It begins its history on August 8, 1934, with the commissioning of the "500" medium-section mill. The start-up of the first rolling mill meant that MMK became an enterprise with a complete metallurgical cycle, since it had a rolling stock. On May 3, 1935, mill "300" No. 1.5 was put into operation. On February 5, 1938, mill "300" No. 3 was put into operation. In July 1942, all three mills were combined into a single section - section rolling. Its chief was engineer Laur K., who worked in this position until 1949.

During the Great Patriotic War, the shop mainly carried out military orders, especially a lot of shell steel was produced. For the successful fulfillment of front-line orders, the staff of the SOC was repeatedly awarded the rolling Red Banner of the State Defense Committee. In the third quarter of 1945, by the decision of the State Defense Committee, this banner was transferred to the shop staff for eternal storage. With the beginning of the war, 130 quality distributors were mobilized to the front from the shop, 40 of them fell on the battlefields. In 1947 mill "300" No. 3 became the industry's first comprehensively automated mill. For the successful implementation of this major technical event, specialists K. Laura and V. Sindin were awarded the State (Stalin) Prize.

Since 1960, a program of reconstruction and modernization of equipment has been carried out at all mills of the shop. As a result of its implementation, roller tables and straightening machines were replaced at the mills, exhausters were mounted on heating furnaces and pushers of steel billets were replaced, lifting tables were eliminated. The outdated saws for cutting hot metal and cold cutting shears on the "500" mill have been replaced with new, more productive ones. Instead of the old drives of the rolling stands, more powerful engines of domestic production were installed.

The SOC introduced the first uncontrolled silicon rectifiers at MMK, high-power thyristor converters - 10 thousand A to power the motors of the rolling stands. Knitting machines for tying bundles of rolled metal have been developed and introduced at all mills. At the adjuster of the shop, bridge cranes are equipped with ring grippers for transporting bundles of metal. The implementation of this entire program made it possible to triple the design capacity of all three SPC mills.

In 1996 mill "300" No. 3 was removed from work as morally obsolete and ineffective. In 1999, the old equipment was dismantled, a new mill was installed in the mill premises. In July 1995, by order of the General Director of OJSC "MMK", the SPC was merged with the wire-strip one and became known as a high-grade one.

The section rolling shop operates as part of a medium-section mill "450" ​​and a small-section mill "320" and produces rolled sections with a round profile with a diameter of 11 to 110 mm, a hexagonal profile with a size of 12 to 75 mm, a square profile with a size of 55 to 90 mm and reinforcing steel with a diameter from 12 to 28 and 40 mm. The mills were commissioned in 1904.

A rack cooler was put into operation at mill 320 in 1997, which currently allows the plant to produce reinforcing and section steel up to 11.7 m in length (along the length of the car).

Section mill 170, 370, 450 "Section Shop" of OJSC MMK produces high quality finished products. The products of section mills are in high demand in the market. The range of products manufactured is very diverse and varies depending on orders and consumer needs. The manufactured products meet all quality criteria. Equipment downtime and an increase in transshipment time lead to large material losses from non-produced products.

To reduce the time required to switch from production of one product to another, it allows to increase the productivity of the mills. To speed up the process of setting the stands for a certain assortment, the Italian company DANIELI has developed a mechanism and an algorithm for automatic positioning of the roll gap. This auto-positioning system ensures the automatic setting of the roll gap of the rolling stands of the mill in accordance with the rolling flow charts entered in the OWS. In addition to the operator entering the required stand clearances, the operator must enter the exact diameter of the rolls in each stand in the OWS. Thus, it was not possible to completely eliminate the human factor when adjusting the gaps, since the maintenance personnel need to accurately measure the diameters of the rolls and enter these data into the gap control system; fine adjustment of roll clearances.

Long products are used in various industries, both in agriculture and in construction. Full-fledged work of a number of industries is impossible without the use of rolled metal products. The development of industry and an increase in the pace of construction requires an increase in the output of rolled metal. The most widespread products of long products are: beams and railroad rails, channels, wire rods, various metal profiles, fittings.

The standard length of long products is from 6 to 12 meters.

The workshop also produces hollow rolled products of round and hexagonal section with a round axial channel for drilling tools and shafts of submersible electric motors (SEM). The main tasks of the workshop:

Production of long products;

Release of rolled stock for the calibration shop.

The continuous section rolling mill is designed for rolling small- and medium-section rolled products of the following assortment:

Hot rolled round steel with a diameter of 14 to 50 mm; (Fig. 11., a)

Hot-rolled reinforcing steel from 8 to 32 mm; (Fig. 11., b)

Hot-rolled steel square with a side of a square from 12 to 40 mm; (Fig. 11., c)

Rolled angle steel of equal flange, profile numbers from 32 to 63 mm;

Unequal angle rolled steel, profile numbers from 45 to 80 mm;

Steel strip with a width of 40 to 90 mm;

Steel channel 50 mm, 65 mm, 80 mm;

Tavr steel 50 mm, 80mm.

The starting material for a section rolling mill is a square billet (bloom) of calm and semi-calm, low-alloy and alloy steel grades.

After rolling in the finishing line of the mill, the rods enter the heat treatment system, where they are heat-strengthened due to the sharp cooling of the rolled metal by the water supplied under pressure. There are devices for cutting rolled products to lengths and for automated packaging of finished products.

a. b. v.

G. etc. e.

Fig. 11. Products of the Section Rolling Shop

(fig. 168) is designed for a productivity of 1 million tons / year. The mill includes the following equipment. To receive blanks, schlepper-type racks are installed. Heating of blanks is carried out in five two-zone methodical furnaces operating on gas fuel, with an end task and delivery of blanks and with double-sided heating.

The mill consists of nine stands, located on three parallel lines: on the first line - five stands, on the second - three stands, on the third - one finishing stand. After IV and before VII, after V and before VI, after VIII and in front of the IX stands, transfer channels are installed, respectively, intended for moving, transferring the roll from one rolling line to another. Tilters are installed in front of the stands. There are five skid type hot cut circular saws in the discharge roller line. For cooling the metal, a double-sided chain-type refrigerator is installed behind the saws. The refrigerator sections are equipped with cold-cutting shears for finished metal and cantilever-type roller levelers. Pockets and knitting machines are used to decorate packs of finished products.

The technological process of rolling profiles is carried out as follows. The prepared blanks, after removing surface defects, are fed with the help of cranes to the racks (see Fig. 168), from which the blanks are transferred by slippers or batches to the feeding furnace roller table. Further, the billet goes to heating furnaces, against which lifting tables are installed on the roller table line, which raise a batch of billets to the level of stationary tables. These blanks are pushed onto stationary tables by pushers and fed into the working area of ​​the heating furnace.

Depending on the steel grade, the following temperature range is adhered to when the metal is heated, ° С:

As the blanks are pushed along the furnace, the latter are fed to the line of the furnace roller table and transported to the first line of the mill stands.

Depending on the rolling pattern, the rolled stock can be compressed either in four stands or in five. Then it is transferred to the second and third rolling lines and, thus, a roll of a finished profile of a certain length comes out of the last stand. The speed mode of rolling, depending on the profile, ranges from 3.0 to 7.35 m / s; the temperature of the end of rolling is 850-950 ° C. After the IX stand, the rolls are collected in a batch (5-7 rolls). If the roll of this profile is to be cut to length using hot saws or piece by piece, it is fed to the central roller conveyor of the refrigerator. Hot-cut circular saws are set at a distance corresponding to the required cutting length. Then the roll in batches of a certain length is fed to the central roller table of the refrigerator and shifted to the right or left section of the refrigerator. Here the strips are cooled and transported to roller straighteners. After straightening, the strips are dumped into the pockets. When a bundle of the appropriate mass is collected, they are tied using a machine. A special tag is attached to each bundle, which indicates the steel grade, heat number, bundle weight, rolling time and manufacturer.

Hot cutting is performed on profiles of round and square steels of large sections; in a cold state, cutting them is associated with great effort. Further technological operations are performed in the stream, as described earlier.

In the 60s, 650 line mills of the EZTM design were built at the Zhdanovskiy metallurgical plant "Azovstal", Nizhniy Tagil and Orsk-Khalilovskiy metallurgical plants with a design capacity of 750-1200 thousand tons / year; semi-continuous large-section mill 600 at the Kommunarsky plant with a design capacity of 1.6 million tons per year, designed by the Izhora plant, etc. The rolling process on the mills is fully mechanized: they have production lines for finishing. Consider one of the installed large-section mills of the linear type.

Large section mill 950/800(fig. 169) consists of three continuous heating furnaces, four rolling stands, shears for trimming the rolled stock after the first stand, hot-cutting circular saws, a cooler, roller straightening machine and other equipment installed for finishing the finished profile. The mill is designed for a capacity of 1.2-1.3 million tons / year. The strip exit speed from the last finishing stand is 5.0-10 m / s.

Blooming works in front of the mill. Therefore, depending on the profile being rolled, blooms can be fed directly to the mill if the surface quality fully satisfies the conditions for possible subsequent rolling and the quality indicators of the finished profile.

If necessary, the bloom surface is processed, defects are removed, after which these blooms are fed to heating furnaces.

