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Technologies

BASIC TRAINING ON COLD ROLLING

Process, Theory and Controls

Presented by:

SANGAM KAPIL
Henkel Technologies
31, January, 2007
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Topics Covered

1. Cold Rolling Definition

2. General Overview
3. Process Flow
4. Rolling oils and our role
5. Brief description about ingredients of RO
6. Emulsion systems
7. Line Wise Details and Critical Parameters
8. What Is Important to Monitor
9. Line Wise Major Defects And Trouble Shootings
10. Open Questions
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BROAD STEEL PROCESS OVERVIEW
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HR COILS
Direct To Customers
COLD ROLLING PROCESS FLOW
HR COILS
PICKLING LINE
HRPO to Customers

Cold Rolling Mill

1. Cleaning Line
Annealing
TPM
Finishing Lines

2. CR Full Hard to Coating Lines like HDG, HGL
PL

Roofing, Perlings

Electronics/ Computer

Fabricators, White goods

Automobiles etc..
3. CR Full Hard Pre Paint Applications
4. CR Full Hard to fabricators

LOT MANY COMBINATIONS ARE POSSIBLE

DEPENDING ON MARKET DEMANDS
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Value Chain
Steel Industry
ORGANIC WASTE WATER
COATINGS TREATMENT
PRE
HOT MILL PICKLING ROLLING CLEANING COOLING WATER
TREATMENT
PRIMERS/ TREATMENT
PAINTS MAINTAENANCE

Gerolub Cleanox Gerolub Percy P3 Gerolub Granocoat Ferrofos

Rodines Novaclean Granodine Novacoat Ferrolin
Gerolub
SM Alodine Ferrocryl
Plus 10B
Ferrolix

TPM – WTF , Rust Preventive

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PICKLING LINE
• Pickling is the process of removing the scales by treating the steel surface
with acid from the HR coils prior to cold rolling process. (Surface Treatment).
• Acid used is HCl mostly but some lines use H2SO4.
• Inhibitor is used to protect the base metal and the scale losses and helps in
reducing the acid consumption
• Rinse Anti stain Plus 10B is used to avoid Rinse stains during line stoppages.
• Anti rust Oil or the Rolling oil spray is applied to improve the storage time.
• Line Flow Diagram:
Uncoiler
Scale breaker
Tension Leveller
Welder
Main Acid Tanks

Rinse Tanks
Dryer
Trimmer
Electrostatic Oiler
Recoiler

• Major Line Defects :

• Under pickling / Iron Carbides residues ( Low acid concn, High Fe, Low Temp )
• Over Pickling ( due to line stoppages )
• Cascade marks / Rinse stains ( Oxidation From Rinse tanks During Line Stops )
• Poor Trimming ( Trimmer Block / Knife problem / eccentricity )
• Scratches ( Line problem metal to metal contact )
• Chloride Carry over ( Rinse parameters: High Cond, High Cl , Low pH)
• Oiling Problems ( Low voltage, contaminations , perception )
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Composition of scale
Cracks in scale
Fe2O3 (Hematite)
Fe3O4 (Magnetite)
FeO (Wustite)

Mixed oxide and

metal

Fe2O3 (Hematite) contains 30 % oxygen and is insoluble in acid

Fe3O4 (Magnetite) contains 28 % oxygen and is soluble in HCl
FeO (Wustite) contains 22 % oxygen and is soluble in acid
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Scale formation
• The structure of the scale from HSM depends on
the :

– Temperature
– Heating time
– Atmosphere of the Furnace
– Composition of the steel
– Cooling conditions
– Position on the sheet
- De-scaler Pressure and Nozzles condition
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REMOVAL OF SCALES IN PICKLING LINE

• Methods:

– pure chemical effect

– pure mechanical effect

– combined mechanical and chemical effect

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Pickled steel sheet - requirements
• Scale free surface (not underpickled)
• Not overpickled
• Low residues
– mechanical impurities
– carbon
– acid and salt residues
– Chlorides
• Uniform surface
• No Rinse Stains
• Dry Strip
• Good Trimming
• No Telescopic Winding
• No Physical Damages like Edge folds , bends , Gouges
etc
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H2SO4 pickling
• Characteristics:
– max. 28% aqueous solution
– high temperature required
– low oxide dissolution properties
– good scale braking required
– overpickling danger
– relative high residues on the surface
– relative low cost process
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HCl Pickling

