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Consulting on Improved Design for Wire Rod and Bar Mills

Metal Pass LLC provides consulting services for steel mill vendors to upgrade their mills for higher technical level. Examples of the work areas are to increase rolling speed, to improve roll pass schedule and mill technological performances, and to optimize temperature profile throughout the rolling and controlled cooling processes. Metal Pass also upgrades steel mills by developing new or improving existing Level 2 system (see Metal Pass wire rod and bar mills supply).

1.  Mill Speed Improvement

The rolling mills that some suppliers currently provide seem to have great potential for increased rolling speed, and improved design and pass schedule. This portion of the work is typically a consulting work, with the schedule discussed below.

Design Review

General review for the technical drawings and all related documents will be conducted. This is to understand the existing design in order to propose improvement remedy.

Current Design Analysis

This is to study strengths and weaknesses of the current design, especially the bottleneck for the speed restriction. On the basis, the improvement opportunities will be drawn out. The analysis may cover most items listed in the section "Detailed Calculation and Verification".

Improvement Planning

A general plan for the areas to be improved will be outlined based on the analysis on the current design.

Detailed Calculation and Verification

Detailed calculation for the verification of the planned improvement will be conducted. Examples for the items/parameters to be examined, particularly those affected by the speed increase, are listed below.

(1) Temperature profile, entry and exit temperatures for every piece of steel

(2) Water cooling capacity (water volume, pressure, speed, temperature, turbulence, etc.)

(3) Possible impact on the rolled steel properties

(4) Force, torque and power

(5) Motor capacity, transmission system (e.g. gear) strength and capacity

(6) Dynamic stage. Particular attentions are also paid to the dynamic stage from the moment the sock enters roll gap to the time a stable rolling is established.

(7) Roll size (diameter and barrel length) optimization, roll strength, biting condition, and roll deflection, etc.

(8) Metal deformation (shape, spread, forward slip) due to higher speed and possible increase in roll diameter

(9) Mill strength and system stability

(10) Reversing feature evaluation: impact of reversing on the maximal speed achievable

(11) Loop evaluation: When and whether it has impact on the maximal speed achievable

(12) Laying head and related equipment

(13) Equipment capacity related to the controlled air cooling

(14) Other related equipment, such as guides

Due to the large amount of work, the detailed calculation and verification would span beyond the time of the onsite visit.

Accompanied Modifications

Modifications to other related sections of the mill to be consistent with those improvement. This may also involves non-equipment, mill operation, material flow, etc.

2.  Roll Pass Design and Mill Parameters Determination

High-quality roll pass schedule should fit each individual mill. This part of the consulting work consists of followings:

Roll pass constrains identification

Mill layout will be reviewed, and other requirements (max/min roll diameter, max/min roll barrel length, max/min weight, etc.) will be identified.

Existing roll pass schedules evaluation

The evaluation covers some suppliers’ past and current roll pass schedules, together with past Metal Pass schedules, and the schedules of other companies that are related to the current mill.

Roll pass schedule requirements and technological parameters


  • Data format (with drawing? Readable with AutoCAD?)
  • Roll pass schedule following certain mill layout
  • Speed and temperature requirement affected by Roll pass schedule

3.  Temperature Profile and Rolled Steel Property

Based on our metallurgical model and empirical data, we determine the preferred temperature profile along the rolling and controlled cooling (water box and/or air) stages. Than we apply our finite-differential program to perform temperature profile analysis. Based on the required heat transfer coefficients in the controlled water-box cooling, together with our heat transfer models in dependence of water volume flow, water pressure, surface and turbulence, etc. for the water-box cooling, we determine the preferred water-cooling parameters. In the same way, we also determine the cooling parameters for the controlled air-cooling.

Please contact us via email admin@metalpass.com for top quality products and services.

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