Three-zone methodical furnaces are used with bottom heating, end task and bloom dispensing, operating on natural gas, characterized by an average heating value of 36.1 MJ / m 3. The oven has five adjustable zones. With a given calorific value of fuel and a furnace capacity of 110 t / h, the fuel consumption is 8400 m 3 / h.
The blooms discharged from the furnace are transported to the first reversible twin-roll stand with a roll diameter of 950 mm. In this stand, which is essentially a small blooming stand, the bloom is rolled in five to seven passes into a roll of a certain size and cross-section. Further, on the roller table line, scissors with a cutting force of 5 mn are installed, which cut the front and rear ends of the roll, and, if necessary, cut the roll after the first stand to measured lengths. After the first stand, the roll is set sequentially into the first roughing three-roll stand, where 3-5 passes are performed; then into the second roughing three-high stand, where three passes are carried out, after which the roll is set into the finishing two-high non-reversing stand with a roll diameter of 850 mm. In this stand, only one pass is carried out, the purpose of which is the final design of the profile.

The rolled section of the finished profile is fed to hot-cutting circular saws, where it is cut into lengths and transported further to refrigerators. This mill uses chain-type one-way refrigerators. After the finished profile has cooled, it is straightened on a straightening machine, in which rollers with two supports are installed instead of rollers. The straightened profile goes to special racks, from which it is removed, placed in bags, weighed and stored.

If the flow requires heat treatment of the finished profile, it is fed to special heat treatment furnaces installed in the general technological chain of equipment location.

Semi-continuous large section mill 600(fig. 170) is the most productive in the world. Seventeen working stands - two-roll stands with horizontal and vertical rolls with a diameter of 850, 730 and 580 mm - are located in three parallel lines, which contributes to good maneuverability, manufacturability during rolling and reduction of mill downtime. In the first line of the mill there are two continuous groups: the first of five working stands and the second of three. The rest of the working stands are located in series.

A feature of the mill is the use of working stands with vertical rolls driven by four vertically positioned 300 kW electric motors with a rotation frequency of 12.5-16.7 s -1. The developed drive circuit provides transmission of electric motor power to each roll. This improves the performance and reduces the size and weight of the working stand.

The finishing work stand 580 with horizontal rolls has open-type beds, but with rigid wedge joints of the legs and the cover, providing rigidity close to that of closed-type beds. The work rolls rotate in fluid-friction angular contact bearings. The balancing of the upper horizontal roll is carried out by springs mounted in the chocks of the lower roll. The pressure mechanism of the upper roll, driven by a DC motor, generates a force on the pressure screws, calculated for the compression of the roll during rolling, and maintains the speed of movement of the screws equal to 0.8 mm / s. To install the bottom roll, a manually operated pressure device is used.

For tilting the roll of the profile, a universal rotator with a tilting sleeve is installed, which allows the roll to be rotated at any angle within 90 ° both without displacement, and with its displacement along the width of the roller table.

The new cutting system, consisting of 10 circular saws, allows to combine in time transport and cutting, as a result of which it became possible to cut one roll at a length of 96 m at a cutting rhythm of 12 seconds.

The large section mill 600 has three separate sections: finishing of long products on a straightening press and a cold saw; rail finishes; round bar finishes. This mill is a combination of two mills: billet and section mills. This is due to the fact that at the metallurgical plant where this mill is installed, the blooming mill does not have a continuous billet mill. It is extremely impractical to roll ingots into billets (blooms) only on blooming, especially in conditions when blooming must also roll slabs. Therefore, to obtain the necessary billet, the billet mill is installed in front of the section mill and, thus, in the combination under consideration, both of them represent a single system, and in general - a shop.

The billet mill, consisting of six stands, has a separately installed first stand, and the remaining five stands make up a continuous group. Such an arrangement of the first stand provides a free exit of the roll and its tilting before the task into the next continuous five-stand group of the billet mill. The upper horizontal edge passes into the lateral vertical one and, thus, during rolling, the scale is freely separated from it.

Further rolling on a section mill of a billet of the required dimensions, obtained after the billet mill, requires an increase in temperature. For this purpose, a continuous reheating furnace with a length of 107 m was installed. After the reheating furnace, there is a stand with horizontal rolls. This decision is associated with the following technological considerations. The range of the mill includes many shaped sections, the rolling of which requires a split billet (I-beams, channels, rails, etc.). A split billet cannot be obtained on a billet mill, since it is intended only to reduce the cross-section of the billet coming from the blooming mill. Moreover, for a wide assortment of shaped profiles, several sizes of cut blanks are required. That is why it is technologically necessary to separate the first stand: in it, a split billet is obtained with free widening or in calibers. In this case, it is important that this workpiece has the maximum required dimensions; this and. provided by the first stand.

Next, a three-peg continuous group is established; the first stand with vertical rolls ensures maximum processability of the mill as a whole. When receiving a split billet of any width emerging from the first stand, the required width is provided by lateral compression by vertical rolls; a well-known universality of the mill is created. The arrangement of the stands on three parallel lines with the distribution of the stands on each line and the connection of the line with slipppers allows rational use of the main equipment.

The large section mill 600 includes unique equipment for finishing finished products, taking into account the entire rolled product mix. The considered mill with a linear arrangement of stands is one of a group of mills of this type, including specialized ones.

(Fig. 171) designs of VNIImetmash, EZTM and UZTM with a design capacity of 1.5 million tons / year were installed at the West Siberian Metallurgical Plant. In terms of the composition of the equipment, the arrangement of stands and the technological process, this mill is the only one in the world practice. Use the original workpiece 'square and rectangular sections with a size of 150 × 150; 135 × 200, 150 × 200; 160 × 270 mm; the length of a workpiece weighing 0.7-4.7 tons is in the range of 4-12 m.

The mill has two heating furnaces. The roughing stands form three groups, three stands in each of which the outer stands have a horizontal arrangement of the rolls, and the middle one (combined) can work with the installation of rolls both in a horizontal and vertical position. In front of the first three-stand continuous group, shears are installed to cut the workpiece to a certain length. The shears have a cutting force of 400 tons. Tilters are provided in front of each three-stand continuous roughing group.

The finishing continuous group consists of seven stands. The stands here are also different in their design and purpose according to the arrangement of the rolls: I, IV and VI - combined (K), the rest of the stands with horizontal rolls and universal (G, U). They carry out the compression of the flanges of I-beams and channels with ensuring the parallelism of the edges. Flying shears with a cutting force of 1.30 MN are installed in front of the finishing group of stands, after the finishing group - with a cutting force of 0.63 MN.

The rolling speed on the mill is 4-12 m / s; the average productivity, depending on the profile, is 180-300 t / h.

To cool the rolls of the finished profile, a double-sided refrigerator is installed, while each section (side) of the refrigerator can work independently. On each side of the refrigerator there are two lines of discharge roller tables, each of them has two similar units installed: two roller straightening machines (one in operation, the other in reserve), two cold-cutting shears (one in operation, others in reserve). For additional processing of the finished profile, cold-cutting shears, collecting pockets, grids, bag tying machines and other auxiliary equipment are used.

Let us consider the operation of the equipment of a large-section mill 450 in the course of the rolling process. The billet can be fed to the mill cold or preheated in furnaces up to 300-800 ° C. Then it is transferred through the refrigerator by slippers to the methodical heating furnaces. The heating of the metal is carried out in three-zone methodical furnaces operating on gas fuel with an end task and the issuance of blanks. The bottom is equipped with walking beams. The furnace can be loaded in two rows (with a billet length from 4 to 6 m) and in one (with a billet length over 6 m). The saddle of the furnace when the blanks are located on the hearth with a pitch of 400 mm is approximately 68 blanks weighing 320 tons. The heated blank is discharged from the furnace using a machine, placed on a furnace roller table and transported to the first continuous group of roughing stands.

If a defect in the front or rear ends of the workpiece is found, it becomes necessary to cut it into pieces, while the scissors are included in the work.

In roughing continuous groups of stands, combined stands can also operate with horizontal rolls. In the finishing group, the universal stands are put into operation when rolling shaped sections; when rolling other sections, they can operate as conventional stands with horizontal rolls.

The rolling stock leaving the finishing stand is cut to length according to the rational cutting with shears installed behind the last finishing stand.

The rolls are fed to a double-sided refrigerator 120 m long with an adjustable step of shifting the cooled strips and a device that provides two strips with predetermined distances between them to be dispensed onto any of the two outgoing roller tables simultaneously, which makes it possible to divide the metal flow, which is the same to the refrigerator, into four parallel finishing flows of finished rolled products ... After cooling on the refrigerator, the rolls undergo technological operations: straightening, cutting to length, bundling, bundling, weighing and storage.

The installed eight straightening machines for the straightening of shaped and round profiles operate in the starting mode: the input speed is 1.4 m / s, the straightening speed is adjustable in the range of 2-6 m / s. Four cold shears with a cutting force of 6.30 MPa with a knife length of 1000 mm and its stroke of 240 mm are designed for 360 cuts in 1 hour with a normal cycle between cuts of 10 s.

In the finishing equipment in the stream, there are two inspection racks for strips up to 25 m long and two for short strips. These racks are intended for additional inspection of individual strips on which signs of rejection are visible. Eight palletizing devices have been installed, including two sections 12 m long, designed for strips 6-12-24 m long. The packet diameter is 250-500 mm. For bundling bundling, 32 bundling machines are installed; weighing is carried out on 16 scales, designed for strips 12-24 and 6-12 m long. The division price on the scales is 10 kg; weighing cycle 10 s.

