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Presentation - China and Russia - Final 01.11.2019
Presentation - China and Russia - Final 01.11.2019
Presentation - China and Russia - Final 01.11.2019
• Two Rail and Section Mills – Total Capacity 2.1 MT (Rail and Sections)
• Mill – 1 – Commissioned in 2005, 0.9MT Capacity
• Mill – 2 – Commissioned in 2012-13, 1.2MT capacity
• Plant Visit
• Campaign Life
1. UR – 3000- 3500T
2. UF – 1500-2000T
3. E – 6000T
4. BD2 – 5000T
5. BD1 – 12000 – 15000 T
6. HRSM – 10000 – 12000 T
• Roll Pass design changes have been done in BD1 and BD2 (not
disclosed by BAOGANG)
Layout
Baotou Iron & Steel Line 1
Layout
Baotou Iron & Steel Line 2
Plants at a Glance
Rail output Design:1.4mt, Rail capacity-1mt, Rail actual last year- 0.84mt, 90% Heat Treated
Sections produced last year: R65 (0.8mt), Rest other sections, mill started-2013
Rolling Rate 200 t/h
Furnace 250 t/h, Walking beam furnace by Techint, Italy, Less than one percent scale loss
Mill availability 73 %
No of CNC machine 4
No of passes BD1-7, BD2-3, TM-3-3-3, UF0-1
Descaling Primary 200 bar before BD1
Secondary 200 bar before TM
Roll Materials BD1 & BD2- Alloy graphitic steel (45-50 ShC), UR – Steel Roll Arbor ring adamite
shell, Edger-Pearlitic CI (58-68ShC), UF-Pearlitic CI with CI shell (58-63 ShC),
Edger- pearlitic cast iron (58-63 ShC)
Scrap Diameter BD1- -200, BD2- -200, TM- -150, UF0- -150
Offtake BD1-14-15mm, BD2-14-15mm, TM-
Roll life/campaign life BD1- */12000 , BD2-*/12000, Edger-70,000/4,500, UF-50,000/4500, UR-
50,000/4500, UF0-*/2000
Rolled length, m 110m hot rolled length, 105m after cutting 5 crops at hot saw
Process highlights of EVRAZ NKMK, Novokuznetsk
RRSM Make BRONX, Cantilever Type HRSM, VRSM Web Working, Residual Stress – 250
NDT Machine FMG (Russian Make), ECT (NDT Canada Make), UT (Phased Array technology, Dry
UT, Make NDT Canada)
Hot Hours 18 hours
Hot Rail Head Cutting Only Rail Head Cutting @650 deg C by Cold Saw
Layout UF-0 introduced at a later date (helps in better tension – compression control
rolling)
One NDT Station
After NDT Station – defective rails are cut in 2 pieces for offline processing in
different beds
OK rails are cut to 100M and sent to Visual Inspection Stations
Bent end, if any, are corrected by Gag Press installed just after the Visual Stations.
Finishing Layout
100 M Prime Rails
2X52M Rails for Offline Processing
VIS-2
Gag Press
Bed with Chain Transfer
Mechanism
100 M Prime Rails
VIS-1
• Campaign Life
1. UR – 3000- 3500T
2. UF – 1500-2000T
3. E – 6000T
4. BD2 – 5000T
5. BD1 – 12000 – 15000 T
6. HRSM – 10000 – 12000 T
PLASMA HARDENING
• Heat treatment of specific portion of roll structure to increase wear
resistance done in UR,E,UF,U0 ROLLS to take care of localised wear
out of rolls
EVRAZ – Chocks
• BD-1 and BD-2 – 9
• UR, U0 and UF – 12 sets
• E – 6 sets
• Vertical – 24 sets
EVRAZ – Roll Pass
• Roll Pass design changes have been done in BD1 and BD2 (not
disclosed by EVRAZ)
EVRAZ NKMK – Points after
Discussion
1. Total 7 passes in BD1, 1st pass of URM BD2 is 7th PASS OF Evraz BD1.
2. T pass in Evraz is inverted therefore no downward tendency.
3. BD2 few passes are inclined.
4. Total 9 passes in tandem UR – E – UR
5. One more universal ( UF0) after tandem.
6. Recommended cast iron rolls in UF operator side to avoid sticking,
hardness 62 shore C.
7. All tandem and UF rolls having hardness > 60 shore C.
EVRAZ NKMK – Points after
Discussion
1. Only roll cooling
2. No pass lubrication in any of the rolls.
3. Plasma hardening at flange portion in BD2, UR and UF rolls.
4. Maintaining eccentricity less than 0.05 mm.
5. Presently doing manual branding on bottom roll of UF0.
6. Cutting 5 m from the front and then sending 105 m to finishing.
7. Web straightening as in RSM.
8. Calibration time for NDT machines – about 1 hour. Calibration
frequency – once in Shift of 12 hours
Heat Treatment line BAOGANG
• Not Shown
Heat Treatment line EVRAZ
NKMK
• Online Heat Treatment using Proprietary Air Quenching Technology
• Heat Treatment is done at one go for the entire rail (rail is head up and
stationary)
• After Heat Treatment, rails are transferred to the roller table and fed to
the cooling bed entry roller table
• Rail processing both combination of Online Inspection (for full length rails) and Offline
Inspection in beds (for defect marked rails which are salvaged in shorter acceptable
lengths).
• Component of full length 100M prime rails is 50-60% maximum in both the plants
• NDT at EVRAZ
1. Dry type phased array UT Machine by NDT Canada
2. ECT machine by NDT Canada
3. FMG machine – Russian Make
4. PMG Machine – Not Available
• NDT at Baotao
1. Not Shown
BAOGANG China
Maintenance Strategy
BAOGANG China
Spare Management
EVRAZ Novokuztesk
Maintenance Strategy
• Scheduled maintenance of 8 hrs . every week.
• One capital repair of 6 days every year
• No AMC is in place.
• Evraz technical support headquartered at Moscow to support in case of
complex problems. Technical Support team is available at site.
• Operative maintenance during shift changeover – 30 minutes
• Scheduled replacement of components as per the maintenance
schedule.
o Edger Block changed every week
EVRAZ Novokuztesk
Spare Management
EVRAZ Novokuztesk
Spare Management
• Spares procured on proprietary basis from SMS Group Spare Division Only
• Commissioning spares and two years spares’ were ordered with the
Project
Implementable Points
Use of SGCI (Cast Iron) Rolls for Vertical Rolls
of UF to avoid sticking problem
Plasma Hardening of selected roll portions
(prone to maximum wear out) BD-2, UR and
UF Rolls
Adequate spares and consumables including
insurance spares from OEM/OES
Periodic replacement of sensors and
cylinders
Implementable Points
Changes in the Roll Pass Design to be
explored.
Modification in BD-1 passes (tapered) to
minimize lap.
Modification in Leader and Finishing Pass of
RSM to address the flange thickness issue in
line with 60E1 profile requirement.
Installation of Head Hardening Unit (EVRAZ
Model) parallel to RT101 Roller Table of RSM.
THANK YOU