• Characteristics:
– Good pickling effect even at room temperature
– High pickling speed
– Dissolves all scale types
– Has low attack on base metal
– Less overpickling
– Easy to rinse
– Brighter, cleaner surface
– High cost process
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Rodine® Acid Inhibitors
Rodine® Acid Inhibitors are high molecular weight, complex
organic compound formulations.When added in small
quantities to acid solutions, Rodine will retard (or inhibit) the
attack of acid on metal surfaces, while not preventing the
attack on metallic scale.This inhibition is the result of a thin
film formed by Rodine on the base metal surface. The film
creates a barrier which interferes with the electrochemical
reactions that dissolve metal.All mineral acids, organic acids or
combinations of acids can be inhibited, except those which are
considered strong oxidizing acids (i. e., nitric or chromic).
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PRODUCT LINE AVAILABLE
Rodine 31 A Universal inhibitor for phosphoric and sulfuric acid
for iron, copper and brass
Rodine 31 AS as RODINE 31 A, but without surfactants, suited for
vacuum regeneration
Rodine 32 high efficient inhibitor, special suited for continous
pickling with sulfuric acid

Rodine 50 Inhibitor for hydrochloric acid

Rodine 58 Inhibitor for phosphoric and sulfuric acid, no surfactants,

esp. for higher temperature
Rodine 60 Inhibitor for hydrochloric acid at lower temperature
Rodine 85 Simelar to Rodine 58, but lower content on high molrcular organics,
special recommanded for strip pickling
Rodine 140 C powered inhibitor esp. for sulfamic acid and hot dip
galvanized surfaces
Rodine A 213 Inhibitor for hydrochloric acid, esp. with hydrofluoric acid

Rodine XL 1110 Inhibitor esp. for continuous strip pickling

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Steel / Coil special products
RINSE ANTI STAINING ADDITIVES

• “PRA” additives are based on acidic or alkaline

complexing agents
• After pickling they complex the remaining iron (II)
so it can not convert to Iron (III) and form visible
rust (stain).
• Protects up to 30 min. against stain during line
stops.
• Application
» Conc: O.4 g/l
» pH 1-2 or >11
» Into the last rinse stage (counter-flow)
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PLUS 10B TECHNICAL PROCESS BULLETIN
PLUS-10B Pickle Line Rinse Tank Additive
PLUS-10B is an acid stain inhibitor recommended for use in pickle line rinse tanks to
prevent staining of the sheet during line stops.

Characters
PLUS-10B is an alkaline product including hydramine. It keeps the PH of rinsing water
stable to ensure PH not changed very much. In this case, The chelating functions for
ferrous ion of the "PLUS" rinse additive also ensures effective inhibition of stain
formation during line stops.

Addition
PLUS-10B is recommended for use at 0.2-0.5% concentration. Henkel surface
Technologies service representative will demonstrate and help to install the necessary
quality control procedures to ensure incoming product consistency and in use control.

Typical specifications
Appearance: Clear straw
PH: 10
Gravity: 1.0~1.1
Solubility: 100% in water
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PICKLED SHEET AFTER 15 MIN STOPPAGE WITH PLUS 10B

PICKLED SHEET AFTER 5 MIN STOPPAGE WITH OUT PLUS 10B

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KEY PARAMETERS AT PICKLING LINE

1. MAIN ACID TANKS:

- Acid concentrations as per std.
- Temp > 70 DegC
- Fe in First Tank < 130 ppm
- Inhibitor Concentration

1. RINSE CASCADING TANKS:

- Temp > 70 deg
- Conductivity < 50 micro siemens / cm in final tank
- pH Of Final Tank > 6
- pH of Incoming DI water 4 - 5 micro siemens / cm
- Volume of DI water addition / Hr = 6-8 m3
- Concentration of Plus 10B 0.10 – 0.30 %

Chloride Content On Strip after Rinsing should be < 20 ppm

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TANDEM MILL
Stand 2 Stand Stand Stan
Stand 1 3 4 d5
hydrau mec mech mech mec
lic hani anic anic hani
c c

X-
K K K K K Ray
W W W W W ∅
1400
550 530- 530- 550- 575- m/min
Ra 1,1-
mm Ra
5500,3 Ra
5500,3 Ra
5650,3 Ra
5953,5
entry:1,5- 1,2 µm
[mm] µm
[mm] µm
[mm] µm
[mm] Shape
5,0[mm] [ µm] contro
exit: 0,18- l
1,5[mm]1270- 1270- 1270- 1270- 1270-
1425 1425 1425 1425 1425
[mm] [mm] [mm] [mm] [mm]

