Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

Cold Rolling Mill (CRM) Complex is a set of different sequential Processes includes the following
Operations/Processes.
1. HR Slitter:
Slitting serves three purposes (i) HR coils are available in width which are wider than the required
for Cold Rolling. In order to make them compatible with the Cold Rolling facilities and the
requirement of the end product, these coils are required to be slitted. (ii) have the profile being
thicker in the center and sloping down towards the edges. In order to minimize the variation in the
final output, it is imperative that edges on both sides of the HR coils are trimmed.This trimming /
slitting is done with the HR Slitter. (iii) The HR coils available may have width variation of the
order of upto 20 mm, so to get the uniform width these coils are slitted.
Specifications:
1
2
3
4
5
6

Line Speed
Arbor diameter
Strip width range
Strip thickness range
Max coil weight
Max no. of slits

0-50-100 mpm
225 mm
750 1850 mm
1.6 6.00 mm
42.55 tons
15

2. Pickling:
The HR Coils, in their raw form, have deposits of ferric oxide (Rust) and other similar
impurities on the surface. Before further processing these impurities are required to be
removed.
For this purpose, the HR Coils after slitting are passed through a hot water bath, before
being introduced in the pickling line. Picking means cleaning of HR Strips in hydro
choleric acid tanks. During the process, the HR coils are passed, at a constant speed,
through three/five tanks full of hydro choleric acid, with the help of roller fitted in these acid
tanks. At the time of exit from the last tank, because of chemical reaction of the hydrochloric
acid with the steel, a corrosion in the steel occurs with a resultant loss of around 0.5% to
0.75%. After this acid bath, in order to provide the strip with an acid free surface, the HR
sheet is rinsed first in hot water and then fresh water in five stages to remove the carry-over
acid from the strip. And finally this strip is coated with a thin layer of rust preventive oil
after being dried by hot air blast, in order to avoid further oxidization of the strip surface.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

Specification:
1
2
3
4
5
6
7

Line Speed
Winding tension
Acid temp in pickling tank
Water temp in rinse tanks
Coil Weight
Strip Thickness
Strip Width

0-120 mpm
10 tons max
80-85 oC
75 80 oC
38 tons
1.6 8.0 mm
700 - 1650 mm

This Pickling operation can be controlled with the help of four factors:(i)

The concentration of the acid in the pickling tank, more the concentration faster will
be the reaction and vice versa. The concentration of acid varies from 2.5% at the
time of entry of HR coils into the first pickling tank to 18% at the time of exit from
the last tank.

(ii)

The temperature of the acid in the pickling tank, more the temperature faster the
reaction will be and vice versa. The temperature of the acid is kept about 80-85oC in
all the tanks.

(iii)

Speed of the steel strip into the pickling tank, more the speed lesser the pickling will
be and vice versa. The max speed can go upto 120 meters per minute.

(iv)

The quality of the steel strips to be pickled, more rusty the strip will be longer time it
will take to be pickled and vice versa.

If the HR sheet remains in the acid both for a longer duration, it can results on over pickling due to
excessive exposure to chemical reaction, and the HR sheet which have passed through acid remain
exposed to air before entering the water tanks, and due to oxidization may develop rust on its
surface.To avoid such occurrence the acid is drained out, in case of interruption in the plant
operation so that strip doesnt get rusted/over pickled.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

3. Acid Regeneration Plant (ARP):

The ARP (Acid Regeneration Plant) regenerates hydrochloric acid from waste pickle liquor from
the acid pickling line on the principle of pyrohydrolysis by applying fluidized bed technology.
The rinse water and the waste acid which are needed during the process are stored in the tank farm
and pumped to the regeneration.
Regenerated acid which is generated during this process is pumped to the shifting tank regenerated
acid inside the tank farm.
Capacity:

2.5

m/h

>

18

wt%

470

kg/h

Products
(A) Regenerated Acid

HCl
(B) Iron Oxide

quantity

3.1 Gas cooling and preconcentration

After the waste acid coming from the tank farm the liquor is directed into the liquid separator. The
liquid separator is also the feeding bin for the preconcentrator feeding pumps, which circulates the
waste acid through the venturi evaporator.
By this, the hot roast gas is cooled down from 850C to approximately 98C and dedusted. While
the solution is heated and concentrated, the latent heat of the roast gas is recovered.
The liquid drops are separated from the gas in the liquid separator. From the separator, the
concentrate is directed to the reactor. The liquid level in the separator is controlled by the feed of
waste acid while the density of the concentrate is controlled by adding rinse water. Adding rinse
water is necessary to avoid crystallizing of iron chloride.
3.2 Roasting process
The concentrated solution is pumped into the reactor via one acid lance from the wall onto the
fluidized bed. At the bottom of the reactor a burner system consisting of multiple tuyere nozzles is
installed. The combustion air is delivered by the combustion air fan to the wind box chamber. From
this chamber the air enters the reactor via the burner nozzles. Inside the burner nozzles fuel and air
are mixed and the combustion takes place directly within the bed thus fluidizing the oxide
granulates and generating the heat for water and free acid evaporation and iron chloride
decomposition according to the following reaction equation.
2 FeCl2 + 2 H2O + O2

