30, 000 Ton Tpy Wire Rod Mill Production Line

The finished product of this production line is hot rolled 5.5 wire rod. The main technological process is: 70 × 70 square continuous casting billet smelted by intermediate frequency furnace and continuous casting machine is sent to the full continuous rolling unit through the conveying roller table to be directly rolled into shape; then after pressure feeding, spinning and cooling, it is rolled by the turning machine and push the small coil to the winder. N small rolls are merged and bundled into a large roll on the winder; then list, weigh, and store.

Parameters:
1. Designing one production line of 6tons/hour

2. Raw materials: steel scrap
3. Produced billet size:70*70*2300mm
4. Finished product: 5.5wire rod
5. Total power consumption:8700kw

Process flow:

Intermediate Frequency Furnace Smelting——Continuous Casting Mold——Rough Rolling Unit—Cut the Head and Tail—Middle Rolling Unit—Broken Tail—Prefinishing Rolling Unit—Finishing Rolling Unit—Pinch Roll—Spinning—Loose Cold Cooling-Rolling-Collecting-Packing-Listing-Lifting and Weighing-Storage

Equipment composition:

• Φ320 roughing rolling mill     1set

• Φ250 one drive two rolling mill     7set

• Accessory Equipment:

        1. coil upender   1set
        2. scatter-cold chain     1set
        3. Head cutting shear    1set
        4. Tail cutting shear     3sets
        5. Roller bed before breakdown     1set
        6. Lifting platform      1set
        7. Hanging arm roll     1set
        8. Roller bed before continuous rolling      1set
        9. Collection machine    1set
        10. Laying head (include pinch roll set)      1set

•  Melting equipment:

1. 2 tons medium frequency induction furnace   3sets
2. R4000-70 single-strand casting machine    1set

• Heating furnace:

1. Furnace body    1set
2. Pushing device    1set 
3. Discharge machine    1set 
4. Chimney     1set 
5. Burner      1set 
6. Fan     1set 
7. Heat exchanger      1set

If you are interested in the wire rod production line, please mail at marketing2@hanrm.com.

More Articles You May Be Interested:

More Articles You May Be Interested:

What is Laying Head?

The Main Factors Affecting the Quality of the Wire Rod

Technical Progress of High-speed Wire Rod Mills

Bar And Wire Rod Direct Rolling Technology without Heating

Common Phenomena and Processing Methods in Wire Rod Production

How to Improve the Assembly Quality of the Roller Box of the Wire Rod Mill?

Process Adjustment of Wire Rod Mill

Development of High Speed Wire Rod Mill

Processing Technology of Parts in High-speed Wire Rod Mill

Wire Rod Mill Structure and Arrangement

The Production Process of Wire Rod

Technical Characteristics of Bar and Wire Rod Mill

Temperature-Control of Wire Rod Rolling

Common Accidents on the Site of High-speed Steel Rolling and Measures (4)

15. What are the reasons for stacking steel between the stands of the finishing mill?

(1) The rolling guide sticks the steel;

(2) The guide wheel does not turn or the bearing burns out;

(3) The rolled piece split;

(4) The guide or the roll ring is installed incorrectly;

(5) The roll gap is not set properly or the incoming material size is not reasonable;

(6) The guide is not fastened.

16. What are the reasons for the poor wire loop of the laying head outlet?

(1) The tension between the rolling mills is too large;

(2) the alignment deviation of the water cooling section, the nozzle duct wear and corrosion cause the rolling operation to be unstable;

(3) The clamping force of the pinch roller is not appropriate due to the wear of the pinch roller ring or the failure of the cylinder link mechanism;

(4) The deviation of the bending line of the spinning tube, the spinning tube is seriously worn, and the spinning tube is sticky connected, the unbalance of the spinning tube causes the loop formation difference;

(5) Improper speed configuration of the finishing mill, pinch roll, and laying head, serious speed fluctuation of the rolling mill, causing the rolling speed to be faster or slower, resulting in uneven coil size;

(6) When the temperature of the rolled piece is high, the coil is too soft, and the coil falls on the receiving platform, and it will become an ellipse or a random circle.

17. What are the common types of damage to rolling guides in finish rolling? What are the causes? How to prevent it?

1) The guide roller bearing is broken, so the guide roller cannot rotate;

2) The guide roller is short of oil, and the bearing is locked;

3) The guide roller lacks water, causing the guide roller to not rotate or burst;

4) The guide roller shaft is broken;

5) The guide roller moves, the screw of the pin is loose;

6) The guide arm is loose.

