TO LEARN

ABOUT COLD
ROLLING MILL
OVERALL PROCESS LAYOUT
COLD ROLLING MILL-PROCESS
Cold roiling mill carried out under recrystallization
temperature.
The starting material of cold-rolled is steel sheet is pickled
hot-rolled breakdown coil from the continues hot strip mill.
The total reduction achieved by cold-rolling generally will
vary from about 50-90%.
Generally the lowest percentage reduction is taken place in
the last pass to permit better control of flatness, gage, and
surface finish.
Cold rolling provide product with superior surafce finish
(due to low temperature-no oxide scale)
Better dimensional tollarance compared with hot rolled
products due to less thermal expansion.

COLD ROLLED METALS ARE RATED
AS TEMPER
Skin rolled: metal undergoes the least rolling
~0.5-1% harden, still more workable.
Quarter hard: Higher amount of deformation.
Can be bent normal to rolling direction
without fracturing
Half hard: Can be bent up to 90
Full hard: Metal is compressed by 50% with no
cracking. Can be bent up to 45.
PICKLING LINE

WHAT IS PICKLING?
Pickling is a metal surface treatment used to remove
impurities, such as stains, inorganic contamination, rust or
scale from ferrous metals, copper, and aluminum alloys.
A solution called pickle liquor, which contains strong
acids, is used to remove the surface impurities. It is commonly
used to descale or clean steel in various steelmaking process.
HOT ROLL SCALE FORMATION
Many hot working process and other process that occur
at high temperatures leave a discoloring oxide layer or
scale on the surface.
In order to remove the scale the work piece is dipped
into a vat of pickle liquor.

PICKLING AGENTS
The primary acid used is hydrochloric
acid, although sulfuric acid was previously
more common, hydrochloric acid is more
expensive than sulfuric acid, but it pickles
much faster while minimize base metal loss.
The speed is requirement for
integration in automatic steel mills that run
production at high speed; speed as high as
243 mpm have been reported
PICKLING LINE #1
SPECIFICATIONS
Semi Continuous line
Line speed 170 MPM maximum
Entry looper capacity 20 MTRS
Exit looper capacity 10 MTRS
4 Acid tanks
6 Rinsing tanks
1 Hot air drier
Capacity of line 6,00,000 MTPA
Manual arc welder


PICKLING LINE #2
SPECIFICATIONS
Continuous line
Line speed 150 MPM maximum
Entry looper capacity 400 MTRS
Exit looper capacity 200 MTRS
5 Acid tanks
4 Rinsing tanks
2 Hot air drier
Capacity of line 8,00,000 MTPA
Manual arc welder
Online trimming
Coil preparation before pickling
PARAMETERS
HCL Concentration
% of Scale formation (Fe2O3,Fe3O4,FeO)
Flow rate of HCL
Temperature
Line speed
PREPARATION FOR PROCESS
Perfect HEAD end of roll
Remove Edge Wavy
Remove telescopic error
Do notching before Welding
Align HEAD end to TAIL end

PRECAUTIONS DURING PROCESS
Keep Tension in line for reduce waviness
Reduce sleeping of sheet using pinch roll
Maintain speed above optimum value to reduce
high contamination of HCL
Maintain Looper for some undesired time delay
Maintain HCL concentration, temperature and
flow rate
Maintain RINSING water flow and Air drier flow.
RECOILER PRECAUTION
Maintain Shearing time and Alignment
Keep mandrel perfectly positioned to reduce
telescopic error
Maintain Coil CAR Speed and Alignment to
reduce telescopic error and time delay

MODIFICATION ACCORDING TO ESSAR
PICKLING LINE
HCL FLOW RATE
NOZZEl
CONSENTRATION
PUMPING PRESSURE
LOOPER ARRENGEMENT
VERTICAL LOOPER INSTEAD OF LOOP PIT


COLD ROLLING
MILLS
TANDEM
MILLS
Rolling mills may be classified according to the number and
arrangement of the rolls.
(a): Two high rolling mills
(b): Three high rolling mills
(c): Four high rolling mills
(d): Tandem rolling mills
(e): Cluster rolling mills
Four high rolling mill:
It has a roll stand with four parallel rolls one above the
other. The top and the bottom rolls rotate in opposite
direction as do the two middle rolls. The two middle are
smaller in size than the top and bottom rolls which are
called backup rolls for providing the necessary rigidity to
the smaller rolls.