System 1: System 2: System 3:

Capacity: Capacity: Capacity
80m³ 80m³ 80m³
Temperature: Temperatur: Temperatur:
48°C 48°C 42°C
Konzentratio
n:2,2-2,5[%]
Konzentratio
n:2,2-2,5[%]
Konzentratio
n:0,5-3,0[%] REVERSING MILL
Skimming- Skimming-
Skimming- System System
System
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COLD ROLLING
 Rolling is the process of plastically deforming the metal by passing
it between rolls under load and tension. This process is used for
reducing the thickness of the Incoming slab / sheet stock to the
desired thickness.

 Above re-crystallization temp it is called Hot Rolling and below RC

temp it is called Cold Rolling. At MS we deal with Cold Rolling only.

If thk. > 6mm – Plate

If thk. < 6mm - Sheet
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TYPES OF ROLLING MILLS

1. Reversing Mills / Tandem mills

2. 2 hi / /3hi / 4hi / / 5hi / 6hi / 20hi / Cluster Mills

Stand 1 Stan Stan Stan Sta

mec
hydraul
dmech
2 dmecha
3 dmech
4 nd Sample Nozzle Diagram
ic anic nic anic hani BUR cooling
5c
IMR cooling

X- Nozzle Sup.
K K K K K Ray
W W W W W ∅ 1400
Work roll cooling

m/min
550 530- 530- 550- 575-
Ra
mm1,1- Ra
5500,3 Ra
5500,3 Ra
5650,3 Ra 3,5
595 Work roll cooling
entry:1,5- 1,2 µm µm µm µm Shape
[mm] [mm] [mm] [mm] control
5,0[mm] [ µm] Nozzle Inf.
exit: 0,18-
1,5[mm]1270- 1270- 1270- 1270- 1270-
1425 1425 1425 1425 1425 6- HI MILL
[mm] [mm] [mm] [mm] [mm]
optional
System 1: System 2: System 3:
Capacity: Capacity: Capacity 80m³
80m³ 80m³ Temperatur:
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MAIN EQUIPMENT OF ROLLING MILL
1. Coil Preparing Station
2. Uncoiler / Pay Off Reel
3. Entry Side Guide Unit
4. Entry Hold Down Clamp
5. Mill Housing
Spray Headers
Bending Blocks
Sample Nozzle Diagram
Roll Force Cylinders BUR cooling

Tension Rolls
Pass Line Arrangement IMR cooling

WRs & BURs Nozzle Sup.

Roll Chocks Work roll cooling

Roll Neck Lubrication

Main Motors Work roll cooling

Drive & Control Logics Nozzle Inf.

Gauge Detection Source

6. Shape Control 6- HI MILL

7. Exit Blow Off optional

1. Recoiler
2. Exit Coil Storage Car, Roll change cars etc
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LINE DIAGRAM:
RF
Uncoiler –> Mill stand / stands –> ReCoiler

 Major Factors involved in the FT

cold rolling Mill Process are:

 Roll Force ( Desired Low )
 Tensions ( Interstand / reel ) des low
 Roll Bite Friction ( optimum ) BT
 Neutral Point
 Lubrication and Cooling ( opt )
 Torque ( Power ) ( Min)
 Rolls ( Higher Roll Life Desired)
RF
 No Surface Defects Allowed Roll Force

 Cleanliness ( High Desired) tension

 Mill Shape Controls ( WRB,

IRB, Zonal cooling etc ).
 Mill Thickness Control (½ ASTM )
 Mill Dynamic Logical Controls
 Drive and Other Controls
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KEY REQUIREMENTS FROM COLD ROLLING

1. Thickness Accuracy Desired ( min 50% of ASTM )

2. No Change in Strip width ( No Necking )
3. No Roll Marks of any kind
4. Strip Cleanliness ( Normally > 60% reflectivity index )
5. No Mill Chatter
6. No Skidding / Slip
7. No Lubrication issues ( Friction marks , High RF, High Tensions, Slip
8. Coiling Temp to be 110 Deg max
9. Minimum Strip Breakages
10. Higher Yield ( Ratio of input to Output )
11. Higher productivity rate
12. Optimum Speeds
13. Low Consumption rates
14. Improvements on Power consumptions
15. No coolant carry Over
16. Higher Roll life
………………….. LIST IS ENDLESS
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THEORY OF COLD ROLLING

roughness, reduction, ( Strip speed = WR speed )

tension and lubrication
ARE CRITICAL Rolling direction

( Strip Speed < WR speed )