Solutions:

1) Strictly control the size of the red billet, ensure the same size as the guide, and prevent the thickness of the material from impacting the guide roller.

2) Prevent misalignment of the roll ring, prevent twisting of the rolled piece, and the rolling guide is damaged. The bottom surface of the roll ring needs to be aligned with copper skin.

3) To prevent the roll ring from moving, due to the roll ring movement, the torsion moment is generated in the rolled piece.

4) The guide guard must be aligned to prevent excessive force on one side of the guide roller.

5) Strictly control the installation quality of the rolling guide, prevent the guide roller from moving, the guide guard arm is loose, and the cap screw is tight.

6) Strictly check whether the oil pipes and water pipes are working properly.

18. What common accidents will occur during the production of 27 high-speed roll rings with misaligned holes? How to solve it?

1) The serious slope of finished product;

2) The rolled parts are twisted, are unstable in the water-cooled channel, and are easy to get out of the waste box;

3) Due to the torsion of the rolled parts, the finished guides are easy to damage, resulting in the quality accident;

4) The guide is not easy to align.

Solution: Add copper skin to the bottom of the roller ring.

19. How to deal with the sudden stoppage of the high-speed wire mill?

1) Immediately start flying shearing machine #1, #2, and #3;

2) Emergency stop finishing and pre-finishing;

3) Notify the dispatch room to find the reason;

4) After stopping, ask an operator to the finishing mill to check the condition inside the machine;

5) Roller ring was all replaced or slowly cooled, it is strictly prohibited to cool the roller ring with water.

More Articles You May Be Interested:

1. What are the Main Safety Technologies for Steel Rolling?

2. How to Choose Steel Rolling Mill Machine?

3. Heat Treatment Method for Steel Rolling Mill

4. Rolling Steel Pressure Processing Technology

5. Rolling Steel Production System

6. The practice of Direct Rolling without Heating

7. What Adjustment Devices Are There in the Rolling Mill?

8. What Are the Rolling Process Systems?

9. Key Factors Affecting Rolling Mill Prices

10. Should Customers Choose Used Rolling Mill?

Common Accidents on the Site of High-speed Steel Rolling and Measures (3)

12. How to judge the tension between each rolling mill stand in production?
For the tension between the stands of the rolling mill, the adjuster generally hits the tensional rolled piece with a pipe, and judges the magnitude of the tension based on his experience, and can also observe the load (current magnitude) of each mill stand. If the load of one motor in the adjacent frame is particularly small, and the load of the other motor is too large (the current is too large), it means that there is severe steel drawing between the frames, which is easy to pull off the rolled piece and cause piling-up of steel.

13. How to deal with common faults in loopers?

The most common failure is that the looper cannot detect the rolled piece, the looper cannot afford the loop, the looper raises the high loop, and the looper shakes greatly.

(1) The looper cannot detect the rolled part. The usual reason is that the looper scanner lens is dirty or the looper scanner is not aligned with the steel. The solution is to wipe the looper lens first, and then test looper scanner (calibration loop) with the test rod.

The test method is to put the test rod in the looper table. The brightness of the test rod is similar to that of the red steel. Move the test rod slowly from the bottom of the looper table. If the signal does not arrive or is unstable, move the looper scanner to the left and right until it is aligned with the looper scanner head, unless the steel hits the scanner and is fixed after alignment. The possible reason is that there is too much cooling water in the looper table, and the cooling water needs to be reduced appropriately.

(2) The looper can't afford. There may be two situations: the air valve is leaking; the air valve pressure is not enough; The valve is not energized. The first two reasons are dealt with by overhaul, and the latter is checked by electrical to check whether the cable and wiring are firm.

(3) The looper raises its height. If the operator sets the parameters improperly, it can be solved by the operator modifying the parameters.

(4) The looper shakes greatly. It may be that the water mist is too large, which affects the looper signal. A fan can be placed next to the looper to blow.

14. Reasons and countermeasures for looping tail

① Improper setting of the set-up time will cause the set-up time to be too late, which will directly lead to slipping of the loop.

②Severe out-of-tolerance of the red billet size of the front frame of the looper and the excessive opening or excessive wear of the corresponding rolling guide will cause the looper at the tail of the rolled piece to flick intermittently in the retracted state.

③ The electrical control system is abnormal, and the joint adjustment between the roughing and intermediate rolling units is interrupted. The intermediate rolling speed continues to rise with the loop rising, but the speed of all 6 rolling mills in roughing rolling does not increase with the joint adjustment but always remains the same. The situation caused 4# or 6# tails to be flicked, and in severe cases caused the tail to be held back.

