Tag: rolling mill in gujarat

Categories
Blogs
Optimizing Production Efficiency: A Guide to Hot Rolling Mill Scheduling

 

The steel manufacturing industry heavily relies on rolling mills to convert raw materials into finished products in an accurate and efficient manner. In India, where the demand for high-quality steel products is continuously increasing, rolling mill manufacturers need to focus on improving their production efficiency. Hot rolling mill scheduling is a crucial aspect of this optimisation process, as it ensures smooth operations and maximizes output. This process is complex but vital and helps businesses achieve their goals for efficient and high-quality metal production.  

Understanding Hot Rolling Mill Scheduling

Definition and Basics:

Hot rolling mill scheduling involves the systematic planning and organization of various production tasks within a mill facility. It encompasses the coordination of processes such as heating, rolling, and cooling to ensure a continuous flow of materials and efficient utilization of equipment. The scheduling process is essential for meeting production targets, maintaining product quality, and minimizing downtime.

The role of scheduling in managing production processes cannot be overstated. It acts as a bridge between the demand for finished products and the capabilities of the rolling mill. Scheduling involves creating a timeline that optimally sequences tasks, from preparing raw materials to the final product’s dispatch. Key terms and concepts in the scheduling include job sequencing, batch processing, lead times, and setup times. 

Importance of Scheduling in Hot Rolling Mills

Effective scheduling is a cornerstone of overall production efficiency in rolling mills. A well-designed schedule ensures that each stage of the production process operates at its maximum potential, resulting in higher throughput and reduced idle time. Conversely, poor scheduling can lead to downtime, delays, and increased operational costs.

Consider a scenario where the scheduling of heating and rolling processes is not aligned. This misalignment can result in overheating or underheating of materials, leading to defective products and increased scrap rates. Moreover, inadequate scheduling may cause equipment to remain idle, reducing the mill’s overall efficiency and affecting the bottom line.

Challenges 

The challenges associated with scheduling in hot rolling mills are multifaceted. These challenges include the dynamic nature of market demands, the variability in raw material quality, and the need to balance maintenance activities with production requirements. Addressing these challenges requires a strategic approach and a deep understanding of the factors influencing scheduling decisions.

Factors Affecting Hot Rolling Mill Scheduling

1. Raw Material Availability:

Raw materials are the lifeblood of any rolling mill, and their availability in quantity and quality is crucial for efficient scheduling. Schedulers must work closely with procurement teams to ensure a steady supply of raw materials. Additionally, implementing strategies for managing and optimizing raw material inventory, such as just-in-time delivery and effective storage solutions, can contribute to a smoother scheduling process.

2. Equipment Maintenance:

The significance of well-maintained machinery in hot rolling mill scheduling cannot be overstated. Regular preventive maintenance is essential to minimize unexpected breakdowns and downtime. Schedulers must collaborate with maintenance teams to develop maintenance schedules that align with production demands. Proactive measures, such as condition monitoring and predictive maintenance, can help anticipate potential equipment failures and plan maintenance activities accordingly.

3. Production Demand and Market Trends:

Adapting scheduling to meet varying production demands is a dynamic challenge faced by rolling mills. Schedulers must stay informed about market trends, customer orders, and industry forecasts to adjust production schedules accordingly. Flexibility in scheduling is essential to accommodate changes in demand, whether due to seasonal fluctuations or unexpected market shifts. Collaborating closely with sales and marketing teams ensures the production schedule aligns with customer requirements and market demands.

4. Data-Driven Scheduling:

In this digital age, data is an integral aspect of processes. For hot rolling mill scheduling, collecting and analyzing relevant data is a game-changer. Data-driven scheduling involves the systematic gathering of information from various stages of the production process, including raw material procurement, equipment performance, and product quality metrics.

By leveraging data, schedulers gain valuable insights into the historical performance of the rolling mill. This information enables them to identify patterns, predict potential bottlenecks, and make informed decisions to optimize the schedule. For example, analyzing the historical data on equipment downtime can lead to proactive maintenance planning, reducing the risk of unplanned stoppages.

