Bar Mill

BAR MILL
PRESENTATION
(FURNACE AND COOLING BED)
PRESENTED BY
Satyam tripathi
0816440406
BAR MILL
INTRODUCTION:
MILL IS PROVIDED WITH FULL PRODUCT RANGE
OF THERMO MECHANICALLY TREATED RE-BARS
ACHIEVED WITH
HYQST(HIGH YIELD QUENCHED AND SELF
TEMPERED TECHNOLOGY)
THE SI Z ES RANGES FROM 8 MM TO 40MM DIA.
THE MILL IS CAPABLE OF ROLLING PLANE
ROUNDS OF 20MM TO 63MM DIA,40MM TO

63MM ROUND CORNERED SQUARES.
BEST E C ONOMI C S IN
MILL OPERATION
LOWER ROLL COST DUE TO COMMON PASS
ROLLING
REDUCED MAN-POWER
REDUCED OFF-LINE EQUIPMENT
REDUCED DOWNTIME
SPECIAL FEATURES OF THE

MILL
HOT BILLET CHARGING FACILITIES
BILLET WEIGHING FACILITIES
WALKING BEAM TYPE REHEATING FURNACE
HIGH PRESSURE WATER DESCALING
FACILITIES
SINGLE STRAND HIGH SPEED CONTINUOUS
MILL ARRANGEMENT IN H-V CONFIGURATION
FOR TWIST FREE ROLLING FOR THE MILL
REHEATING FURNACE
Supplier Capacity
Type
furnace
Material processed
Max. no. of billets

Ch arging roller table spee d
Ch arge to d isc h arge time
Cooling system
Discharge temperature
TENOVA
160 TPH
Walking beam
Top and bottom fired reheating
Low medium carbon steel
Low alloy steel
72
1.6 m/s
80 minutes
Water cooled
max. 1160C ( generally 950 1020 C)
Furnace operating temperature max. 1230 C
FUEL IN FURNACE
Fuel type Mixed gas ( LD gas + BF gas + Corex
gas)
Inlet gas pressure 950 1080 mmWC
Calorific value of fuel 1850 Kcal/kgK
Air/Fuel 1.6
Initial firing Manual
( Z one 6 & 7 are manually fired. For other zones,
firing is enabled only when the
relevant zone temperature is higher than 800C)
FURNACE DIMENSIONS
Wall to wall internal length = 21000 mm
Wall to wall internal width
= 12800
mm
Number of walking beams 4
Number of fixed beams 5
Charging schemes Row (single)
Cycle diagram Upward = 235 mm
Forward = 250 mm
FURNACE ZONES
ZONE
PREHEATING
ZONE NUMBER
1
NO.OF BURNERS
8
TOP HEATING
BOTTOM HEATING
TOP SOAKING RIGHT
12
TOP SOAKING LEFT
12
BOTTOM SOAKING
RIGHT
BOTTOM SOAKING
LEFT
TOTAL NO. OF
BURNERS
52
UTILITIES
Industrial water (for seal trough s)
IC W
Supply pressure 3 bar

Installed flow 30 m3 /hr
(rolls, cooled beams, kick off)
Inlet pressure 5bar

Outlet pressure 2bar
Flow 200 Nm3/hr
Emergency cooling water for 10 hrs
Supply pressure 3 bar

Flow rate 30 m3/hr
COMBUSTION SYSTEM
Burners
Recuperator
Combustion air fans
Furnace pressure regulating valve
Combustion air system
Nitrogen system
Orifice plates
C OMBUSTOIN AIR FAN

Type - Centrifugal
Numbers 2
Suction 52500 Nm3/hr
Rate d speed 1480 rpm
Motor rating 315 kW
Combustion air set point temperature
440 C
Avg. temperature 330 375 C
Exit gas temperature max. 675 C (If more
than this, dilution fan is turned on)
DILUTION AIR FAN

