MOST MODERN COMBINATION PICKLING AND GALVANIZING LINE

MITHALESHWAR YADAV
SENIOR SALES MANAGER
DANIELI INDIA LTD.
4TH GALVANIZING
COATING & PROFILING
SUMMIT
12TH FEBRUARY 2016
MUMBAI
MOST MODERN
COMBINATION PICKLING
AND GALVANIZING LINE
COMBINATION PICKLING
AND GALVANIZING LINE
1. INTRODUCTION
2. GENERAL LAYOUT
3. MAIN EQUIPMENT
4. SUMMARY
INDEX
1. INTRODUCTION
2. GENERAL LAYOUT
3. MAIN EQUIPMENT
4. SUMMARY
^
COMBINATION PICKLING
AND GALVANIZING LINE
INTRODUCTION
INTRODUCTION
COMBINATION PICKLING AND GALVANIZING LINES
Since 1999 Danieli Wean United has scored the world’s
largest total of wide gauge range of galvanizing lines
with seven installations. With all of these installations,
Danieli has proven that is very successful in terms of
final quality and transformation cost, and able to
produce
in a single plant both heavy gauges (up to 6.0 mm)
for structural applications -including welded pipes
and construction profiles- as well as thin gauges
for pre-painting application. So, one single plant
supplies the full range of construction and building
market products.
Furthermore, when our customer’s internal strategy
allows single plants to be “specialized by end-product”,
an additional benefit is gained by adding an in-line
pickling section that allows the one-step finishing
from hot band to galvanized coil.
1. INTRODUCTION
2. GENERAL LAYOUT
3. MAIN EQUIPMENT
4. SUMMARY
^
COMBINATION PICKLING
AND GALVANIZING LINE
GENERAL LAYOUT
GENERAL LAYOUT
ENTRY & PICKLING SECTION
MAIN DATA
Production capacity
Material
Yield strength
Strip thickness
700,000 tpy
SPHC SPHD SPHE
HSLA330-440 (JIS 3131)
500 N/mm2 max.
0.8 - 4.0 mm
Strip width
Coil weight
Max Speeds
Products
Coating weight
900 - 1,650 mm
35 t max.
250 m/min
GI
50 - 350 g/m2 total
GENERAL LAYOUT
ENTRY & PICKLING SECTION
MAIN FEATURES
>
>
>
>
Double payoff reel
6-strand horizontal entry accumulator
Scale Breaker Unit
3*24 m High Speed Turboflo Pickling with Rinsing Section
>
>
>
>
2-strand horizontal No.1 intermediate accumulator
No.1 Skin pass mill (1200 t) - 8% Elongation
Carousel side trimmer with scrap chopper
4-strand horizontal No.2 intermediate accumulator
GENERAL LAYOUT
ZINC COATING & EXIT SECTION
MAIN DATA
Production capacity
Material
Yield strength
Strip thickness
700,000 tpy
SPHC SPHD SPHE
HSLA330-440
500 N/mm2 max.
0.8 - 4.0 mm
Strip width
Coil weight
Max Speeds
Products
Coating weight
900 - 1,650 mm
35 t max.
250 m/min
GI
50 - 350 g/m2 total
GENERAL LAYOUT
ZINC COATING & EXIT SECTION
MAIN FEATURES
> Vertical Furnace/Induction coating pot/X-jet Air
Knives
> No.2 skin pass mill (1200 t)
> Tension leveler
> Roll coater for post treatment horizontal application
> No.2 Carousel side trimmer with scrap chopper (Space
provision)
> 6-strand horizontal exit accumulator
> Inspection station (horizontal and vertical type)
> Double tension reel
1. INTRODUCTION
2. GENERAL LAYOUT
3. MAIN EQUIPMENT
4. SUMMARY
^
COMBINATION PICKLING
AND GALVANIZING LINE
MAIN EQUIPMENT
MAIN EQUIPMENT
The entry section is equipped
with
> two uncoilers
> leveller
> laser welder
An horizontal looper guarantees
the necessary strip storage
during
the coil welding sequence.
