HBIS Tangsteel broke the traditions in technology and equipment introduction. With the combination of Danieli caster, Bricmont roller hearth heating furnace, Mitsubishi PC mill and other technologies, HBIS Tangsteel has formed an ultra-thin hot strip production line with a price of 30% lower than CSP technology , and the engineering equipment localization rate is up to 84%, thus breaking the monopoly of CSP technology in the Chinese market, and the international thin slab casting and rolling efficiency and production process reach a new level.
Through ongoing optimization and innovation of introduced advanced technology, HBIS Tangsteel develops the low-carbon steel ferritic rolling, mixes rolling of slabs of different thickness. achieve outlet, fluxes, funnel-type mold re-innovation and key refractory localization, and it has 19 independent intellectual property rights. Especially the application of dynamic liquid core reduction technology enables the 90mm thickness mold to be applied to the continuous casting machine for the production of 90-65mm slab, that makes HBIS Tangsteel became the world first enterprise that can produce flexible thickness slab. The successful application of hot rolled thin strip semi-endless rolling technology and short-flow ferritic rolling technology fill gaps of domestic steel industry. The continuous casting fluxes and long nozzle fully achieved localization. Stopper localization rate reached 70%. The technology reached the international advanced level. The "technical integration and independent innovation of ultra-thin hot strip production line" project won the 2006 National Science and Technology Progress Award.
The project is a scientific supporting project for national "Eleventh Five-Year" undertaken by HBIS Tangsteel and participated by North China University of Science and Technology China Iron and Steel Research Institute Group, University of Science and Technology Beijing. This project has two sub-topics "Low-pressure residual heat and steam power generation technology and energy system optimization", "Liquid slag modified and gas quenching process technology".
"Low-pressure residual heat and steam power generation technology and energy system optimization", which focus on flue gas heat transfer mechanism and heat transfer model, enhanced heat transfer and efficient sintering heat recovery technology, the efficient recycling utilization of converter gas residual heat, steam and power generation system performance analysis and steam parameters matching analysis, and HBIS Tangsteel has solved lower heat recovery efficiency of the low pressure residual heat and steam power generation project and also the poor stability problem. On the basis of the key technology research, HBIS Tangsteel has constructed of standard model projects: one 25MW sintering heat generators; one 15 MW converter low temperature heat generators. Converter project can generate12kW/h of each ton, sintering project can generate 18kW/h of each ton, which reached a leading domestic level.
"Liquid slag modified gas quenching process technology", which has constructed pilot project in the Medium plate company of Hesteel Tangsteel with processing 300,000 tons of slag annually, and it has completed the industrialization program design and construction of model program.
The project has applied nine patents and was granted seven authorizations (four inventions, 3 utility model); developed one gas quenching&granulation automatic control software; published 39 academic papers; won the Second Prize of 2013 National Science and Technology Progress Award.
The project focuses on technology introduction, technological innovation and transformation that related to clean production, and makes comprehensive improvement of factory and on-site environment, optimizes plant layout, so the material and energy flow can be fully optimized, takes international level of cleaner production as the highest standard, fully realized energy conservation and emission reduction. Through the utilization of slag gas quenching and low pressure residual heat, efficient recovery of gas and steam, and also network unified remediation measures, which makes comprehensive energy consumption lower than the First Level of cleaner production indicators; By adoption of sewage water treatment and other measures, the sewage water discharge and COD emissions have reduced significantly, which makes water recycling rate reached 98.1% with far higher than the 95 % level indicators. Emissions especially sulfur dioxide dust and smog emissions, which has reduced a lot with the installation of desulfurization facilities. The project is conducive to environmental improvement, and the company has completed the country's emission reduction task; Green coverage rate has increased from 21% to 42.4% with improving the factory environment. HBIS Tangsteel’s overall level has reached the national cleaning production requirements; some key indicators have reached or even exceeded the national-level indicators. The overall project of clean production technology has reached the international advanced level, it won the First Prize of 2011 Metallurgy Science and Technology Award and First Prize of 2012 Hebei Science and Technology Progress Award.