Fe2O3 + 4 HCl

2 FeCl3 + 3 H2O

Fe2O3 + 6 HCl

A certain amount of excess air delivers the oxygen needed for roasting reaction. Inside the reactor

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

the temperature is controlled by the feed rate of acid and is kept constant over bed and freeboard
due to good mixing of particles and gas.
The oxide produced forms layers (onion structure) on the existing particles. The fines produced in
the reactor are carried out together with the reaction gas and are separated in a cyclone and recycled
back into the reactor.
IMPORTANT NOTE: Hot part of the plant is protected by refractory on the inside of equipment
(reactor, cyclone, roast gas duct). Refractory material must be handled with care and shall always
have the same temperature. For that it is strictly recommended that the plant is being operated
smoothly, and heat up/ cool down operations shall not be done more often than five times per year,
as otherwise there will be immoderate wear.
3.3 Oxide handling
The oxide is discharged into a cooled screw conveyor and transported by a bucket elevator to the
oxide bin.
Above the roaster are the oxide start up bin and the fine oxide bin. The roster is filled with oxide out
of these bins.Absorption Downstream of the preconcentrator, the cooled roast gas enters the
absorption column. Here the roast gas is intermixed with rinse water. Withdrawn from the bottom of
the absorption column regenerated acid is led by absorption transfer pumps to the tank farm. HCl of
the roast gas is absorbed into the liquid and allows producing a 17% to 18% hydrochloric acid,
provided the correct ratio between roast gas and rinse-water is applied.
The safety column is fed with rinse water which is led to the bottom of the column and circulated to
the top and to the top of the absorption column.
3.4 Exhaust gas cleaning
The exhaust gas is drawn through the plant by a speed controlled exhaust gas fan which controls
negative pressure in the roast gas pipe. Thus neither fugitive gases nor dust can escape to the
environment. As the fan is sprayed with water to prevent it from corrosion and further aerosol
removal, a droplet separator is installed behind the fan and the wash water which is collected von
the bottom off the droplet separator is directed to the safety column.
After the droplet separator the exhaust gas enters a venturi scrubber charged with industrial water
from the final scrubber which is circulated to the throat. HCl and dust are removed here by the
water spray. The liquid drops are separated from the gas in a flooded elbow. Before the exhaust gas
leaves the process via the stack to the atmosphere it passes a final scrubber where the gas again is
brought into contact with industrial water.
3.5 Tank farm
Connected to the regeneration plant is the tank farm, in which the liquids from and to regeneration
can be stored. The tank farm is also connected to the pickling line, to receive waste acid and rinse
water from the pickling line.
Additionally inside the tankfarm there is a fresh acid loading from the fresh acid wagon.
The fumes from the tank farm are cleaned in the tank fume scrubber and transported to the final
scrubber.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

3.6 Tank farm Capacity

Rinse Water
: 160 KL
Waste Pickle Liquor : 320 KL
Regenerates Acid
: 160 KL
Fresh Acid
: 160 KL

BSL Acid Regeneration Plant Schematic Diagram

Rinse
Water

Waste
Acid

Regenerated
Acid

Fresh
Acid

Waste
Acid

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

Rinse
Water

Waste
Acid

Regenerated
Acid

Fresh
Acid

Waste
Acid

BSL Acid Regeneration Plant -- Tank Farm Area

4.Cold Rolling:
The primary function of Cold Rolling is to reduce the thickness of Hot Rolled Pickled strip
at room temperature. During the operation overall max reduction of upto 85 % in thickness
of the HR Coil can be achieved.
The reduction in the thickness of HR Coil is achieved by passing the steel strip at room
temperature between a pair of rolls (called work rolls) which are made of induction
hardened special alloy steels, under heavy rolling force being applied from top and bottom
sides of the rolls with the help of hydraulic system and tension between the entry reel and
delivery reel of mill.
Every time the strip passes through the work rolls of CR mill, it is referred to as a Pass
and on an average during each Pass there is a reduction of between 15-40% in the
thickness of steel strip.
The broad specifications of the 1020 mm 6HI mill are listed below
1
2

Strip width range

Strip thickness range

3
4
5

Mill Speed
IMR shifting
Roll separating force

500 1020 mm
1.4 4.5 mm (Incoming)
0.14 2.0 mm (Outgoing)
0 450 1200 mpm
+/- 420 mm
1200 tons

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

6
7

Coiler tensions
Coiler tensions

10000 kg max. upto 960 mpm

8000 kg max upto 1200 mpm.

