Pickling and Tandem Cold Mill Automation Systems

The Pickling Line and Tandem Cold Mill (PLTCM) automation systems assists mill operators, process engineers, maintenance technicians, quality control specialists, and production managers in a pickling line or tandem cold mill, who want to achieve high-quality strip production with minimal thickness variations by increasing the precision and reliability of the rolling process and improving strip quality through advanced rolling and pickling models, real-time adaptation, and comprehensive flatness and thickness control systems. The PLTCM reduces strip thickness variations and deviations caused by the cold rolling process, minimizes the impact of specific disturbances like roll eccentricity, lubrication issues, and temperature deviations on the strip quality, and optimizes the rolling strategy and process parameters to ensure high-quality strip production and maximizes yield.

The Pickling Line and Tandem Cold Mill (PLTCM) is a sophisticated system that integrates the processes of pickling and cold rolling to enhance the quality and efficiency of steel production. The pickling line cleans the steel strip by using a series of acid baths, followed by rinsing and drying. This process improves the quality of the strip surface and removes any impurities, preparing it for the next step of cold rolling.

The tandem cold mill then takes the cleaned strip and performs a series of rolling operations to reduce its thickness. This is achieved through precise control of rolling parameters such as speed and tension. The tandem mill employs advanced models for pass schedule calculation, rolling force, and flatness control, ensuring optimal thickness quality and surface finish. Advanced thickness and flatness control systems ensure that the strip maintains precise dimensions throughout the process, using feedback and mass flow control concepts.

The automation system features a comprehensive line speed optimization module that maximizes production rates while maintaining consistent quality. This module dynamically adjusts the speeds of entry, pickling, and trimming sections based on real-time process data, ensuring smooth and efficient operation.

Level 2 automation integrates rolling models based on the mass flow concept that optimize load distribution and speed settings for each rolling stand, ensuring each strip segment is processed under optimal conditions. Additionally the temperature models determine the strip temperature. All of them are essential for efficiency and precision of steel processing, enabling superior product quality, optimized yield and operational performance.

Benefits of PLTCM Automation Systems from Primetals Technologies

• Increased production efficiency: by optimizing line speed and process parameters, the PLTCM Automation system significantly improves production efficiency, reducing downtime and increasing throughput.
• Enhanced quality control: advanced flatness and thickness control features ensure that the steel strip meets exact specifications, reducing defects and improving the overall quality of the final product. The system's ability to maintain precise flatness and thickness throughout the rolling process enhances product reliability and customer satisfaction.
• Cost reduction: the system's optimization features help reduce operational costs by minimizing material waste and improving energy efficiency.
• Scalability and flexibility: designed to integrate seamlessly with existing infrastructure, the PLTCM Automation system offers a scalable solution that can be customized to meet specific production requirements.
• Improved safety and reliability: the automation system incorporates advanced safety features and real-time monitoring capabilities, ensuring safe and reliable operations.

Features of Pickling Tandem Cold Mill Automation

• Advanced pickling model: the system includes a sophisticated pickling model that calculates the optimal pickling speed and temperature for each strip segment. This ensures precise control over the pickling process, reducing the risk of under- or over-pickling, which can lead to material losses.
• Line speed optimization: the automation system maximizes production rates by maintaining a constant, high-speed operation in the pickling line and tandem mill. This feature ensures that the line operates at the highest possible efficiency without compromising quality.
• Material tracking and coordination: the system's material tracking capabilities ensure accurate synchronization of material flow and process parameters. This feature enhances the overall efficiency of the production line by coordinating the movement of materials through the mill.
• Hydraulic and media functions: the automation system includes advanced hydraulic and media functions that ensure optimal operation of the mill's mechanical components. These functions are crucial for maintaining the integrity and performance of the mill.
• Basic automation technologies: the PLTCM Automation system incorporates basic automation features such as gauge control and mass flow control to maintain consistent material flow for enhanced strip quality.
• The Line Coordinator manages the coordination and activation of movements and control signals, handling different operation modes such as threading, run-up, and tail-out.
• The Master Ramp Generator works together with the Line Coordinator to control strip movement, providing speed and acceleration settings for the strip drives. This ensures smooth speed ramp-up and ramp-down as well as optimal tension control for the complete PLTCM.
• TPO features and benefits: the Through-Process Optimization (TPO) system offers advanced assistance functions, providing decision support tools that help operators maintain quality and efficiency. TPO includes features like real-time monitoring, alarms, and root cause analysis to ensure optimal operation.
• ALEX user interface: the ALEX UI offers an intuitive interface for monitoring plant conditions and managing alarms and reports. This interface supports operators with real-time data and recommended actions, enhancing decision-making and operational efficiency.
• Flatness expert: the system includes a flatness control module that ensures the rolled strip meets precise flatness specifications, enhancing product quality and reducing material waste.
• Rolling models: this feature enhances the rolling process by using advanced models to adjust load distribution and speed settings based on real-time data, optimizing efficiency and performance. The temperature models control the strip temperature during the rolling process, improving process stability and ensuring consistent results.
• Roll eccentricity expert: the automation system includes a roll eccentricity control function that minimizes deviations caused by roll eccentricity, ensuring uniform thickness and reliable output.
• Edge drop control: this feature precisely manages the edge thickness of the strip, ensuring consistency across the width and enhancing the overall quality of the final product.