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Presentation On

HRAP

By,Vikrant Patel

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Type:- Continuous Annealing Pickling Line.

Line Direction: - Left to Right (viewing from operator side)

Material: - HOT ROLLED COILStainless Steel Strip,

Strip width: - 850 mm (min.) 1,560 mm (max.)

Strip thickness: - 2.0 - 7.0 mm

Coil weight: - 28,000 kg max. Exclusive sleeve and interleaving

Coil ID: - ID - 660 mm

Coil OD: - OD - 2200 mm max

Basic Technical Data

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Entry Coil Storage Saddle :-

Capacity : 28,000 kg

Coil OD : 2200 mm max / 850 mm min

Entry Coil Car :- Lift capacity 28,000 kg

Uncoiler 1 :-

Coil ID : 660 mm

Coil OD : 1850 mm (max.)

Expand diameter : 760 mm

Collapse diameter : 608 mm

Uncoiler 2 : -Coil ID : 660 mm

Coil OD : 1850 mm (max.)

Expand diameter : 760 mm

Collapse diameter : 608 mm

Entry Section Specification

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This welding process is a MIG welding. An endless wire is fed

through a torch with 100 % Argon (shielding) gas supply. The

wire movement is motorized. Inert gas is chemically neutral, no

reaction with the molten metal. Active gas is an inert gas with an

addition of an active gas (i.e. 3 % oxygen ), this reacts with the

metal and heats up the weld.

Welder Unit comprising of:-

1. Shearing Operation2. Welding Operation

3. Notching Operation

Oxytechnik Welding

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Parameters:-

Feed wire rate:- 1150 ~1170 rpm

Welding Current :- 220~240 amp

Argon flow rate :- 15 m3/hrWelding Carriage speed :- 2-5 mpm

Precautions:-

While working on shear or handling scrap pieces, use hand

glovesDont put hands below the shear while cutting

Dont see welding light with naked eye

Welding Parameters & Precautions

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This is an arrangement used for accumulatingthe strip for uninterrupted operations of the

process while joining the two coil ends together inorder to make the strip continuous.

The storage capacity is 200 mtrs.

Entry Horizontal Accumulator

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Overall dimension.

Total length from entry -seal to exit seal roll 72.510 mtrs Length of furnace no 1. 14.600 mtrs Length of furnace no 2 14.600 mtrs

Length of furnace no 3. 18.760 mtrs Length of furnace no 4. 18.760 mtrs Width inside furnace No 1 & 2. 3.438 mtrs Width inside furnace No 3 & 4. 2.638 mtrs

Furnace section

Zone temperature and strip temperature Burner operation (switch over) Furnace roll condition Catenary position Excess Oxygen (periodically) Gas leaks

Follow proper procedures for lighting up and shutting down

FURNACE TECHNICAL

SPECIFICATION

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Furnace Parameters

NO OFFURNACE

NO OFHEATINGZONES

NO OFBURNERS EACHZONES

TYPE OF BURNERS TOTAL NOOF PILOTBURNERS

NO OFREGENRATIVEBOX

F#1

F#2 3 14 Nos EJ 18 Burner06 Nos60/80 Burner08 Nos

14 Nos 14 Nos

F#3 318 Nos 30/40 Burner18 Nos 18 Nos 18 Nos

F#4 3 16 Nos 30/40 Burners06Nos20Therm05 Nos

15 Therm -05 Nos

06 Nos 06 nos

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Zone 4

inCZone 5

inCZone 6

inCZone 7

inCZone 8

inCZone 9

inCZone 10

inCZone 11

inCZone 12

inC

1000 1000 1030 1060 1100 1120 1120 1120 1100

FURNACE TEMPERATURE

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QUENCHING SECTION & Dryer

Air Quenching Air & WaterQuenching

Water Quenching

Dryer

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Shot blast Specification:No. of wheels 4 /Chamber

No. of wheels on top 2 /Chamber

No. off wheel on bottom 2 /Chamber

Shot Blasting Chamber 3

Elevator 2 /Chamber

Dust Collector Shaker type

No. of shaker 2

No. of filter 132

Steel Shots used S-110

Shot Blasting Section

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Mixed Acid Pickling Tanks 1, 2, 3, 4 & 5Tank capacity : 65 m each

Pickling Section

Acid Bath Parameter Aim Range

HNO3 Concentration 135g/l (13.5%) 120-145g/l (12-14.5%)

HF Concentration 36g/l (3.6%) 32-40 (3.2-4%)

Temperature (0C) 60 55-65

Metals (g/l) 25 25-30

Re-circulation Flow (m3/hr) 2 x 200 -

Re-circulation Pressure (bar) 2

Tank Turbulence 100% 100%

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HNO3 penetrates the cracks/pores in the oxide

Pickling Reactions

+ + + + + + + + + + + + + + + +

+ +++

+

+

+

+

The chemical dissolution of thechromium depleted zone ceases whenthe concentration of Fe3+ is high

enough

2 Fe + 3 NO3- + 6 H+ 2 Fe3+ + 3 NO2

- + 3 H2O

Only nitric acid (HNO3) is operating

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Pickling

+ + + + + + + + + + + + + + + + + + + + + + +

##

#

#

#

##

##

##

##

#

##

#

##

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.

Both HNO3 and HF are operating!!!

Fe3+ + 2 HF FeF2+ + 2H+

Fe3+ + 3HF FeF3 + 3H+

2 NO2- + 2H+ NO + NO2 + H2O

Clean surface

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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 Condition)

Flow rate 25m3/hr Water pressure 2 bar

Tempreture - 50 60 0C

Brushes 16 to 20 amps

Rinsing Section

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Exit AccumulatorThe storage capacity is for 180 mtrs.

Recoiler

Coil ID : 660 mm

Maximum coil OD : 1850 mm

Maximum coil weight : 22000 kg.

Nominal dia. : 660 mm

Exit Coil CarExit Coil Storage Saddle with coil weighing system

EXIT SECTION

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LINE SPEED

Thickness (mm) Speed (m/min)

1025 & 1275 mm wide 1525 mm wide

2.5 30 24.6

3 30 24.6

3.5 28 24.6

4 24.6 23.9

4.5 21.8 21.4

5 19.6 19.2

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Tension Unit Factors:-Uncoiler - 0.3 -0.5 kg/Cm

Entry Accumulator - 0.8 -1.0 kg/Cm

Furnace - 0.5 -0.8 kg/Cm

Shot Blast - 0.8 -1.0 kg/Cm Pickling - 0.3 0.5 kg/Cm

Exit Accumulator - 1.5 1.8 kg/Cm

Recoiler - 2.5 - 3.0 kg/Cm

Formula For Calculating Tension:-

Width thickness unit factor = Tension

Tension Parameters

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Thank You