Forward slip
( Strip speed > WR speed )
N – Neutral Point
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MAIN EQUIPMENTS OF THE EMULSION SYSTEM
1. Main Recirculation tank
2. Premixing tanks
3. Main Re-circulating Pumps
4. Main filters ( basket , Hydromation etc )
5. Magnetic seaparators
6. Flow Control valves
7. Pressure Control Valve
8. Bypass valves
9. Agitators
10. Magnetic Separators
11. Skimmers
12. Drain Valves
13. Level Indicator
14. Tank heating Arrangement
15. Spray Headers
16. Blow Off header
17. Zonal Controls
18. Gauge Indicators etc…… many more
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STANDARD EMULSION PARAMETERS ( MS )
T T T T T T T T T T T T2 T1 T2 T T T T T T
1 2 1 2 1 2 1 2 1 2 1 1 2 1 2 1 2

Temperature pH Concentratio Chloride( Iron(ppm) Conductivity(u Sap Tramp(%) Rolling ESI(%)

(°C) n (%) ppm) S/cm) Value(mgKOH/ oil(%)
g)

45- 45-55 5.0- 5.0- 0.4- 2.0- < < < < < < 250 130- 130- < < 0.4- 2.0- 50- 50-
55 6.8 6.8 0.6 3.5 25 30 15 300 100 165 165 20 20 0.6 3.5 70 70
0

T1 = Entry Tank
T2 = Exit Tank
1. Standard Parameters to be maintained for Consistent Rolling Performance
2. Any Deviation to be highlighted to customer immediately
3. Major Issues to be brought to the notice of regional support immediately
4. Parameter testing at least once a shift
5. ESI, pH, Conductivity, Concentrations, SAP value are critical to performance
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Base Oil Boundary Lubricants

Surfactants Miscellaneous

Viscosity Modifier
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• Surfactants
• Extreme Pressure Additives
• Viscosity Improvers
• Defoamer
• Buffer
• Maskants
• Biocide
• Anti Oxidants
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Mineral Oil

Natural fats

Synthetic oil
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The Webster dictionary defines “synthetic” as

"produced by synthesis; specifically, produced by
chemical synthesis, rather than of natural origin."
In the lubricant business this basically means a product that
does not rely on animal fats or vegetable oils as the base.
For the most part, all cold rolling lubricant contain synthetic
additives.

Synthetic Lubricant vs Pertroleum Lubricant

Synthetic Ester vs Natural Ester
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Chemical Reaction

O
||
CH2OH CH2-O-C-(CH2)xCH3
| |
CHOH 3CH3(CH2)xCOOH CH-O-CO-(CH2)yCH3
| |
CH2OH CH2-O-C-(CH2) zCH3
||
O

Glycerol Fatty Acid Triglyceride

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Chemical Reaction
O
||
CH2OH CH2-O-C-(CH2)xCH3
|
|
C2H5-C- CH2OH 3CH3(CH2)xCOOH C2H5- C-C-OOC-(CH2)xCH3
| |
CH2OH CH2-O-C-(CH2) xCH3
||
O

Trimethylol propane Fatty Acid Trimethylol propane ester

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ROLLING OILS
CLASSIFICATIONS: TYPES:

Conventional EMULSION
Synthetic DISPERSION
Semi-synthetic HYBRID

APPLICATIONS:

Direct
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Low speed, low reduction Mill

5-Minute Emulsion Stability
Index >85%
Particle Size Distribution 8 –
16 microns by Lasentec Oil is emulsified in water.
Analyzer Emulsion allowed to sit for
5 minutes then a sample is
Conventional, Semi-synthetic taken from the bottom.

or Synthetic ESI = % Oil after 5 min x 100

Initial % Oil
Anionic & Nonionic
surfactants
Average Plate-out range of
about 75 – 225 mg/m2 (7 – 21
mg/ft2)
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Generally for Tin Mills

5-Minute Emulsion Stability
Index of less than 15%
Conventional formula E
M
Particle size distribution of U
18 – 28 microns by Lasentec L
Analyser S
I
Cationic surfactants O
N
Average Plate-out of about
430 mg/m2 (40 mg/ft2) or
greater
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High Speed Sheet Mill