Based the equipment and product mix and after a lot of practices and researches, the Long products department has created a platform that with high efficiency of construction long products and low cost of clean steel production. Six integrated supporting technologies: hot metal slag processing, efficient converter smelting technology, the whole process bottom blowing argon technology, stable continuous casting technology, smooth&simple "process network" technology, dynamic &orderly information technology, through the effective integration of these technologies enables the department to build a high-efficiency, low-cost clean steel production platform. Long products of construction steel manufacturing platform includes:Converter-No.5caster-No.2bar production line with an annual output 1.2 million tons, the caster effective operation rate over 96%, rolling heating furnace energy consumption 0.57GJ/t, power consumption 0.19GJ/t. Steel-making energy consumption reaches -18.92 kgce / t; about 100 minutes from the torpedo liquid iron charging to bar products listed and to packaging; converter tapping temperature from about 1655℃in 2009 fall to about 1635℃in 2010; iron and steel completed material consumption 1052kg/t (excluding steel slag), lime consumption completed 40kg/t; slab casting process changed traditional mode of supply using weigh-oriented supply, improve the finished product rate of 0.15%; 5 # 6 # caster DHCR furnace, hot charging rate reached 90% or more. All kinds of economic indicators ranks the leading place of the industry, the overall application has reached international advanced level. Project won Second Prize of 2011 Metallurgical Science and Technology Award.
Considering the processing characteristics of 1700mm casting and rolling production line, HBIS Tangsteel optimized the heating furnace and combustion systems structures, taking crown control as center with perfecting control system parameters, and formed an optimized rolling model includes: cold-rolled material, medium carbon steel, pipeline steel, silicon steel, alloy steel, oil casing steel, and automotive steel, and also applied technical method that makes high-brightness laser line light radiate to the surface of the strip and through linear CCD cameras capture the strip surface image of detection system, so that the production level, product quality and development and other aspects have made great achievements and great value, and generally reached the international advanced level.
optimization and innovation of Cold Rolling System
Through digestion and absorption of cold rolling, annealing, galvanizing production line and secondary development and innovation, HBIS Tangsteel optimized the production process, formed an independent technical and value-added production process includes automotive sheet, home appliance plate, electrical steel and others. The development of oxidation annealing board filled the domestic production gap, and cold rolled non-oriented electrical steel, ultra-thick coating plate of aluminum&zinc&silicon filled the provincial production gap; through process research and innovation, the continuous galvanizing line has achieved fast switching between continuous galvanizing line and the annealing line, the multi-coated variety fast switching, the bright annealed products and oxidation annealing products switching, and formed a flexible production line with varieties of products and fast switching of the of new technology; through innovative transformation of PLTCM, annealing and galvanized and other production units, and improvement of liquid leakage problems of the PLTCM emulsion system, it achieved plate surface cleanliness standards within shortest distance between the racks; the development of online carbon cleanup technology of batch annealing furnace, it achieved the lowest binding rates with 6.5m stacking height of annealing unit for the first time of domestic production line; the improvement of air-tightness and relief efficiency of annealing furnace, which makes surface quality and efficiency improved significantly. The project has reached international high level in continuous annealing oxide board production technology, thick coating of aluminum&zinc&silicon plate production technology, high stacking annealing furnace binding rate control technology, galvanized annealed flexible production technology.
Slitting Rolling Technology
HBIS Tangsteel introduced rebar slitting rolling technology from Baden Company, which as the international advanced level technology, but there are still some defects and deficiencies. HBIS Tangsteel optimized and improved the slitting rolling technology in the application process, developed a 4-slitting rolling pass sequence system to solve steel stack problems after slitting rolling process; redeveloped and localized of slitting guides and high speed steel rolls, developed some related technical know-how that can solve the flat steel material reverse, compensation adjustment of rolling groove abrasion, and tension adjustment, which ensures product quality stability and high production efficiency, theφ12mm rebar has reached world-class level of monthly average daily production, the overall level of technology has reached the international advanced level. Project won the Second Prize of Metallurgical Science and Technology Award.
