UTTHAN-47

BAND PROBLEM IN DR
TEAM:
1. SK Mehabub (4HI OPR)
2. Deep (4HI OPR)
3. Abhinandan (4HI QA)
 CRM KMI/KPI Tracker
KMI- KPI- KAI LINKAGE: KK PILLAR
Actual KMI KPI UoM Plan Actual Plan Actual
FY 22 FY 23 FY 23(Till Apr’22) Apr’22 Apr’22
1 394306 CRM Pack Production Mt 394300 33517 33050 33517
Production
2 432979 Six Hi Production Mt 410600 37500 35200 37500
3 2.4 Coil Defect % <3 2.1 <4 2.1
4 - Complaints – CRM related ppm <200 0 <200 0
5 1.72, 0.89, 1.03, Quality Process Cpk. – thickness, temper, roughness, Cpk >1.33 1.48, 0.90, 1.2, >1.33 1.48, 0.90, 1.2,
2.21 width 1.86 1.86
6 0 Non conformance ISO Nos 0 0 0 0
7 5557 Process Cost Rs/Mt 5650 6682 5650 6682
Cost
8 88.7 Material Yield % 89.0 88.7 89.0 88.7
9 3.5 (0.3) Delivery CRM Diversion (With, W/O order) % <3.5(0.3) 3.3 (0.6) <5(0.4) 3.3 (0.6)
10 1 (LTI) Fatality, LTIs Nos 0 0 0 0
11 0 Safety Fire Incidences Nos 0 0 0 0
12 3 Safety Observation Participation Nos/TE 4 4 4 4
13 0 Deviation- Treated Effluent % 0 0 0 0
14 0 Deviation - Air % 0 0 0 0
Environment
15 4.5 Solid Waste** (Kg/Mt) <4.5 4.0 <4.5 4.0
16 1.95 + 0.3 Sp. Water Cons. (CRM + Boiler Feed) m3/Mt <2.25 1.9 + 0.3 2 + 0.3 1.9 + 0.3
17 135 Employee KYT sessions/ Kaizens Nos 150 21 12 21
 Problem Statement – Band in DR
What is Band in DR?
It is a defect coming in DR product , where wet rolling done to Annealed coils at Temper Mill. It is an impression ,
visible on the top or bottom surface and sometimes it is visible on both surface even after tin coating.

BAND visible on TMBP BAND visible on Tinplate

 Understanding the type of bands
Generally, There are Two types of band comes in DR
1. Heat band 2. Dull Band
Heat band generally appears due to shade It is physical abrasion on the sheet due to
difference ,the major reason is heat direct contact on non rolling component ,
generation at work rolls and cooling is not speed mismatch, picked up from I/C coils.
homogeneous –this band cannot be felt by
touching the surface i.e. no roughness
difference.
 Understanding the observation / condition
1. This band was coming on the both surface
2. There was no roughness difference between the shades, So its basically Heat band .
3. It was coming on the edges on both surface with varying intensity (within 100-150mm) .
4. This band was visible only by wiping the finished surface with cotton cloth.
5. To mitigate this band issue we stopped using RI, resulting no band found on surface of the sheet. But it was not a
permanent solution to process coils without RI.
6. Set point of Water temperature was 90-95 °c.
7. RI was used as mist form (mixture of air and RI).
8. RI concentration was 0.3 -0.5%
9. Emulsion concentration was 3-5 %

Rolling Nature of Band

Direction

O/S D/S

100-150mm 100-150mm
 Understanding point of generation
RI guard
Emulsion & water
Emulsion Guard AIR WIPING
Guard
HOT WATER
DAMMING
RI SPRAY
ROLL
EMULSION HOT WATER AIR WIPING EMUL SPRAY
SPRAY RI spray
SPRAY
Emulsion
spray

AIR WIPING
Entry EMULSION
SPRAY
tensiometer
STRIP
0.238 mm

1st STAND 2ND STAND

• Emulsion is sprayed at stand 1 while DR rolling
• Just after stand 1 rolling , hot water is sprayed to wash out the plate-out and Damming roll squeezes the further carry over
• Then we use RI (Rust Inhibitor) to avoid rust formation as well as to cool down the surface
• Heat Band is more prominent just after stand 2 Rolling– explained in Why –Why analysis
 Why-Why Analysis heat band
Phenomena W1 W2 W3 W4 G/NG Remarks 
Issue with Emulsion G
Pump/Motor
Improper G
Emulsion Flow Nozzle chocked
G
Leakage in supply line
Emulsion Concentration is Conc was within norms
Not ok G (3- 3.6)%.
Sheet shade was
Improper Heat
Heat Band different along the
visible in DR Distribution Improper cooling Process Issue with RI mist NG width
on sheet Condition issue
coils surface Sheet temperature
Water Temp Not ok NG was very high
Conc was within norms
RI conc Not ok G (0.3- 0.5)%.
RI pump Not ok G
Poor RI flow RI Nozzle Not ok G
Issue with Supply Pipelines
(leakages or blockage) G
 Heat Control a major issue

