000 tpy
Strip thickness
1.2 – 5.0 mm entry,
Steel grades
CQ, DQ, DDQ, EDDQ, SEDDQ, DP
0.2 - 2.0 mm exit Line speeds (max)
1,400 mpm at TCM exit
DWU COLD ROLLING AND PROCESSING
LATEST ORDERS / YIEH PHUI (P.R. CHINA)
Mill stand
6-Hi OSRT technology
Strip width
800 - 1,650 mm exit
Production output
1,080,000 tpy
Strip thickness
1.8 – 6.0 mm entry,
Steel grades
CQ, DQ, DDQ, EDDQ, SEDDQ, DP
0.2 - 2.5 mm exit Line speeds (max)
1,250 mpm at TCM exit
DWU COLD ROLLING AND PROCESSING
LATEST ORDER /ATAKAS (TURKEY): REVERSING MILL WITH OSRT TECHNOLOGY
Highlights of the Plant PRODUCTION Capability
410,000 tpy
Rolling Speed Separating Force Material Quality
Max. 1,400 m/min 1,800 t Pickled Coils, Low Carbon Steel CQ Max. 280 N/mm2 1.5 - 5.0 mm 0.25 - 2.0 mm 600 - 1,550 mm Max. 35 t Average 22 t
Steel Grades Yield Strength Entry Strip Thickness Exit Strip Thickness Strip Width Coil Weight
6-high OSRT Technology
DWU COLD ROLLING AND PROCESSING
LATEST ORDER / LYSVA (RUSSIA)
CRM PLUS 2-STAND REVERSING MLL WITH ENTRY SIDE WELDER
Danieli patent applied
DWU COLD ROLLING AND PROCESSING
LATEST ORDER / LYSVA (RUSSIA)
CRM PLUS 2-STAND REVERSING MLL WITH ENTRY SIDE WELDER
HIGHLIGHTS OF THE PLANT PRODUCTION CAPACITY Rolling Speed Separating Force
820,000 tpy Max. 1,400 m/min 2,000 t
Material Quality
Pickled Coils, Low Carbon Steel
BENEFITS > > >
INCREASED PRODUCTION DUE TO SEMI-CONTINUOUS OPERATION REDUCTION OF YIELD LOSSES MORE CONSTANT PRODUCT QUALITY
Entry Strip Thickness
1.5 - 6.0 mm
Exit Strip Thickness
0.25 – 3.5 mm
Strip Width
800 - 1,600 mm
Coil Weight
Max. 30 t Average 15 t
DWU COLD ROLLING AND PROCESSING
DANIELI CRM PLUS COLD ROLLING MILL
COMPARISON OF 2-STAND MILL CONFIGURATIONS: CONVENTIONAL MILL VS. DANIELI CRM PLUS MILL EXAMPLE: CUSTOMER N.N. IN ASIA
MILL CONFIGURATION
ANUAL PRODUCTION (t)
PRODUCTION YIELD (%)
ADDITIONAL NET INCOME IN COMPARISION TO CONVENTIONAL MILL (USD)
CONVENTIONAL MILL
350.000
97.96
------
DANIELI CRM PLUS MILL
424.499
99.32
5.1 MIO
FAST RETURN OF INVESTMENT
DWU COLD ROLLING AND PROCESSING
DANIELI CRM PLUS COLD ROLLING MILL
DANIELI 1-STAND OSRT 4-HI REVERSING MILL CRM PLUS WITH LASER WELDER
Targets: • • • • • •
Reduce yield losses Increase production Reduce CAPEX Reduce OPEX Improve Edge Drop Thin gauge rolling
Danieli patent applied
DWU COLD ROLLING AND PROCESSING
LATEST ORDER: 2 CGL’S FROM VIETNAM
Ton Dong A (Vietnam): CGL #5
PRODUCTION CAPACITY
150,000 tpy (33 tph)
Material
Products Coating weight
CR low carbon steel, CQ, FH 750 N/mm2 max. 0.10 ÷ 1.0 mm 750 ÷ 1,250 mm 25 t max. Entry 250 m/min Exit 200 m/min Process 150 m/min GI, GL 60 ÷ 360 g/m2 total
PRODUCTION CAPACITY
150,000 tpy (33 tph)
Material Yield strength Strip thickness Strip width Coil weight Speeds
Low carbon steel CR & HR, 740 N/mm2 max. 0.25 ÷ 2.5 mm 750 ÷ 1,250 mm 27 t max. Entry 270 m/min Exit 300 m/min Process 200 m/min GI, GL 60 ÷ 360 g/m2 total
Yield strength Strip thickness Strip width Coil weight Speeds
Ton Dong A (Vietnam): CGL #6
Products Coating weight
DWU COLD ROLLING AND PROCESSING
DANIELI TECHNOLOGY: LASER WELDER
DANIELI LASER WELDER: CUTTING AND WELDING BY LASER > > > >
Fiber Laser with high energy efficiency High speed laser cutting of strip ends Laser cutting for notching and hole punching Reduced maintenance due to high equipment reliability and less wear parts > Laser monitoring System > No Vacuum Pumps, no CO2 (minimized consumption of Technical Gases and reduced maintenance)
Reduced installed power and equipment dimension saving = > REDUCED CAPEX
TECHNOLOGY PACKAGES FOR GALVANIZING LINES
THE PACKAGE CONCEPT OVERVIEW
FULLY INTEGRATED TECHNOLOGICAL PACKAGE TO PERFORM WIPING PROCESS WITH HIGH QUALITY
Q-Zinc CLC
BENEFITS > Quick return on investment thanks to zinc saving > Superior coating uniformity > Long service life with minimum maintenance > Simple setup and operation
X-Jet DESTM
Q-Robot Zinc > X-JET HEART IS A COMPLETELY NEW NOZZLE BODY BASED ON THE VERY LATEST FLUID DYNAMIC CONCEPTS TO REACH VERY MINIMUM COATING THICKNESS AT HIGH SPEEDS
CONCLUSIONS
SUMMARY
DANIELI WEAN UNITED THE RELIABLE INNOVATIVE PARTNER IN THE METALS INDUSTRY
