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H.

R slitting
Metal specification
Hot rolled carbon steel coils
1.0 dimensional specification
2.0 max width 2000 mm max
3.0 max thickness 7mm max
4.0 wt. of coil 35 MT max
line specification
maximum line speed 100 met/min


the hot rolled coils which are used as raw material for next processes may get damaged during
transportation resulting in burring in edges. This may be overcome by trimming out the edges.
Also HR coils have to be slitted in different width either due to customer requirements or due to
limitations in maximum allowable width in successive processes. Slitting or trimming is carried out
by slitters, positioned in rollers according to the required width and clearance which depends on
thickness of sheet and whose relation with thickness is mentioned below:
Clearance specification for cutter
Thickness in mm Gap settings in mm
1.6 0.16
1.7 0.18
2.0 0.20
2.2 0.22
2.5 0.25
2.6 0.26
2.8 0.28
3.0 0.30
3.2 0.32
3.5 0.35
4.0 0.40
4.5 0.45
5.0 0.50
6.0 0.60

The trimmed scrap is collected by a scrap collector and is sent for recycling.
During the process, scratches may develop due to roller condition which can be avoided by proper
inspection and maintenance of rollers.
Another problem which may occur is improper build-up during slitting. Guide rolls are provided and
a loop is given after slitters for proper build-up.
The coils are then recoiled, labelled and strapped and are ready for the processing.

PICKLING
Pickling is a process of acid treatment of hot rolled coils, performed in order to remove the oxidized
layer developed on HR coils. Process specification is as follows:
Material specification: hot rolled steel coils
Dimensional specification:
Width 1700mm max
Thickness 6mm max
Weight of coil 30MT max
Line specification
Line speed 120 mtrs/min
Acid specification
Concentration 30% min
Specific gravity 1.147 min
HF 2ppm max
Oil or wax layer 1% max

The slitted and trimmed coil is loaded on uncoiler and is feeded to four acid tanks which contain
different concentrations of HCl and Fe. Tank nearest to uncoiler is tank no. 1, the next tank is tank
no. 2 and so on. 2000 liters of fresh commercial acid is added to tank no. 4 for every 100 to 140 mtrs
of coil pickled and acid is moved subsequently to every other tank by cascade action.
The acid treated coils are then rinsed in rinsing tanks numbered from 1 to 5. Water is also moved
from one tank to another through similar cascade action. Exit of water tank has squeeze rolls to
avoid the movement of water outside the tanks.
Then the coil is dried in the air dryer functioning above 100
0
C. Drying is necessary to remove water
content from the coil which may result in rusting.
Some special grade steel coils are coated with oil spray after drying.
Precautions
pH, temperature and concentration of acid tanks as well as line speed should be maintained
for proper pickling. Lower pH or lower line speed may result in over pickling, while higher pH
or higher line speed may result in under pickling.
pH and temperature of water tanks should be monitored regularly as lower pH of water
indicates movement of acid from acid tank no.4 to water tank no. 1. In such situation, utility
department should be informed or squeeze roll should be checked.
Acid fumes generated in acid tanks are collected and circulated in scrubber to remove
acidity and then released in atmosphere. Also to suppress excess acid fumes, acid inhibitor
is added.
Acid after tank no. 1 will be drained in spent acid tank from where recirculated after
treatment.


HITACHI MILL
Hitachi mill is a 6-HI rolling mill used to reduce the thickness of coil upto 70% after pickling. Rolling of
coil should be done maximum 72 hours after pickling or else coil is sent for re-pickling. Process
specifications are as follows:
Material specification: pickled HR coils/annealed CR coils of various grades
Dimensional specification min max
Width 700mm 1700mm
Material I/P thickness 1.8mm (HR) 7mm
Weight of coil 3MT 30MT
CR thickness 0.11mm 6.95mm
Line specification
Maximum speed: 1200mpm
Tension: 16T max
Maximum load: 1500MT max
Coolant specification
Temperature: 50-65
0
C
pH value: 4-6
Conductivity: 630 max
Chloride: 150 ppm max
ESI: 0.5-0.85
Oil concentration: 1.2-3.5%
Tramp oil %: max 25% of total oil
SAP value: 160 min
Acid value: 21 max
Fe content: 150 max

DM water
pH value: 6.0-8.5
Chloride: 2ppm max
Hitachi mill contains six rolls- a pair of work rolls, a pair of intermediate rolls and a pair of back up rolls.
Upper three rolls are fixed and lower three rolls can be moved up and down by hydraulic action to
create compression of coil passing between upper and lower work rolls. Pickled HR coil of known
thickness is loaded on POR or pay off roll. Now desired thickness is feed in the program which then
generates various parameters automatically like number of passes, load generated by rolls in each pass
and hence reduction in each pass etc. A touch load is given to feed the coil to RTR where the coil is
recoiled for the first pass. Once the coil starts to recoil at RTR, line speed and load is increased gradually
to desired value. Thickness reduction in each pass is monitored by X-ray gauge system which measures
the thickness upto 4 decimal places. Once the coil is recoiled at RTR, the coil moves from RTR to LTR in
the next pass for further reduction and then again LTR to RTR. This cycle continues till desired thickness
is achieved. Reduction is achieved by combined effect of compression by work rolls and tension by
recoiler. This also prevents expansion of coil in third undesired direction. Flatness of sheet can be
maintained by shifting the rolls and creating a bending force by creating a set-off distance between work
roll and intermediate roll. Huge amount of

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