④ The action of the roller wind valve of the rising looper is delayed, resulting in the looper falling time being too late, which will directly cause the looper to flick.

⑤ The main method of controlling the looper tail dumping is as follows: reduce the height of the tail of the rolled piece and set the closing time of the take-up loop roller accurately.

More Articles You May Be Interested: 

1. Development of High-Speed Wire Rod Mill

2. Leak Proof Measures for High-Speed Hot Rolling Mill

3. Processing Technology of Parts in High-speed Wire Rod Mill

4. Technical Progress of High-speed Wire Rod Mills

5. What Are the New Technologies for Bar Steel Rolling?

6. Precautions during Rolling Mill Installation

7. Why Is the Oil Film Bearing of Finishing Mill Damaged?

8. Finishing Equipment of the Rolling Mill

9. Wire Rod Mill Structure and Arrangement

10. Technical Characteristics of Bar and Wire Rod Mill

Common Accidents on the Site of High-speed Steel Rolling and Measures (2)

5. What are the reasons for holding back the steel during rolling?

(1) Defects caused by the billet itself, such as inclusions, delamination, severe bubbles, etc., are rolled to half during the rolling process, causing cracking and holding the steel;

(2) When the speed of the certain intermediate rolling mill is set improperly, the steel rolling state is actually produced. The first half of the rolled piece is maintained by the front rolling mill to maintain tension rolling. When the tail of the rolled piece leaves the front rolling mill, the tension suddenly loses there, causing the holding back of steel;

(3) It is caused by the sudden increase or decrease of the speed of the motor of a rolling mill, which destroys the original continuous rolling relationship;

(4) Due to the sudden breakage of the roll or the severe damage of the guide in the previous passes, the cross-section of the rolled piece is changed and the steel is held.

Measures: ① Strengthen the picking of raw materials, strengthen the inspection of steel rolling, and take timely measures;

② Eliminate excessive tension;

③ Notify electrical treatment;

④ Regularly shut down to check the wear of the rolling guide to avoid holding back the steel.

6. Adjustment of the intermediate rolling mill unit: When adjusting the material type, you must first pay attention to the state of the stacking steel between the two rolling mills, and then adjust the ellipse material type. You must pay attention to whether the input splint is seriously worn.

7. Heavy iron hitting at the outlet of the rough and medium rolling mill:

(1). The front frame round hole material is too full or the input guide wears seriously (With severe scratches).

(2). The material type of this frame is inappropriate and too large.

(3). Change the exit guide.

8. Pre-finishing rolling mill: (1) 14 output is seriously ironed: the incoming material is too large, the amount of reduction is too large; the material shape is wide; the inner wall of the exit guide is not smooth, and the grinding is not good.

(2) 15 input is severely ironed: 14 outlets are worn and the torsion angle is not suitable; 15 inlet guide guard gaps are not suitable or severely worn and cannot support the steel;

(3) 15 input guide roller: the input guide is not installed correctly, and the incoming material hits the single-side guide roller when biting; the guide gap is not suitable, too tight; the guide roller is not cooled.

9. 17, 19 guide guard hit iron:

Measures: The guide gap is small, and press the 16, 18 material to re-find the tension.

10. Pre-finishing rolling leaving tail

Reasons: Tension before continuous finishing (continuous adjustment), the material shape is not good.

Measures: After pressing the material to the standard value, adjust the tension again; the delay time of the looper is not suitable; the height of the looper is not suitable.

11. 3# Shear steel pile

(1) Head pile steel

Reason: cutting head of 3# is too short, bring the head into 7 sets; 3# shear is without the head.

Measures: Lengthen the cutting head of 3# shear.

(2) Steel pile in the middle or tail

Reason: The pre-finishing rolling speed is set too high continuously.

Measures: adjustment to reduce pre-finishing 5 consecutive adjustments.

More Articles You May Be Interested:

1. The Main Factors Affecting the Quality of the Wire Rod 

2. How to Improve the Assembly Quality of the Roller Box of the Wire Rod Mill?

3. Process Adjustment of Wire Rod Mill

4. Technical Requirements of Rolls and Reasons for Broken Rolls 

5. Finishing Mill Roll Assembly Technology

6. The Practice of Direct Rolling without Heating

Common Accidents on the Site of High-speed Steel Rolling and Measures (1)

1. Jamming of steel

Reasons: ① The roll gap on both sides of the roll is inconsistent.

② The gap of the input box is severely worn, the gap is too large.