A four high rolling mill is used for the hot rolling of armor
and other plates as well as cold rolling of plates, sheets and
strips.
Tandem rolling mills:
It is a set of two or three stands of roll set in parallel
alignment. So that a continuous pass may be made through
each one successively with change the direction of
material.
5-STAND 4-HI SPEED CONTINUES
TANDEM MILL (CTCM)
5-STAND 4-HI SPEED CONTINUES
TANDEM MILL SPECIFICATIONS
Supper-SVAIC
Capacity-1.2 MTPA
Work roll Diameter-480 to 560
Backup Diameter-1350 mm to 1500 mm
Rolling force-3000T by stand
MILL SPECIFICATION
Mill type
4-HI-5-Stand continuous cold rolling mill
mill speed maximum 1000 mpm
entry product thickness 1.55 to 5.00 mm
exit product thickness 0.2 to 3.00 mm
coil max width 650 (min) to 1625 mm(max)
Special Features
Flush butt welder
90 turning pit
6-Stand-600 meters entry looper
L-2 automation
Mill clean system
Automatic flatness control
Automatic thickness control
Coil maximum weight -28MT
DSRI In Std#5 for better shape control
Flying shear to cut the sheet at 200 mpm
Product control
Shape less than 10IU
Thickness +- 1% and 98TOG


6-HI-1-STAND REVERSING
COMBINATION COLD MILL
LINE SPECIFICATION
MATERIAL
Hot rolled and pickled low carbon steel
THICKNESS
1.20 mm to 4.80 mm
WIDTH
700 mm to 1270 mm
FINISH PRODUCT THICKNESS
0.15 mm to 1.60 mm
MAXIMUM TENSION
12.2 MT
Continues
Galvanizing Line

GALVANIZING
Hot-dip galvanization is a form of galvanization. It is the process of coating
iron, steel or aluminum with a thin zinc layer, by passing the metal through
a molten bath of zinc at a temperature of around 860 F (460 C). When
exposed to the atmosphere, the pure zinc (Zn) reacts with oxygen (O
2
) to
form zinc oxide (ZnO), which further reacts with carbon dioxide (CO
2
) to
form zinc carbonate (ZnCO
3
), a usually dull grey, fairly strong material that
stops further corrosion in many circumstances, protecting the steel below
from the elements. Galvanized steel is widely used in applications where
rust resistance is needed, and can be identified by the crystallization
patterning on the surface (often called a spangle).
Galvanized steel can be welded; however, one must exercise caution
around the resulting zinc fumes. Galvanized steel is suitable for high-
temperature applications of up to 392F (200C). The use of galvanized
steel at temperatures above this will result in peeling of the zinc at the
intermetallic layer. Electro galvanized sheet steel is often used in
automotive manufacturing to enhance the corrosion performance of
exterior body panels; this is, however, a completely different process.

CONTINUES GALVANIZATION LINE #1
SPECIFICATION
In put material : Cold rolled / hot rolled low carbon,
including structural steel
Strip thickness : 0.30mm (min) to3.25mm (max)
Strip width : 800mm(min) to 1370mm
Coil weight : 25 T (max) / 5 T (min)
Coil inner Dia() : 508 / 610 mm
Outer Dia : 1800 Max
Line speed : 160 mpm
THREAD SPEED : 20 mpm
Process : 160mpm
Entry and recoiling : 200mpm
Furnace : 56 tph

