Reducing Steel Breakages and production stoppages in a cold rolling mill plant
Key Takeaways Problem: Frequent strip breakages and stoppages in a Bangladesh cold rolling mill. Diagnosis: 360° assessment identified process and procurement issues. Solution: Optimised rolling patterns, lubrication, and roll specifications. Enhancements: Improved pickling line and implemented alternative roll sourcing. Impact: +30% productivity, USD 35M revenue increase per annum, 3 new SOPs approved. $ 0 M […]
Addressing Edge Crack Issues in Duplex Stainless Steel during Hot Rolling
Key Takeaways Comprehensive Process Analysis – A systematic review of the hot rolling process identified key factors contributing to edge cracking in duplex stainless steel plates. Enhanced Product Quality – Improved slab handling, including edge chamfering, significantly reduced edge cracks and improved final product quality. Optimised Chemical Composition – Adjusting the balance of ferrite and […]
Controlling Spangle Formation During Galvanising process
Key Takeaways Precise Process Control is Essential – Managing zinc bath chemistry, cooling rates, and substrate standards helped achieve consistent spangle formation. Optimised Temperature Management – Adjusting burners to maintain a minimum strip temperature of 500°C improved spangle consistency. Unnecessary Additives Eliminated – Removing 53 metric tonnes of tin annually saved £700K per year without […]
Reducing Longitudinal Depression and Hot Cracking in Duplex Stainless Steel Slabs
Key Takeaways Problem: A stainless steel producer in Asia faced defects in duplex stainless steel slabs due to improper casting parameters and powder formulations. Challenge: Defects led to material loss, reducing yield and disrupting downstream operations. Solution: Identified defect causes, optimised casting settings and powder formulations, and provided staff training. Improvements: Reduced grinding loss to […]