In addition, the mill is serviced by installations for longitudinal straightening of individual strips and for straightening and cutting of large sections with a straightening accuracy of 1 mm / m. The operation of the equipment and the performance of technological operations are automated as much as possible, which excludes the use of manual labor, stabilizes the rhythm of the entire mill.

Continuous large section mill 450 designs of VNIImetmash, EZTM and UZTM with a design capacity of 1.5 million tons / year was first installed and has been successfully operating since 1975 at the West Siberian Metallurgical Plant.

In terms of the composition of the equipment, the arrangement of stands and the technological process, the 450 mill is the only one in the world practice.

Mill range: round steel with a diameter of 32-60 mm; square 30-53 mm; angular equal flange (75X X75) - (125X125) mm, angular unequal equivalent section; rolled profiles according to special specifications: lightweight (thin-walled) I-beams No. 16-30; normal I-beams with parallel flange faces No. 16-30; normal channels with parallel flange edges No. 16-30; rolled profiles in accordance with GOST 8239-72 and GOST 8240-72 I-beams and normal channels No. 10-18; strip steel (9-22) X (125-299) mm.

The original workpiece of square and rectangular sections are: 150X150; 135X200; 150X200; 160X X270 mm; workpiece length within 4-12 m, weight 0.7-4.7 tons.

Two reheating furnaces are installed on the mill, leaving space for a third furnace. The roughing group of stands consists of three groups, three stands in each, of which: extreme with horizontal rolls, middle (the so-called combined) can work with rolls installed both horizontally and vertically. The distance between continuous groups of stands is taken differentially, taking into account the maximum length of the rolled section from the entire range of rolled profiles, so that the strip freely comes out and is between the continuous groups of stands. In front of the first three-stand continuous group, there are scissors for cutting the workpiece to a certain length. Shears cutting force 400 tf. Tilters are provided in front of each three-stand continuous roughing group.

The finishing continuous group consists of seven stands. The stands here are also different in their design and purpose, according to the arrangement of the rolls: I, IV and VI-combined (K), the rest of the stands with a horizontal arrangement of rolls and universal (G, U). In them, the flanges of I-beams and channels are compressed and the parallelism of the edges is ensured. Flying shears with a cutting force of 130 tf are installed in front of the finishing group of stands, and after the finishing group - with a cutting force of 63 tf.

To cool the rolls of the finished profile, a double-sided refrigerator is installed, while each section (side) of the refrigerator can work independently.

Rolling speed on the mill 4-12 m / s; average productivity depending on the profile 180-300 t / h.

Such a high rolling speed and productivity, a complex range of the mill determined the composition of the auxiliary equipment after the cooler. On each side of the refrigerator there are two lines of discharge roller tables, each of them has two units of the same type: two roller straightening machines (one in operation, the other in reserve), two cold cutting shears (some in operation, others in reserve ).

For additional processing of the finished profile, cold-cutting shears, collecting pockets, grids, bag tying machines and other auxiliary equipment are used.

Let us consider the operation of the equipment of a large-section mill 450 in the course of the rolling process and its characteristics.

The billet can be fed to the mill in a cold state or preheated, which is determined by the steel grade. If it is necessary to roll this profile from alloy or high-carbon steel, then the billet is preliminarily slowly heated in preheating furnaces to 300-800 ° C. Then it is transferred through refrigerator 1 by transferring slippers to the heating furnaces. Further, the workpiece can be heated intensively in continuous furnaces, without fear of the occurrence of large internal stresses, up to the required dispensing temperature. If the workpiece has been processed (surface defects are removed and it is cooled), it is placed on loading racks, and then transported to heating furnaces. Weighing of the incoming batch of blanks and each blank separately.

Heating of the metal is carried out in three-zone methodical furnaces operating on gas fuel with the end task and the delivery of blanks. The bottom is with walking beams. The furnace can operate as a double-row (with a workpiece length from 4 to 6 m) and as a single-row (with a workpiece length over 6 m). The setting of the furnace when the blanks are located on the hearth with a pitch of 400 mm is approximately 68 blanks weighing 320 tons.

The heated billet piece by piece, according to the rolling rhythm, is discharged from the furnace by a machine, placed on a sub-furnace roller table and transported to the first continuous group of roughing stands.

If a defect in the front or rear ends of the workpiece is found, it becomes necessary to cut it into pieces, the scissors are included in the work.

In roughing continuous groups of stands, combined stands can also operate with a horizontal arrangement of the rolls, which is determined by the calibration and rolling pattern of this profile.

In the finishing group of stands, the universal stands are put into operation when rolling shaped sections; when rolling other sections, they can operate as conventional stands with horizontal rolls.

The rolling stock coming out of the finishing stand is cut to the measured length according to the rational cutting and the length of the cooler with scissors installed behind the last finishing stand. In the case when the roll should be cut to lengths immediately after the finishing stand, the shears are switched on to a higher operating mode, and strips of a certain length are immediately fed into the pockets provided for this.

The rolls are fed to a double-sided refrigerator 120 m long with an adjustable step of shifting the cooled strips and a device that provides two strips with predetermined distances between them to be dispensed onto any of the two outgoing roller tables simultaneously, which makes it possible to divide the metal flow, which is the same to the refrigerator, into four parallel finishing flows of finished rolled products. ...

After cooling on the refrigerator, the rolls undergo technological operations: straightening, cutting to length, bundling, bundling, weighing and storage.

The equipment is designed for improved mechanical properties of the metal. So, the strength of the metal being straightened in the cold state is taken equal to 100 kgf / mm2.

Installed eight correct machines 7X630 for straightening shaped and round profiles operate in the starting mode: the input speed is 1.4 m / s, the straightening speed is adjustable in the range of 2-6 m / s.

Four cold-cutting shears with a cutting force of 630 tf with a knife length of 1000 mm and a knife stroke of 240 mm are designed for 360 cuts per hour with a normal cycle between cuts of 10 s.

In the finishing equipment in the stream, there are two inspection racks for strips up to 25 m long and two for short strips. These racks are intended for additional highlighting and inspection of individual strips, on which signs of rejection are noticeable.

Eight baling devices were installed, including two sections 12 m long, designed for strips 6-12-24 m long. The diameter of the package is 250-500 mm. For bundling bundling, 32 bundling machines were installed; weighing is carried out on 16 scales, designed for strips of length: 12-24 and 6-12 m. The division price on the scales is 10 kg. Weighing cycle 10 s.

In addition, the mill is serviced by installations for longitudinal straightening of individual strips and for straightening and cutting of large sections with a straightening accuracy of 1 mm / m.

The operation of the equipment and the performance of technological operations are automated as much as possible, which excludes the use of manual labor, stabilizes the rhythm of the entire mill.

While finishing and trimming operations are usually the bottleneck on working section mills, on mill 450 they are mechanized as much as possible. At the same time, units for scrap metal harvesting remove rejected strips from the flow without disturbing the basic rhythm of metal movement. High-performance units for stacking rolled sections in the stream ensure the alignment of the ends before dropping each strip into a pocket, form and bundle the bags with continuous metal supply. Tilters for structural shapes provide strip feed to the stacker table in a strictly oriented position, as well as variable orientation of angle steel with strip laying in a "lock". The stackers of structural shapes create the possibility of stacking strips without pauses in the supply of metal and tying finished packages by machines. Conveyors of packages of finished rolled products are provided, operating according to an automatic cycle and providing the supply of packages to scales and storage devices without cranes. Separately installed units for metal sorting, cutting and sanding strips are operating.

At this mill, the mass of technological equipment with spare adjacent parts of the mill itself, including equipment for heating furnaces, is 13,282 tons; at the metal finishing and cleaning section, the weight of the installed equipment is 9829 tons. Power of the main drives of the mill is 32000 kW.

The area of ​​the entire workshop consists of the area of ​​the mill itself (39792 m2) and the area for finishing and metal cleaning (62,280 m2). The area for metal storage is 6600 m2, taking into account a possible three-day stock in the finished product workshop. The mill is served by 854 people, of which 778 are workers. With a mill capacity of 1.5 million tons / year, output per worker will be 1928 tons / person per year.

The productivity of the mill according to the accepted assortment is calculated for the equipment load by 81%. Of course, a more complete development of the installed unique equipment will increase the productivity of the mill and bring it up to 1.6-1.7 million tons / year.

As part of the technical and economic indicators, it is necessary to highlight the reduction in the consumption coefficient for the established assortment from 1.040 to 1.028 (mill

Mill 450 was designed as an endless rolling mill with in-line welding of billets. However, there are still no reliably working movable butt-welding machines, so mill 450 operates with separate rolling of billets.