ENTRY SECTION
MAIN EQUIPMENT
MAIN FEATURES
> Mandatory to process HSS
(DP and TRIP) prior to pickling
> Quick open system
> 4 rolls bridle at entry and exit
> Cassette change system
MAIN DATA
Yield strength
Strip thickness
Strip width
Max tension
Speed
Type:
780 N/mm2 max.
1.8 - 6.0 mm
800 - 1,650 mm
600 kN
220 m/min
dry
HIGH-TENSION SCALE BREAKER
MAIN EQUIPMENT
EXTENSION CASSETTE
Quantity
two cassettes
Type
4-Hi
WR diameter 80 mm
BUR diameter 120 mm
ANTI-CROSSBOW CASSETTE
Type
4-Hi
WR diameter 114 mm
BUR diameter 120 mm
QUICK OPENING SYSTEM
Type
2 hydraulic cylinders
SCALE COLLECTION
Type
dry type with dust
exhauster
HIGH-TENSION SCALE BREAKER
MAIN EQUIPMENT
TURBOFLO® PICKLING TANKS
MAIN DATA
>
>
>
>
Medium: HCl
3 pickling tanks, 28 m each
5 stage rinsing
Danieli TurboFlo® tank design
MAIN FEATURES
> Channel concept: the only one proven on high speed
(up to 450 mpm) and for ultra thin gauges (0.8 mm)
with full turbulence (for Arvedi cold complex - Italy)
> The only proven solution at low speed for AHSS steel
grades
MAIN EQUIPMENT
Danieli TurboFlo® tank:
> 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 THE
HEATING OF THE ACID
(LOWER OPEX)
TURBOFLO® PICKLING TANKS
MAIN EQUIPMENT
The in-line Furnace is utilized to
heat and anneal the strip before
the zinc coating is applied.
PROCESS SECTION
MAIN EQUIPMENT
DANIELI KOHLER X-JET AIR KNIVES
BENEFITS
> Compact nozzle design
> High coating uniformity
> Long service life with minimum maintenance
> Simple setup and operation
ACHIEVEMENTS/BENEFITS
DANIELI KOHLER X-JET WIPING NOZZLES
X-JET HIGH SPEED WIPING FOR
LIGHT COATING WEIGHT
Z50 at
Z70 at
Z80 at
Z100 at
140 m/min
175 m/min
185 m/min
200 m/min
MAIN EQUIPMENT
SKIN PASS MILL AND TENSION LEVELER SECTION
MAIN DATA
> Hydraulic cylinders for automatic gap control
> Positive and negative bending
> E-block or Mae-West system
> Single or double work rolls diameter
> Automatic pass line adjustment
> Dry or wet rolling system (demi-water or
detergent)
> Work roll cleaning system
> Anti-crimping and cross breaking rolls
> Work rolls changing device
MAIN EQUIPMENT
The chemical treatment section
is designed to apply all types
of passivation and antifingerprint Product required for
the specific market.
CHEMICAL PASSIVATION SECTION
MAIN EQUIPMENT
SIDE TRIMMER CAROUSEL TYPE
> One complete side trimmer/scrap chopper unit
in 180° stand-by position
- Maintenance during line runs under safe
conditions
- In case of cobbles clearance during line run
possible
> Fully automatic knife gap/overlap adjustment
via eccentrics
- Extended lifetime for blades and best cutting
qualities
> No calibration after knife change required due to
special design
> Significantly less scrap cobbles due to chute
design between trimmer/chopper
> Quick width adjustment of trimmer/chopper unit
without any extra scrap
> Change of trimmer scrap chopper unit within 60
sec.
> Maintenance or clearance of scrap cobbles during
line run in safe working position
> In case of troubles quick replacement of working
unit by fresh standby unit
MAIN EQUIPMENT
FULLY AUTOMATIC,
QUICK SAFE CHANGE
OF CUTTING TOOLS,
NO CALIBRATION
REQUIRED AFTER
KNIFE CHANGE:
OPEX DECREASE
SIDE TRIMMER CAROUSEL TYPE
MAIN EQUIPMENT
The exit section features:
> an inspection station
> electrostatic oiler
> crop shear
> tension reel
EXIT SECTION
1. INTRODUCTION
2.
GENERAL LAYOUT
3. MAIN EQUIPMENT
4. SUMMARY
^
COMBINATION PICKLING
AND GALVANIZING LINE
SUMMARY
SUMMARY
TARGETS
> High productivity and ability to cover the complete
range
of market demands
> Low production costs compared to separate
installations
for pickling and galvanizing
> Space-saving installation
MITHALESHWAR YADAV
SENIOR SALES MANAGER
DANIELI INDIA LTD.
4TH GALVANIZING COATING &
PROFILING SUMMIT
12TH FEBRUARY 2016
MUMBAI
MOST MODERN
COMBINATION PICKLING
AND GALVANIZING LINE