Implementing data-driven decision-making in hot rolling mill scheduling involves the use of key performance indicators (KPIs) and analytics tools. KPIs, such as throughput rates, equipment utilization, and defect rates, provide a quantitative measure of the production process’s efficiency. Analytics tools can process vast amounts of data quickly, offering real-time visibility into the status of the mill and facilitating rapid decision-making.

The shift towards data-driven scheduling empowers rolling mill operators in India to move from reactive to proactive planning, ultimately reducing production costs and improving overall efficiency.

5. Advanced Scheduling Software:

Modern scheduling tools and software have revolutionized the way rolling mills plan and execute their production schedules. These advanced solutions go beyond traditional methods, offering real-time insights, optimisation algorithms, and automation capabilities.

Scheduling software tailored for hot rolling mills provides a centralized platform for managing all scheduling aspects. It allows schedulers to input various parameters, such as production targets, equipment capabilities, and maintenance schedules. The software then uses optimisation algorithms to generate an optimal production schedule that maximizes efficiency and minimizing downtime.    

One of the notable benefits of using advanced scheduling software is the ability to make real-time adjustments. As market demands fluctuate or unexpected disruptions occur, the software can quickly recalculate the schedule, ensuring that the production plan remains aligned with the business objectives. This flexibility is crucial for rolling mill operators in India, where market dynamics can change rapidly.

Additionally, scheduling software enhances collaboration among different departments within the mill. By providing a transparent and accessible platform, it facilitates communication between production, maintenance, and quality control teams. This collaborative approach ensures that everyone is on the same page and can work together to address any challenges that may arise during the production process.

6. Collaboration and Communication:

Effective communication is a linchpin in successful hot rolling mill scheduling. The complex coordination of various tasks, from raw material preparation to the dispatch of finished products, requires seamless communication among different departments and teams.

Schedulers must collaborate closely with procurement teams to ensure a steady and reliable supply of raw materials. By sharing information about inventory levels, lead times, and material specifications, scheduling decisions can be made with a clear understanding of the available resources.

Furthermore, communication with maintenance teams is crucial to align preventive maintenance schedules with production requirements. By sharing insights into equipment performance and maintenance needs, schedulers can avoid unplanned downtime and ensure that machinery is in optimal condition during peak production times.

Commonly Asked Questions 

1. How does data-driven scheduling benefit hot rolling mills?

Data-driven scheduling provides hot rolling mills with valuable insights derived from historical performance data. By analyzing key metrics such as throughput rates and equipment utilization, mills can make informed decisions, predict potential issues, and optimise their production schedules. This approach enables a shift from reactive to proactive planning, reducing downtime and improving overall efficiency.

2. What role do advanced scheduling tools play in optimizing production schedules for rolling mills?

Advanced scheduling tools revolutionize production planning for rolling mills by offering real-time insights, optimisation algorithms, and automation features. These tools enable schedulers to input various parameters and generate optimal production schedules. The real-time adjustment capabilities of these tools are particularly beneficial for adapting to fluctuating market demands, ensuring that mills can maintain flexibility in their production plans. 

3. How can scheduling software enhance collaboration within rolling mill facilities?

Scheduling software facilitates collaboration by providing a centralized platform for managing production schedules. It enables transparent communication between departments, such as production, maintenance, and quality control. This collaborative approach ensures that all teams are aligned, making it easier to address challenges and make coordinated decisions during the production process.

4. Why is effective communication crucial for hot rolling mill scheduling?

Effective communication is vital for the complex coordination of tasks within hot rolling mills. Schedulers must collaborate closely with procurement teams to ensure a reliable supply of raw materials and communicate with maintenance teams to align preventive maintenance schedules with production requirements. Clear communication helps avoid unplanned downtime and ensures that equipment is well-maintained during peak production periods.

5. How can rolling mills adapt their schedules to varying production demands and market trends?

Rolling mills can adapt their schedules by staying informed about market trends, customer orders, and industry forecasts. This knowledge allows schedulers to adjust production schedules accordingly, ensuring that the mill can meet changing demands. Flexibility in scheduling is essential for accommodating seasonal fluctuations or unexpected shifts in the market, helping rolling mills maintain a competitive edge.