Type Centrifugal
No. of fans 1
Suction pressure 7700 Nm3/hr
Rate d speed 2940 rpm
Motor rating 37 kW
Set point temperature 675 C
FILLED GAS INSTRUMENTS

Thermocouples
Thermoresistance
Control valves
Shut off valves
Pressure switch
NITROGEN SYSTEM
Nitrogen purging is done to avoid back firing

and explosion in the gas line
MECHANICAL EQUIPMENTS
Charging rollerway
Charging door
Bumper
Walking beam
Kick off mechanism
Discharge rollerway
Charging door
FURNACE DETAILS
Walking beam
Shifting: Beam stroke
=cylinder stroke=265mm
Lifting : Beam stroke
=200mm
Cylinder stroke=265mm
KICK OFF MECHANISM
Shifting stroke = 880 mm (working) + 910
mm(maintenance)
Cylinder stroke = 2000mm
Lifting stroke = 50mm
Central arm to each half machine is equipped with a
detector called TOUCHER. It is operated by a double
acting pneumatic cylinder with a stroke length of 250mm.
GAS SHUT OFF SAFETY VALVE

Pneumatic actuator
Normally closed type
CONTROL VALVE Butterfly type
FLO W RATE MEASURE Orifice plate
HYDRAULIC SYSTEM
Controls following
Walking beams
Discharging kick-off machine
PNUEMATIC SYSTEM
Controls following
Charging and
discharging gates
Toucher
Valves
IMPORTANT POINTS
Weight measurement of each billet is done at
entry to furnace.
After 1500 working hours the combustion air
fans are inter changed.
In shut down in absence of billets in the
furnace 600c is maintained.
Laser centering is done to ensure the correct
positioning of incoming billets.
Photo electric devices are present to sense
the billet positions.
COOLING BED
AND
COLD SHEAR
FUNCTIONS
TO COOL STRAIGHT BAR LENGTH TO A
TEMPERATURE SUITABLE FOR SUBSEQUENT

PROCESSING TO ALLIGN FRONT ENDS OF BAR
FOR BETTER YIELD.
TO FORM LAYER OF BARS FOR FEEDING TO
COLD SHEAR.
TO TRANSFER BAR LAYER TO RUN-OUT
ROLLER TABLE.
COMPONENTS OF COOLING BED

ROTARY ENTRY SYSTEM(RES):
IT IS A DEVICE TO TRANSFER BAR FROM THE TWO LINE ON TO THE COOLI NG BED.THIS
IS THE LATEST TECHNOLOGY AVAILABLE AT JSW.
MOVABLE RAKES :
IT LIES BELOW THE FIXED RAKES AND IT LIFTS THE BARS AND MOVES IT FORWARD BY
PLACING ON THE FIXED RAKES.
FIXED RAKES:
V-TYPE GROOVES ARE CUT TO HOLD THE BARS BEING PLACED BY MOVABLE RAKES.
ALLIGNING ROLLERS:
IT IS USED TO ALLIGN THE BARS ON THE COOLING BED.
PINCH ROLL:
IT IS USED TO HOLD AND PUSH THE BARS AND TO CONTROL THE SPEED OF INCOMING
BARS.
CHAIN TRANSFER SYSYETM:
IT USES A DETECTOR WHICH COUNTS THE NUMBER OF BARS AND
THE CHAIN ADVANCE EQUALS TO THE DISTANCE BETWEEN THE

CENTRES OF THE TWO BARS
TRAY TRANSFER SYSYETM:
IT IS USED TO FEED THE BARS TO THE STAIGHTENING GRID IN
LAYERS.
STRAIGHTENING GRID:
TO KEEP THE BARS STRAIGHT WHILE THEY ARE HOT.
WATER SPRAY SYSTEM FOR COOLING ANGLES:
THESE ARE USED FOR PROVIDING THE COOLING EFFECT
PROCEDURE
BARS SUBDIVIDED BY THE FLYING SHER IN MULTIPLE OF COMMERCIAL
LENGTH ARE SENT TO COOLING BED.
IT USES EITHER HIGH SPEED ROTARY ENTRY SYSTEM (RES) OR VIA
ROLLER TABLE PROVIDED WITH BRAKE SIDE ELEMENT.
TWO SETS OF PINCH ROLLS ASSIST IN BREAKING THE BARS AT THE RES
AND DROPPED TO THE COOLING BED NOTCHES.
THE APPROACH TABLE IS PROVIDED WITH INDIVIDUALLY DRIVEN
HORIZONTAL ROLLS THAT ARE INCLINED TO MATCH WITH THE INCLINED

