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Title

DANIELI COLD PROCESSING TECHNOLOGY: INNOVATIVE APPROACHES FOR NEW LINES AND UPGRADES

Authorship

Holz, Ruediger; Settimo, Tommaso; Vignolo, Luciano

Holz, Ruediger

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Settimo, Tommaso

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Vignolo, Luciano

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DOI

10.5151/9785-9785-32379

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Abstract

Optimized CAPEX, OPEX, yield and product quality and introducing of new products in new process equipment as well as by upgrading of existing facilities are the key factors for success and profitable operation. For this, innovation in processes and design is crucial. Danieli is supporting these customer and market demands by offering innovative and well-thought-out process equipment and upgrade solutions. In 2019, Danieli has put into operation a complete cold processing complex in Turkey, which includes a new continuous pickling tandem mill featuring latest generation of market oriented technologies. In this line, dedicated to run a broad range of size and grades (IF to AHSS as DP1000), the highly efficient Turboflo® pickling process was selected. This technology already proved its efficiency and ability in former applications handling ultra-thin gauges at speeds even exceeding 400 m/min in the pickling tanks. The 5-stand 6-high OSRT tandem mill features important developments, like actuators to improve significantly strip flatness and a special air knife arrangement on the tandem mill exit side to generate perfect strip surface cleanliness. Fast startup and thin gauge rolling already short time after production start are further proves for the technological superiority of this innovative mill design. In dis-continuous operating rolling mills, the Danieli Yield Boost technology is the right answer to significantly increase material yield with limited CAPEX. As an example, the usual way to operate a cold reversing mill for strip threading and tail-out is to open the roll gap. Danieli developed a method for already partial strip thickness reduction during threading in and tail out phases. Operating results at a two-stand reversing mill show an impressive increase in material yield. Depending on specific conditions, this technology can create annual savings in six or even seven-digit US Dollar figures. In the last 10 years, Danieli has supplied most of the worldwide construction and high speed galvanizing plants. In those lines, the zinc pot is the most effective area to reduce costs in operation and consumables and increase the product quality. Danieli has spent significant efforts in developing most advanced technology for the wiping process. A fully integrated system solution has been designed to perform a wiping process with high quality, economy, accuracy and productivity. Center part is the newly developed X-Jet / Compact X-Jet air knife. Its innovative design creates highly stable static pressure with direct impact on the shear effect, and extremely accurate pressure along the strip width. The new generation electromagnetic stabilizer is cutting down strip vibrations and improves strip flatness, leading to further increase in wiping process. Robotic systems are supporting to reduce human intervention and health risks in the zinc pot area. These technological packages are ideal also for upgrade of existing lines, typically generating a return of investment in less than 1 year, proven in latest revamp installations. On top, Danieli has developed advanced automation systems including L2 and L1 controls to achieve outstanding product performances.

Keywords

Yield Boost, Turboflo®, air knife, X-Jet / Compact X-Jet air knife