Consult Us for Custom Turnkey Solutions for Productive Rolling Mill Operations

Unlock the potential of your rolling mill operations with our tailored turnkey solutions! At The Steefo Group, we specialize in delivering custom solutions designed to enhance the productivity and efficiency of your rolling mill. Our experienced team understands the unique challenges of the industry and is ready to collaborate with you to optimize every aspect of your production process.

Whether you’re seeking to improve scheduling, implement advanced technologies, or streamline communication across departments, our experts are here to guide you. Consult us for personalized insights and strategies that align with your specific goals and challenges. Together, let’s transform your mill into a powerhouse of efficiency. Elevate your operations, reduce costs, and stay ahead in the competitive landscape.    

Contact us at +91 87589 98607 or email us at marketing@thesteefogroup.com for a consultation and take the first step towards achieving excellence in your rolling mill operations. 

Categories
Blogs
The Importance of Regular Maintenance and Upkeep for Rolling Mill Machinery

 

Introduce the topic of rolling mill machinery and emphasize the importance of regular maintenance and upkeep for keeping the machinery functioning at its best.

Mention The Steefo Group and their commitment to providing high-quality rolling mill equipment.

Rolling mill machinery is a vital component of the steel manufacturing industry, enabling the efficient production of high-quality steel products. However, like any machinery, rolling mills require regular maintenance and upkeep to function at their best. Regular maintenance has been shown to significantly reduce the risk of equipment failures, downtime, and costly repairs and improve safety and overall production efficiency.

In this blog, we will explore the various benefits of regular maintenance and upkeep for rolling mill machines and the vital maintenance procedures necessary to keep the machinery functioning at its best. We will also discuss the factors affecting maintenance frequency, common maintenance mistakes to avoid, and more.

The Benefits of Regular Maintenance and Upkeep of Rolling Mill Machinery 

Regular maintenance and upkeep of rolling mill equipment can benefit steel manufacturing businesses. Here are some of the key benefits that have been observed:

1. Increased Efficiency

Regular maintenance and upkeep can help keep rolling mill machinery operating at peak performance, resulting in increased efficiency. Well-maintained machinery can produce high-quality steel products more quickly and with fewer errors. This, in turn, can lead to increased production output and improved overall efficiency.

2. Improved Safety

Regular maintenance and upkeep of rolling mill machinery can help prevent accidents and injuries in the workplace. By identifying and addressing potential safety hazards during routine maintenance, steel manufacturers can reduce the risk of workplace accidents and improve the safety of their employees.

3. Reduced Downtime

Equipment failures and unplanned downtime can be costly for steel manufacturers in terms of lost production time and repair costs. Regular maintenance and upkeep can help prevent equipment failures and identify potential issues before they become major problems, reducing the risk of unplanned downtime.

4. Cost Savings

Regular maintenance and upkeep can also help steel manufacturers save money by preventing equipment failures and reducing downtime. The cost of routine maintenance is generally much lower than the cost of repairing or replacing damaged equipment. Additionally, increased efficiency and reduced downtime can lead to higher production output and increased revenue.

Key Maintenance Procedures For Rolling Mill Machinery

To keep rolling mill machinery operating at peak performance. Here are some of the key maintenance procedures that are necessary for rolling mill equipment:

1. Cleaning

Regular cleaning of rolling mill machinery can help prevent the buildup of dust, debris, and other contaminants that can interfere with machinery operation. Dust and debris can cause equipment to overheat, resulting in reduced efficiency and potentially costly equipment damage.

2. Lubrication

Proper lubrication of rolling mill machinery is essential to smooth operation and prevent equipment damage. Regular lubrication can reduce friction and wear and extend the life of rolling mill machinery.

3. Inspection

Regular inspection of rolling mill machines is necessary to identify potential issues before they become major problems. Inspection procedures should include a visual inspection of machinery components and non-destructive testing techniques to identify defects or other issues that may be hidden from view.