CONTINUES GALVANIZATION LINE #2
SPECIFICATION
In put material : Cold rolled, including structural steel
Strip thickness : 0.12mm (min) to 0.60mm (max)
Strip width : 700 mm (min) to 1250 mm
Coil weight : 22 T (max) / 5 T (min)
Coil inner Dia () : 508/610 mm
Outer Dia : 1800 Max
Line speed : 150 mpm
THREAD SPEED : 20 mpm
Process : 150 mpm
Entry and recoiling : 180 mpm
Line Capacity : 25 TPH
Cold Rolled
Close
Annealed
(CRCA)

PROCESSES
ECL
Batch Annealing Furnace
Cold Skin Pass Mill
LIR
FIMI
ICTL
DMS
ELECTROLYTE CLEANING
Electrolyte - A substance, in solution with water
or another liquid, which is chemically changed by
passage of electric current through it.
The electrolyte we use and refer to is the
substance you mix with water in a bucket into
which you place an electrode and the part you
wish to clean.
Ion - An atom or group of atoms that carries a
positive or negative electric charge as a result of
having lost or gained one or more electrons.


.
REQUIREMENT OF ELECTROLYTIC
CLEANING
Cold rolled coils processed in cold rolling mills have a thin film of residual rolling oil on the surface
after rolling. The alkaline cleaning of cold rolled coils by the use of high current density (HCD)
ensures totally clean surface of the strip before annealing. This electro-chemical cleaning process is
called Electrolytic Cleaning and the processing line the Electrolytic Cleaning Line.
These techniques are more effective in cleaning cold rolled steel than conventional cleaning
processes used on high speed electro tinning and alkaline-cleaning lines.
A cleaning of 92% was achieved by Essar Indonesia using Dassnagar's high-current-density
Electrolytic Cleaning lines
They are categorized into two types :
High Current Density (HCD) Electrolytic cleaning lines
Low Current Density (LCD) Electrolytic cleaning lines
Fact sheet
Following figures have been achieved :





Cleanliness : 95%
Cleaning solution used : Na
4
SiO
4


Contaminants Incoming Strip Outgoing Clean Strip

Oil and Dirt 800 mg / sq. meter 20 mg / sq. meter
Iron Fines 200 mg / sq. meter
ELECTROLYTE CLEANING LINE(ECL)
SPECIFICATION
THICKNESS
0.25 to 3.0
WIDTH
600 to 1650 mm
LINE SPEED
270 mpm
STRIP TENSION
12 N/mm
OIL AND DIRT INPUT
400 mg/m/face
IRON FINES INPUT
200 mg/m/face
STRIP FLATNESS
50 IU
PARAMETERS
Hot alkaline tank temp 70-79C
Hot alkaline concentration 30-70 mg/lit
Residual oil load in hot alkaline tank-5 mg/lit
Iron load in hot alkaline tank 1.5 mg/lit
Electrolytic cleaning tank temp 70-90C
Electrolyte cleaning concentration 40-90 mg/lit
Residual oil load in electrolyte cleaning tank 3 mg/lit
Dissolved iron in electrolytic cleaning tank1.5 mg/lit
Dryer temperature >80 C
Iron level on the strip at output (max 25 mg/m per surafce OR reflectivity >70%)
Reflectivity of the strip at output min 70%
Oil level on the strip at output max 50 mg/m per surface OR reflectivity >70%
Alkaline/water carry over
No carry over allowed
Scratchiness latent
Not allowed