The broad specifications of the 1250 mm 6HI mill are listed below
1
2

Strip width range

Strip thickness range

3
4
5
6
6

Mill Speed
IMR shifting
Roll separating force
Coiler tensions
Coiler tensions

650 1250 mm
1.4 4.5 mm (Incoming)
0.14 2.0 mm (Outgoing)
0 450 1400 mpm
+/- 420 mm
1500 tons
12000 kg max. upto 960 mpm
9600 kg max upto 1200 mpm.

6 HI MILL HAVING THE FOLLOWING FEATURES:

1

Universal Crown Control Mill - 6 Hi Mill i.e. perfect flat work roll, there is no

2
3
4
5

concave are convex crown in the work rolls.

Mass flow,automatic gauge control
The above mill specially design to roll thinner gauge in five passes.
On line Gamma ray thickness gauge for measurement of thickness of sheet.
Mill master control comprises of normal operation, quick stock, emergency stock,
corner rounding, mill idle run, revision of mill roll dia meter, rolling direction,
reduction ratio (draft) setting, reel stall tension, treatment of coil width,
mechanical loss compensation, control at the time of strip breakage, mill speed

reference, reel control

Automatic slow down, Automatic intermediate slow down, automatic tail end

7
8
9
10
11
12
13

stop, Automatic speed slow down Control, automatic deceleration control

Elongation Control
Operation mode, consist of rolling mode and roll change mode
Emergency dynamic braking system
Auto strip centering device
Mill management system
A CCTV camera system is provide for good supervision of the operation of mill
Computerization level-II, comprises of mill set up.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

5.Rewinding & Trimming Line

During the process of cold rolling the edges of the strips are cracked which need to be trimmed
before further processing. Therefore, BSL proposes to set up a trimming line with a facility for rewinding of the coil after trimming.
Parameter
Line speed
Arbour dia meter
Strips width range
Strip thickness range
Max Coil weight

Specifications
0-200-500 mpm
100 MM
500 1250mm
0.12 to 2.00 mm
28.75 ton

6. Galvanizing:
The Cold Rolled sheet in their raw physical form is vulnerable to rusting and corrosion. To
prevent this the CR sheets are coated with a thin layer of Zinc ie, galvanizing.
(i) Non-Ox Galvanizing/Galume Line
For Galvanising the sheet is first degreased with the help of alkali in the degreasing section.
Then the strip is heated in oxygen free environment (called non-ox zone of the Line)
through Open firing. The temperature in this zone is upto 450 Deg. C. Then the strips moves
into another heating section where the strip is further heated indirectly through radiant tubes
(the zone is called RTF). After this the strip moves into soaking section where the strip
temperature is maintained at a constant level. Then the strip moves into cooling section
where the temperature is brought down to zinc bath temp level. The entire process imparts
annealing properties to the strip. The part of the process is optional so that in case the strip is
desired to be full hard the annealing process is not done.
After this, the CR coil is passed through a Zinc bath, which is heated upto a temperature of 450 deg
C. The duration for which the CR coil is kept in the bath is very meticulously controlled to ensure
consistent quality of the finished product. With the bath/ dip a thin layer of Zinc gets deposited on

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

both sides of the coil. On an average, the CR coil gets a coating of about 0.03 mm thickness on each
side.
Galvanizing is a Process of Zinc / Aluminium coating on CR sheet. CR Coil after rolling is to be
passed through de greaze Section and then through Non Ox. Furnace and then through molten
Zinc/Aluminium Pot. After coating sheet will be passed through water quenching and then Chromic
acid /Acrylic Coating will be applied and then coiled.
The list of major equipments for Non-OX Galvanising Line with Alkali Cleaning, BSL will
put up are as mentioned hereunder :(C)
1
2
3
4
5
6
7
8
9
10
11
12
13
(B)

Entry Section
Two nos. coil storage saddles
Two nos. entry coil cars
Two nos. uncoilers with roll centering
Peeler table
Pinch roll
Two nos. entry crop shears
Deflector roll
Scrap box with table
Seam welder
Weld hole punch
Carry over table
Tension bridle
Steering system
Degreasing section -

14

Two nos. Alkali cleaning tanks with alkali sprays and brush scrubber

15
16
17
18
19
20
21

Hot water rinse tank

Dryer
Fume exhaust system
Entry accumulator (vertical type)
Steering unit
Tension bridle
Tension-meter rolls

