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全连轧带钢总结介绍

2021-12-17 13:41:03 来源: 作者: admin888
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1. 生产成本降低10-15%(10-15% lower production costs)

与半连续工艺布置相比,全连续布置吨钢生产成本下降10-15%,主要是通过提高产量、降低燃料消耗、降低轧制电耗、降低轴承消耗、提高成材率等多方面实现。

中国的普碳钢厂家吨钢生产成本均降至70-90元之间。

Compared with semi-continuous process arrangement, fully continuous arrangement reduced production costs per ton of 10-15%, mainly by increasing production, reduce fuel consumption, lower rolling power consumption and lower bearings consumption and improve the finished product rate and other aspects of implementation.

For carbon steel manufacturers, the cost of production per ton decreases to between 70-90 RMB.

2.产量提高20-30%(Yield increase 20-30%)

解决了半连轧方案,粗轧可逆时间长,温降大的瓶颈问题。全连续粗轧轧制总时长45-60秒(含穿带),粗轧大于精轧产能。

比半连轧年产量可提高约20-30%,650-750mm全连轧带钢线,月产已突破15万吨,极限月产达16万吨,最大日产6000多吨。

It solves the problems of long reversal rolling and big temperature droop in the semi- continuous process. The overall rolling time for rough rolling is  45-60 seconds (with threading),the rough rolling has more output capacity than finish rolling.

The annual output increased by about 20-30% compared with the semi-continuous process, and for the 650-750mm-wide strip rolling line, the output has exceeded 150,000 tons per month, The maximum monthly output is 160,000 tons,the maximum daily production is over 6,000 tons.

3.产品板型质量大大提升(The product quality has been greatly improved . )

粗轧机组也采用全液压压下轧机,中间坯的宽度和厚度准确控制、厚度差小。

头尾温差减小和中间坯板型的最优化,使得精轧机组AGC厚度自动控制更加精确,使得成品板型质量大大提升。

Roughing train has a fully hydraulic roll mill, precise control of the width and thickness of the intermediate slab, with small thickness difference.

Reducing the temperature difference between the head and tail and optimal intermediate blank plate so that the thickness of the finishing train AGC automatic control is more accurate, and greatly enhance the quality of the finished plate.

4. 卷重增加50%(Coil weight increased by 50%)

因半连轧温降较大,头尾温差大,无法使用长坯料。全连轧一举解决了这个问题,使得成品卷重大大增加。由原来6米坯料增加至10-12米(150-165mm厚时)。

Semi-continuous rolling has a big temperature drop due to large temperature difference between head and tail along the long billets. Fully continuous  rolling one solution to this problem, so that the finished roll great big increase. Increase the billet from its original  six meters to  10-12 meters(the billet thick is 150-165mm).

5. 立式卷取+超快冷的全球首创冷却工艺,大大提高产品质量(The first global innovative cooling process combining the vertical coiler with super-fast cooling device to greatly improve the product quality)

卧式卷取机+层流冷却是带钢通用的产品冷却方案,但卧式卷取存在卷取薄规格带钢时事故率高的缺点。相反,在轧制超薄规格和产量提升方面,立式卷取反而有很大优势,但平板运输链产生氧化铁皮的现场是影响产品质量的关键缺点。中重全球首创使用了带钢出口的三叉区使用超快水冷的生产工艺,并迅速向市场推广,使得立式卷取产品质量大大提高。

It is common practice for strip production lines to combine horizontal coilers with laminar cooling devices as its cooling method. However, for horizontal coilers, it is plagued with high accident rates when coiling thinner products. On the contray, vertical coiler has its advantages when ultra-thin materials are rolled and of improving the producion capacity.  But scales on the product transportation chain used together with the vertical  coiler is the main shortcoming influencing the final product's quality. The first innovative design by ZZ that adopts the super-fast water cooling process at the two-route area has remarkably improved the final products' quality by the vertical coiler and has been rapidly promoted in the market.

