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Mill Performance Improvement

There are many mill operational approaches to improve the mill performance, rolled steel geometry and properties. Improvement is based on the knowledge and understanding of the mill practice. Though many consultants could provide rough direction, Metal Pass can do better job by applying our accurate process/product models. Most concepts described below have been proved in the real mill practices during our past consulting service. See Mill Related Projects.

Work areas for mill performance improvement

Mechanical properties improvement  (Ask a question)

  • Increasing reductions in certain temperature range and certain thickness range (e.g. later roughing and certain finishing passes) to improve mechanical properties.

  • Increasing reductions in certain finishing passes together  with adjustments in roll bending schedules, to improve mechanical properties.

  • Increasing the accuracy of crown predictions with better models of deflection and statistical tuning.

  • Increasing the control of mechanical properties and bow with feed forward laminar quenching model that included balanced patterns of water flow.

  • Decreasing the segregation and cracking on continuous caster by tuning of soft reduction, oscillation and water distribution.

  • Increasing temperature prediction accuracy to allow the actual rolling to more closely reach the scheduled temperature points for controlled rolling, etc.

  • Improving the water cooling by modeling the heat transfer coefficients in various water volume, speed, pressure and initial surface temperature, etc., to make sure the scheduled temperature profile is achieved.

Shape and yield improvement  (Ask a question)

  • Decreasing camber with automatic camber detection and prevention system. The camber detection can be performed through digital image caption and image processing, and the camber prevention achieved by automatic adjustment of the left/right roll gap through AGC. The principle can be showed in a Preliminary Proposal for Camber Problem Solution.

  • Decreasing hooking and camber with better shape control in the later passes with adjustments in roll bending and force distribution on passes.

  • Decrease edge wave and center buckle with adjustment in force distribution and roll bending.

  • Decreasing the turn down of the head on later passes that cause missed slots, kinks, knuckles or other defects.

  • Decreasing wave and bow by setting hot and cold leveler.

  • Controlling interstand tension through better roll pass to improve product geometry, in the rolling such as in the wire block.

Productivity improvement  (Ask a question)

  • Decreasing the number of passes in the rolling schedule with fuller use of force and torque, by more accurate prediction of the force and torque.

  • Scheduling reheat furnace slab line up and firing

  • Decarburization and degassing of liquid metal

  • Maximize production of a plant with flow analysis

Energy saving and cost reducing  (Ask a question)

  • Optimize reheating time and reheating speed to achieve best reheating effect and to avoid the over-heating and the energy loss.

  • Optimize the slab size by balancing productivity (prefers large slab) and total energy consumption (prefers small slab), finish coil size and finish dimension, etc.

  • Most possibly reduce the slab cost by increasing the mechanical properties through optimized rolling and selecting lower-cost grades.

Metal Pass resources on mill performance improvement  (Ask a question)

Examples of the related resources and experiences are listed below:

Metal Pass has dozens of research reports and some software applications available at no charge for the Metal Pass Consulting clients (under approval by Dr. Benjamin Li).

See the profile for the primary consultant Dr. Benjamin Li. You may also view our company and personnel profiles. Please contact us via email admin@metalpass.com or by phone (001) 503 516 9625 for top quality consulting services.


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