CRAP LINE

Presented By..

Chandan kr. Singh

KEY SECTIONS OF LINE

ENTRY

QUENCHING SECTION

PICKLING SECTION

WELDING MACHINE

FURNACE

EXIT ACCUMULATOR

DEGREASING SECTION

ENTRY ACCUMULATOR

EXIT

TECHNICAL SPECIFICATIONS OF CRAP LINE

BASIC TECHNICAL DATA
Type: Continuous Annealing Pickling Line. Line Direction: Right to Left Line speed: 10 60/80 m/min Uncoiler section 10 - 60 m/min Process section 10 60/80 m/min - Recoiler section Material: Cold rolled Stainless Steel Strip, (AISI 200, 300 and 400). Strip width: 850 mm - 1,280 mm Strip thickness: 0.4 - 4.0 mm Coil weight: 20,000 kg max. Exclusive. sleeve and interleaving paper Coil ID: 610 mm (nominal) ,660 mm (With Adapter) Coil OD : 1829 mm max / 850 mm min. Length of C-APL approx. 400 m

ENTRY SECTION

Entry

Coil Storage Saddle : Capacity Coil OD :20,000 kg. : 1829 mm max / 850 mm min.

Entry

Coil Car : 1:

Lift capacity 20,000 kg. Coil ID :585mm , Coil OD : 1829mm

Uncoiler

Expand diameter:785 mm, Collapse diameter 585 mm.

Uncoiler 2 : Coil ID : 590 mm , Coil OD: 1300 mm Expand diameter: 650 mm, Collapse diameter 585 mm.

BRITISH FEDERAL SPOT WELDING MACHINE

Specification: - Application - For Welding Strip ends on continuous AP line. - Material to be welded - Cold rolled stainless steel (uncoated) - Strip Width - Strip Thickness
-

- 600 mm (min) - 1600 mm (max) - 0.20 mm to 2 mm - 1700 mm x 150 mm. - Overlap Spot weld. - 0.5 mm to 6.0 mm - 250 KVA

- Max. Capacity of welder - 1600 mm wide x 1.6 mm thick Max. strip clearance - Type and quality of Weld

- Direction of Weld
- Rating

- Right to left

- Overlap adjustment range

PARAMETERS OF WELDING MACHINE

THICKNESS OF THINNER SHEET HYD PRESSURE WELD ON TIME IN BAR (CYCLE) HEAT(%)

FORCE

TAP NO

0.4 0.5 0.7 0.9 1.2 1.6

150 185 275 340 550 685

7.5 9.25 13.75 17 27.5 34.25

8 8 8 8 8 9

65% 65% 65% 65% 65% 70%

2 2 2 2 2 2

2
2.4

865
1000

43.25
50

12
14

70%
70%

2
2

DEGREASING SECTION

Alkali Cleaning Tank

Hot Water Rinse Tank Hot Air Dryer

ENTRY ACCUMULATOR SECTION

This is an arrangement used for accumulating the strip for uninterrupted operations of the process while joining the two coil ends together in order to ma the strip continuous.

The storage capacity is 330 meters.

FURNACE TECHNICAL SPECIFICATION
OVERALL DIMENSION.

Total length from entry -seal to exit seal roll Length of furnace no 1. Length of furnace no 2 Length of furnace no 3. Length of furnace no 4. Width inside furnace No 1 & 2. Width inside furnace No 3 & 4.

72.510 meters 14.600 meters 14.600 meters 18.760 meters 18.760 meters 3.438 meters 2.638 meters

NO OF FURNACE

NO OF HEATING ZONES

NO OF BURNERS EACH ZONES

TYPE OF BURNERS

TOTAL NO OF PILOT BURNERS

NO OF REGENRATI VE BOX

F#1

F#2

4,4,4

10 No's- 60/80 Therm / 2 No's EJ18

12 NOS

12 NOS

F#3

4,4,4

12 NOS 60/80 THERM

12 NOS

12 NOS

F#4

4,4,5

4 NOS-60/80NA,9 NOS -20 THERM

12 NOS

4 NOS

FURNACE TEMPERTURE FOR 300 SERIES

Thickness (mm)