5-minute Emulsion Stability
Index 20 – 80%
D
Particle Size Distribution 14 I
E
M
– 22 microns by Lazentec S U
Analyser P L
E S
Conventional, Semi- R I
synthetic, Synthetic S O
I N
Mixed surfactants O
N
Plate-out of about 265 – 430
mg/m2 (25 – 40 mg/ft2)
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O H
H 2) n
C
O C H2
// - ( O
) 7 -C
H 2
H( C
C
C H=
H )
2 7 R (C H
(C –N / 2 CH
CH 3
2 O)
\ x H

(C H
2 CH
2 O)
y H
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ASTM ESI
% Total Oil
% Tramp
Iron, ppm
pH
Chloride, ppm
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Product Differentiation
EXAMPLE OF PROPERTIES:

CONVENTIONAL SEMI- SYNTHETIC

SYNTHETIC

SAP NO. 200 200 200

mg KOH/g

ACID NO. <10 <10 <10

% as Oleic
VISCOSITY 48 48 48
@ 40 OC, cSt
% ADDITIVES 10 10 10

POUR POINT 35 25 -30

O
C
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Product Differentiation
EXAMPLE OF PROPERTIES:

CONVENTIONAL SEMI- SYNTHETIC

SYNTHETIC

BASE OIL Occurs naturally Mixture of natural Man-made

and synthetic chemical

FLUIDITY at Varies, but mainly Varies, but can be Varies but mainly
RT heterogeneous to homogeneous homogeneous
soft solid
ABILITY TO BE Good Better Best
CLEANED
LUBRICITY Can be matched Can be matched Can be matched
by Semi and Syn by Con and Syn by Con and Semi

COST Inexpensive Inexpensive to Expensive

Expensive
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Product Differentiation
EXAMPLE OF PROPERTIES:
CONVENTIONAL SEMI- SYNTHETIC
SYNTHETIC

HEATING Necessary Not necessary Not necessary

If RT < 25 OC
MIX OR Necessary Necessary Recommended
RECIRCULATE
AGEING: Good Good Good
Recirculating
AGEING: Not relevant Not relevant Not relevant
unless reclaimed unless reclaimed unless reclaimed
Direct App
Oxidative Good Better Best
Stability
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Product Differentiation
EXAMPLE OF PROPERTIES:
CONVENTIONAL SEMI- SYNTHETIC
SYNTHETIC

HEALTH Non-hazardous Non-hazardous Non-hazardous

HAZARDS
MILL-CLEAN Successful Successful Successful

CLEANLINESS Dirty especially Not as dirty Basically clean

OF HOUSING during winter during winter

CONSUMPTION Dependent on the Dependent on the Dependent on the

RATE system system system

WASTE Biodegradable Biodegradable Biodegradable

TREATMENT
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MAIN EQUIPMENTS OF THE EMULSION SYSTEM
1. Main Recirculation tank
2. Premixing tanks
3. Main Re-circulating Pumps
4. Main filters ( basket , Hydromation etc )
5. Magnetic seaparators
6. Flow Control valves
7. Pressure Control Valve
8. Bypass valves
9. Agitators
10. Magnetic Separators
11. Skimmers
12. Drain Valves
13. Level Indicator
14. Tank heating Arrangement
15. Spray Headers
16. Blow Off header
17. Zonal Controls
18. Gauge Indicators etc…… many more
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FRICTION PICK UP MARK
IDENTIFICATION:

1. Feeling With Finger nails ( Might vary Light to Heavy )

2. Always Along The Rolling Direction
3. Normally Localized And Not Scattered Over The WR Width Unlike The
Slippage Or Skid Marks.
4. Very Straight and Shorter Thin Line / Lines Appearing Like Scratch On
The WR. Other Forms Are Generally Associated With Other Defects.
5. Very Often Located At The Work Roll centre
6. Will Occur Mainly At Higher Speeds While Rolling Higher reductions
( Sometimes Might Be Visible At The Coil Body Only )

PHENOMENA:
Friction Pick Up is caused By the metal to metal contact at the roll bite
between Work rolls and the strip surface. This will happen if the Oil
Film at the roll bite is too thin or too weak and is unable to stand the
lubrication demands with respect to the Temp , RF , Speed and the
stand reductions.
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FRICTION PICK UP REASONS AND REMEDY
S.N MOST PROBABLE REASON SUB REASON ACTION
O.
1) High Tramp Contamination ( > 1. Hydraulic 1.) Stop the agitators and the recirculation pumps for
20% ) ( Low SAP Value of The Leakages about 30 min to keep the tank stand still. Top skim all
Emulsion causing less % of the 2. Morgoil Leakages the black scum from the top. Add fresh water and oil
Rolling oil in the emulsion and 3. Greases for build up.
weaker film) 4. Pickling 2.) Check for possible causes of leakages and fix them
Oil