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Ministry of Education of the Russian Federation

GOU VPO "Ural State Technical University - UPI"

on technological practice

at JSC "Metallurgical plant named after A.K. Serov "

Student Mayevskaya Ksenia Sergeevna

Specialty "Economics and Enterprise Management"

Practice leader:

Chief calibrator of the plant ________ A.V. Semkov

Practice manager USTU-UPI ________ S.V. Dudin

Serov 2008

1. Information about JSC "Metallurgical plant named after A.K. Serov ", its products, production structure, dynamics of development

2. Technical characteristics of the main equipment of rolling shops

2.1 Large section shop

2.2 Section rolling shop

2.2.1 Methodical heating furnaces of mills

2.2.2 Mill 450

2.2.3 Mill 320

2.2.4 Adjustment

3. Description of the technological process in the rolling shops of the plant

3.1 Large section shop

3.2 Section rolling shop

4. Characteristics of raw materials, fuels, basic materials

5. Operating parameters of the technological process of rolled products production

5.1 Large section shop

5.2 Section rolling shop

6. Safety conditions, labor protection in rolling production

7. Characteristics of industrial waste, air emissions,

environmental friendliness of production

1. Information about JSC "Metallurgical plant named after A.K. Serov ",

its products, production structure, development dynamics

JSC "Metallurgical plant named after A.K. Serov ”(formerly the Nadezhdinsky Steel Rail Plant) was put into operation in 1896 and is one of the oldest metallurgical plants with a full metallurgical cycle in the Urals and in Russia. All its equipment was manufactured by firms in Germany, France, Belgium.

In terms of the production of charcoal cast iron, it was a competitor to the Swedish charcoal metallurgy, and in terms of the total volume of production it accounted for about a quarter of all metal production in the Urals. In 1899, the plant already had 4 blast furnaces, 4 open-hearth furnaces, a 750 mm trio rolling mill, dinas and fireclay brick factories, a forge, and a gas-electric shop. In 1906, a section-rolling shop was built, consisting of two mills: 450 mm and 320 mm for rolling long products and a slab for sheet, as well as a sheet-rolling shop with 11 rolling stands for rolling from a slab of roofing iron. In 1912, a duo mill of 850 mm was installed (instead of a mill of 750 mm) with an engine - a steam engine with a capacity of 10 thousand hp, a forging and mechanical workshop was built.

The main products of the plant were wide and narrow gauge railroad rails, roofing iron, slug billets, high-quality iron, as well as the production of refractory products, dinas and fireclay bricks, siphon supplies for the plant's own needs. In 1931 the production of roofing iron and rails ceased. Rolling of round and square billets of various cross-sections, round and hexagonal rolled products from low and medium alloy steel grades begins. In 1932, for the first time in the world, rolling of the most complex profile - a tractor shoe for tracks of tractors and tanks - was mastered on a linear mill.

Also, for the first time in the world, for all three mills (850, 450 and 320), a universal roll calibration was developed and implemented, which opened up huge reserves of rolling production. In 1933, the construction of a cold drawing steel workshop was started and completed in 1935, which became the largest workshop in the country and ranked second in terms of capacity in the world. In the same years, the plant mastered the production of ball bearing steel and hollow drilling steel. During the war years, the plant mastered over 100 different grades of high-quality alloy steel. For the first time in the history of blast-furnace production, smelting of ferrochrome has been mastered in blast furnaces. In 1944-1945, ferrosilicon was smelted in blast furnaces. During the war years, the volume of production of the plant for steel and rolled products increased by 1.7 times in comparison with the pre-war period.

Built and equipped at the end of the 19th century with the latest technology of that time, today the predominant part of production is carried out using extremely worn-out equipment and outdated inefficient technologies.

The development of the plant until the nineties was characterized by an increase in production volumes due to partial reconstructions, improvements without radical replacement of the main equipment and production technology.

To date, the following immediate development prospects have been identified and are being prepared at the plant: installation and development of a ladle furnace, a VD / VOD vacuum degasser, Continuous casting machines (CCM), expansion of steel smelting by the electric furnace method. A radical change in the technology of smelting, casting and processing steel should significantly increase the yield of steel suitable for smelting, reduce consumption during casting and then waste, improve the quality of steel and, as a result, reduce the cost of producing finished products.

In parallel, it is necessary to radically modernize the section rolling production and the finishing of rolled products.

To ensure the competitiveness and survival of the plant, the most urgent task now is a comprehensive, consistent re-equipment of its production with the most advanced technologies and equipment for the production of high-quality and special steels in a wide range of brands and in a wide range of rolled sections with the most progressive quality characteristics.

At the same time, the cost of production per unit of product must be reduced many times, both in terms of the consumption of metal, fuel, energy, and for most other factors.

Table 1. - Products manufactured by the plant (product mix)

P / p No.	Name	Characteristics (dimensions)	Note
	Agglomerate
	Open-hearth steel
	Square billet		needed by the plant
	Hot-rolled long products
	round - pipe billet		delivery with turning is possible
	round large	160-270 mm, 280 mm
	square large
	round small-medium
	hexagon small-medium
	two-slot hollow core drilling steel	diameter 32 mm
	hollow round drilling steel	diameter 32 mm
	drilling steel hollow hexagon		with thermomechanical hardening
	Calibrated rental
	hexagonal
	round with special surface finish

table 2... - Dynamics of output of main types of products, t

P / p No.	Name of production	1999 year	year 2000	year 2001
	Agglomerate
	Open-hearth steel
	Long products
	Calibrated steel, including:
	carbonaceous
	automatic

Diagram 1

1 - agglomerate;

2 - open-hearth steel;

3 - long products;

5 - calibrated steel.

Products of JSC "Metallurgical Plant named after A.K. Serov "is also exported.

Table 3 ... - Dynamics of export, thousand tons

Product type	1998 year	1999 year	year 2000	year 2001
Blank

Table 4 ... - Structure of long products export in 2001

Country	Supply volume
	tons	thousand US dollars
Germany
United Kingdom
Kazakhstan
Total:

The structure of JSC "Metallurgical plant named after A.K. Serov ”includes Turinsky mine, Sinter plant, Blast furnace shop, Open-hearth shop, Mills 850, 450 and 320, Calibration shop with two departments. Auxiliary shops: railway, motor transport, gas, power plant, mechanical, foundry and some others.

Turinsky mine includes

b the Kapitalnaya mine, 587 m deep, with a crude ore mining capacity of 230 thousand tons per year;

ь concentration plant with a capacity of 500 thousand tons per year of processed ore.

The manufactured products are iron and copper concentrates.

Reconstruction is required with an increase in production volumes or maintenance of equipment in a working condition while maintaining the volume and quality of existing production.

Sinter plant includes two sintering tapes:

b No. 1 with a sintering area of ​​30 m 2 (for conservation);

b No. 2 sintering area 50 m 2.

Reconstruction with a gas treatment unit is required in order to reduce environmentally harmful emissions and improve the quality of the sinter.

Blast furnace shop includes 3 blast furnaces:

b No. 1 with a volume of 260 m 3;

b No. 3 with a volume of 205 m 3;

b No. 5 with a volume of 212 m 3;

It is required to maintain the furnaces in working order with the reconstruction of the coke warehouse and the ore yard. Also, modernization of the foundry yard is needed.

Open-hearth shop It includes 4 open-hearth furnaces with a capacity of 180 tons with the main lining, operating with the scrap-ore process. The first stage of reconstruction of the shop with a ladle furnace for out-of-furnace steel refining was completed.

Currently, the production capacity of the workshop is 580 thousand tons per year. In the composition of the charge, about 50% of liquid pig iron is used, supplied in pig iron ladles from the blast furnace shop. Casting steel produces 5.6 tons of ingots. The lining of the ladle is made of fireclay bricks or as poured quartzite, the resistance of which is 9-11 fillings. The blowing of liquid metal in the ladle with imported nitrogen through the gate is carried out in a small amount, since it does not ensure complete mixing of the metal in the ladle. The surface quality of the ingot generally does not meet the requirements for rolling, and the ingot has to be cleaned or turned to remove defects, converting 10-20% of the metal into chips, as well as to produce a significant cut of the ends.

Large-section shop includes mill 850.

A phased reconstruction of both the mill and the preventive adjustment equipment and processes is required, with reference to the reconstruction of the steelmaking production.

Section rolling shop includes mills 450 and 320.

It is required to continue the reconstruction of mill 320 and to determine the directions and terms of reconstruction of mill 450 and the sections serving the mill.

Calibration workshop consists of two departments in different production buildings, where equipment for heat treatment, cold drawing, turning and polishing of rolled products is installed. Also, a section has been created in the workshop and oil pumping rods are produced using a new special technology - friction welding of the rod with its threaded part and wedge rolling of the connecting parts. In combination with rolling, the technology for the production of hollow sucker rods is being tested.

A piece of worn-out equipment is required to be renewed to ensure guaranteed quality.

After the reconstruction of the section rolling shop, it will be necessary to replace equipment to introduce the drawing and turning technology "from coil to coil" or "from coil to bar".

The scheme of interaction of structural divisions of the plant in the production cycle is shown in Figure 1.

Picture 1

In 1996, the plant was issued a certificate of the Russian Federation, certifying that OJSC Metallurgical Plant im. A.K. Serov "is one of the 5000 leading enterprises with the status of" Leader of the Russian Economy ". In the same year, the plant was awarded the "International Prize for Quality".

2. Specifications of main equipment

rolling centersehov

The production of hot rolled steel at the plant is carried out in the large-section and section-rolling shops.

2.1 Large section shop

The large-section shop includes mill 850 with heating wells, hot metal cutting, and delayed cooling sections serving it. For finishing, control, heat treatment, turning, shipment of rolled products in the shop there is an adjuster department. The location of the equipment is shown in Figure 2.

Picture 2

equipment for mill 850

Heating wells

The type of wells is single-bed regenerative. The number of groups is seven. The total number of cells is 165. Cell section - 900x900 mm, depth - 3000-3300 mm.