Zone 4 in C

Zone 5 in C

Zone 6 in C

Zone 7 in C

Zone 8 in C

Zone 9 in C

Zone 10 in Zone 11 in Zone 12 in C C C

0.38 - 0.55 1000

1000

1000

1170

1190

1170

1160

1180

1160

0.56 - 0.65 1130

1150

1130

1190

1210

1190

1160

1180

1160

0.66 -0.83

1150

1170

1150

1210

1220

1210

1180

1200

1180

0.84 - 4.10 1170

1190

1170

1210

1220

1210

1180

1200

1180

FURNACE TEMPERTURE FOR 200 SERIES

Thickness Zone 4 in Zone 5 in Zone 6 in Zone 7 in Zone 8 in Zone 9 in (mm) C C C C C C

Zone 10 in C

Zone 11 in C

Zone 12 in C

0.38 0.55

920

940

940

960

960

960

950

950

950

0.56 0.65

950

960

960

980

980

980

980

980

980

0.66 0.83

980

980

980

1000

1000

1000

1000

980

980

0.84 4.10

1020

1020

1020

1050

1050

1050

1080

1050

1050

QUENCHING SECTION

Air flow to air quench Water and air flow to caster jets

Water flow to water quench

Total length of quenching section Length of Air Quenching section. Length of 12 Pair caster jet Length of Water quench. Length of Dryer Length of Dryer (Future Scope)

48.000 mtr 22.900 mtr 14.500 mtr 5.300 mtr 1.750 mtr 3.550 mtr

Max working pressure

3.5 bar

PICKLING SECTION
This process section of the pickling line consists mainly of the following treatment stages: Neutral electrolytic pickling with Na2SO4 Mixed acid pickling Scrub brush machine with PP brushes Final rinse with scrub brush machine Edge Blow-Off Device and Strip drier

OVERALL DIMENSION OF PICKLING SECTION

Total length of pickling section Length of Electrolytic section.

88.290 42.660

mtr mtr

Length of Mixed acid section.

Length of Squeeze & Brush Section Length of Dryer 1.750

27.917
10.255 mtr

mtr
mtr

ELECTROLYTIC PICKLING SECTION

Specification details: No of Tanks : 03 Tank Capacity :13 m Anode type : flat mild steel covered with lead Set of Anodes : 24 set (8 set in each tank each set consists of a separate electrode for upper & a separate electrode for lower side). Cathode type : Stainless steel (AISI 316) Set of Cathodes :48 set (16 set in each tank each set consists of a separate electrode for upper & a separate electrode for lower side) Electrolyte circulation system, consisting of: No of Circulation tanks : 03 Tank capacity : 35 m each No of circulation pump : 09 No of sump pump : 02 No of Heat exchanger : 02

Electrolytic pickling section with Sodium sulphate

Neutral

electrolyte Operating Temperature Heating and Cooling Rectifier Current Density

150- 220 Na2SO4 g/l : 60 65 Deg C : In direct by heat exchanger : 1 Sets - 8,000 A : 8 to 10 Amp /dm

NEOLYTE SECTION /THEORY

GOAL: Convert the stable Cr3+ to the soluble valence Cr6+

Anode reactions:
Cr3+ => Cr6+ + 3e 2H2O => O2 + 4H+ + 4e

Cathode reactions :

2H2O + 2e- => H2 + 2 OH- + 2e-

LAYERS OF STAINLESS STEEL (ANNEALED )

Cracks and pores Oxide layer (iron-, chroium oxides etc.)

