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Steel mill rolls play a vital role in the steel end product making such as Plates ,sheets Hot rolled or cold rolled through HSM and CRM process, but they experience significant wear and tear at various stages of making (Thickness reduction process) .
Steel Mill Rolls being expensive and essential spare part contributes significantly to the cost of manufacturing of steel plate ,as every stage of size reduction in typical Hot Strip Mill these rolls encounters combination of wear factors such as :
Severe sliding friction and pressure -Due to hot plate rolling over the surface for movement and due to the weight of the slab to plate at different stages of production
Corrosion – Hi Pressure water spray of 125 Bar pressure at descaling ,roughing and finishing stand of the mill.
To tackle this challenge, advanced roll cladding techniques where as per the base metal of these forged Steel Mill roll suitable weld build up is provided to resort their original diameter after wearing out up to 25-30 mm on diameter are used to improve their productive wear life and extend their lifespan. TNA specializes in maintenance and repair welding of various Steel Mill Rolls such as
ERT Rolls -Entry Run out table rolls
ROT Rolls- Run out table rolls
Furnace Rolls
Pinch Rolls -Bottom and Top at Roughing stand and Colier units
Bending Rolls- for Straightening the bend rolls during the process also called leveller rolls
Descaler Rolls-Rolles used for descaling purpose subjected to hi pressure water jet spray to remove scaling.
Increased roll life: By applying wear-resistant coatings, the service life of steel mill rolls can be extended as good at new at 55-60% cost of new roller without waiting for spares parts and maintaining huge new roll inventory cost.
Improved productivity: up 800,000 MT to 1 million Ton of rolled steel production from repaired rolls rebuild up to 35-40 mm are working successfully in various steel plants with longer-lasting rolls, steel plants can maintain consistent production schedules and minimize disruptions due to roll failures.
Cost savings: Repair, rather than replace. This is the mantra for a sustainable industry practice. Repairing and reusing the worn components helps the companies save in millions.
Cladding Techniques
TNA employs various cladding methods to protect steel mill rolls, including:
Arc welding: Techniques such as Flux cored Arc welding (FCAW) and Metal Core, gas-metal arc welding (GMAW) are used to deposit wear-resistant alloy layers onto the rolls using fully automating twin roll cladding system
Submerged arc welding (SAW): This process utilizes a wire electrode and a bucket of granular flux to deposit a uniform, high-quality cladding layer.
The choice of cladding method depends on factors such as the roll material, wear conditions, and desired coating properties.
In addition to cladding, TNA offers comprehensive roll refurbishment and reconditioning services. This includes:
Roll inspection: Using advanced techniques like ultrasound and eddy current testing to detect surface and subsurface defects.
Machining: Precision grinding to restore roll profiles and dimensions to exacting tolerances.
Heat treatment: Post-weld heat treatments to ensure proper bonding and stress relieving of the welded material.
Steel mill roll reconditioning is essential to enhance the life of the various Rollers used in Hot or cold mill process (HSM and CRM) By collaborating with Tarek Nasser Al Akeel Co. (TNA), steel plants in Saudi Arabia can take advantage of advanced cladding techniques and thorough roll refurbishment services. This partnership can help optimize their operations while significantly reducing maintenance costs. If you're interested in learning more about this reach out to us today!