2) ESI Fluctuations causing the 1. Incoming DI 1.) Check and fix the DI water Quality if the pH is low
changes in the emulsion stabilty water 2. Higher 2.) Check the Pickling Rinse parameters and fix them
and the plate out characterstics. Chlorides on strip 3) In case of Bacterial attack ( pH will go extremely
Normally fluctuates with change from pickling low ) Top skim the tank to remove all the top scum,
in pH. 3. Bacterial Attack Heat the tank to about 75 deg to kill bacteria and then
drain by 1/4 level and add fresh water and oil for build
up. In extreme cases full dumping might be required.
4.) To avoid bacteria tanks
should be kept heated to 50 deg with agitators always
on even when mill is not running. Recirculation will
also help.
3) Lower Total Oil Concentrations Standard concentrations should be maintained at all
the times. In case of friction pick up increase in
concentration will definitely help.
4) High Iron Content in the Run magnetic separators to the level where we can
emulsion ( > 500 ppm ) keep the iron in emulsion lower than 500 ppm
regularly. Bottom draining partially the tank with
agitators off and recirculation pumps off from time to
time will also help
5) Higher Reductions than Normal Stick to normal industry standards
6) Higher Temp At Roll Bite ( Coil Improve Roll Coolant pressure / Flow
temp > 115 Deg C )
7) Higher Roll Roughness causing Stick to standard work roll roughnesses
higher friction at roll bite
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EFFECT OF INCOMING STRIP DEFECTS

1) ROLLED IN SCALE:

Might open up and result into tiny holes during rolling and cause strip
break sometimes during thinner gauges especially during tail out. As
such considered more critical to surface quality then to the rolling

1) LAMINATIONS ( SKIN / CROSS )

Skin Laminations or Slivers are more critical to surface quality then to

rolling but occasionally these may stick to the work roll surface causing
roll marks . Cross laminations on the other hand are always dreadful.
They will open up during rolling and cause strip breakage and major
metal pick ups on work rolls most of the times.

If any cross lamination is sighted at entry before entering the roll bite , it
should never be allowed to enter the roll bite as 99 times of hundred there
will be a definite roll mark / strip breakage.
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EMULSION STAINS
SOME KEY POINTS
- Blow Off Header Angle 45 deg with the strip towards roll bite
- Closer to strip as much as possible to act as a air knife and avoid
pressure drop at the strip surface.
- C- type header to allow gradual blow off to the sides
- Maintain the constant air pressure at header
- Put a pressure gauge near operator
- Check the Fume exhaust system for
avoiding the drippings from mill top.
- Block the points of splashing inside
mill housing by providing the metal
/ Rubber guards/ curtains.
- Check the condition of these curtains
during every roll changes.
- Tray below exit cobble Guard
- Entry Back Up Roll Wiper
- Rubber sheet / curtains on the exit on both the sides just ahead of
work roll bite fixed to housing to avoid excessive coolant on strip.
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SLIPPAGE / SKID MARKS ON WR
Some Probable Reasons :
MILL RELATED:
1. Very Low Roll Force
2. Low stand Reduction %
3. High Back Tension
4. High +ve WRB combined with Low RF
5. Very Low Friction at Roll Bite
- High lubrication
- Low W/R roughness
- worn out work Rolls
6. High Pressure of entry HD clamp
causing higher Back Ten. during tail out
7. Low area of contact /small arc of contact
8. Higher draft for Thicker gauges
9. Very Low Iron content in Emulsion

ROLLING OIL RELATED:

1. High Concentrations
2. Unstable Emulsion
3. ESI Fluctuation
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THORY ABOUT SLIP
At Neutral Point “N”
roughness, reduction, ( Strip speed = WR speed )
tension and lubrication
ARE CRITICAL Rolling direction

F1 F2

( Strip Speed < WR speed )

Forward slip
( Strip speed > WR speed )

Back Tension
Roll Life
Roll Force
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LINE DIAGRAM OF THE ELECTROLYTIC
CLEANING LINE

