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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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