Fuel: for groups I, II, IV, V, VI, VII - a mixture of blast furnace and natural gases; in group III - blast furnace gas. All groups of wells, except for group III, are equipped with automatic devices for flame reversal.

Stan 850

Mill type - linear, duo-reversible. Composition: blooming stand 900, roughing and finishing stands 850. Drive - group, from the side of the finishing stand.

Main drive engine - MPS-800-63V4, has the following characteristics:

rated power - 8000 kW;

rated current - 9050 A;

voltage - 930 V;

rated speed - 65 rpm;

maximum number of revolutions - 125 rpm;

the flywheel moment of the armature - 240 t * m 2.

Stand 900 is designed to produce intermediate rolls of rectangular sections from ingots weighing 4.5-5.6 tons. The stand type is closed. The pressure device is electromechanical. The lifting height of the upper roll is 550 mm. The lifting speed of the upper roll is 2 mm / s. Engine power - 125 kW.

To move the rolls along the barrel of the rolls of the blooming stand, manipulators are installed from the front and rear sides of the stand. The front manipulator is equipped with a hook-type rotator. The working stroke of the manipulator rulers is 2250 mm. The movement speed of the rulers is 0.2-1.2 m / s. The length of the rulers is 5000 mm.

The roughing and finishing stands have the same design and are used to obtain a finished grade from intermediate rolls. The stand type is closed. The pressure device is electromechanical. The lifting height of the upper roll is 250 mm, the lifting speed is 20 mm / min. Engine power - 75 kW. To service the roughing and finishing stands, two mobile roller tables (rolling tables) equipped with tilters are used. Speed ​​of movement of tables - up to 5.9 m / min.

The characteristics of the mill 850 mill rolls are shown in Table 5.

Table 5

Textolite bearings (sliding) are used in all working stands of the mill for rolls. Spring-type balancing devices. Cooling of necks, bearings and roll calibers is carried out with water under a pressure of 1.5-2.0 kgf / cm 2.

Hot metal cutting area

Consists of three hot impact circular saws with the following characteristics:

disc diameter - 2010 mm;

disc thickness - 10 mm;

disk rotation speed - 98-100 m / s;

feed speed - 0.03-1.6 m / s.

temperature at the time of cutting - 800-900 о С;

water pressure for disk cooling - 5-8 kgf / cm 2.

Dimensions and profile of sections to be cut:

square - 130-210 mm;

circle - 140-280 mm.

Delayed cooling section

The characteristics of the delayed coolers are shown in table 6.

Table 6

Figure 3 . - Adjustage

2.2 Section rolling shop

The Section Rolling Shop includes two mills (mill 450 - medium-section and mill 320 - small-section), sections - billet warehouse, trimming, finished steel warehouse. The mills and the billet warehouse are located in a common two-span building. Adjustage and warehouse for finished rolled products - in separate buildings.

2.2.1 Methodical heating furnaces of mills

Purpose - heating billets before rolling on mills 450 and 320.

Quantity - 3 pcs. (2 - at Mill 450 and 1 - at Mill 320)

Type - methodical, double-row, three-zone, with end loading and delivery of blanks.

Gas curtains are installed in the end window for dispensing workpieces; in the loading window - air bumpers.

The size of baking ovens is shown in Table 7.

Table 7

The monolithic hearth of the heating zone of the furnaces is made of corundum blocks of the KOR-93 brand. Fuel - natural gas with a calorific value of 7940 kcal / m 3. Combustion air is supplied from the VD-12 fan. The recuperator is tubular, single-turn for smoke and three-turn for air. Air heating up to 280-320 0 С. Chimney height, m: for furnaces No. 1 and No. 2 - 60; for furnace No. 3 - 50.

Automatic control systems for furnaces:

ь automatic regulation of gas and air;

ь remote control of the rotary gate;

ь remote control of gas and air consumption;

ь gas safety automatics.

Methodical furnaces are equipped with charging devices and pushers. Type of loading devices - with walking rails, quantity - 3 pcs. Maximum loading capacity of the loading devices: on furnaces No. 1 and No. 2 - 40 tons; on furnace No. 3 - 20 tons. Pushers: quantity - 3 pcs. Electric motor drive type MT-63-10; power - 48 kW; number of revolutions -58 rpm. The total force of one pusher is 22,200 kg. The pusher path length is 800 mm.

2.2.2 Mill 450

The main technological equipment of the mill is located in the span of a building 30 m wide and 288 m long.

Figure 4 ... - Layout of the main technological

equipment for mill 450

1 - transfer devices of heated metal to mill 320;

2 - crimping three-roll stand 680;

3 - working line of stands 450;

4 - three-roll calibrating unit;

5 - movable slide saw;

6 - stationary slide saw;

7 - refrigerator section.

Mill type - linear, medium-sized. Composition - crimping stand 680, finishing line of four stands, section for hot cutting and metal cooling.

Crimping stand 680

Purpose - obtaining intermediate rolls of square and rhombic sections from the original workpiece. Cage type - trio. Bed type - open, cast. Spring-type balancing device. Screw manual pressure device. The stand is driven by an electric motor ДСП-213-59-16. Engine power - 2000 kW, number of revolutions per minute - 375. Six-wheel stand - type A - 450x450. Reducer: gear ratio -1-4.96; the number of revolutions - 75.6 rpm. The roll characteristics are shown in Table 8.

A feature of the 680 crimping stand equipment is that the rolls are driven from an electric motor through a reducer, a main clutch, the middle shaft of the stand, a gear stand to the upper and lower rolls of the crimping stand (typical arrangement: motor - gearbox - gear stand - working stand).

To facilitate manual tilting and movement of the rolled metal from the calibers of the upper horizon to the lower one, “tilting” sheets are installed on the front side of the crimping stand 680. To move the rolled metal from the lower horizon to the upper one, a lifting and swinging table is installed on the rear side of the stand (length - 6000 mm, lifting height - 315 mm, lifting angle - 4 degrees). Lift table roller tables (number of rollers - 6 pcs., Roller diameter and length - 426x2200 mm, roller pitch - 650 mm, speed - 2 m / s) work reversibly. The table is counterbalanced by the counterweight.

Mill 450 finishing line

Designed for pre-finishing and finishing passes when rolling medium-sized sections. Composition - 4 stands: I-III stands - trio, IV stand - duo. Stands of stands I-III are open, stand IV is closed. Spring-type balancing devices. The drive of the pushing devices is manual. The transfer of rolled metal from stand to stand is carried out by means of schleppers, from horizon to horizon - by lifting and swinging tables.

The characteristics of the rolls of the finishing line of Mill 450 are shown in Table 8.

Mill finishing line drive: motor P2-630-202-8SUCHL4, power - 2300 kW, nominal rpm - 290, maximum - 515. Gear ratio - 2.76, gear type - A-160. Gear stand - type A - 450x450, speed - 134 rpm.

Hot roll stand block 450

Purpose - to obtain, among other things, round and hot-rolled high-precision hexagonal rolled products, including hot-calibrated ones (TU 14-1-4542-88).

The stands of the block are three-roll, of the type of reduction pipe-rolling. Quantity - 3 pcs. Roll diameter, nominal - 450 mm. The maximum allowable roll force is 24 tf. The maximum torque on the drive shaft is 800 kg / cm. Dimensions of the calibrated rolled profile: for round profiles -30-80 mm; for hex profiles -32-65 mm. Rolling speed - 3.5 m / s. The water consumption for cooling the rolls per stand is 100 l / min. Air consumption for engine cooling - 186 m3 / min.

With the help of a calibrating unit, "precision rolling" is carried out with small reductions of the finished profile of 0.52.5 mm in three-roll calibers.

Hot cutting and cooling section for metal mill 450.

Consists of two skid saws for cutting rolled steel into rods of the required length in the hot state and schlepper coolers.

1. Sled saw (mobile) No. 1. Sled movement: minimum speed - 140 mm / s; maximum reverse speed - 280 mm / s. Saw movement: speed - 40 mm / s. The diameter of the cutting discs is 1500 mm. The saw blade speed is 100 m / s. Saw drive from an electric motor - type A-103-8M. Power - 125 kW. The number of revolutions is 730 rpm. Combined reducer.

2. Sled saw (stationary) No. 2. The technical characteristics are the same as for the saw # 1, except: the speed of movement of the slide - 167 mm / s.

3. Refrigerators of the mill 450 are chain, five-thread. Quantity - 2 pcs. Length x width - 7.2x18.4 m. Drive from an electric motor: type - МТМ-512-8; power - 30 kW; number of revolutions - 720 rpm. The rental from the refrigerator pockets is transported by an electric bridge crane.

2.2.3 Mill 320

The main technological equipment of the mill is located in the bay of the mill building of the Section Rolling Shop, 27 m wide and 312 m long.

Figure 5 ... - Layout of equipment for mill 320

1 - methodical furnace;

2 - crimping stand 550;

3 - lifting and swinging table;

4 - flying scissors;

5 - line of stands 330x750 mm (No. I-VI)

6 - line of frameless stands 330x600 mm (No. VII, VIII);

7 - flying scissors;

8 - accelerated cooling unit;

9 - rack refrigerator;

10 - cold cutting scissors;

11 - assembly pocket;

12 - line of preliminary accelerated cooling;

13 - continuous (new) finishing group of stands 330x600 (№IX, X) - not put into operation.