4. Repair

If issues are identified during inspection or routine maintenance, timely repair is critical to prevent further damage to rolling mill machines. Repairs may range from minor adjustments to major component replacements, depending on the severity of the issue.

Factors That Affect Maintenance Frequency

The frequency of maintenance for rolling mill equipment can vary depending on several factors. Here are some of the factors that can affect how often maintenance should be performed:

Type of Machinery

The type of rolling mill machines can significantly impact maintenance frequency. Different types of machinery may require different maintenance procedures, and some may be more durable and require less frequent maintenance than others.

Operating Conditions

The operating conditions of rolling mill equipment can also affect maintenance frequency. Machines operating in harsh environments, such as high temperatures, humidity, or corrosive materials, may require more frequent maintenance to prevent damage.

Production Volume

The production volume of rolling mill machinery can also affect maintenance frequency. Machinery that operates at high volumes may experience more wear and tear and require more frequent maintenance to prevent breakdowns and prolong the lifespan of the equipment.

Common Maintenance Mistakes to Avoid

Regular maintenance and upkeep of rolling mill machinery are critical to ensure smooth operation and longevity. However, some manufacturers make mistakes that can compromise the efficiency and effectiveness of the machinery. Here are some common mistakes to avoid:

1. Neglecting Regular Maintenance

Skipping regular maintenance schedules or delaying repairs can lead to major breakdowns, downtime, and increased maintenance costs in the long run. Therefore, it is essential to follow the recommended maintenance procedures as outlined by the manufacturer and schedule regular inspections and maintenance services.

2. Using Improper Lubricants

Lubrication reduces friction and wear and tear on rolling mill machines. However, using the wrong lubricant or failing to lubricate the machinery adequately can cause severe damage to the machinery. It is crucial to use the recommended lubricants and follow the lubrication schedules specified by the manufacturer.

3. Failing to Keep the Machinery Clean

Dirt, debris, and other contaminants can accumulate on rolling mill machinery, reducing efficiency and increasing wear and tear. Regular cleaning of the machinery is necessary to prevent these issues. Following the recommended cleaning procedures and using appropriate cleaning agents is crucial.

4. Overlooking Safety Precautions

Safety should always be a top priority when maintaining rolling mill machines. Failing to follow safety precautions can lead to severe accidents and injuries. It is essential to wear appropriate safety gear, follow lockout/tag-out procedures, and receive proper training to avoid accidents.

In conclusion, regular maintenance and upkeep are essential for maximizing the lifespan and performance of rolling mill equipment. The Steefo Group understands the importance of proper maintenance and provides high-quality machinery designed for durability and reliability.

Why Choose The Steefo Group For Your Rolling Mill Machinery Needs? 

If you’re in need of rolling mill equipment, The Steefo Group is your trusted partner. Contact them today to learn more about their products and services and how they can help your business succeed.

You get your hands on the most innovative, advanced, and energy-saving rolling mill machinery that will help you improve your business and reduce manufacturing costs.

Our rolling mill machinery undergoes strict testing and rigorous quality checks to provide the best-in-class products. Our focus on technology and innovation also provides you with the most up-to-date rolling mill machinery for your rolling mill. 

To learn more about the Steefo Group and their products and how they can improve your productivity and profits, contact +91 98240 76873 or drop a mail at marketing@thesteefogroup.com.

Categories
Blogs
A Comprehensive Guide to Hot Rolling Mill Process

 

The main objective of the entire steel rolling process is to create complete or semi-complete parts by deforming the massive plates and ingots to decrease the cross section in them. In metalworking processes, hot rolling mill is considered to be a commonly-used technique. In this technique, metal is heated beyond the recrystallization temperature, and the plasticity is distorted during the rolling procedure. This process ensures that the volume and features of the metal are maintained while creating various shapes and dimensions.

After being heated, the metal goes through rolling devices to retain its volume and uniformity while flattening and reducing the overall cross-sectional area.  The construction sector often employs the hot rolling process and the product it creates. The hot-rolled steel from this process is great as raw material and the final product.