③ The axially fixed pressing block of the roll is not fastened, which causes roll error in rolling.

④ Incoming materials are out of square or severely reversed.

⑤ Long-term wear of the hole type is on the left or right side.

Measures: ① Adjust roll gap;

② Replace the input box;

③ Tighten the axial fixed pressure block to eliminate the roller error;

④ Remove the raw materials with serious detachment;

⑤ Change the slot.

2. Rolled piece do not bite

Reasons: ① The reduction is too large;

② The grinding groove is not good or there are water and oil on the surface of the groove;

③ The sliding plate on the inner side of the card-breaking shear is not welded or moved laterally;

④ The head of the incoming material is off square or has a large deformation during cutting, and it is stuck in the input box.

Measures: ① Reduce the reduction of this pass, enlarge the roll gap appropriately, and then press back to the normal range after normal rolling, the billet head is cut into a wedge or cone shape, when changing the roll or groove (When the rolling stop time is sufficient), press the head of the billet a little bit in advance, stop the machine and then go out of the rolling mill and return to the heating furnace to reheat.

② Grind the grooves in place to increase the surface roughness of the grooves and remove oil stains;

③ Check the shearing machine and rolling mill processing;

④ Remove the raw materials with severe head deformation or cutting.

3. Rough and medium-rolled slipping steel

Reasons: ① The reduction is too large;

② The grinding groove is not in place;

③ Turn on the cooling water in advance;

④ There is oil on the surface of the groove;

⑤ The gap between input guides is small;

⑥ The speed of the front frame has not been reduced (2.5% ～ 3%) just after the rolling.

Measures: ① Properly enlarge the roll gap and press it back to the normal range after normal rolling;

② Grinding groove in place;

③ Avoid turning on the cooling water in advance;

④ Remove the oil stain on the surface of the rolling groove;

⑤ Check the gap between the input guides;

⑥ Slow down after changing the roller and groove.

4. Head rolling steel during rolling

Reasons: ① The size of the rolled product in the previous pass is too large, so that when the rolled product enters the next pass, it is squeezed in the entrance guide plate to cause suffocation;

② Due to the uneven deformation of the billet head during rolling, the temperature of the billet head is low may cause the steel to split;

③ The rolling guide is seriously worn, the guide roller does not rotate, and the guide roller arm is loose, which causes the guide roller gap to change, causing steel holdback;

④The elbow of the rolled piece does not lead to the next lane, causing steel holdback.

Measures: ① Adjust the material type;

② Avoid low-temperature steel, pay attention to the condition of the billet head and avoid splitting the head;

③ Regular shut down to check the input and output guide to avoid holding back the steel;

④ Avoid elbows;

What we can do:

We are specialized in manufacturing high-speed morgan wire rod mill, high-speed rebar rolling mill, TMT rolling mill, high-speed gearbox, hard-faced gearbox.
We also provide complete design for your rolling mill workshop, not only turnkey project but also tailor-made service.

And we provide all the parts for roughing rolling mill, intermediate rolling mill process, including pinch roll, all kinds of shears, laying head, all of these crucial parts work extremely precisely and reliably.


If necessary, please feel free to contact me. Email: marketing2@hanrm.com

Reasons and Solutions for the Piling of Wire Rod Rolling

1. Piling of Steel Head

The Reason:

1) The friction of the rolling groove after changing the roll and groove is too small, causing the head of the rolled product to slip;

2) The head of the rolled product is tilted out of the rack, causing it to fail to bite into the downstream rack or the head guide position smoothly;

3) There are foreign objects in the rolling groove or guide groove;

4) The billet is severely out-of-square, unable to enter the rolling mill or take out the outlet pipe;

5) The blank is split out of the guide or wrapped around the roller.

Solution:

1) Increase the groove friction when changing rolls and grooves. Grind the grooves with the grinder or use spot welding, and turn off the cooling water of the rolls until they are completely bitten.

2) Check whether the guide base is loose and whether the rolling line is centered, and replace the old guide in time.

3) In the rolling process, timely clean up the oxide scale;

4) In the rolling process, unqualified billets are removed in time, and splitting occurs. Emergency stops should be taken as soon as possible to reduce the waste steel processing time.