The development of High Strength Angle
Steel of Q420,Q460 for
Using VN micro-alloying technology, through research of steel chemical composition , mechanical properties, micro-structure, welding properties, HBIS Tangsteel produced the high-strength Q420 angle steel for power transmission tower, during 2006--2011 it produced Q420 with a total of more than 200 thousand tons, which all applied to 750 kilovolt(or above) high-voltage power transmission tower manufacturing and test, Q460TB full-scale tower passed test by the national power company, and became China's first officially Transmission Project Q460TB angle supplier. The successful development of high-strength tower angle, which changed the low strength grade and heavy condition of power transmission tower, Q420 angle steel takes more than 20% of total domestic Q420 supply, Q460 angle steel takes 90 % or more a total domestic Q460 supply, which lead a dominant position of the tower angle steel in domestic. "The research and development of power transmission tower angle with the Q420 level” project won the third prize of Metallurgical Science and Technology.
The innovation and optimization of Oxygen Generation System
The project takes the optimization of oxygen generation system with energy conservation and emission reduction as the starting point, it developed a multi-product process (Exergy) efficiency analysis software, put forward the optimized operation model of modern system with multi-products, established the method of matching between multi-station oxygen generator and liquefaction device, optimized the process oxygen and nitrogen delivery system for the first time, developed independently of internal&external integration of oxygen and nitrogen interchangeable unique variable load operation strategy, which has achieved zero-emission of oxygen, nitrogen, and argon with very good demonstration effect. Since the implementation, oxygen system achieved zero-emission of-oxygen, nitrogen, argon, hydrogen, and power consumption dropped significantly, all kinds of energy get a reasonable recovery and efficient use which not only eliminates noise pollution for surrounding residents, but also gained 39.93 million yuan for every year. It has published two papers, got nine patents, won the First Prize of 2013 Metallurgical Science and Technology Award.
The Technical Innovation of Ultra-thin Hot Rolled Plate Mass Production of Thin Plate Casting&Rolling Line
Using thin slab solidification theory and modern plate steel rolling theory to make comprehensive analyze of factors that restrain thin plate stable production, HBIS Tangsteel developed the high thermal efficiency, good quality heating roller hearth furnace and regenerative combustion technology, centering technology in insulation section of the continuous casting; developed the high speed thin slab continuous casting fluxes series, mold’s key technology of non-uniformed distribution of high speed submerged nozzle and small water slits, rolling precision control technology, stable rolling technology and ultra-thin leveling technology; It has solved technical FTSR production of high-end products problems, and developed high-carbon steel, weathering steel, electrical steel, high-strength automotive steel and other typical varieties and specifications also achieved mass production; caster maximum casting speed reaches 6m / min, ranked first in domestic and second in the world; 1.6mm(or less) thickness coil ratio reached 62%, and achieved 1.0mm stable production, reached the international advanced level, and played an exemplary role to realize light weight, hot rolling replace cold rolling, and quality and efficiency improvement, won the First Prize of 2014 Hebei Science and Technology Progress Award.
The Development of FTSR Thin Slab Short Process and High Carbon Steel Production
Conventional high carbon slab production has lots of defects: decarburized layer surface out of limits, poor dimensional accuracy, uneven organizational performance, poor control of plate and coil problems, HBIS Tangsteel takes advantage of FTSR thin slab casting and rolling production technology, which brought significantly improvement of cleanliness slab, mold flux and temperature distribution, heat transfer and lubrication conditions, and the production of hot-rolled coil’s chemical composition and organizational performance fully meet the relevant standards as well as the user's requirements. The innovative technologies - mold flux performance optimization, select ion the shape of the mold and secondary cooling strong cooling process, which has been extended to the production of thin-slab with mini-low carbon steel and other conventional products, and effectively reduced the steel leakage ration, improved the slab internal quality and pass percentage of hot rolled coil with directly created 186 million yuan. The project filled the blank of FTSR short thin slab production process with high carbon content with enormous potential for development and expanding the thin slab ranges of products, promoting the metallurgical industry casting technology for further development. Project won the Second Prize of 2013 Hebei Science and Technology Progress Award.