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

(C)
22

23
(D)
24

25
26
27
28
29
30
31
32
(E)
33
34
35
36
37
38
39
40
41
42
43
44
45

Furnace Section Non-Ox Furnace

- non ox section
- radiant tube heating section
- soaking section
- jet cooling section
- turn down roll section
- control instruments
Galvanising pot with pot furnace
Galvanising Equipment Sink roll assembly
- stabilizer roll assembly
- Jet nozzles pair
- jet blower
- jet nozzle controls
- mini spangle equipment
Deflector roll no. 4 with snubber roll and motor
Cooling tower with cooling pendants and blowers
Water quench tank with squeeze rolls and accessories
Tension bridle
Skin pass mill 4 HI type
Tension bridle
Tension leveller unit
Tension bridle
Chromating Section Chromating tank
Fume exhaust system
Hot air dryer
Branding machine
Deflector roll
Steering system
Exit accumulator vertical type with hydraulic controls
Weld hole detector
Exit shear
Pinch roll
Steering system
Carryover table
Recoiler threading apron

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

46
47
48
49

Recoiler with pusher plate

Belt wrapper
Exit coil car
Coil storage saddle for two coils

Ceramic Pots: Non Ox galvanizing shall be equipped with Ceramic Induction pots for
Ajax ,USA for melting of Zinc, Zinc-Aluminum
There are 3 nos. of Induction pots are used one for Zinc only , one for
Zn-Al alloy and one as premelt pot.

(ii) Flux Galvanizing Line

For Galvanising the sheet is first degreased with the help of alkali in the degreasing section
and then passed through light acid for removal of any oxides.The strip then enters preheater
where it is heated to 180 200 oC before it is dipped inside the zinc pot.
After this, the CR coil is passed through a layer of ( NH4Cl + NaCl )flux bath, which is
maintained above the lead bath. The Flux bath
finally cleans of any oxides before it enters the molten Zinc at temperature of 450 deg C.
The duration for which the CR coil is
kept in the bath is very meticulously controlled to ensure consistent quality of the finished
product. With the bath/ dip a thin layer of Zinc gets deposited on both sides of the coil. On
an average, the CR coil gets a coating of about 0.03 mm thickness on each side.
The list of Major equipments for Flux Galvanising Line with Alkali Cleaning, BSL will put
up are as mentioned hereunder :(A) Entry Section
1

Two nos. coil storage saddles

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

2
3
4
5
6
7
8
9
10
11
12
13
(B)

Two nos. entry coil cars

Two nos. uncoilers with roll centering
Peeler table
Pinch roll
Two nos. entry crop shears
Deflector roll
Scrap box with table
Seam welder
Weld hole punch
Carry over table
Tension bridle
Steering system
Degreasing section -

14

Two nos. Alkali cleaning tanks with alkali sprays and brush scrubber

15
16
17
18
19
20
21

Hot water rinse tank

Dryer
Fume exhaust system
Entry accumulator (vertical type)
Steering unit
Tension bridle
Tension-meter rolls

(C)

Acid section -

22

One no. Acid Cleaning tanks

23
24

Cold water rinse tank

Fume exhaust system

(D) Strip Pre Heater and Furnace Section 25

26
(E)
27

Horizontal gas heated Strip Preheater

Galvanising pot with pot furnace
Galvanising Equipment Galvanizing Pot
Pot Heating Furnace ( Recirculating type with imported Fans

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

28
29
30
31
32
33
34
35

(E)

Sink roll assembly

- Deflector roll assembly
- Wiper roll assembly
- Jet nozzles pair
- jet blower
- jet nozzle controls
- Zinc box and SS flux Box
-Flux Fume Exhaust System
Zn/ Al Feeding basket and Alloy Weir
Deflector roll no. 5 with snubber roll and motor
Cooling tower with cooling pendants and blowers
Water quench tank with squeeze rolls and accessories
Tension bridle
Skin pass mill 4 HI type
Tension bridle
Tension leveller unit
Tension bridle

Chromating and Exit Section -

36

Chromating tank

37

Fume exhaust system

38

Hot air dryer

39

Branding machine

40

Deflector roll

41

Steering system

42

Exit accumulator vertical type with hydraulic controls

43

Weld hole detector

44

Exit shear

45

Pinch roll

46

Steering system

47

Carryover table

48

Recoiler threading apron

49

Recoiler with pusher plate

50

Sleeve feeding arrangement

51

Belt wrapper

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

52

Exit coil car

53

Coil storage saddle for two coils

7. Cut to Length(CTL) lines (FOR GP)

BSL has 5 nos. high capacity Cut to Length lines to cut galvanized coils into sheets . The
emphasis of GP Strip processing has totally shifted during the past many years towards high
quality scratch or mark free material, more so in the case of cut sheet. Further, modern
manufacturing techniques demand a very high degree of flatness in the cut sheets besides
being free from marks. The present market also demands sheets cut to fairly accurate lengths
thus demanding incorporation of sophisticated electronic length measuring system.
This necessitates equipment which must not introduce any marks whatsoever during
processing. To meet the very high degree of flatness requirement a precision backed up
eleven roll straightener is proposed at the entry side followed by a precision seventeen roll
sheet leveler at the exit. To enable production of mark free sheets a flying die shear is
proposed. Although this equipment is marginally more expensive than the stationary shear
incorporated in start stop lines no mark is generated from the feed rolls. To cater to the
stringent length accuracy requirement the latest and most sophisticated electronic system is
installed.
A combination air float/drop sticker has been installed to ensure no marks on the sheets are
introduced in this area.
A roller table type side discharge unit is proposed for automatic removal of sheet pile from
the stacker and providing a suitable packing station.
The list of major equipments for Cut To Length Line, BSL will put-up are as mentioned
hereunder :1
2
3
4
5