L
L

Lineguard 96

P1 P2 P1 P2 P4
P3
assembly disk
demi-water

CM
CM CM
Brushing Alkali electrolytic rinsing

product dosing standard signal assembly disk, measurements:

measuring and control line L*H*W=1.1*0.7*0.35 m
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Electrolytic Cleaning Line
precleaning electrolytic rinse
spraying brushes cleaning brushes spraying

cascade rinse

cleaner cleaner
solution solution

max. LIC
HL

circulation tanks
LI

LA
Q

horizontal cleaning line

premix tank resp.
storage tank for liquid cleaners
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Electrolytic Cleaning
cathodic reaction:
When the electrode is anode, a) 4 H+ + 4 e- -> 4 H b) 4 H -> 2 H2
the strip gets cathode.
- hydrogen development
- pH-value remains in the alkaline range
(excess of OH-)
- precipitation of metal layers
anodes, cathodes,
strip is cathode strip is anode
H+ H+ OH- OH-

OH- H+

OH- H+

H+ H+ OH- OH-
anodic reaction:
a) 4 OH- -> 2 H2O + 2 O + 4 e- b) 2 O -> O2

- oxygen development
When the electrode is cathode,
- pH-value decreases into the acidic range
the strip gets anode.
(less OH-, excess of H+)
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Surface Contaminations
after cold-rolling after annealing /
temper rolling

- rolling oils - carbon

- rolling emulsions - cracked hydrocarbons
- metal soaps - sintered metal particles
- cracked hydrocarbons - anti-corrosion oils
- metal particles - wet temper agents

i.e.: 100 - 200 mg/m² oil

50 - 150 mg/m² iron fines
After Cleaning max 30 mg/m² max
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Cleaning Effect
Depends on:

Efficiency of the cleaning line

(95 - 99 % oil removal, 70 - 90 % removal of iron fines)

Soil layer of the incoming strip

(50 - 250 mg/m² oil, 50 - 200 mg/m² iron fines)

Efficiency of the cleaning agent

(compound: alkalinity, phosphates, silicates,
complexing agents, surfactants, etc.)

Type of soil
(cracked oil residues, EP-[extreme-pressure] additives)
One! Technologies
Cleaning Process Parameters
Temperature:
70 - 75 °C in spray/brush cleaning sections
80 - 85 °C in electrolytic cleaning sections
Cleaning time:
8 - 12 seconds in spray/brush cleaning lines
5 - 8 seconds in electrolytic cleaning lines
Cleaner concentration:
20 - 30 g/l (powder products)
Spray pressure:
2 - 4 bar (at the spray nozzles)
Current density:
10 - 15 amps/dm² (alternating polarity)
One! Technologies
Cleaning Bath Contaminations
M V1
bath soil
drag-in drag-out
max. bath soil

cleaner solution

overflow bath maintenance

V2 V3 time
life time A life time B
(without maintenance) (with maintenance)

Cleaning of cold-rolled strip

max. oil/fat: 5.0 - 7.0 / 2.0 - 3.0 g/l
max. iron fines: 0.6 - 0.8 / 0.2 - 0.3 g/l
(pre-clean. / electr. cleaning)
One! Technologies
Bath Maintenance

floating oil: - oil separator

- static or dynamic
separators

emulsified oil: microfiltration / ultrafiltration

iron fines: magnetic filter systems

sludge / particles: sedimentation / filtration

One! Technologies
CRITICAL CLEANING LINE PARAMETRS
TANK

ECL Alkali Brush ECL Alkali Brush ECL Alkali Brush ECL Alkali Brush

Concentration Iron Total Oil P-Value

3.0-5.0% 3.0-5.0% 3.0-5.0% < 200ppm < 700ppm < 700ppm < 2g/l < 7g/l < 7g/l >80% M-value >50% M-value >50% M-value

1. Temperature , Conductivity , Brush Pressure, Concentration,

Alkalinity Ratio Checks are critical.
1. Centrifuge, Magnetic filters , skimmer should be used regularly.
2. Alkali Carry Over Check must be carried out every 5th Coil
3. Reverse Reaction can happen if Parameters go out of hand.
 ● High Conductivity
Sodium Hydroxide
One!
(NaOH) Technologies
● Sticking Prevention Ability

