CRM Complex(Tata Steel Ltd.

Jamshedpur), equipped with its continuous Pickling-Tandem

cold rolling mill for HR coil, Electrolytic Cleaning Line to remove Rolling-oil from sheet, Batch
Annealing Furnace, Temper/Skin Pass Mill, inspection Line & Zinc Coating line as major
production Processes.

The Continuous Pickling Line:

In the Hot rolling process the hot slabs are rolled into coil form. During the hot rolling
process the coil (iron) surface comes in contact with the air (oxygen) and thus forms an
oxide layer over the coil surface. The oxide layers are of mainly three types depending
on amount of oxygen the iron (base metal) comes in contact with (detail shown in figure
different oxide layers). These oxide layers also acts as coating on the coil surface which
stops further oxidation. That is the reason why the hot rolled coils can be stored for
longer time.

Hardest layer
Softest layer

Fe2O3 (515%)
Fe3O4 (1015%)
FeO (7580%)
Base metal

Different oxide
layers
Before any further rolling/ thickness reduction it is essential to remove the oxide layer first.
Oxide removal is done by a process called Pickling. In case we dont remove the oxide layer
before cold rolling, then while rolling the oxide layers (scales) will separate out and will generate
surface imperfection. The rolled coils thickness will not be uniform and during rolling it may also
damage the rolls of the cold rolling mill.
The Word continuous itself is self explaining that in this pickling process does not stop
between processing of two the consecutive HR Coil. In CRM Complex HR coil received from
Hot Strip Mill & the processing of HR Coil starts with its Pickling.

Continuous Pickling Line: The Overview

The Entry
1. POR (Pay of Reel): The HR Coil Coming from HSM is feed as per schedule in POR.
POR used to uncoil the HR coil for pickling. Maximum Coil weight can be processed is
28 MT (Max.) with Outer diameter 1000-2100 mm. The diameter of POR is and
expendable +/- mm. Pickling Coil width can be feed is 800-1580mm
2. Pinch Roll: This roll is used to push the strip to the line initially till it welded to next coil.
3. Leveler cum Straightner Roll: This is a five set of roll used to flatten head portion of HR
coil for welding.
4. Dividing shear: This shear is used to cut the HR coil fish- tail end & Head-end so that it
can be feed perfectly in the next process of the mill.
5. Side Guide: Side-Guide keeps the strip align to rest part of the mill. It uses the CPC
system feedback to control the strip.
The Welding
6. Pneumatic Flash Butt Welder: Flash welding is a type of resistance welding that does
not use any filler metal & an electrical resistance based butt welding process used for
joining components end-to-end across the full joint area. The parts to be joined are
clamped and brought together slowly while a flashing voltage is applied. The pieces of
metal to be welded are set apart at a predetermined distance based on material
thickness, material composition, and desired properties of the finished weld. Current is
applied to the metal, and the gap between the two pieces creates resistance and
produces the arc required to melt the metal. Once the pieces of metal reach the proper
temperature, they are pressed together, effectively forging them together. The Advantage
of Flash Butt Welder us
a. Strength of FB joint is almost equal to parent Material.
b. Less prone to Acid attack.
c. Failure rate < 10 %.
d.

The defects like porosity, inclusions & lack of fusion are eliminated.

In the Pickling Line HR coil ends are joined at welder by flash welding Process. The
Rotary-shear cut the ends again at welder for final welding process. Then a gap of 1mm1.5mm is adjusted between the ends to be welded & voltage is applied to generate arc &
a butt force is applied to join the material.
Welding time: 2mm thickness (7sec max.), 6mm Thickness (18 sec Max.)

Thickness Ratio: Both coils which are being welded have thickness difference not more
than 30% or 1 mm whichever minimum.
Width difference: Maximum 200mm width difference is allowed between both coils.
7. Trimmer: Trimmer removes the extra material from weld portion and brings the
thickness of weld portion almost equal to the strip thickness.
8. Punching: Here a hole is created by punching the sheet just after weld so that weld
portion of coil end can be detected in subsequent process by sheet hole detectors.
9. Notcher: This creates notch at the weld edges so that the stress concentration reduces
at weld edges due to strip tension & prevent any strip breakage or weld failure.
10. Side Guide: Side-Guide keeps the strip align to rest part of the mill. It uses the CPC
system feedback to control the strip.
11. Welding Inspection Point: Here the welding is being inspected for any welding defect.
12. Bridle#1: Bridle #1 Consist of two set of roll, called entry & exit bridle roll #1. The
purpose of bridle #1 is to maintain the strip tension in entry looper to bridle#2.
13. Entry Looper: Looper used as buffer for next process after bridle. The effective length of
looper is 480 meters.
14. Bridle roll#2: Bridle #2 Consist of three roll set-up. The purpose of bridle #2 is to
maintain the strip tension in pickling line in tension leveler.
HR Coil Scale breaking process
15. Wringer Roll: Tension leveler unit is just after bridle#2 rolls. It consists of one pair of
wringer roll at entry of tension meter unit. Purpose of these roll are __________.
16. Scale Breaker: Tension leveler has a six roll set-up after wringer called scale breaker.
Purpose of these rolls is to break the hard scale on HR coil providing deformation of
sheet. By action of these rolls strip elongation occurs up-to 0.65%