Coil storage saddle

Floor Mounted Scissor type coil car with Saddle
Single mandrel uncoiler
Coil opener
Five high leveler with pinch roll and Sunday roll

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

6
7
8
9
10

Loop pit accessories

Feed roll with measuring roll unit
Hydraulic shear
Air stacker
Automatic length cutting system

The broad specifications of this line are as below 1

2
3
4
5
6
7
8
9

Line speed
Strip thickness range
Strip width range
Cut length
Max no of cuts
Stack weight
Stack height
Stack height
Diagonal accuracy

10 110 mpm
0.13 0.70 mm
600 - 1250 mm
1000 - 3000 mm
50 per minute
5000 kg max
500 mm max
+/- 0.3 mm
+/- 0.8 mm

8.End Straightning & Cutting lines for Ends

This line used for levelling & cutting for off gauge & leader ends, Which is being produced
during cold rolling .
The list of major equipments for this Line, BSL will put up are as mentioned hereunder :1
2
3
4
5
6
7
8

Shaft stands for small coils

Uncoiler
Roller Table
Side Guide
Pinch roll cum Leveller
Hydraulic Crop Shear
Gauge table
Hydraulics & Electricals

The broad specifications of this line are as below

1
2
3
4
5
6

Line speed
Strip thickness range
Strip width range
Cut length
Max no of cuts
Cut length accuracy

15 mpm
0.11 - 6.00 mm
500 - 1250 mm
3000 mm
5 per minute
+/- 2.0 mm

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

9. BP sheet furnace:BP sheet furnace is used for annealing of CR sheets which are generated from
Mill Scrap/Baby Coils.There are a total of 12 abses and 6 heating furnaces in the plant.CR after
receiving from CTL used be load in BP furnace as per width & length of the sheet on bases.After
that heating furnace is to be put on the base and heating of the base will be started.Following is the
heating/Annealing cycle for BP Sheet.

Annealingcycle for BPsheet

10.

6500 C

Temperature 0C

5500 C

3500 C

18hr

2hr
4hr

6hr

24hr

24hr

Total 78Hrs

Time (Hours)

Corrugation Machines:
In case the finished product requirement is in the form of Corrugated Sheets, the sheets are
fed into a corrugation machine and the plain sheets are converted with the help of the
rotating rollers into Corrugated sheets.
Description
Corrugating Machine is used for corrugating galvanised sheets as per ISI and JIS standards
i.e. 11/12 crests for 900 mm strip width.
Our Corrugating Machine comprises of:

Gear Box with gear ratio 30 : 1.

A.C. Motor of power 22 kW, 1500 rpm.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

Corrugating Machine is driven by an A.C.Motor through a full geared coupling,

worm Gear Box, half gear coupling and then through the gear pair to bottom
corrugating roll.

Flattening roll is driven by a Chain & Sprocket drive arrangement through the
Corrugating Roll.

An Entry Table is provided with machined slots on either sides to facilitate sliding of
the Sliding Frame with a Roller arrangement.

The movement of the Sliding Frame is achieved by the Crank, Adjusting Block &
Links. The Crank is mounted on the Bottom Corrugating Roll.

A Stopper Block is provided for adjusting the length of the strip to be Corrugated.
For these adjustments Measuring Scales are provided on the Sliding Frame.

An Entry Guide Plate is placed in between the Entry Table and the Housing, for
providing the entry of sheet into the Corrugating Rolls along the Pass- Line.

An Auxiliary Table is placed between the Corrugating Ross Assy. and the Pinch Roll
Assy., for the proper entry of the Corrugated Sheet/s into the Pinch Roll Assy.

An Exit table is provided for removing the finished Corrugated sheets.

Screw Down is for increasing / decreasing the number of crests formed on the sheets.

A Jactuator is provided for adjusting the gap between the Flattening Roll Assy., for
maintaining the proper flatness on the crests of the corrugated sheets.

The broad specifications of this line are as below

Length of the sheet
Width of the sheet
Thickness range of sheet
Material to be corrugated
Drive
Space requirement
No. of corrugator teeth
Outer Diameter of Corrugator Rolls
Diameter of Flattening Rolls

3700 mm max.
762 mm to 1250 mm.
0.12 mm upto 0.25 full hard only.
Galvanised sheets.
22 Kw; 1500 rpm AC; 3 Phase.
6 mtr. x 6 mtr.
24 teeth.
381 mm.
317 mm.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

Barrel Length
Speed

3800 mm.
15-18 sheets per minute approx.