Mill type - linear, small-section. Composition - crimping stand, finishing line of 8 stands, section for cutting and cooling of rolled products.

Crimping stand 550

Purpose - reduction with section reduction and deformation from the original workpiece. Trio cages with open beds. Spring-type balancing device. The pressure devices of the upper and lower rolls are screw, manual. The stand rolls are driven by an electric motor (type - ДСП-213-59-16, power - 2000 kW, speed - 375 rpm, gear ratio -3.5, center-to-center distance of gear stand - 575 mm).

The roll characteristics are shown in Table 8.

Moving the rolls from groove to groove and their turning from the front side of the 550 swaging stand is carried out with the help of turning sheets. Moving rolls from the lower horizon to the upper one is carried out using a lifting and swinging table (table length between 1 and 8 rollers - 5350 mm, table lifting height - 330 mm, table lifting angle - 4 degrees) The table roller conveyor works reversibly, the table is balanced by counterweight. Length x diameter of the roller table - 1700x426 mm, the number of rollers - 8 pieces, the speed of the table roller - 2.4 m / s.

Finishing line of mill 320

Purpose - hot rolling of small-section sections from the rolled stock after the swaging stand in preparatory and finishing grooves.

Composition: two lines. The first line - 6 stands: I, III-VI stands - variable duo, II stand - trio, stands from a common drive N = 2300 kW. Beds I-VI of closed stands. The second line - 2 stands: VII, VIII, each from an individual drive N = 500 to W, frameless design of high rigidity. Stand type - NNZhK 320x600 (unstressed rigid). The characteristics of the rolls of the stands of the finishing line of mill 320 are shown in Table 8.

In front of the first stand for turning and the task of intermediate rolling, a tribrater is installed in the caliber. An electric tilting sleeve is installed for tilting the rolled stock in the second stand.

The drive of the finishing line of mill 320 for stands I-VI from an electric motor: type P2-630-202-8SUHL4, power - 2300 kW, speed (nominal / maximum) - 290/515 rpm.

For cutting the ends of the rolled steel behind stand 550, flying flying shears for hot cutting are installed (cutting force - 150 kN, maximum allowable section of the cut strip - 1870 mm 2).

Table 8

P / p No.	Mill	Cage	Roll material	Barrel dimensions in roughandde, mm	Dimensions nethKi, mm	Club dimensions, mm
				nomin. diameter	dlandon	diameter	dlandon	diameter	dlandon
			Steel 150Х2ГНМФ
			Cast iron brands SP and SPHN
		Caliber. block 450	Cast iron brand SP
			Steel 150Х2ГНМФ
			Cast iron brands SP and SPHN

Section for cutting and cooling finished rolled steel mill 320

Includes flying shears for hot cutting of rolled products, accelerated cooling units, transport roller tables, rack cooler, with a discharge roller conveyor, cold cutting shears and a means of collecting rolled products.

1. Flying scissors. Purpose - cutting hot rolls to the length of the rack cooler, as well as for cutting the front end of the strip and emergency cutting. The place of installation is in the flow of the mill behind the finishing stand. Type - lever volatile "start-stop". The sections to be cut are 10-36 mm and equal in area - hexagonal, strip, square corners, etc. The maximum area of ​​the section to be cut is 1020 mm 2. The temperature of the rolled products is 800-900 o C. The speed of the rolled products during cutting is 2-8 m / s, the permissible cutting force is no more than 20 kg. In front of the scissors, the set includes pulling drive rollers (tribar).

2. Installations for accelerated cooling of rolled products. Located in the stream of the mill behind the flying scissors. Designed for thermomechanical processing (hardening) of rolled products from rolling heating.

3. Refrigerator Mill 320. Type - rack. Length - 48 m, width - 7.6 m. Purpose - receiving hot rolled in bars, cooling it to a temperature of 180-400 o C and further transfer of bars 10-48 m long to cold-cutting shears with a force of 500 tf.

Cooled rolled products Ø 10-40 mm, hexagons - 10-38 mm, strip t = 4-12, B = 25-60, corners No. 2ch5, shaped rolled products with a width of no more than 60 mm. The length of rolled products is not more than 48 m. The length of the cooler (rack system) is 49.5 m. The width of the cooler (along the axes of the roller tables) is 7.66 m. The speed of the feeding roller table is 3-7.2 m / s, the time of lifting and lowering the valves - 3.6 sec.

The travel of the movable rails is 120 and 240 mm.

4. Shears for cold cutting. Purpose - cutting to finished lengths of rolls after the refrigerator. Cutting force - 500 tf. The length of the cutting edge of the knife is 700 mm. Movable knife - upper. Knife stroke 155 mm. The tensile strength of the cut material y = 100 kg (mm 2), relative to the elongation of the material d = 6%. The temperature of the material to be cut (calculated) is 100 ° C, the number of knife strokes is 18 per min. The number of cuts - 10 pcs / min. The power of the main drive of the scissors is 75 kW, the number of revolutions is 575 rpm.

2.2.4 Adjustment

The trimming equipment of the Section Rolling Shop is located partly in a separate production building, partly in the tail section of the aisles of mills 320, 450. (useful area - 5200 m 2).

Grading machines

1. Grade straightening machine 8x800 (2 pcs.).

2. Grade straightening machine RRK-5 (made in Poland).

3. Straightening machine for corner straightening.

4. Grade-straightening machine 11x200.

5. Machine grade straightening 7x600.

Machines for abrasive stripping of rolled metal

Type - suspended, swinging, quantity - 5 pcs. Abrasive wheels - flat, straight profile, grain size - 80-125, wheel dimensions 300x40x76 mm, permissible peripheral speed - 50 m / s. Purpose - selective manual cleaning of surface defects on round, hexagonal and square bars.

Drill Steel Core Drawing Machines

Quantity - 2 pcs. The dimensions of the rods of drilling hollow steel are 26-37 mm round, 22.25 mm hex. Core steel grades - EI-94. The cross-sectional dimensions of the cores in finished rolled products are 6.5-12.5 mm.

3. Description of the technological process in rolling shopsawater

3.1 Large section shop

The large-section shop, with the main metallurgical unit - the large-section mill 850, is the main one in the rolling process: it accepts ingots from the open-hearth shop (and periodically - from the side) and processes (crimps) from billets of square or circular cross-section and into finished round or square rolled large-section assortment.

The transfer of ingots from the open-hearth shop to the KSC is carried out after the appointment of melting by the quality control department of the open-hearth shop. The purpose of melting by chemical analysis is carried out no later than the end of the holding time of the ingots in the molds.

The ingots are transferred by float at the highest possible temperature.

Ingots with a temperature of not less than 700 ° C and, as an exception, not less than 500 ° C are transferred to the BCC. Ingots with a temperature of 800 ° C are classified as hot, with temperatures from 500 ° C to 799 ° C - warm, with a temperature of less than 500 ° C - cold.

The ingots transferred to the KSC are marked in the open-hearth shop. On special plates attached to the trolleys, the melt number, the number of ingots and the beginning of extracting ingots from the molds are indicated. At the BCC, the ingots are accepted by the QCD inspector (the correctness of the marking of the ingots and the information on the plates, the heat number, the steel grade, the number of ingots, the time of arrival, the temperature of the ingots landing, etc.) are checked and recorded in a special journal. The temperature of the surface of the ingots before being placed in the heating wells is determined depending on the time of holding them in the molds and transferring them to heating (according to special tables).

The order of landing in the heating groups of heating and the implementation of heating modes of ingots is provided in accordance with the approved technical documentation.

The final heating of the ingots to the temperature of the beginning of rolling (1100-1230 o C) is carried out in the first group of wells.

After the final heating, the ingot is transferred for rolling in the mill 850 at the command of the operator of the main control room for ASM. The data on the section being rolled is reported to the rolling section and to the operators of the main control room (stand 900), to the operators of rolling tables and to saws No. 1 and No. 3

Reduction modes, speed and temperature modes of rolling are carried out in accordance with the approved technology and roll calibrations.

Mill 850 can roll several heats to different profile sizes simultaneously without rebuilding the mill.

In the stand 900 ingots are set with their profitable part. From stand 900, rolls for circles 140-220 mm and squares 130-210 mm are transferred for cutting off to PLC No. 3 parts of defective ends, and then into roughing and finishing stands 850. Rolls for wheels over 220 mm are transferred to the roughing stand without preliminary cutting to PUD No. 3.

The rolling of the rolls and the movement from caliber to caliber in stand 900 is carried out using a hook turner (on the front side of the stand) and manipulators; in the roughing and finishing stands - with rope tilters and rolling tables.

Cutting of rolls to the required lengths of finished rolled products and technological trimmings is carried out at PUD No. 1 and PUD No. 2.

Cutting is carried out with the help of dimensional rulers and stops installed at the saws for hot cutting. Maximum deviations along the length when cutting the rolls into workpieces of measured and multiple lengths, the slant of the cut must comply with the requirements of GOST 2590-88, GOST 2591-88.

After cutting the rolled stock, each marketable blank is marked with hot stamping at the end with the indication of the heat and siphon number, steel grade, the plant's trademark and the team's mark.

After rolling, the metal is cooled, depending on the grade, profile and purpose of the steel:

b in stacks or brackets in a calm air in the workshop;

b in thermoses with the lids closed.

