MOST MODERN COMBINATION PICKLING AND GALVANIZING LINE
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1 MITHALESHWAR YADAV SENIOR SALES MANAGER DANIELI INDIA LTD. 4 TH GALVANIZING COATING & PROFILING SUMMIT 12 TH FEBRUARY 2016 MUMBAI MOST MODERN COMBINATION PICKLING AND GALVANIZING LINE
2 COMBINATION PICKLING AND GALVANIZING LINE INDEX 1. INTRODUCTION 2. GENERAL LAYOUT 3. MAIN EQUIPMENT 4. SUMMARY
3 COMBINATION PICKLING AND GALVANIZING LINE ^ 1. INTRODUCTION 2. GENERAL LAYOUT 3. MAIN EQUIPMENT 4. SUMMARY INTRODUCTION
4 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.
5 COMBINATION PICKLING AND GALVANIZING LINE ^ 1. INTRODUCTION 2. GENERAL LAYOUT 3. MAIN EQUIPMENT 4. SUMMARY GENERAL LAYOUT
6 GENERAL LAYOUT ENTRY & PICKLING SECTION MAIN DATA Production capacity Material Yield strength Strip thickness 700,000 tpy SPHC SPHD SPHE HSLA (JIS 3131) 500 N/mm 2 max mm Strip width Coil weight Max Speeds Products Coating weight 900-1,650 mm 35 t max. 250 m/min GI g/m 2 total
7 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
8 GENERAL LAYOUT ZINC COATING & EXIT SECTION MAIN DATA Production capacity Material Yield strength Strip thickness 700,000 tpy SPHC SPHD SPHE HSLA N/mm 2 max mm Strip width Coil weight Max Speeds Products Coating weight 900-1,650 mm 35 t max. 250 m/min GI g/m 2 total
9 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
10 COMBINATION PICKLING AND GALVANIZING LINE ^ 1. INTRODUCTION 2. GENERAL LAYOUT 3. MAIN EQUIPMENT 4. SUMMARY MAIN EQUIPMENT
11 MAIN EQUIPMENT ENTRY SECTION The entry section is equipped with > two uncoilers > leveller > laser welder An horizontal looper guarantees the necessary strip storage during the coil welding sequence.
12 MAIN EQUIPMENT HIGH-TENSION SCALE BREAKER 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 780 N/mm 2 max. Strip thickness mm Strip width 800-1,650 mm Max tension 600 kn Speed 220 m/min Type: dry
13 MAIN EQUIPMENT HIGH-TENSION SCALE BREAKER 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
14 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
15 MAIN EQUIPMENT TURBOFLO PICKLING TANKS 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)
16 MAIN EQUIPMENT The in-line Furnace is utilized to heat and anneal the strip before the zinc coating is applied. PROCESS SECTION
17 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
18 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
19 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
20 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
21 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
22 MAIN EQUIPMENT FULLY AUTOMATIC, QUICK SAFE CHANGE OF CUTTING TOOLS, NO CALIBRATION REQUIRED AFTER KNIFE CHANGE: OPEX DECREASE SIDE TRIMMER CAROUSEL TYPE
23 MAIN EQUIPMENT The exit section features: > an inspection station > electrostatic oiler > crop shear > tension reel EXIT SECTION
24 1. INTRODUCTION 2. GENERAL LAYOUT 3. MAIN EQUIPMENT 4. SUMMARY ^ COMBINATION PICKLING AND GALVANIZING LINE SUMMARY
25 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
26 MITHALESHWAR YADAV SENIOR SALES MANAGER DANIELI INDIA LTD. 4TH GALVANIZING COATING & PROFILING SUMMIT 12TH FEBRUARY 2016 MUMBAI MOST MODERN COMBINATION PICKLING AND GALVANIZING LINE
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