Presentation On

HRAP
By, Vikrant Patel

KEY SECTIONS OF LINE

Uncoiler Welding Section Entry Looper

Shot Blast

Quenching Section

Furnace

Pickling

Exit Looper

Recoiler

Basic Technical Data

Type:- Continuous Annealing Pickling Line. Line Direction: - Left to Right (viewing from operator side) Material: - HOT ROLLED COILStainless Steel Strip, Strip width: - 850 mm (min.) 1,560 mm (max.) Strip thickness: - 2.0 - 7.0 mm Coil weight: - 28,000 kg max. Exclusive sleeve and interleaving Coil ID: - ID - 660 mm Coil OD: - OD - 2200 mm max

Entry Section Specification

Entry Coil Storage Saddle : Capacity : 28,000 kg Coil OD : 2200 mm max / 850 mm min Entry Coil Car :- Lift capacity 28,000 kg Uncoiler 1 :Coil ID : 660 mm Coil OD : 1850 mm (max.) Expand diameter : 760 mm Collapse diameter : 608 mm Uncoiler 2 : Coil ID : 660 mm Coil OD : 1850 mm (max.) Expand diameter : 760 mm Collapse diameter : 608 mm

Oxytechnik Welding
This welding process is a MIG welding. An endless wire is fed through a torch with 100 % Argon (shielding) gas supply. The wire movement is motorized. Inert gas is chemically neutral, no reaction with the molten metal. Active gas is an inert gas with an addition of an active gas (i.e. 3 % oxygen ), this reacts with the metal and heats up the weld.

Welder Unit comprising of:1. Shearing Operation 2. Welding Operation 3. Notching Operation

Welding Parameters & Precautions

Parameters: Feed wire rate:- 1150 ~1170 rpm Welding Current :- 220~240 amp Argon flow rate :- 15 m3/hr Welding Carriage speed :- 2-5 mpm Precautions: While working on shear or handling scrap pieces, use hand gloves Dont put hands below the shear while cutting Dont see welding light with naked eye

Entry Horizontal Accumulator

This is an arrangement used for accumulating the strip for uninterrupted operations of the process while joining the two coil ends together in order to make the strip continuous. The storage capacity is 200 mtrs.

FURNACE TECHNICAL SPECIFICATION

Overall dimension.
Total length from entry -seal to exit seal roll Length of furnace no 1. Length of furnace no 2 Length of furnace no 3. Length of furnace no 4. Width inside furnace No 1 & 2. Width inside furnace No 3 & 4. 72.510 mtrs 14.600 mtrs 14.600 mtrs 18.760 mtrs 18.760 mtrs 3.438 mtrs 2.638 mtrs

Furnace section
Zone temperature and strip temperature Burner operation (switch over) Furnace roll condition Catenary position Excess Oxygen (periodically) Gas leaks Follow proper procedures for lighting up and shutting down

Furnace Parameters
NO OF FURNACE

NO OF HEATING ZONES

NO OF BURNERS EACH ZONES

TYPE OF BURNERS

TOTAL NO OF PILOT BURNERS

NO OF REGENR ATIVE BOX

F#1 F#2 F#3 F#4

3 3 3
14 Nos
EJ 18 Burner 06 Nos 60/80 Burner 08 Nos 30/40 Burner 18 Nos

14 Nos

14 Nos

18 Nos

18 Nos

18 Nos

16 Nos

30/40 Burners 06Nos 20Therm 05 Nos 15 Therm -05 Nos

06 Nos

06 nos

FURNACE TEMPERATURE

Zone 4 in C 1000

Zone 5 in C 1000

Zone 6 in C 1030

Zone 7 in C 1060

Zone 8 in C 1100

Zone 9 in C 1120

Zone 10 Zone 11 Zone 12 in C in C in C 1120 1120 1100

QUENCHING SECTION & Dryer

Air Quenching

Air & Water Quenching

Water Quenching

Dryer

Shot Blasting Section

Shot blast Specification:
No. of wheels No. of wheels on top No. off wheel on bottom Shot Blasting Chamber Elevator Dust Collector No. of shaker No. of filter Steel Shots used 4 /Chamber 2 /Chamber 2 /Chamber 3 2 /Chamber Shaker type 2 132 S-110

Pickling Section
Mixed Acid Pickling Tanks 1, 2, 3, 4 & 5 Tank capacity : 65 m each
Acid Bath Parameter
HNO3 Concentration HF Concentration Temperature (0C) Metals (g/l) Re-circulation Flow (m3/hr) Re-circulation Pressure (bar) Tank Turbulence Range 120-145g/l (12-14.5%) 32-40 (3.2-4%) 55-65 25-30 -

Aim
135g/l (13.5%) 36g/l (3.6%) 60 25 2 x 200 2 100%

100%

Pickling Reactions
HNO3 penetrates the cracks/pores in the oxide
+ + + + + + + + + + + + + + + +

+ +++
+

The chemical dissolution of the chromium depleted zone ceases when the concentration of Fe3+ is high enough

2 Fe + 3 NO3- + 6 H+

Only nitric acid (HNO3) is operating

+ + +

2 Fe3+ + 3 NO2- + 3 H2O

Pickling
# # # # # # # # # # # ## #

# # # +++++++++++++++++++++++

The positive iron ions (+) reacts with hydro fluoric acid forming complex ions (#) allowing HNO3 to continue dissolving the chromium depleted zone. The nitrous fume contributes to the scale breaking.

Clean surface
Fe3+ + 2 HF Fe3+ + 3HF 2 NO2- + 2H+ FeF2+ + 2H+ FeF3 + 3H+ NO + NO2 + H2O

Both HNO3 and HF are operating!!!

Rinsing Section
High Pressure Rinse
One pump on duty, one pump on standby Flow rate 270 l/min 4 spray bars on duty (2 top, 2 bottom) and 4 spray bars on standby Water pressure 95-110 bar Water temperature ambient Contamination non- recirculating system

Low Pressure Rinse ( Hot Condition)

Flow rate 25m3/hr Water pressure 2 bar Tempreture - 50 60 0C Brushes 16 to 20 amps

EXIT SECTION
Exit Accumulator The storage capacity is for 180 mtrs. Recoiler Coil ID : 660 mm Maximum coil OD : 1850 mm Maximum coil weight : 22000 kg. Nominal dia. : 660 mm Exit Coil Car Exit Coil Storage Saddle with coil weighing system

LINE SPEED
Thickness (mm) Speed (m/min) 1025 & 1275 mm wide 2.5 3 3.5 30 30 28 1525 mm wide 24.6 24.6 24.6

4
4.5 5

24.6
21.8 19.6

23.9
21.4 19.2

Tension Parameters
Tension Unit Factors: Uncoiler Entry Accumulator Furnace Shot Blast Pickling Exit Accumulator Recoiler 0.3 -0.5 kg/Cm 0.8 -1.0 kg/Cm 0.5 -0.8 kg/Cm 0.8 -1.0 kg/Cm 0.3 0.5 kg/Cm 1.5 1.8 kg/Cm 2.5 - 3.0 kg/Cm

Formula For Calculating Tension:Width thickness unit factor = Tension

Thank You