How Does The Hot Rolling Process Work For Steel And Stainless Profiles?

Steel billets and blooms are heated at an extreme temperature to initiate the hot rolling procedure. The temperature surpasses a minimum of 1100 degrees and is changed depending on the requirements of the process. The metal is passed via the rolling mechanism to ensure there is damage on the edges and structure of the metal grain. This process ensures that new and sturdy designs and boundaries are produced with uniform grain structures and volume,

At a high temperature, the slabs or blooms pass through the casting process and are then fed into the rolling mills. The metal’s strength, toughness, ductility, formability, resistance to vibration and shock, and weldability are all increased by rolling operations.

During the treatment process, extreme force and pressure are used for metal cleaning and eliminating the mill scales.  Doing so ensures that no surface defects on the final finished items. When the metal cools down, the cooling rate of the steel is to be checked to correct the crystallization and, in general, microstructure depending on the various uses.                                                                       

Why Is Hot Rolling Preferred?

Hot rolling is the preferred method amongst steel rolling mills due to the certain characteristic that it instills in the steel. Steel that goes through the hot-rolling process tends to be

  • Stronger 
  • Tougher
  • More Ductile 
  • Resistant to Shock and extreme vibrations
  • Weldable 
  • Formable 

What Are The Advantages Of Hot Rolling 

When the hot-rolling process is selected for steel rolling , numerous advantages are attached to it that benefits the end product being created. Here are some of the various advantages:

Enhanced Mechanical Properties 

When steel goes through a hot rolling mill, several characteristics and properties of the steel are altered due to heat and pressure. Certain mechanical properties encounter the most change but improve the quality of steel. For example, properties such as elasticity, elongation percentage, shock resistance and overall toughness improve drastically. 

Altered Grain Structure

In the hot rolling mill, the metal’s grain structure changes. The grain structure that plays a vital role gets refined. The usual coarse grain gets transformed into finer grains which alters the properties of the metal. 

Change In Porosity

The hot rolling mill and its process ensure that the porosity of the metal is removed and eliminated. This alternation due to hot rolling creates a stronger, tougher, uniform metal in the structure.

Distribution Of Impurities

Metals and steels have numerous impurities that can affect the final result and how the product is formed. In hot rolling mills, impurities,  such as slag, are distributed throughout in an even manner. If they remained concentrated, those areas would have become weaker and would be prone to breakage. 

Requirement Of Low Pressure:

In hot rolling mills, the metal deformation process is easier due to the extremely high temperature of rolling. This temperature reduces the requirement for high pressure, making the process easier. 

Why Rely On The Steefo Group For The Hot Rolling Mills?

So you are looking for suitable hot rolling mills and their equipment. Look no further, as The Steefo Group delivers you with anything your steel rolling mill will ever need. We have been the ultimate and most favoured integrated hot rolling mill manufacturer for almost four decades. The Government of India also recognizes us as the Star Export House, and we adhere to our reputation. With over 100+ locations, we are a renowned name worldwide and in the country. 

Understanding The Steefo Group’s Hot Rolling Mills 

When you choose The Steefo group, you are getting assured quality. You also obtain the most innovative and futuristic products in hot rolling that will enable you to convert and reinvent the face of your business.  The Steefo Group specializes in everything,  from turnkey projects to single modular projects, depending on the needs of your business. From TMT bar rolling and wire rod mills to products such as mill stand, rolling mill gearboxes, and reheating furnaces. 

We undergo stringent testing and quality checks to provide you with the best. Our priority is technology and innovation, providing you with the most updated products for your rolling mill. 

To learn more about the Steefo Group and their products and how they can improve your productivity and profits, contact +91 98240 76873 or drop a mail at marketing@thesteefogroup.com. 

Categories
Blogs
Key Factors to Consider While Choosing a Rolling Mill Manufacturer

 

When picking a rolling mill machinery manufacturer, you want to select the best out of all of them. The proper rolling mill machinery manufacturer ensures that your needs are met without errors and still upholds your standard. Here are some factors you need to consider when picking your manufacturer. 

