Mega-Coil Endless Rolling Layout for Ultra-Thin Hot Strip
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Solution Overview
Problem
Current combined continuous casting and metal strip hot-rolling plants face limitations in producing thin, high-quality hot-rolled products due to mechanical property constraints, requiring both hot and cold rolling processes, which increases production time and reduces flexibility, especially for low-carbon steels, and poses challenges in handling and processing ultra-thin strips.
Innovation Solution
A combined continuous casting and metal strip endless rolling plant with a mega coil system, featuring a continuous casting line, multiple rolling mills, high-capacity reels, and a reversible rolling mill, allowing for the production of ultra-thin strips without jamming issues, and enabling the production of high-quality coils with reduced processing time by integrating all heat and rolling treatments in a single layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hot-rolling is performed immediately after continuous casting to reduce processing time, then productivity is improved, but the mechanical properties and surface quality deteriorate requiring subsequent cold-rolling
Solution Approach 1:
The patent combines hot-rolling and cold-rolling operations into a single continuous production line. The hot-rolled strip is directly fed into cold-rolling mills without intermediate storage or handling, merging two previously separate processes into an integrated system that maintains productivity while ensuring product quality.
Solution Approach 2:
The patent implements continuous processing where the strip flows continuously from hot-rolling through cooling and pickup operations directly into cold-rolling. This eliminates idle time and discrete handling steps, maintaining continuous useful action throughout the process while achieving both high productivity and quality standards.
2Manufacturing precision
If cold-rolling is performed to achieve high surface quality and mechanical properties, then manufacturing precision is improved, but productivity decreases due to extended processing time and warehouse storage
Solution Approach 1:
The patent eliminates the traditional warehouse storage step by implementing direct continuous transport from hot-rolling to cold-rolling. The strip is picked up immediately after hot-rolling and fed continuously into the cold-rolling mills, maintaining uninterrupted useful action and eliminating idle storage time.
Solution Approach 2:
The patent merges the hot-rolling and cold-rolling production lines into a single integrated facility. By combining these operations in one continuous flow, the system achieves high manufacturing precision through cold-rolling while maintaining high productivity through eliminated storage and handling time.
3Manufacturing precision
If ultra-thin strips are produced to meet dimensional requirements, then manufacturing precision is improved, but reliability decreases due to jamming risks during handling
Solution Approach 1:
The patent implements continuous picking and rolling operations where ultra-thin strips are processed without interruption or storage. The strip is picked up immediately from the hot-rolling line and fed continuously into the cold-rolling mills, eliminating the jamming risks associated with handling and storing ultra-thin strips while maintaining precise thickness control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables the production of thinner strips with improved mechanical properties, reduces processing time from two months to one month, and allows for the production of DQ, DDQ, and EDDQ products with properties comparable to cold-rolled products, enhancing production flexibility and efficiency.
Implementation Method 1
a first rolling mill for roughing the slab and for obtaining a transfer bar; a second rolling mill for finishing the transfer bar and for obtaining a strip; a third rolling mill, comprising at least two first rolling stands, for further reducing the thickness of the strip
Implementation Method 2
accumulation means of the strip, downstream of said third rolling mill, comprising at least one first high-capacity reel, sized to wind and unwind a coil weighing from 80 to 250 metric tons and/or up to 6 meters in diameter, named mega coil
Data Source
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AI summary
A combined continuous casting and endless rolling plant for a metal strip, comprising - a continuous casting line (1 ) for casting a slab; - a first rolling mill (6) for roughing the slab and for obtaining a transfer bar; - a second rolling mill (11) for finishing the transfer bar and for obtaining a strip; - a third rolling mill (18), comprising at least two first rolling stands (17), for further reducing the thickness of the strip; - accumulation means (20) of the strip, downstream of said third rolling mill (18), comprising at least one first high-capacity reel (37, 37') dimensioned to wind and unwind a coil weighing from 80 to 250 tons and/or up to 6 meters in diameter, named mega coil; - flying cutting means (13), arranged between said third rolling mill (18) and said accumulation means (20), configured to cut the strip after the mega roll has been wound on the at least one first reel (37, 37'); - a cutting and winding line (22), downstream of said accumulation means (20), for cutting the strip of the mega coil and winding portions of said strip of the mega coil to a predetermined weight limit or coil diameter limit, producing a plurality of coils; wherein said cutting and winding line (22) is provided with a reversible rolling mill for performing at least one rolling of the strip before producing said plurality of coils.