Some of the rolled products are heat treated (annealed) in four chamber-type thermal furnaces with pull-out hearths.

Annealing of some steel grades is carried out only at the request of the customer.

The KSC produces finished (commercial) rolled products and rework billets for the section rolling shop.

In addition to metal annealing on the adjuster, the following is carried out:

1. Cleaning with abrasive wheels on Sh7-05 machines

Defects identified by the Quality Control Department are cleaned in accordance with the technical requirements for the metal. The depth of occurrence of defects is determined by "testing" with an abrasive wheel. Workpieces with defects, the depth of which exceeds the allowable one, are rejected.

Billets with increased curvature are preliminarily straightened on the correct press.

2. Turning round bars.

Round bars with a diameter of 140-280 mm are turned. Before turning, the metal is ruled on the press.

Turning is carried out on special centerless lathes with plentiful and continuous cooling of the cutters with emulsion.

3. Fire stripping of workpieces.

Workpieces stacked in one row on a rack, inspect, mark defects with chalk and melt with hand oxy-fuel cutters. Cleaning should be flat, its depth should not exceed 4% of the diameter of the workpiece.

4. Processing of commercial square products.

Cleaning is carried out selectively using a hand-held pneumatic tool. Unacceptable surface defects and burrs found during inspection are subject to cutting down. In this case, the width of the felling must be at least 5 times the depth.

The commercial rolled products accepted by the Quality Department are loaded onto the railroad cars of the Ministry of Railways or sent to the warehouse of finished rolled products.

Large-section steel with square sections of 130-170 mm is a rework billet for the production shop.

Depending on the purpose, the rework billet is subdivided into three processing (quality) groups.

group P1 -	billets of carbon steel, alloyed steels, intended for production of rolled stock, subjected to continuous stripping in the Sizing shop; shipped to SPC with control in the flow.
group P2 -	billet for rolled stock, which is not subjected to cleaning in the Sizing shop; billet square 140 mm of steel ШХ15 for rolling using drawing; billet, pre for SPC for hot-rolled steel on orders of MAP and export with continuous abrasive or fireandstack.
group P3 -	blanks for all other appointments with removal from the surface visible to the naked eye defects.

Processing of the rework billet includes:

b Abrasive cleaning on suspended emery machines (P3);

b Abrasive cleaning on grinding and grinding machines (P2, P3);

b Fire cleanup (W2, W3).

The depth of stripping should not exceed for square 170 mm - 20 mm, square meters. 140 mm - 15 mm. If the depth of the defect is higher than the permissible value, the workpiece or part of it is rejected. The stripping width must be at least five times the depth.

The rework billet is transferred to the SPC after receiving positive results for macrocontrol.

3.2 Section rolling shop

The workpieces coming from the KSC are weighed before being placed in the continuous furnaces. The workpieces are planted in the furnace with whole melts, without rupture, they are checked for the prevention of mixing in chemical composition, the correctness of the marking.

The melts of the billets in the furnace are separated from each other by refractory bricks, which are placed on the first billet of a new melt.

Heating of blanks of various grades of steel is carried out differentiated according to several groups of grades, depending on their heating properties (tendency to overheating, cracking) and rolling (plasticity, deformation resistance).

Special heating modes have been established for each group and section sizes of billets with technological documentation, which indicates the parameters for fuel consumption, air, heating rate and temperature in the furnace zones, the temperatures of billet delivery and the start of rolling are indicated (most often 1080-1180 о С)

Positive pressure is maintained in the welding and milling zones of the furnace. It is normal for the flame to be slightly knocked out of the viewing windows. Air suction into the oven is not allowed. Fuel consumption in the zones of the furnace should determine the optimal heating of the workpieces. The temperature difference between the lower and upper edges of the workpiece should not exceed 50 ° C.

Billets are rolled out by float, in order to prevent overmixing during issuance, the Quality Control Department checks the marking of the last two and the first two billets of each heat. Blanks with or without unclear markings are rejected.

Rolling of unheated, burnt and unevenly heated workpieces is prohibited.

In the Section Rolling Shop, the profiles are rolled, given in Table 9.

Table 9

The rolling modes on the mills are developed taking into account the characteristics of the sizes and shapes of profiles and steel grades in accordance with the technical parameters of the equipment of the mills and are established by the approved drawings and calibration diagrams of rolls for each profile size, tables and instructions for the reduction modes, rolling speeds and temperatures.

Schematic diagrams of the rolling process on mills 450 and 320 are shown in Figures 6 and 7.

Figure 6. - Diagram of the technical process on mill 450

	workpiece 170-180, 150-154, L = 1.3-3.0 m, heating up to 1080-1200 о С
	Methodical heating furnaces No. 1; No. 2
		broadcast	blanks for the crimping stand roller conveyors
periodic temperature control, stand settings	Crimping stand trio 680	t start of rolling = 1060-1180 о С
manual tilting with partial mechanization using PKS	in 1-3 rhombic	rolling speed V = 2.3-3.0 m / s, number of passes 5-7
		t = 1000-1130 о С	transfer by roller conveyors to 1 stand of finishing line 450
	Swinging sleeve	tilting of the section of the roll
	1 stand 450 "trio"	rolling in 1-5 passes according to the schemes: "square - rhombus - square" "oval - rhombus oval", "rhombus - rhombus" for
transfer of rolled stock by roller conveyors, PKS and slipppers to stand 2			reduction of cross-sections to sq. 56-80 mm
tilting at 90 o, 45 o, 0 o	2-3 stands 450 "trio"	rolling in 1-5 passes in preparatory and pre-finishing gauges
	4 stand "duo" 450 (finishing)	final pass to finished profile
V release of the roll = 2.0-3.5 m / s, t = 850-1000 о С,			release of the finished profile roll onto the roller conveyor feed of rolls to the feed roller conveyor of hot saws
	Hot saws	cutting off end defective parts, dividing the rolled stock into rods L = 3-6 m, ordered length
end trim
for disposal	Waste containers		Saw discharge roller conveyor, bar transfers to coolers
					t = 700-900 о С
		Schlepper chain coolers (2 pcs.)	bar cooling; partially - manual marking (stamping) of rods by impact method
			t = 100-500 о С
	Ready-to-roll pockets
			packing, hooking with slings (package weight up to 6 t)
	Electric bridge crane,
			transportation for adjuster

Figure 7. - Diagram of the technical process on mill 320

	from KSC or from the side of the workpiece 130-140, L = 1.1-3.0 m, cross-sectional area 17000-19000 mm 2, heating up to 1080-1200 о С
	Methodical heating furnace No. 3, three-zone
		transfer to and a schlepper	roller conveyor mill tilting more heated side up
	Crimping stand trio 550	t start of rolling = 1080-1180 о С
	Rolling in boxes (rectangular) calibers 4 passes with intermediate edging according to the "2-2" scheme	rolling speed V = 2.8-3.5 m / s, for 100: 7 skips for 130h140: 9-11
periodic temperature control, roll settings (dimensions, shape, cross-sections of rolls), adjustments	Rolling in calibers of the "rhombus-square" system 5-7 passes according to the scheme cantovy "1-1-1 ..."	tilting by hand, lifting the roll into the upper horizon of the trio 550 stand with the help of the PKS on the front side of the stand, t at the entrance = 1020-1150 о С
	Drum scissors volatile Q = 15 tf	cutting front and rear defective ends on the fly,
roll transfer roller conveyors to the line stands 320x750 No. I-VI			L trimmings = 50-200 mm, rolling of a rhombic section t = 40-50 mm, B = 65-80 mm pl. section 1570-2100 mm 2
	Tilter - tribapparatus	tilting of the section of the roll on edge 90 about task in rolls I (II) stand
	Line of working stands No. I-VI (320x750)	transfer of the roll using bypass
checking the filling of the calibers, the shape and dimensions of the sections, adjusting the rolls, fittings, bypass devices	Rolling in 3-7 passes of rolled stock from compression 550 to smaller sizes of square or ribbed sections	devices (automatically), tilting - automatically with the help of the overturning outlet fittings
	Caliber systems: "square-oval", "rib oval-oval", "square-strip", etc.	t start. rolling = 1000-950 o C t end of rolling = 950-900 о С rolling speed V = 3.5-4.5 m / s
transfer and tilting automatically using	Crates No.VII, No.VIII (330x600)	section 140х1250 mm 2 t start. rolling = 950-900 o C
bypass devices and fittings	Prefinishing and finishing passes in oval-circle or hexagon-hexagon gauges, etc.	t end of rolling = 820-920 о С rolling speed V = 4.0-6.0 m / s
periodic temperature control, adjustment of rolls and reinforcement settings			release of rolled stock from the finishing stand for cutting and cooling of finished rolled stock
			rolling out the finished profile (see Table 9), V out of the stroke from the mill = 4.0-6.5 m / s, t = 800-900 о С, roll length 50-260 m
	Flying scissors, Q = 20tf	hot cutting front, rear ends cutting
receipt of roll on installation in stream			for the length of the rack cooler 25-48 m, transfer of rolls to the rack cooler, discharge by valves
Accelerated cooling unit (with water)		Rack refrigerator, L = 50 m, B = 7.6 m	bars on rails, roll braking, transfer in the transverse direction
					bars with walking rails of the refrigerator
thermomechanically hardened metal		Infeed roller conveyor cold shears	with cross-section tilting and cooling to 100-300 о С, alignment of ends
water pressure 16 atm, surface cooling up to 300-400 о С, temperature equalization over the section				bars, transfer of bars from refrigerator rails, grouping of a package of bars.
Control of dullness of knives, cut shape, curvature of ends, change of knives	Cold shear press Q = 500 tf, knife length 700 mm	Leveling and setting the length of the cut (cutting) of the bars using a stop, the distribution of the bars over
feeding bars of the ordered length to the transport. roller table			streams of knives, cutting a package of rods from 9-20 pcs. peals
control of cutting length, defects	Bar conveyor
			pockets of finished rolled products
	Electric bridge crane,	hitching of bundles of rods, transportation, shipment to railway platforms for consumer
			body or for finishing and control

Before the start of the shift and rolling of a new profile size, the mill foreman is obliged to inspect the condition of the rolls and mating armature and immediately eliminate the noticed deficiencies. During the adjustment of the mills to a different profile or size, it is necessary to reduce the number of revolutions of the motors of the finishing lines of mills 320 and 450 in order to improve the capture of the rolled product by the rolls.