6. 二次氧化铁皮及表面质量对比

(Secondary iron oxide and surface quality comparison)

•全连轧方案粗轧时间约为45-60秒,半连轧时间约为90-120秒。

 •半连轧可逆轧制过程,产生的二次氧化铁皮较多,并且直接轧制到带钢表面,影响带钢表面质量。

 •全连轧的粗轧连续轧制过程中产生的氧化铁皮极少,表面质量非常好。

•The fully continuous rolling is about 45-60 seconds, while the time for semi-continuous rolling is about 90-120 seconds. 

•Semi-continuous reversible rolling process produces more secondary iron oxide, which are rolled directly into the strip surface, affecting the quality of the strip surface. 

•The fully continuous rolling  process produce less iron oxide, thus very good surface quality.

7.轧制温度对比(Rolling temperature contrast)

•全连续轧制各道次紧密衔接,温降很小。

 •全连轧方案,粗轧后全部设置保温罩,中间坯头尾温差小,约为40度。 

•可逆轧机,不易采取简单有效的中间保温措施。需投资热卷箱,投资大。

•For fully continuous rolling , each pass coordinates closely ,so the temperature drop is small. 

•For fully continuous rolling ,soaking hood is adopted after the roughing mills, so that the temperature difference for the intermediate billet on its head and tail is small, about 40 degree only.

 •For reversible mills, simple form of soaking hood is not recommended, hot recoiling box is preferable, but it requires big investment.

8. 燃料消耗和烧损对比(Fuel consumption and scale loss comparison)

•半连轧工艺出炉温度约为1250℃,根据我们10几条生产线的实际数据,可直接将出炉温度降到1100℃-1150℃。

•使得燃料消耗降低约20-30%,半连轧高炉煤气消耗340-350m^3/t,全连轧高炉煤气消耗230-260m^3/t。 

•加热时间也大大缩短,可直接减少氧化铁皮烧损0.15-0.2%,按照年产150万吨计算,成品与废渣差价2000元/吨计算,每年直接经济效益450-600万元。 

•加热时间的减少,使加热炉产能大大提高。

•Semi-continuous rolling process has a leaving temperature (from the RF) of about 1250 ℃, based on actual data we have collected from over 10 production lines, the leaving temperature can be directly dropped to 1100 ℃ -1150 ℃.

•So that the fuel consumption is reduced by about 20-30%, the blast furnace gas consumption for semi-continuous rolling is 340-350m^3 / t, while that for the fully continuous rolling is 230-260m^3 / t.

•The heating time is also greatly reduced, directly reducing iron oxide loss by 0.2%

The shortening heating time  can greatly increase productivity of the RF.

9.减少坯料种类(Less varieties of billets are required)

粗轧采用连轧机组,可采用粗轧宽展孔型,也可采用立辊收窄,使得一种坯料可对应多种规格,最多可宽展出100mm,减少坯料的规格种类,可减少连铸结晶器的数量,和减少应换结晶器造成的产能损失。全线设置3-5台立辊轧机,可在±30mm自动控制宽度。

Roughing mill train is used, with broadened pass on the roughing mill, or the vertical rolls  may also be used to narrow billets, so that one kind of billet may correspond to a variety of specifications, we can increase the maximum width about 100mm, so we can reduce the billet specifications, reducing the number of continuous casting mold as well the yield loss caused by changing the molds.There are 3-5 vertical rolling mills are set up on the whole line, and the width can be automatically controlled at + 30mm.

10.水雾除尘效果(Water spray dedusting)

•全连轧容易在机架间设置水雾除尘,使得轧钢车间环境良好。

 •可逆轧机时,不容易采取除尘手段,作业环境比较恶劣。

•It is easy to set water spray dedusting device between the stands for the fully continuous rolling process, so that the rolling plant condition is good. 

•For the reversible mills, dedusting measures are not easy to implement, so the operating conditions are hard. 