ANNEALING
In A Cold Rolling Mill, Hot Rolled Steel Strips Are Rolled At Low
Temperature To Achieve Improved Surface Quality And Mechanical
Properties To Decrease Thickness Of Steel Sheets.
Extensive Deformation During The Cold Rolling Operation And Low
temperatures Reduces The Formability And Ductility Of Cold Rolled
Sheets Significantly.
Therefore Cold Rolled Sheets Must Be Annealed.
During The Annealing Operation, Deformed Microstructures Of The
Cold Rolled Sheets Are Recovered And Recrystallization Takes Place.
There Are Two
Types Of Annealing Process:
The Continuous Annealing Line (CAL)
And Batch Annealing Furnace (BAF)
BATCH ANNEALING FURNACE
PROCESSES
Charge preparation-At first, on the base unit, several cold rolled steel coils are
place done above the other. These cylindrical shaped coils are called charge.
Loading-After loading the base with the coils, a protective cover is put in place and
hydrogen gas is circulated with in this enclosure.
Clamping-Then a furnace is placed over this cover.
Tightness test
Initial nitrogen purging
Heating and soaking-The protective cover is heated through burners of furnace,
and it heats circulating hydrogen gas, then inner and outer surfaces of the coils get
heated by convection from circulating hydrogen gas and by radiation between the
cover and the coil. The inner portions of the coil are heated by conduction.
Radiating
Cooling-Cooling hood is placed on protective cover.
Final nitrogen purging
Unclamping-Remove protective cover from charges.
Unloading and coil identification
LIR
Specifications:
Slitting line 2 LIR LINE
Make M/S DMS France
Capacity 18000 MTPA
Strip thickness 0.4-2.5
mm
Strip width 600-1500 mm
Slit minimum width
300mm
Slit maximum width 3
pieces
Yield strength 45
kg/mm^2(maximum up to
3 mm THK)
FIMI
Specifications:
Shearing line -FIMI LINE
(cut out length line)
Make M/S FIMI Italy
Capacity 140000 MTPA
Strip thickness 0.3-3.0
mm
Strip width 400-1600 mm
Shear length 500-3500
mm
Yield strength 42 N/50mm

DMS
Specifications:
Slitting line 1 DMS LINE
Make M/S DMS France
Capacity 69900 MTPA
Strip thickness 0.3-3.0
mm
Strip width 500-1300 mm
Slit minimum width
250mm
Slit maximum width 5
piece
Yield strength 42
kg/mm^2(maximum up to
3 mm THK)

ICTL
Specifications:
Slitting line 3 ICTL LINE
Make M/S DONG BANG,
korea
Capacity 300000 MTPA
Strip thickness 0.3-3.0
mm
Strip width 600-1650 mm
Slit minimum width
1000mm
Slit maximum width 1
pieces
Yield strength 45
kg/mm^2(maximum up 3
mm THK)

COLD SKIN PASS MILL

Against the background of a global market, rolling-mill owners are under
constant pressure to cut their production costs and to open up new market
segments with the help of innovative products. At the same time, requirements
in terms of strip quality, such as thickness and flatness tolerances, surface
structure and mechanical properties, are becoming increasingly strict.
SMS Siemag, as a provider of complete solutions for rolling mill equipment, is
faced with the challenge of taking appropriate measures to help achieve these
targets. Therefore, conducting continuous and wide-ranging development
activities is indispensable to SMS Siemag. Long-standing solutions need to be
questioned and new technologies examined for their usability and benefits in
rolling mills. With regard to skin pass rolling, our main areas of development are:
Improving flatness and surface quality
Increasing flexibility to handle high-strength material such as DP1000 as well as very soft
material like interstitial-free (IF) grades
Improving the automation by process models and control systems based on innovative online
measurement devices
REQUIREMENT
Besides the feed-forward module the
structure of the controller consists of a
tension control component as well as
an adaptive force control component
for feedback control. The feed-forward
module calculates, based on the
implemented model, the actual set-up
as well as the actual speed, the force
and tension values, which are added
to the output of the feedback
controller. Thus, the elongation control
achieves the desired elongation faster
in transient situations and so reduces
the length out of tolerance.
The difference in the adjusted force by
the feedback control and the predicted
force by the feed-forward module is
shown in Figure . It is apparent that
the feed-forward controller would
raise the force faster and thus reduce
the off-tolerance length.
SKIN PASS MILL
APPLICATIONS OF COLD ROLLED
STEEL SHEET
GENERAL PURPOSE COLD ROLLED
STEEL SHEET AND COIL(JIS:G 4131)
THANK YOU
CREATED BY:
HARSH A. KALSARIYA