In DR , sheet cooling play a major role for surface finish , to control there are three steps

Cooling through emulsion Cooling though Hot water Cooling through RI mist

1 2 3
Emulsion , controls the roll Hot water – Have two functions Cools down the bite and
bite temperature , which 1. Sheet cool down sheet at stand 2
arises due to reduction 2. Removal of emulsion oil patch

Variation in temp at point 1, 2 and 3 may cause surface defect

1 – if at point 1 increase in emulsion temp will have impact on emulsion lubricity – may cause shape
issue due to less heat dissipation
2 - increase in hot water temp will reduce oil patched (UCO) post stand 1 but sheet temp will go high,
may result to heat band
3 - Any issue with RI spray may cause the further heat generation at stand 2 , will further add to
increase system heat in over all
 Let us understand cooling circuit

Hot RI Tank
exchanger

1st STAND 2ND STAND

AIR WIPING
HOT WATER
RI SPRAY
HOT WATER
EMULSION RI spray AIR WIPING EMUL SPRAY
SPRAY
SPRAY
Emulsion
spray

AIR WIPING
Entry EMULSION
SPRAY
tensiometer

Cooling zone Cooling zone Cooling zone

Heating zone Heating zone

 Addressing the NG – High sheet temp after ST1

Standard – Hot Water temp = 85-90 Degree C

Why Hot water temp kept High ??

The main purpose of hot water to clean the oil patch – high temp made it easier to clean UCO
In winters – Heat loss due to cold environment was high- hot water kept high to compensate the los
High Temp of hot watrer 

Plotting the trend between hot water temperature , no of

UCO cases found Less at higher temp – i.e between 85-90
Degree C

No of UCO 
 High water temp – Creation on new heating zone

Hot RI Tank
exchanger

1st STAND 2ND STAND

AIR WIPING
HOT WATER
RI SPRAY
HOT WATER
EMULSION RI spray AIR WIPING EMUL SPRAY
SPRAY
SPRAY
Emulsion
spray

AIR WIPING
Entry EMULSION
SPRAY
tensiometer

Cooling zone Cooling zone Cooling zone

Heating zone Heating zone

 Why new heating zone if system was working
earlier ?
Hot RI Tank
exchanger

1st STAND 2ND STAND

AIR WIPING
HOT WATER
RI SPRAY
HOT WATER
EMULSION RI spray AIR WIPING EMUL SPRAY
SPRAY
SPRAY
Emulsion
spray

AIR WIPING
Entry EMULSION
SPRAY
tensiometer

Cooling zone Cooling zone Cooling zone

Heating zone Heating zone

What was RI role to add another heat zone
Less impact of RI
cooling on WR

RI
spray

RI SPRAY
effect
RI nozzle
ed
WR
zone

Less impact of RI
cooling WR
 Actions Taken

1. Hot water temperature Set point has been revised to 75°c.

2. New heat exchanger has been taken into circuit (doing bypass the Old one) . Because:-
 Volume of Old heat Exchanger was very low.
 The control valve was not working properly. As a result sometimes water temperature would remain very high
than desired temperature.
 Efficiency of Old heat exchanger degraded.
3. RI flow revised i.e previously RI was used as mist form (Mixture of air and RI), So the quantity of RI would
accumulated on sheet was very less sometimes it would vary along the width .Due to this Sheet temperature
also would vary along the width as we know RI also helps to cool down the temperature of sheet .But presently
we are using RI without mixture of Air. So it is purely in liquid form instead of mist form and along the width RI
distribution is sufficient to cool down the sheet.
4. In case of mill idleness ,circulation of RI flow (through return line to RI tank) will remain continue.
 Impact and current trend

Diversion in DR due to Band (%) High due to

2
Heat Band 1.72 v
1.8
1.6
1.42
1.4 Under Good
1.2 control
1
0.8
0.6
0.27 0.35
0.4 0.24
0.2
0
Jan'22 Feb'22 March'22 Apr'22 May'22

Result : As we can see that improvement has been seen in last DR campaign ( May’22).
Fra

Thank You

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