ROLLERS OF RUN IN ROLLER TABLE.
RUN IN ROLLER TABLE ALSO INDIVIDULAAY DRIVEN IS PROVIDED WITH
INLINED ROLLERS SO THAT THE BARS CAN BE CONTROLLED BETTER

WHILE IT SLIDES ON THE BRAKE SLIDES.
THE BRAKE SLIDES ARE MOVABLE ELEMENTS LINKED TOGETHER AND
DRIVEN ELECTROMECHANICALLY FROM A SINGLE DRIVE.
BRAKE SLIDES LIFTS THE BAR FROM THE RUN IN ROLLER TABLE AND
ALLOW BRAKING OF THE BARS UNDER FRICTION
A PNEUMATIC CYLINDER IS PROVIDED FOR THE CUSHION EFFECT TO ACT
AGAINST THE BRAKE SLIDE WHILE LOWERING FOR SMOOTH CONTROL.
IN THE INITIAL PART THE COOLING BED IS PROVIDED WITH A SPECIALLY
SHAPED STRAIGHTENING GRID TO KEEP THE BARS STRAIGHT WHILE

THEY ARE HOT.
A SERIES OF FIXED AND MOVING RAKES ARE PROVIDED TO COLLECT
AND COOL THE BARS COMING OUT FROM DIVIDING SHEAR OF EACH
LINE.
THE MOVING RAKES ARE OPERATING AUTOMATICALLY BY VARIABLE
SPEED MOTORS.
ALLIGNING ROLLERS ARE LOCATED AT THE END
OF RAKE SECTION TO ALLIGN THE FRONT OF

BARS IN LAYERS BEFORE CUTTING AT THE COLD
SHEAR.
DURING THEIR TRANSPORT BARS ARE COOLED
AND THEN DISCHARGED ONE BY ONE ON TO THE

GROUPING CHAIN TRANSFER SYSTEM WHICH
SHIFTS LAYERS OF BARS IN REQUIRED NUMBERS.
A LIFTING TRAY SYSTEM PICKS UP EACH BAR
LAYER AND DISPLACES THEM TO COOLING BED

RUN OUT ROLLER TABLE TO FEED THE
COMMERCIAL CUTTING LINE.
RIH
ETN
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AS
TO
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F
COLD SHEAR CUTTING OPERATION:
TWO METER LONG HORIZONTAL BLADES WHICH ARE OPERATED

BY CAM ARE USED TO CUT THE BARS BY COLD SHEAR ACTION.
COLD SHEAR LUBRICATION:
HLP-68 LUBRICANT IS USED IN COLD SHEAR CUTTING MACHINE

FOR LUBRICATION.
COLD SHEAR JOGGING OPERATION:
IT IS USED WHEN THE COLD SHEAR IS OPERATED MANUALLY.
COLD SHEAR SHORT TAIL CLEANING SYSTEM:
TO HOLD THE TAIL OF THE BAR DURING CUTTING AND DROPPING

THE SCRAP TO BUCKET.
COLD SHEAR BAR CLAMPING SYSTEM:
IT IS USED TO HOLD THE BAR DURING CUTTING OPERATION.
COLD SHEAR DIAPPEARING STOP:
IT IS USED TO TAKE THE FRONT CUT OF THE BARS.
LIFT ROLLERS:
TO LIFT THE BARS AND PUSH THEM FOR THE SAGFER CUTTING
OPERATION.
THANK
YOU