The list of major equipments for Corrugation Line, BSL will put up are as mentioned
hereunder:1
2
3

Housing
Corrugating Base Frame
Corrugating Rolls
a. Top

4
5
7
8
9
10

b. Bottom
Flattening Rolls (Top & Bottom)
Gears & Pinions
Entry & Exit Tables
Worm Gear Bos (12 Size, 30:1)
AC Motor, 22 Kw 1500 rpm
Motor Base Frame
Coupling (103 & 104

11. Roll Grinding Machine:

During rolling of strips rolls surface may get damaged/spoiled due to various reasons, some
of which are mentioned hereunder:(i)
(ii)
(iii)
(iv)
(v)
(vi)

Operational faults , pinching

Improper coolant oil supply
Bad surface of strips/sheets
Bad quality of rolls
Surface work hardening of rolls
Surface cracks and surface sub cracks etc.

These results into the strip surface defects like Roll marks, Cracks, Slivers, Holes,
Edge burr etc. which ultimately degrade the strip quality.
Therefore, to remove the above defects from the surface of the rolls, it is necessary to
regrind the rolls on the roll grinding machine to make it reusable in the rolling mill.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

BSL proposed to install Waldrich Siegen

Roll Grinding Machine along with EDDY

Current Tester, Ultrasonic Testing Machine, Demagnetized Unit & Calibration Unit in the
Roll Grinding Shop. The proposed shop shall be among the most sophisticated roll grinding
shops in the world.
The list of major equipments for this Roll Grinder is as mentioned hereunder:1
2
3
4
5
6
7
8
9
10
11

Workpiece bed.
Carriage bed
Headstock
Tailstock with mounted dressing unit
Coolant pumps with mounted motor and strainer
Prism for checking the alignment of the bed.
Mandrel for checking the alignment of the bed.
Mandrel for checking the alignment between headstock and tailstock
Grinding wheel holder
Puller and lifting device for grinding wheel holder
Dressing unit at tailstock suited for acceptance of demand

Technical data 1
2
3
4

Range of roll dia to be ground

Overall grindable length of roll
Max grindable roll weight
Grinding wheel dia

200 - 1200 mm
4 mtr.
23 tons
915 mm

The Roll grinding machine having the following main features :

1.

Grinding carriage with CNC control and cambering device

2.

Hydrodynamic steady rest for work roll and back up rolls

3.

CNC control system GPC including programme for wheel dressing, wheel diameter
is measured in directly after wheel dressing.

4.

Measuring beam for measuring scales for axes X,Z and U

5.

Direct indication, regulation and control of the cutting speed

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

6.

Automatic grinding wheel retraction incase of power failure or emergency.

This Roll Grinder has got the latest technology available in the world with fully automatic CNC
Operational Control to enable to get the best of the accuracy which are mentioned below I.

Roundness

0.001- 0.002 mm

ii.

Straightness of the generating

0.001- 0.002 mm

line
iii.

Cambering accuracy

+/-0.002 mm/M on 0.1 mm

Reground rolls may under go for surface inspections with help of Eddy Current
Testers and Ultrasonic Testing for Sub-Surface Inspection.
Eddy Current Tester will display the following main information :
1.

Presence of spall cracks

2.

Presence of pinch bruises

3.

Presence of Magnetic field

4.

Crack depth indication

12.Colour Coating Line:

Manufacturing Process & equipment Design

The color coating line may be broadly divided into following sections:

Entry section

Entry accumulator

De-greasing and Pre-treatment section

Coating and Baking section

Exit accumulator

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

Exit Section.

Salient features of Process Equipment

The cleaning and treatment sections are both located at one end of the building. The coating
and thermal sections are also grouped in a specific area. Thus the surface treatment and the
thermal treatment, which are different activities are separated, thereby making line
management easier. It facilitates overall maintenance
and optimizes energy supply. All these points contribute to reducing both the investment and
operating costs.
Features of the cleaning and treatment section
Cleaning
The cleaning section is one of the most important part of a coil coating line. The coil must
be perfectly degreased to guarantee paint adherence. Even if the raw material is a galvanised
strip coming from a continuous galvanising line in the same plant, the installation of a
degreasing section in this coil coating line is recommended. It gives more flexibility in terms
of storage time and raw material origin.
Choromating Treatment
Choromating is necessary to prepare the surface of the strip just before painting. It improves
the adherence of the paint coat and prevents corrosion. The proposed spray system is of NO
Rinse spray type. The chromate solution does not need to be rinsed and hence no overflow is
necessary for rinsing leading to waste water.
Features of the Coating and Oven Section
Coating
The coating machines are horizontal coating machines. They are entirely built by GFG.
This type of machine ensures an excellent coating that provide the incoming strip is tension
leveled and skin passed, which are usual features for a painted strip. In this case, an
excellent and uniform coating is achieved at low cost.
Nevertheless , coating rooms are designed to protect the coating area against possible dust
by a slight overpressure inside the room. It also protects the working atmosphere for
operators. This enables the production of higher quality products.
Ovens
The prime and finish ovens are of catenary type. This type of oven offer a good adherence
of the strip on the applicator roll. Unlike floatation type ovens, no energy is required to
support the strip. Furthermore, there is no risk of strip vibration.
These ovens have the following features :