● High pH
● Saponifying Ability
Sodium Ortho CLEANER
Silicate
● Emulsifying Ability
CHEMISTRY
(2Na20.Si02) ● Dispersing Ability
Ingredients Vs.
● Reflocculation Ability
Performance
● Water Softening
Attributes
Phosphate-type ● Chelating Ability Ca++, Mg++
Builder
● Chelating Ability -Fe+++
● Wettability
Organic Chelating ● Low Surface Tension
Agent ● Rinsing Ability
● Low-foam Characteristics
Surfactant ● Keep Electrode Clean
● Carbon Depressant
Defoamer
● Corrosion Prevention
● Keep Sediments Tank Bottom
One! Technologies
Powder or Liquid Cleaners

P3 container (Tote-System)
max. LIC

bags screw HL

(dust, steam) conveyor

LI

LA
Q

P3

premix tank storage tank

for for
powder products liquid products

circulation tank
One! Technologies
Powder Products vs. Liquid Products

powder products liquid products

advantages: - highly concentrated - easy handling

- one-package-system - direct dosing
with surfactants - no dust
- no sticking

disadvantages: - manual handling resp. - high water content

premix tank for dosing - dissolving agents are
- risk of sticking required to incorporate
(container/screw conveyor) surfactants
- dust

packaging: - plastic bags - barrels

- steel containers - plastic containers
- tanker
One! Technologies
Liquid Cleaner Versions

Concept: one-package products additives to caustic

description: - all builder substances like - all builder substances like

alkalies, phosphates, silicates, like phosphates, silicates,
surfactants and defoamers surfactants and defoamers
are included are included, but no alkalies

advantages: - unproblematic handling - use of the own, reasonable

caustic soda solution,
- higher concentration of the
active substances

disadvantages: - low concentration - more complex dosing

- expensive dissolvents equipments
One! Technologies
 One! Technologies
HEAT TREATMENT OF CR STRIP
After cold rolling the strip becomes harder and brittle in nature
And can not be used for various forming or drawing operations.
n order to make the steel reworkable for further applications the
Strip is annealed at certain temperatures to attain desired
Mechanical properties and texture.

wo Type of Annealing Facilities Are used generally:

. Continuous Annealing
. Batch Or Bell Annealing
One! Technologies
BATCH ANNEALING
One! Technologies
Main Reasons for Coil Stickers during BA
Not only the silicate layer has to be regarded:
high annealing temperature
heat distribution in the batch
long soaking time
high coiling tension
composition of the protective atmosphere
strip surface with low roughness
roughness of the working rolls
very clean surface
batch annealing irregular strip profile
size of coils (small coils are less sensitive)
silicate deposition is too low during cleaning
no electrolytic cleaning
One! Technologies
MAJOR ANNEALING DEFECTS
Rolling Oil / Cleaning Related

1. Carbon Segregation ( Embedded Carbon )

2. Surface Carbon ( Removable )
3. Snaky Edge

Process Related :
1. Annealing Colour
- Blueing
- Browning
1. Stickers
2. Surface Carbon
3. Improper Hardness
4. Scales
One! Technologies
One! Technologies
TEMPER PASS MILL
After the steel has been softened in the annealing process, a temper
mill
is used to give the steel the desired flatness, metallurgical properties
and
surface finish. The product may be shipped to consumers as coils or
• Mill Equipment is very similar to Rolling Mill stand
furtherfor very Minor Reductions only
• Suitable
side-trimmed or sheared into cut lengths.
• Wet Or Dry Processing
• Generally Non Reversing ROLLING DIRECTION

• TMBP uses DR Mills

• Surface and properties are critical
• Some Mills Are Used As Combination Mills
ENTRY EXIT
ADVANTAGES AND DISADVANTAGES OF WTF

• Minimum Surface Pick ups

• Better Strip Surface
• Improved Quality TEMPER MILL
• No Need Of Oiling At Mill (Corrosion Resistance) BLOCK DIAGRAM
• No Staining
• Emulsion Carry Over Can Be Problem
One! Technologies
TEMPER FLUID PARAMETRS

Based on the experiences from other similar mills:

Flow maintained: 20 – 40 LPM
Pressure : 3 - 5 Bar ( depends on spray
design )
Concentration : 5% - 7%
Spray Angle : Tangential to work roll
Nozzle Spacing : Should cover the whole barrel length
Overlapping required

MAJOR DEFECTS FROM TPM: Coil Breaks, Carry Over rust

Soot marks, Dents , Edge Build up, Roll marks, shape defects,
Etc.
One! Technologies

Thank You &

GOOD LUCK!