1. Condition of Production Facility 

The condition of the production facility says a lot about the quality of products. You want your rolling mill machinery to be the best in class to create high-quality products. Top-quality rolling mill machinery manufacturers like The Steefo Group pay attention to every detail, from the raw material to the equipment used during the process. When you select good quality manufacturers, you are guaranteed to get premium results up to par with your standards. 

2. Variety Of Products Offered 

An average steel rolling mill manufacturer offers various products for varied industries. Top rolling mill machinery provider, The Steefo Group, has a huge range of products, including reheating furnaces, mill stands, shears, gearboxes, loppers, quenching systems and more. This gives you a better overview of the technology they employ regarding their products. A suitable steel rolling mill manufacturing plant caters to all these requirements by offering superior quality products for different industries.

3. Attention To Quality Control 

When searching for the perfect manufacturer, you must understand their commitment and overall quality control process. Manufacturers like The Steefo Group are consistent in quality and therefore have a 100 percent customer and client satisfaction rate. Your manufacturer should guarantee quality and meet your desired standards through stringent norms. Most high-quality rolling mill machinery manufacturers have a dedicated quality assurance team that examines the products and machines being created. They also should ideally perform quality change throughout all the stages. 

4. Valid Certification 

All rolling mill machinery manufacturers must maintain a certain standard of quality. The bar complies commonly with ISO and viz. One of the most premium rolling mill machinery manufacturers, The Steefo Group, complies with ISO 9001:2015 certification. Therefore, ensure that the manufacturer you will select and work with has the proper and valid certificate to guarantee that your standards are not compromised. 

5. Innovation, Research and Development:

Any manufacturer should always focus on moving ahead, investing in research and innovation and focusing on development. Its dedicated research and development team indicates a great manufacturing company. This indicates that the company is constantly working to fix any errors and improve the current process and create a more streamlined version. Manufacturers such as The Steefo Group utilizes software such as CAD and Kisssoft to enhance ongoing development that meets the industry standards to become not the only provider of both rolling machinery and solutions. Before selecting, find out if there is an R&D team and if so, get in contact with them to see if their vision of the future aligns with the vision you have for your company.

6. Distribution And Delivery 

When you work with a manufacturer, timing is crucial to the entire operation. The delivery of the products and machinery will determine the time required to finish the task efficiently while maintaining customer satisfaction. Distribution and delivery are also important to get ahead of the competition. Check if the rolling mill machinery manufacturer has a well-connected and reliable distribution and delivery model, as it will ensure a seamless and stress-free delivery process. 

Why Should You Pick The Steefo Group To Be Your Rolling Mill Machinery Manufacturer?

When you select The Steefo group, you are getting guaranteed quality. You get access to the most innovative and futuristic products that will allow you to transform your business. The Steefo Group specializes in everything,  from turnkey projects to products, depending on the demands of your business. From TMT bar rolling mills and wire rod mills to products such as mill stand, rolling mill gearboxes, reheating furnaces and more. 

Our projects and products also undergo thorough testing and strict quality checks to supply you with the best machinery and products. Our focus on technology and innovation also provides you with the most up-to-date products for your rolling mill. 

To learn more about the Steefo Group and their products and how they can improve your productivity and profits, contact +91 98240 76873 or drop a mail at marketing@thesteefogroup.com. 

Also Read: 5 Benefits of Rolling Mills for Small Manufacturers

Categories
Blogs
Reheating Furnaces In Steel Rolling Mills

 

Reheating Furnaces serve the purpose of heating steel blooms, billets or slabs in steel rolling mills. Reheating furnaces takes this steel stock up to approximately 1200 degree Celsius. The steel begins to deform at this temperature, and the steel rolling process can begin. In a reheating furnace, the heat provided to the steel stock is constant. The stock is charged at the entrance, heated up to the assigned temperature in the furnace and discharged at the reheating furnace exit. During the process, the heat gets transferred to the stock in the furnace with the help of radiation and convection. This takes place due to the placement of the burner gasses and furnace walls. 