11.投资相当(Relatively the same investment)

与半连轧的粗轧大电机、大轧机相比,采用小电机不可逆形式,降低了电机和电控的投资。以此投资用于机械设备的增加,整体投资与半连轧相差不大。

Compared with the big motors and large mills used in semi-continuous rolling, the non-reversible rolling process with small motors will reduce the investment on motors as well as on electrical control systems. So the overall investment is similar to that of the semi-continuous rolling production line.
责任编辑:admin888 标签:全连轧带钢
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德勤钢铁网 |市场分析

全连轧带钢总结介绍

admin888

|
1. 生产成本降低10-15%(10-15% lower production costs)

与半连续工艺布置相比,全连续布置吨钢生产成本下降10-15%,主要是通过提高产量、降低燃料消耗、降低轧制电耗、降低轴承消耗、提高成材率等多方面实现。

中国的普碳钢厂家吨钢生产成本均降至70-90元之间。

Compared with semi-continuous process arrangement, fully continuous arrangement reduced production costs per ton of 10-15%, mainly by increasing production, reduce fuel consumption, lower rolling power consumption and lower bearings consumption and improve the finished product rate and other aspects of implementation.

For carbon steel manufacturers, the cost of production per ton decreases to between 70-90 RMB.

2.产量提高20-30%(Yield increase 20-30%)

解决了半连轧方案,粗轧可逆时间长,温降大的瓶颈问题。全连续粗轧轧制总时长45-60秒(含穿带),粗轧大于精轧产能。

比半连轧年产量可提高约20-30%,650-750mm全连轧带钢线,月产已突破15万吨,极限月产达16万吨,最大日产6000多吨。

It solves the problems of long reversal rolling and big temperature droop in the semi- continuous process. The overall rolling time for rough rolling is  45-60 seconds (with threading),the rough rolling has more output capacity than finish rolling.

The annual output increased by about 20-30% compared with the semi-continuous process, and for the 650-750mm-wide strip rolling line, the output has exceeded 150,000 tons per month, The maximum monthly output is 160,000 tons,the maximum daily production is over 6,000 tons.

3.产品板型质量大大提升(The product quality has been greatly improved . )

粗轧机组也采用全液压压下轧机,中间坯的宽度和厚度准确控制、厚度差小。

头尾温差减小和中间坯板型的最优化,使得精轧机组AGC厚度自动控制更加精确,使得成品板型质量大大提升。

Roughing train has a fully hydraulic roll mill, precise control of the width and thickness of the intermediate slab, with small thickness difference.

Reducing the temperature difference between the head and tail and optimal intermediate blank plate so that the thickness of the finishing train AGC automatic control is more accurate, and greatly enhance the quality of the finished plate.

4. 卷重增加50%(Coil weight increased by 50%)

因半连轧温降较大,头尾温差大,无法使用长坯料。全连轧一举解决了这个问题,使得成品卷重大大增加。由原来6米坯料增加至10-12米(150-165mm厚时)。

Semi-continuous rolling has a big temperature drop due to large temperature difference between head and tail along the long billets. Fully continuous  rolling one solution to this problem, so that the finished roll great big increase. Increase the billet from its original  six meters to  10-12 meters(the billet thick is 150-165mm).

5. 立式卷取+超快冷的全球首创冷却工艺,大大提高产品质量(The first global innovative cooling process combining the vertical coiler with super-fast cooling device to greatly improve the product quality)

卧式卷取机+层流冷却是带钢通用的产品冷却方案,但卧式卷取存在卷取薄规格带钢时事故率高的缺点。相反,在轧制超薄规格和产量提升方面,立式卷取反而有很大优势,但平板运输链产生氧化铁皮的现场是影响产品质量的关键缺点。中重全球首创使用了带钢出口的三叉区使用超快水冷的生产工艺,并迅速向市场推广,使得立式卷取产品质量大大提高。

It is common practice for strip production lines to combine horizontal coilers with laminar cooling devices as its cooling method. However, for horizontal coilers, it is plagued with high accident rates when coiling thinner products. On the contray, vertical coiler has its advantages when ultra-thin materials are rolled and of improving the producion capacity.  But scales on the product transportation chain used together with the vertical  coiler is the main shortcoming influencing the final product's quality. The first innovative design by ZZ that adopts the super-fast water cooling process at the two-route area has remarkably improved the final products' quality by the vertical coiler and has been rapidly promoted in the market.