Uniform heating of strip

Easy access and cleaning inside the ovens

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

Oven start / stop flexibility

The ovens are designed with independent heating zones in order to allow different paint
curing curve adjustments. Each zone is equipped with one mixing chamber burner.
Oven start / stop flexibility is provided by these mixing chamber burners. Besides strip
heating these burners are necessary to heat up the oven and to quickly adjust the zone
temperatures set point according to each production.
Under standard conditions the atmosphere inside the ovens is maintained at 25% of the
L.E.L. (Lower Explosive Limit). The
exhaust volume flow of air is thus set according to the solvent load This volume flow is
adjusted at the commissioning of the line and can be subsequently remote controlled. This
solvent laden air is incinerated with low gas consumption. The energy is recovered as hot air
supplied to the oven, but in this case additional energy is supplied by the zone burners.
Features of the incinerator and heat recovery system
The incinerator have been designed in conformity with the ruling American regulations on
gas emissions and heats the incoming solvent laden air to approximately 750C for at least
one second.
The basic design is with indirect re-injection having both primary and secondary heat
exchangers.
1. Entry section :
The entry section covers the equipment from Entry coil storage saddles, Entry Coil cars
Uncoilers, Pinch Rolls, Entry Shear, Joiner de-burring roll and Bridle. Coil to be color
coated shall be
deposited by the means to the coil storage saddles in front of uncoilers. There are two
Uncoilers provided in the entry section to allow a next coil to be prepared while first coil is
getting processed to maintain the continuity of the process. Each Uncoiler is provided with
coil car to load the coil on its mandrel.
The Uncoiler is provided with sliding base to center the coil with line center. The Uncoiler
mandrel is hydraulically expanded to grip the coil on its inside diameter. At this moment the
snubber roll mounted on the Uncoiler is actuated and pressed against the coil outer wrap.
This will keep the outer wrap of the coil from falling down after cutting the wrapping band.
Thus the coil is made ready for feeding into the line. The peeler table attached to the pinch
roll is positioned and snubber roll is driven to peel the outer wrap of the coil, which gives
the lead end into the pinch roll. Once the strip is held in the pinch roll unit, the peeler table
is retracted and moved down to its parking position. The lead end of the coil is cut square
with the help of entry shear thus removing any damaged end also. The scrap table guides
the cut ends to fall in the scrap box. The scrap box can be moved out on the rails provided
for unloading the scrap collected.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

The Uncoiler is automatically slowed down to threading speed, by the software provided in
the PLC as soon as the diameter of coil goes below set value. Once the Auto Slow Down
takes place all Snubber Rolls on the Bridle No.1 and Pinch Rolls in the entry section are
closed. The tail end of the previous coil duly squared in the shear is slowly brought up to
the Joiner by jogging Bridle No.1 while the lead end of the new coil duly squared is brought
in the joiner. Strip ends are joined and the hole is punched with the punching facility
provided on the joiner. This way the coil becomes continuous. At completion of joining
operation the joint is pressed on De-burring unit to flatten the joint. TENSION-ON
command is given so that any looseness of the strip formed in the entry section is removed.
The new coil is now ready for feeding into the line. Bridle No.1 is used to maintain strip
tensions in the Entry section. Uncoilers provide back tension on the strip upto No.1 Bridle.
2.

Entry accumulator (vertical)

As the process is a continuous one, when the entry section is stopped for coil joining, the
entry accumulator keeps on feeding accumulated strip into the line at constant speed.
Normally, the entry accumulator is kept full so that the process speed remains un-affected.
The speed of Uncoiler is higher than the process speed. Thus when the Uncoiler starts
feeding the strip, the empty accumulator starts filling slowly. At approximately 80 to 85%
capacity of the accumulator entry speed is reduced upto the process speed. Thus further
accumulation of strip is stopped. The accumulator is designed to hold about 120 seconds of
strip. Steering system is provided at the entry and exit end of the accumulator to center the
strip before it enters the coating section.
3

De-greasing and Pre-treatment section

The strip after entry accumulator is passed in through de-greasing section containing alkali
cleaning tank #1 and tank #2 with brushing tank between the two. Two hot water rinse tanks
and a dryer follow the alkali tank #2. The Alkali and the rinsing water will be heated by
Steam coils inside the tank. The dryer uses stem to air heat exchanger to heat the air being
forced on the strip. The degreased and dried strip is then chemically treated by using roll
type chemical coater. The chemical is dried in a chemical dryer supplied with heat from
incinerator.
4.