How Does The Heat Transfer Mechanism Operate In A Reheat Furnace? 

A steel stock charging temperature can vary drastically, ranging from ambient to the high temperature of 1200-degree celsius. Depending on the dimensions of the steel stock, speed of rolling, and overall steel composition, the exit temperature of a steel stock might differ. The factor of steel quality also plays a huge role when it comes to temperature as it puts limitations on the surface and gradient temperature. It is to be noted that both gaseous and liquid fuels are used in these reheating furnaces.

What Are The Main Characteristics Of A Reheating Furnace?

A Reheating furnace’ size depends on its ability to produce hot steel from the cold steel stock and is calculated in tons per hour. The increased heat content determines a reheating furnace and its energy efficiency. When the steel stock is heated from 10 degrees celsius to approximately 1200-degree celsius and is then divided by fuel energy used, efficiency can then be calculated accurately. The energy efficiency of a furnace also relies upon the design aspects of various reheating furnaces. 

Design Features That Plays A Role In The Energy Efficiency Of A Reheating Furnace

  • Different styles of burners
  • Dimensions of a Reheating Furnace. 
  • The total number of furnace zones 
  • Different kinds of roof and wall insulation
  • Design of skid 
  • Combustion air and preheating fuel in recuperators

An energy-efficient reheating furnace is developed in a particular method to allow the steel stock to heat up at a uniform temperature without consuming too much labour and fuel. 

Here are Some of The Important Parameters That A reheating furnace must include:

  • The amount of heat that must be imparted to the charge
  • Creation of necessary heat inside the reheating furnace required to heat the stock and curb steel losses
  • The transfer of heat created onto the surface of the stock that needs to be heated
  • Temperature equalisation within the stock 
  • A decrease in heat losses from the reheating furnace to a minimum 

Several operational approaches also play a crucial role in the energy efficiency of a reheating furnace. The ideal case of a reheating furnace is when the furnace is operated at the rated capacity with one kind of steel stock, which has the same dimension and composition. But often, this practice is not followed, which hampers the efficiency of the reheating furnace. 

Factors that Affect Efficiency of A Reheating Furnace

  • Differences in the dimension and composition of steel stock 
  • Delays in rolling can delay or halt the movement of steel stock in the furnace 
  • The composition of the fuel and its availability may differ
  • The conditions of the burners and the internal  state of the reheating furnace might deteriorate 

How are Reheating Furnaces Classified?

Several types of reheating furnaces are available in an average steel rolling mill, but how are they classified into different categories? Reheating furnaces are usually placed in four categories based on:

  • Heating Method 
  • Charging the reheating furnace method 
  • Steel stock movement inside the reheating furnace
  • Recovery of the heat method

If the reheating furnace is classified based on the heating method, there will be two types of heating.

  • Electrical Heating 
  • Combustion Heating 

Combustion heating reheating furnaces are able to use solid, gaseous and liquid fuels.

When the classification is based upon the steel stock’s movement in the furnace, a continuous furnace can be categorized further.

  • Pusher Furnace 
  • Walking Beam Furnace 
  • Roller Hearth Furnace 
  • Walking Hearth Furnace 
  • Rotary Hearth Furnace 

When the classification depends on heat recovery, there are only two types of reheating furnaces.

  • Regenerative Type 
  • Recuperative Type

The regenerative type of reheating furnace operates on regenerative burners. On the other hand, the recuperative variety of reheating furnaces functions with recuperators. 

Why Choose Reheating Furnaces From The Best Rolling Mill Manufacturers

When you select reheating furnaces from The Steefo group, you are guaranteed superior quality. Get your hands on the most innovative and futuristic products that will help you change the face of your business.  

Our projects and products also experience strict testing and quality checks to deliver best-in-class products. Our emphasis on technology and innovation also delivers up-to-date products for your rolling mill. 

To learn more about the Steefo Group and our reheating furnace and how they can improve your productivity and profits, contact +91 98240 76873 or drop a mail at marketing@thesteefogroup.com. 

 

Categories
Blogs
Why are Mill Stand A Necessary To Your Rolling Mill?