Chromium depleted zone approx. 1/100 mm

Normal chrom. content > 18% Cr

Annealed stainless steel surface

Oxide 50-60% Cr2O3 20-25% Fe2O3 + Fe3O4 5-10% MnO2 5-10% SiO2 3-5% NiO Chromium depleted zone < 10% Cr

PICKLING OF STAINLESS STEEL

Annealed

Electrolytic pickling Mixed acid pickling Stainless steel surface

Final product

NEOLYTE PARAMETERS
Neolyte Bath Parameter Specific Gravity pH Temperature (0C) Bath Current (kA) Brush Current (A) Re-circulation Flow (m3/hr) Re-circulation Pressure (bar) Aim 1150 7 65 4.5 20 2 x 100 3 Range 1120 - 1180 6-8 60 - 70
-

16 - 20
-

MIXED ACID SECTION

Specification details:
No

of Tanks

: 02

Tank Capacity

: 12 m

Mixed

acid circulation system, consisting of: : 26 m each : 02 : 02

No of Circulation tanks : 02 Tank capacity No of sump pump No of Heat exchanger

No of circulation pump : 06

Pickling
HNO3 penetrates the cracks/pores in the oxide
+ + + + + + + + + + ++ + +++ + + + + + + + + + +++ ++ + ++ + + + + +

The chemical dissolution of the chromium depleted zone ceases when the concentration of Fe3+ is high enough

2 Fe + 3 NO3- + 6 H+

2 Fe3+ + 3 NO2- + 3 H2O

Only nitric acid (HNO3) is operating

20 | 13 July, 2013 | Avesta Research Centre, Process Chemistry

Pickling
# # # # # # # # ## # # # # # ## # # # ++++++++++++++++++ +++++ Fe3+ + 2 HF Fe3+ + 3HF
2 NO2- + 2H+ # ##
The positive iron ions (+) reacts with hydro fluoric acid forming complex # ions (#) allowing HNO3 to continue # dissolving the chromium depleted # zone. The nitrous fume contributes to # the scale breaking.

Clean surface
FeF2+ + 2H+

FeF3 + 3H+
NO + NO2 + H2O

Both HNO3 and HF are operating!!!

ACID BATH PARAMETERS

Acid Bath Parameter Aim Range

HNO3 Concentration HF Concentration Temperature (0C) Metals (g/l) Re-circulation Flow (m3/hr) Re-circulation Pressure (bar)

135g/l (13.5%) 36g/l (3.6%) 60 25 2 x 200 2

120-145g/l (12-14.5%) 32-40 (3.2-4%) 55-65 25-30

-

Tank Turbulence

100%

100%

HIGH PRESSURE RINSE

One pump on duty, one pump on standby Flow rate 270 l/min 4 spray bars on duty (2 top, 2 bottom) and 4 spray bars on standby Water pressure 95-110 bar Water temperature ambient Contamination non-recirculating system

LOW PRESSURE RINSE ( Hot Rinse)

Flow rate 25m3/hr Water pressure 2 bar

Contamination HNO3 25g/l (2.5%) max; HF 5 g/l (0.5%) max; Metals 5g/l max.
Brushes 16 to 20 amps

Dryer
To

remove water content from the sheet.

EXIT ACCUMULATOR SECTION

This is an arrangement used for accumulating the strip for uninterrupted operations of the process when the exit section is stopped for removing the welded joint, unloading the coil from recoiler mandrel, loading the sleeve on the mandrel and wrapping the lead end of new coil on the recoiler mandrel. The storage capacity is for 270 mtrs.

EXIT SECTION
Recoiler: Coil ID : 660 mm : : 1850 mm 22000 kg. Maximum coil OD Maximum coil weight Exit Coil Car : Exit Coil Storage Saddle

TENSION PARAMETERS
Tension Unit Factors:

Uncoiler Entry AccumulatorFurnace Shot Blast Pickling Exit Accumulator Recoiler -

0.3 -0.5 kg/Cm 0.8 -1.0 kg/Cm 0.5 -0.8 kg/Cm 0.8 -1.0 kg/Cm 1.2 1.6 kg/Cm 1.5 1.8 kg/Cm 2.5 - 3.0 kg/Cm

Formula For Calculating Tension:Width thickness unit factor = Tension

LINE SPEED
Thickness (mm) Speed (m/min)

0.4 0.5
0.6 0.7 0.8 0.9 1 1.2 1.5

60 60
60 60 60 60 54.5 45.8 37.9

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