Universal stands with no-housing or housing design provide high rigidity in a compact structure. 3+1 tandem mills increase the yearly productivity in a small installation space. Change-over times are reduced to a minimum by automated change systems. Reversing flat rolling blocks allows the production of a large range of flat-bars, without need of any roll change. Horizontal and vertical straightening systems remove the deformations caused by asymmetrical cooling effects. Stacking systems provide adjustable and flexible operation to process different lengths. Inline cooling technologies improve the mechanical characteristics of medium-large sections and reduce its residual stresses, without expensive alloying elements. The idRHa+ inline and flexible rail hardening system applies defined cooling protocols to obtain the controlled microstructure and hardness distribution required by premium rails.
Primetals Technologies has installed or upgraded more than 1,000 rolling mills on six continents. These mills have set worldwide benchmarks for technological leadership, reliability and performance.
Double Supported Hydraulic Straightener
The Double Supported Hydraulic Straightener features independently driven rolls, which guarantee the full product straightness, within a set level of residual stress and without surface damage. Hydraulic capsules compensate the spring effect in a compact layout footprint. A dedicated mechatronic package controls the operation and the fully automatic roll changing procedure.
idRHa+ Inline Rail Hardening Technology
Premium rails for high-load or high-speed applications need to be resistant to rolling-contact-fatigue as well as to surface wear.
Developed together with RINA-CSM (Italy), idRHa+ is the leading technology for inline hardening of rails, as it allows for precise and flexible cooling protocols to be applied. The rail thermal profile and its metallurgic transformations are monitored in real-time in heating and cooling areas. Hardness distribution and microstructures are selectively applied across the rail section, so that the desired structure be obtained. idRHa+ can process all types and lengths of rails, at the same rate of the rolling mill and without loss of productivity, and with significant energy savings. High-power induction heaters equalize the rail temperature and are followed by independent cooling modules with air-blades or atomized-mist. The technology is based on an integrated suite of thermal, mechanical and metallurgy models, validated in pilot units. The quick ramp-up of industrial operation is guaranteed, as well as the simulation of new rail grades.
3+1 EVO Universal Tandem Mill
The 3+1 EVO Universal reversing tandem mill features the first three stands, arranged in universal-edging-universal configuration, which operate in reversing sequence. The fourth universal-finishing stand is used a single low-reduction pass at the end of the reversing sequence. Its rolls have a low wear-rate and the rolling campaign duration is significantly increased before redressing is needed. The 3+1 EVO mill is available with housing- or housingless-type stands.
Fig.1- Double supported hydraulic straightener
Fig.2- idRHa+ inline rail hardening system
Fig.3- 3+1 EVO universal tandem mill with housingless-type stands
Today’s steel producers face the dual challenge of ensuring on-time delivery and ever demanding product requirements, while also running a lean operation. Every day the management of a long rolling plant requires continuous optimization of both operating and business practices.
Utilizing the ongoing evolution in technology through data collection, communication, internet of things, control techniques and smart sensors, there is now more information available than ever before. This information will both advance control and monitoring of plant performance, revolutionizing long rolling mill plants worldwide and optimizing the entire value chain, along with improved and more flexible production, utilizing the latest control and drive technology.
Digitalization of Long Rolling Control System – Smart Sensors
Fig.1 - Smart Sensors for digitalization of Long Rolling Control System
Primetals Technologies Long Rolling Process Expert - Transparency for your entire production process
“You cannot manage what you do not measure” – Primetals Technologies Long Rolling Process Expert monitors and collects data from the raw material stage through to the finished product. Its domain extends from the enterprise resource planning (ERP), through Manufacturing Execution Systems (MES), to control systems and down to the plant device level.
The system delivers
- Valuable mill reports for operators and management
- Defined KPI’s to assess plant performance
- Plant to plant performance at corporate level
- Fig. 2- Process Expert Long Rolling – cost efficient and modular automation system. Material tracking and roll shop management module included
As an original manufacturer of long rolling equipment, Primetals Technologies offers a true lifecycle support to its customers, and provides them with a unique range of products and services to maximize mill utilization and productivity over the entire plant lifetime. Follow this link to learn more about Lifecycle Services.
ARBZ, Aktobe, Kazakhstan
Type of plant
Rail and section mill
230,000 tons per year of sections and 200,000 rails in length up to 120 m
A fully automatic reversing blooming stand is followed by a 3+1 EVO reversing tandem mill. The rails are inline head-hardened by the flexible idRHa system
The mill produces premium head-hardened rails for the domestic and international market, in compliance to the most recent standards. The idRHa-treated rails successfully passed the Russian pre-certification ring-test right from the very first lot