Multi-Mode Hot-Rolling of Steel Strips and Plates
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Solution Overview
Problem
Current steel production methods for hot-rolled strips and plates face challenges in achieving high productivity, flexibility, and quality while minimizing energy consumption and environmental impact, with limitations in batch production, slab surface quality, and waste reduction.
Innovation Solution
The implementation of a process that includes a 'kiss pass' stand for crystalline structure optimization, a narrow face vertical rolling stand for edge recrystallization, an interconnecting furnace for production flexibility, and a dedicated cooling system for improved plate quality, allowing for both 'endless' and 'batch' production modes with reduced energy consumption and increased plant profitability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a continuous casting-rolling process is used to achieve high productivity, then production efficiency is improved, but production flexibility is reduced
Solution Approach 1:
The patent implements a dynamic production system that can switch between continuous mode (for high productivity) and batch mode (for flexibility). The continuous caster can operate continuously while the rolling mill can process slabs in batches or continuously depending on product requirements. This dynamic operation mode allows the system to adapt to different production scenarios, resolving the contradiction between maintaining high productivity and achieving production flexibility.
2Manufacturing precision
If a roughing mill with high reduction capability is used, then intermediate product quality is improved, but temperature loss increases
Solution Approach 1:
The patent applies preliminary heating actions before the roughing mill to ensure slabs enter at optimal temperatures. Additionally, the system uses insulation measures and optimized rolling schedules to minimize temperature loss during the high-reduction roughing process. By preparing the material in advance and controlling the process conditions, the system achieves both high intermediate product quality and reduced energy loss.
3Temperature
If an induction heater is used to compensate temperature decrease, then product temperature is maintained, but energy consumption increases
Solution Approach 1:
The patent employs localized heating zones within the induction heater system, applying heat only where and when needed rather than heating the entire slab uniformly. This localized approach maintains product temperature in critical areas while minimizing overall energy consumption. The system also optimizes heating parameters based on real-time temperature monitoring to further reduce energy usage.
4Reliability
If emergency extraction of rough-rolled plates is implemented, then continuous casting process stability is improved, but product quality is compromised
Solution Approach 1:
The patent introduces an intermediate storage and processing system between the continuous caster and rolling mill. When emergency extraction is needed, rough-rolled plates can be diverted to this intermediate system for proper cooling and processing, rather than being immediately scrapped. This intermediary system allows the continuous casting process to maintain stability while still producing usable products with acceptable quality.
5Productivity
If cooling system parameters are optimized for coils, then coil production efficiency is improved, but plate production quality is reduced
Solution Approach 1:
The patent implements a dynamic cooling system with adjustable parameters that can be optimized for different product types. The cooling system can switch between coil-optimized parameters (for high efficiency) and plate-optimized parameters (for high quality) based on the current production requirements. This dynamic adjustment capability allows the system to maintain high productivity for coils while achieving excellent quality for plates.
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
This approach enhances productivity, flexibility, and quality of hot-rolled strips and plates, reduces energy consumption, and minimizes waste by optimizing crystalline structure, edge quality, and introducing a flexible production mode, while maintaining high product quality and environmental sustainability.
Implementation Method 1
a heating phase in an induction heater
Implementation Method 2
the slab that enters the rolling mill is separate and with a different speed from the one present in the continuous casting machine
Implementation Method 3
a rolling mill 4 followed by a rotary shear 5
Data Source
Figure 1
AI summary
A process for the endless or batch production of strips and plates of hot-rolled steel, with thickness from 0,6 mm to 50 mm, comprises the continuous casting (1) with liquid core reduction of a thin slab (S) having a minimum thickness of 80 mm, followed by a heating in an induction heater (2), a finishing rolling (4), a controlled cooling (6) and a final shearing (5; 8), and further includes prior to said heating in an induction heater (2) an initial rolling (10) with a thickness reduction of the slab (S) of only about 10% and in any case not more than 20%, starting from a thickness reduction of about 8 mm.