When rolling any profile, the senior roller is obliged to monitor the correct operation of the rolls, mating armature and the setting of the mill. When moving from one profile to another, rolling begins with test blanks (from rejects and under-rolled products).

If a mustache, displacement, scratches, dents and other visible defects are found on the surface of the roll, the senior roller must take measures to eliminate the causes leading to the receipt of rolled defects.

Formed in the process of rolling in the cogging stand, under-rolled and billets for reheating must be marked with a steel grade. Units from mill 450 are transferred by a transfer cart to the pre-production site to be checked for homogeneity and the presence of a stamp, with subsequent joining to the main batch of metal.

Rolled steel is cut while hot from a mill 450 with sliding saws. Metal cutting on hot-cutting saws of mill 450 is carried out in packages, selected depending on the size of the rolled steel.

Bars cut on hot-cut saws are branded. Waste obtained during cutting of metal, as well as scrap obtained during the rolling process, is stockpiled and stored in the shop in accordance with Section 7 of this report.

The products supplied to the adjuster are subjected, if necessary, to straightening, in order to eliminate surface defects, to inspection, sorting and cleaning.

Metal with increased curvature is straightened on cantilever levelers. Straightening is carried out both cold and hot.

Identification and removal of surface defects:

ь Snake lighting is performed on rolled products (diameter 32 mm and more, length no more than 4000 mm). The step of the "snake" should not exceed 300 mm.

b The imposition of "loopbacks" is carried out on round bars (length more than 4000 mm, the same diameter) and on all hexagonal bars at two points at a distance of 100-200 mm from the end of the bar.

The lightening of the rolled stock and the removal of surface defects and burrs obtained during cutting of the rolled stock are carried out on suspended emery machines.

It is forbidden to process metal on racks from which the metal of other heats has not been removed.

The straightener before the task in the straightening machine of the bars inspects them on the receiving table. Found gross defects on the surface of the rods (loose ends, cracks, flaws) are covered over. Individual rods must be turned 180 ° C to orient the defective ends in one direction. In this case, a cold stamp is applied to the opposite end of the rods with an indication of the heat number.

Finished products for export orders, as well as hot-rolled metal with the letter "L" after processing are subjected to sparking. In accordance with the requirement of the order, the painting of the processed metal can be produced.

Inspection of bars after processing is carried out by QCD inspectors. The products accepted by the Quality Control Department are collected in packages with a mass that ensures safety conditions, tightly tied with wire in 2-3 places, depending on the length of the rods. Products tied in bags are hung on two marking and weight tags, which are firmly attached to different straps from the side convenient for viewing.

Delivery of metal to the warehouse of finished products is carried out only after the end of processing and presentation to the QCD inspector.

Export metal, prepared for shipment, is stored in a specially designated place, which excludes metal sagging and damage to the closure. Do not store metal outdoors. The metal is packed so that the cross-section of the bundle is close to a circle, hexagon or rectangle. One end of the bag must be aligned.

4. Characteristics of raw materials, fuels, basic materials

Raw materials are minerals, other natural resources, as well as materials produced from them, subject to further processing A.B. Borisov. Big Dictionary of Economics. - Moscow: Book World, 2003..

Blast-furnace shop of JSC "Metallurgical plant named after A.K. Serov ”smelts pig iron, which is supplied in cast iron ladles to the open-hearth shop, where steel is produced. Steel is poured by a siphon method into molds, thus obtaining ingots. Ingots are subject to processing in the KSC, therefore they are the raw material for the KSC.

In the open-hearth shop, ingots are cast weighing 5.6 tons. Control weighing of ingots is performed once a decade in the presence of representatives of the KSC, the open-hearth shop and the technical department.

In normal casting, the height of the solidified bottom part should be:

b for ingots weighing 5.6 tons with lining of a profitable extension with fireclay bricks - 240-350 mm;

b for ingots weighing 5.6 tons with lining of the profitable extension with inserts - 200-340 mm.

When rolling ingots with an incomplete profit (the last for casting or lagging behind the siphon), the head trim is increased according to Table 10.

Table 10

The height of the profit filling in these cases is determined by a four-stage template with a step height of 165, 225, 285, 335 mm (when using extensions lined with fireclay bricks) and with a step height of 160, 220, 280, 330 mm (when using extensions lined with liners). Bars with partial profits are allocated with separate siphons. In the passport of the smelting and the book of chemical analyzes of the KSC, a record is made about ingots with incomplete profit.

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Rolling mill

Fig. 2

I - stock warehouse; II - separation of heating furnaces; III - back span; IV - scrap span; V - machine room; VI - finished goods warehouse;

1 - heating furnaces; 2 - scissors; 3 - roughing group of stands;

4 - flying emergency shears; 5 - finishing group of stands; 6 - flying scissors; 7 - refrigerator; 8 - finishing area

Depending on the purpose, rolling mills can be divided into two groups:

1) mills for the production of semi-finished products;

2) mills for the production of finished rolled products. The first group includes blooming mills and continuous billet mills that supply semi-finished products for the production of section steel, as well as blooming and slabbing machines that supply semi-products for the production of sheet steel. Blooming and slabbing - large blooming mills with rolls 800-1500 mm in diameter. The main direction in the development of these mills is to increase productivity, primarily due to an increase in the mass of ingots, which reaches 50 tons when rolling slabs. The development of blooming and slabbing machines was also accompanied by an increase in the cross-section of the semi-finished product produced, an increase in the power of the main engines of the mills, mechanization and automation of auxiliary operations. The most widespread are single-stand reversible blooming mills and slabs with rolls with a diameter of 1150-1300 mm.

The modern billet mill is the continuous downstream mill. Previously, 12 stands of a continuous billet mill were installed in two groups of six stands each (Fig. 6). Recently, the main changes in the technology and equipment of these mills are the refusal to turn the strip and an increase in the size of the initial blooms and final blanks. In this regard, the characteristic features of modern continuous billet mills are the alternation of stands with horizontal and vertical rods and an individual drive of the rolls of each stand with speed control. The latter provides regulation of the rolling speed, simplifies the adjustment and calibration of the rolls. In order to increase the cross-section of blooms entering the flocks, the modern continuous billet mill consists of 14 stands, with the first group consisting of eight and the second group of six stands. Increasing the size of the initial blooms and final billets requires the installation of mills with larger diameter rolls and motors with a higher total power.

In the cold rolling shop for electrical steels (Fig. 3), the alternation of spans is provided in the following sequence: a span of the pickling department without increased heat release, a span of continuous annealing units, a span of a rolling department, machine rooms, a span of continuous annealing units and bell-type furnaces, a span of the finishing department. The courtyards of these buildings are located either parallel or at an angle of 0-45 0 to the direction of the prevailing winds with the orientation of the open part of the courtyard to the windward side. To ensure the normal operation of the aeration lantern, the longitudinal axis of the latter should make an angle of 60-90 ° with the direction of the prevailing wind. The main sources of heat dissipation are located directly under the lantern. Heating devices and furnaces for heat treatment of metal are placed at such distances that the heat fluxes from them do not cross.

Fig 3.

I - pickling department; II - separation of continuous annealing units; III - cold rolling department; IV - separation of bell-type annealing furnaces; V - finishing department; 1 - boiler room; 2 - conveyor for hot-rolled coils; 3 - warehouse for hot-rolled coils; 4 - continuous pickling units; 5 - installation for heating mother liquors; 6 - cut-to-length unit; 7, 9, 10, 20, 23 - racks for rolls installation; 8 - transfer cart; 9 - roll grinding workshop; 12 - slitting units; 13 - reversible quarto mill; 14 - continuous five-stand mill; 15 - compartment for coating preparation; 16 - aggregates of a protective coating; 17 - electric furnace OKB-4006; 18 - mechanical repair workshop; 19 - machine room No. 1; 21.22 - workshop for the inspection of rolling bearings and fluid friction; 24.25 - transfer conveyors; 26 - electric furnace OKB-4017; 27 - cleaning and washing units; 28 - straightening machine; 29 - guillotine shears; 31 - a place for packing packs; 32 - loading ramp; 33 - finished goods warehouse; 34 - continuous units for annealing and tempering strips; 35 - twenty-roll mill.