6. 二次氧化铁皮及表面质量对比

(Secondary iron oxide and surface quality comparison)

•全连轧方案粗轧时间约为45-60秒,半连轧时间约为90-120秒。

 •半连轧可逆轧制过程,产生的二次氧化铁皮较多,并且直接轧制到带钢表面,影响带钢表面质量。

 •全连轧的粗轧连续轧制过程中产生的氧化铁皮极少,表面质量非常好。

•The fully continuous rolling is about 45-60 seconds, while the time for semi-continuous rolling is about 90-120 seconds. 

•Semi-continuous reversible rolling process produces more secondary iron oxide, which are rolled directly into the strip surface, affecting the quality of the strip surface. 

•The fully continuous rolling  process produce less iron oxide, thus very good surface quality.

7.轧制温度对比(Rolling temperature contrast)

•全连续轧制各道次紧密衔接,温降很小。

 •全连轧方案,粗轧后全部设置保温罩,中间坯头尾温差小,约为40度。 

•可逆轧机,不易采取简单有效的中间保温措施。需投资热卷箱,投资大。

•For fully continuous rolling , each pass coordinates closely ,so the temperature drop is small. 

•For fully continuous rolling ,soaking hood is adopted after the roughing mills, so that the temperature difference for the intermediate billet on its head and tail is small, about 40 degree only.

 •For reversible mills, simple form of soaking hood is not recommended, hot recoiling box is preferable, but it requires big investment.

8. 燃料消耗和烧损对比(Fuel consumption and scale loss comparison)

•半连轧工艺出炉温度约为1250℃,根据我们10几条生产线的实际数据,可直接将出炉温度降到1100℃-1150℃。

•使得燃料消耗降低约20-30%,半连轧高炉煤气消耗340-350m^3/t,全连轧高炉煤气消耗230-260m^3/t。 

•加热时间也大大缩短,可直接减少氧化铁皮烧损0.15-0.2%,按照年产150万吨计算,成品与废渣差价2000元/吨计算,每年直接经济效益450-600万元。 

•加热时间的减少,使加热炉产能大大提高。

•Semi-continuous rolling process has a leaving temperature (from the RF) of about 1250 ℃, based on actual data we have collected from over 10 production lines, the leaving temperature can be directly dropped to 1100 ℃ -1150 ℃.

•So that the fuel consumption is reduced by about 20-30%, the blast furnace gas consumption for semi-continuous rolling is 340-350m^3 / t, while that for the fully continuous rolling is 230-260m^3 / t.

•The heating time is also greatly reduced, directly reducing iron oxide loss by 0.2%

The shortening heating time  can greatly increase productivity of the RF.

9.减少坯料种类(Less varieties of billets are required)

粗轧采用连轧机组,可采用粗轧宽展孔型,也可采用立辊收窄,使得一种坯料可对应多种规格,最多可宽展出100mm,减少坯料的规格种类,可减少连铸结晶器的数量,和减少应换结晶器造成的产能损失。全线设置3-5台立辊轧机,可在±30mm自动控制宽度。

Roughing mill train is used, with broadened pass on the roughing mill, or the vertical rolls  may also be used to narrow billets, so that one kind of billet may correspond to a variety of specifications, we can increase the maximum width about 100mm, so we can reduce the billet specifications, reducing the number of continuous casting mold as well the yield loss caused by changing the molds.There are 3-5 vertical rolling mills are set up on the whole line, and the width can be automatically controlled at + 30mm.

10.水雾除尘效果(Water spray dedusting)

•全连轧容易在机架间设置水雾除尘,使得轧钢车间环境良好。

 •可逆轧机时,不容易采取除尘手段,作业环境比较恶劣。

•It is easy to set water spray dedusting device between the stands for the fully continuous rolling process, so that the rolling plant condition is good. 

•For the reversible mills, dedusting measures are not easy to implement, so the operating conditions are hard. 

11.投资相当(Relatively the same investment)

与半连轧的粗轧大电机、大轧机相比,采用小电机不可逆形式,降低了电机和电控的投资。以此投资用于机械设备的增加,整体投资与半连轧相差不大。

Compared with the big motors and large mills used in semi-continuous rolling, the non-reversible rolling process with small motors will reduce the investment on motors as well as on electrical control systems. So the overall investment is similar to that of the semi-continuous rolling production line.

市场分析