2. Piling of the Middle and End of the Rolled Piece

The Reason:

1) Due to improper roll gap setting caused by improper size of rolled products, stacking steel;

2) Defects of the billet, such as inclusions, bubbles, etc., are broken during the rolling process and cause stacking of steel;

3) The speed of the rolling mill is improperly designed, and it is in the state of stacking and rolling. When the first half of the rolled product is maintained by the front rolling mill to maintain micro-tension rolling, when the tail of the rolled product leaves the front rolling mill, the tension is suddenly lost there, causing the stack at the stand tail;

4) Sudden increase or decrease in speed of the rack motor caused the stacking of steel;

5) The roll was suddenly broken or the guides were severely damaged in the first few passes, which caused the stacking of steel.


Solution:

1) After changing rollers and grooves, accurately set the groove bottom, correctly measure the diameter and speed of the rollers, and reduce speed errors

2) Strengthen the inspection of unqualified blanks;

3) Correctly adjust the tension between each frame;

4) Inspect electrical equipment and replace damaged electrical components;

5) Check the amount of roll cooling water, adjust the steel temperature, and prohibit rolling of low temperature steel and blackhead steel.


3. Piling steel between Finishing Mill Stands

The Main Reason:

1) The guide wheel does not rotate or the bearing burns;

2) splits of rolled products;

3) The guide or roller ring is incorrectly installed;

4) Improper roll gap setting or improper incoming size;

5) the roller ring is broken;

6) The broken line causes the rolling line to break automatically.


Solution:

1) Replace the guide, and strengthen the correctness of the guide installation;

2) Strengthen the blank inspection and lengthen the cutting head;

3) Recheck and adjust the roll gap;

4) Replace the roller ring and check the cooling water pipe at the same time;

5) Check the switch at the fishing line pendant, check whether there is scrap steel in the guide of the finishing mill. If there is any, it means that the previous one has piled steel in the finishing mill, and reset the roll gap in the finishing mill.

What we can do:

We are specialized in manufacturing high-speed morgan wire rod mill, high-speed rebar rolling mill, TMT rolling mill, high-speed gearbox, hard-faced gearbox.

We also provide complete design for your rolling mill workshop, not only turnkey project but also tailor-made service.

And we provide all the parts for roughing rolling mill, intermediate rolling mill process, including pinch roll, all kinds of shears, laying head, all of these crucial parts work extremely precisely and reliably.

If necessary, please feel free to contact me. Email: marketing2@hanrm.com

Classification and Development of Direct Rolling and Hot Feeding

The real direct rolling is to roll the continuous casting slab sent from the continuous casting machine directly into the final product without any other heating or heating process. However, for many years, most of the production process research and tests for producing high-quality products have reheated or reheated the continuous casting slab before rolling.

Continuous casting slab hot feeding and hot charging and direct rolling technology are new technologies under development, and the specific characteristics are as follows:

Continuous casting slabs are directly rolled without heating or supplemental heating, referred to as CC-FDR, and are classified into 1 type. Under the condition that the surface temperature is above 820 ° C (the core is above 960 ° C), the continuous casting slab is directly sent to the rolling mill without any form of heating and supplemental heating, and without building a heating furnace. The slab has not undergone the γ-α-γ phase transformation recrystallization process before rolling, and the as-cast coarse austenite grains are still retained. The trace elements Nb and V do not have the precipitation and re-dissolution processes in conventional cold-loading furnaces, so they must be developed. A new rolling process to obtain a grain-refined structure.

Continuous cast slab rolling, referred to as CC-DR, is classified into 2 types. The continuous casting slab is directly sent to the rolling mill through the corner heating device during the conveying process without passing through the heating furnace under the conditions above A3 temperature.

Continuous casting slab hot direct rolling, referred to as CC-HDR, is classified into 3 categories. The continuous slab temperature is above A3. The slab does not pass through the heating furnace. During the conveying process, the rollable temperature is reached by supplementary heating and soaking, and it is directly sent to the rolling mill for rolling.

Continuous hot-rolling of continuous casting slabs, referred to as CC-DHCR, is classified into 4 categories. The continuous casting slab temperature is below A3 and above A1, and the casting slab is directly sent to a heating furnace for heating and rolling. Due to the high temperature of hot charging, it is also called red delivery, and the heating furnace acts as a buffer between the continuous caster and the rolling mill.

Continuous hot-rolling of continuous casting slabs, referred to as CC-DHCR, is classified into 4 categories. The continuous casting slab temperature is below A3 and above A1, and the casting slab is directly sent to a heating furnace for heating and rolling. Due to the high temperature of hot charging, it is also called red delivery, and the heating furnace acts as a buffer between the continuous caster and the rolling mill.

The continuous casting slab cold rolling furnace is heated and rolled, referred to as CC-CCR, and is classified into 6 categories. This is the conventional rolling method when there is no hot-feed and hot-fill process.