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BAR MILL

ROUNDS OF 20MM TO 63MM DIA,40MM TO

SPECIAL FEATURES OF THE

Max. no. of billets

Furnace operating temperature max. 1230 C

TOP SOAKING RIGHT

TOP SOAKING LEFT

Supply pressure 3 bar

Inlet pressure 5bar

Emergency cooling water for 10 hrs

Supply pressure 3 bar

C OMBUSTOIN AIR FAN

DILUTION AIR FAN

FILLED GAS INSTRUMENTS

Nitrogen purging is done to avoid back firing

GAS SHUT OFF SAFETY VALVE

TEMPERATURE SUITABLE FOR SUBSEQUENT

TO TRANSFER BAR LAYER TO RUN-OUT

COMPONENTS OF COOLING BED

CHAIN TRANSFER SYSYETM:

IT USES A DETECTOR WHICH COUNTS THE NUMBER OF BARS AND

THE CHAIN ADVANCE EQUALS TO THE DISTANCE BETWEEN THE

TRAY TRANSFER SYSYETM:

IT IS USED TO FEED THE BARS TO THE STAIGHTENING GRID IN

TO KEEP THE BARS STRAIGHT WHILE THEY ARE HOT.

WATER SPRAY SYSTEM FOR COOLING ANGLES:

THESE ARE USED FOR PROVIDING THE COOLING EFFECT

LENGTH ARE SENT TO COOLING BED.

IT USES EITHER HIGH SPEED ROTARY ENTRY SYSTEM (RES) OR VIA

ROLLER TABLE PROVIDED WITH BRAKE SIDE ELEMENT.

AND DROPPED TO THE COOLING BED NOTCHES.

THE APPROACH TABLE IS PROVIDED WITH INDIVIDUALLY DRIVEN

HORIZONTAL ROLLS THAT ARE INCLINED TO MATCH WITH THE INCLINED

RUN IN ROLLER TABLE ALSO INDIVIDULAAY DRIVEN IS PROVIDED WITH

INLINED ROLLERS SO THAT THE BARS CAN BE CONTROLLED BETTER

THE BRAKE SLIDES ARE MOVABLE ELEMENTS LINKED TOGETHER AND

DRIVEN ELECTROMECHANICALLY FROM A SINGLE DRIVE.

ALLOW BRAKING OF THE BARS UNDER FRICTION

A PNEUMATIC CYLINDER IS PROVIDED FOR THE CUSHION EFFECT TO ACT

AGAINST THE BRAKE SLIDE WHILE LOWERING FOR SMOOTH CONTROL.

IN THE INITIAL PART THE COOLING BED IS PROVIDED WITH A SPECIALLY

SHAPED STRAIGHTENING GRID TO KEEP THE BARS STRAIGHT WHILE

A SERIES OF FIXED AND MOVING RAKES ARE PROVIDED TO COLLECT

ALLIGNING ROLLERS ARE LOCATED AT THE END

OF RAKE SECTION TO ALLIGN THE FRONT OF

AND THEN DISCHARGED ONE BY ONE ON TO THE

A LIFTING TRAY SYSTEM PICKS UP EACH BAR

LAYER AND DISPLACES THEM TO COOLING BED

COLD SHEAR CUTTING OPERATION:

TWO METER LONG HORIZONTAL BLADES WHICH ARE OPERATED

COLD SHEAR LUBRICATION:

HLP-68 LUBRICANT IS USED IN COLD SHEAR CUTTING MACHINE

COLD SHEAR JOGGING OPERATION:

IT IS USED WHEN THE COLD SHEAR IS OPERATED MANUALLY.

COLD SHEAR SHORT TAIL CLEANING SYSTEM:

TO HOLD THE TAIL OF THE BAR DURING CUTTING AND DROPPING

COLD SHEAR BAR CLAMPING SYSTEM:

IT IS USED TO HOLD THE BAR DURING CUTTING OPERATION.