Coating and Baking Section.

This section consists of equipments from Steering roll, Bridle No.2, Prime coater to Bridle
No.4 before the Exit accumulator. Resident time in oven will be minimum 30 seconds. After
the chemical treatment the strip is centered before passing to the Bridle and Prime coater.
The bridle no.2 pulls the strip from the entry accumulator to feed the coating section.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

LEL (Lower Explosive) monitor in each zone both oven automatic audiovisual alarm and
automatic triping of line and purging.
Safety: Proper explosion flaps to depressurise the catenary oven incase of any explosion
inside. These flaps should be so designed that entire oven could be depressurized in a very
short time to eliminate any damage to the furnace casing.
The Prime coater is a "S" wrap type and is designed to apply a controlled amount of primer
paint on both sides of the strip. Both forward and reverse methods can be used. It is
followed by convection type Prime oven to cure the paint to the specified PMT. After
curing, the strip is quenched in a water quench tank to cool it and then the excess water
carried on the strip after squeezing is blown off with air blow-off unit. The steam vapor
generated in the quench tank will be exhausted outside the building through a duct.
The strip now is deflected downwards under the support structure of Prime oven and is then
moved back towards the entry side of the line. It is then centered with steering roll before
passing to Bridle. This bridle maintains the required strip tension in the Prime oven so as to
maintain the required catenary inside the oven.

The strip is then passed to Finish coater. The Finish coater is provided with facility for quick
colour change. The finish coater has top head with metering roll to precisely control the
finish paint being applied. Strip then enters the Finish oven, which is similar to
Prime oven, which cures the finish paint to the specified PMT. Then the strip is cooled in a
finish water quench tank. Excess water film is blown off with air blow-off unit. The steam
vapor is exhausted from the quench tank to the common duct. The Strip tension and the
required catenary inside the Finish Oven is maintained with Bridle. The space provision has
been made for the future installation of embosser-laminator unit before the water quench
tank.
When the exit section is stopped as the joint is being cut at the exit shear to separate the
coils and prepare the recoiler for the new coil. Bridle feeds the Exit accumulator to maintain
the process continuity.
The ovens are designed to evaporate the specified amount solvent from the paint as they
heat the strip to PMT. This solvent exhaust is burned in an incinerator and approximately 60
% portion is re-circulated inside the ovens to heat the ovens after passing through a heat
exchanger. This heat exchanger heats the oven exhaust before admitting to the incinerator
thus again recovering some heat from the waste gases. Thus strip is heated inside the oven
with heat recovered from the solvent vapors itself making the total system fuel efficient.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

5. Exit accumulator section

The strip is passed to the Exit accumulator. This accumulator is similar to Entry
accumulator. It is normally kept empty. When the strip joint is to be cut for changing the coil
on Recoiler, the Bridle is stopped and the snubber roll is pressed down. The other Bridle
continues to feed the strip to exit accumulator to maintain the process continuity. The
accumulator starts filling up as the process section runs continuously. The accumulator is
designed to hold 200 meters of strip.
6. Exit section
The Exit Accumulator is followed by Bridle Exit shear, Edge control system (EPC) with
stagger winding feature, Pinch roll, Threading table, Recoiler, Belt wrapper and Exit coil car
and coil storage saddles.
In this section the painted strip is coiled. The Bridle is provided to pull the strip from Exit
accumulator and provide back tension for the Recoiler. The exit shear is provided to cut the
joint portion, samples. Scrap box is provided to collect the cut pieces.
The line has been provided to install the Paper/PVC Guard film interleaving equipment so as
to insert the paper/PVC film on the painted strip protecting the painted surface.
The Belt wrapper is used to make initial few wraps of the strip on the Recoiler mandrel. The
Recoiler has a base shifting arrangement. This base shifting helps in achieving Staggered
winding of coil, if required.

The Recoiler shifting is carried out by a Staggered

winding/Edge winding system which seeks the edge of incoming strip and gives corrective
command for positioning the Recoiler. The coil wound on the Recoiler mandrel is removed
with the help of Exit coil car. Coil car is moved to the home position to enable the removal
of the coil from it.
The Paint coating line is controlled from the Entry and Exit control desk, while Ovens and
Coaters are controlled from the control desk provided in the process section.

Suitable

number of Local control posts are provided for local control. The master control is located
in the exit control desk from where operations of major equipment are monitored and
controlled with the help of PLC. The status of various section is pictorially shown on the
computer screen in the form of mimic. Various alarm signals and status of equipment are
provided for taking required decision.

Cold Rolling Cum Galvanizing Complex at Meramandali (Orissa)

Process Description

13. Electrolytic Cleaning Line ( ECL ) :