 

Mill stands are one of the most crucial pieces of equipment in the entire rolling mill process. A mill stand is usually fit with numerous rolls via which the workpiece bar goes through, achieving its necessary cross-section. Several mill stand designs serve different purposes in the rolling process.

Housing-less Mill Stand 

A Housing-less mill stand is specifically designed to create superior quality TMT bars, wire rods, channels, bars, universal beams, angles and more. The housing-less mill stand can do this effortlessly due to its rigidity and roll change abilities. These mill stands are usually also equipped with complete automation, especially during the connection and disconnection of fluid utilities and spindles. This automation assists the mill stand in becoming more efficient and quick in comparison to others. Housing-less mill stands also have a reduced stress path, screw-down automation, axial roll adjustment abilities along with complete automation, self-balancing spindle and reduced backlash. Roll change is easier in the same.

2-HI Conventional Mill Stand 

A 2-HI conventional mill stand has two work rolls that are pressed together with enormous force. The 2-HI mill stand contains non-reversing rolls that rotate in the same direction, which means that the workpiece bar cannot be fed from the other direction. A 2-HI stand either has to be a vertical or a horizontal stand.

3-HI Conventional Mill Stand 

A 3-HI mill stand is essentially needed in hot rolling reversing mills without switching the order of rotation of the rolls. In this type of mill stand, there are three working rolls. The top and bottom roll rotate in the same direction; meanwhile, the centre roll turns in the opposite direction. This is important as the workpiece bar keeps passing back and forth alternately through the rolls without reversing the direction in which the roll turns.

Pre-Stressed Mill Stand

Pre-stressed mill stands are different from conventional mill stands. In this case, the mill is already pre-stressed with the help of hydraulic four nuts. This allows them to be prepared with the highest force needed for rolls operating during the rolling period. The process allows any deflection of the mill stand to be avoided, especially under the rolling load.

Universal Mill Stand

A universal mill stand is a rolling stand that rolls in four ways. It is used in the rolling section where the section is shaped from all four sides. There are two vertically and horizontally mounted rolls in a universal mill stand. The vertical rolls are inactive and are positioned amid the bearing chocks of the horizontal rolls in the vertical plane. The vertical rolls are essentially present to manage the width of the bar during the rolling process.

Convertible Stands

Convertible mill stands allow conversion in the positioning. The stand allows either vertical or horizontal positioning during the intermediate finishing, depending on the production requirements. Convertible mill stands are convenient due to their speed during changing positions. It takes less than two minutes to do so. The stand rigidity is also an added advantage. The quick stand change system also does require any crane support and is equipped with reduced fountain depth.

Cantilever Stand

A cantilever stand is quite similar to a block mill, has both horizontal and vertical configurations, and can be configured to meet the client’s design requirements. The sleeve bearing on which the rolls are mounted can achieve high speeds and produce wire rods ranging from 5.5mm to 8mm.  The rolls are essentially small discs placed on the cantilever shafts and are available for one or two passes. The material o the roll is often hard and is created out of tungsten carbide.

Vertical Mill Stand

This up-drive type comprises a roll stand, mill spindles, a vertical gear reducer, a pinion stand, and a motor. To protect them from the roll cooling water and mill scale, the gear reducer and motor are installed on a concrete frame. There is also a lifting device under the roll stand that is installed to manage the position of the caliber to pass the level. The roll stand can be moved to the work side during stand changing.

Horizontal Mill Stand

The horizontal mill stand comprises of a roll stand, mill spindles, a pinion stand, a gear reducer and a motor. In the case of a regular pass line, the roll stand slides on the exterior of the sole plate. In a low-speed rolling mill with less than 10 m/sec, the pinion stand and gear reducer are from a single unit. A cross pin joint is used for the mill spindle and is supported by the spindle carrier during rolling.

Bottom line

In a rolling mill, rolling mill stands are used for several purposes, including generating billets, slabs, blooms, bars, plates and other sheet products. Rolling mill stands were initially used for steel casting, but today they are usually created from cast slabs or rolled plates.