Back-up Rolls
Strip
Work Roll( Smaller dia than back-

The scale breaker roll

17. The tensiometer roll: This is used to detect the tension of the strip between bridle #2 &
#3. It is consist of load cell to detect the tension in the strip.
18. Camber Unit: It consists of 5 roll set after tensiometer roll. Purpose of these roll are
_____.

Back-up roll

Strip

Work roll
Camber Unit

19. Cooling system of strip: In tension leveler unit after each roll set the nozzle for water
spray of strip is available. This water cool the strip as heat generated in strip by
deformation.
20. Wringer roll: After camber unit again a set of wringer roll exists for squeeze out the water
from strip surface.
21. Bridle Roll#3: This roll set is used to maintain tension in pickling process line. The

elongation required for scale breaking and leveling can be obtained by creating a speed
difference between bridle rolls # 2 and 3 through a planetary differential gear driven by
stretching motor in the mechanically tied driving system.
Pickling Process (Shallow bath Type)
22. Pickling bath: Four nos. of pickling tank exist in pickling line where HR coil-oxide layer
(of thickness aprox. 10-16 micron depends on coil chemistry) removed by action of HCl
acid. In pickling tank following reaction occurs between acid & oxide layer:

Fe2O3 + 4 HCl

2 FeCl2 + 2 H2O + ( ) O2

Fe3O4 + 6 HCl

3 FeCl2 + 3 H2O + ( ) O2

FeO + 2 HCl

FeCl2 + H2O

Fe + 2 HCl

FeCl2 + H2

Inhibitor also used in pickling tank about 0.20% to avoid over pickling when line stops or
slow down. It react with increase Fe near the strip and make compound over strip surface to
avoid reaction of acid to strip.
Pickling tank is lined with refectory brick. The dimension of tanks are____. The volume of
tank is ____. The strip gets dipped in to the acid bath at a level ___ from surface. The
pickling time reduces with increase in acid concentration .But this is only valid up between
5% weight and 11% weight of the acid concentration. The acid concentration kept varying in
different tank. The temperature to be maintained approximately 80 degree centigrade.

Tank #4

Tank #3

Tank #2

Tank #1

Entry short Tank

Before the entry of the strip into the first tank, an entry tank is provided in which entry
wringer rolls , two water spray nozzles and an acid spray nozzle is provided .The wringer roll
is open in normal running .During line reverse jog operation the wringer rolls are actuated to
close by pneumatic cylinders, which prevents the acid backflow.
The pickling tanks are separated by skids, which separate the tanks, are higher in
configuration as compared to the intermediate skids. The Dam roll prevent acid carryover to
the next tank. Dam roll #1 is not in touch with the strip in normal line operation .There is an
offset of 200 mm provided in squeezer rolls #2, 3, 4 to avoid stretches on strip due to friction
with ceramic skid cap.
The dam rolls during operation are lowered by their self weight and are lifted up by
pneumatic cylinder during strip lifting and maintenance. The dam roll on the strip exerts an
approximate load of 50 kg and this value is maintained by counter weights. The gap of dam
roll to skid is fixed by the jack bolt arrangement provided outside the tank.
Hold-down roll is at exit side of the tank # 4. This roll helps in maintaining the pass line of the
strip inside the acid .This is in up condition in normal running and is actuated by a pneumatic
cylinder (operating cylinders are below the roll, so that their extension makes the roll up).In

case of heavy load coming on the roll because of the strip, stoppers are provided to restrict
its movement.
For working tank acid storage system made as: from Pickling Tank#1 & 2 Waste pickle liquor
tank# 2 is used. For pickling tank 3& 4 storage is made WPL# 3. For entry short tank
storage tank is WPL#1 is used.
23. Rinsing Bath: Rinsing section consisting of four tanks provided with water spray headers

located above and below the pass line. Water is cascaded from tank # 4 to Tank # 1 and
also is re circulated in each tank. Fresh hot water added in Tank #4 through the first three
headers and drained from Tank # 1.
Tank No.

No. of

Nozzle per

No. of

Nozzle per

Flow Rate/

Header(Top)

Header

Header

Header

Nozzle

(Top)
Tank #1
Tank#2
Tank#3
Tank#4

5
5
5
4+3

9
9
9
9

(Bottom)
5
5
5
4+3

(Bottom)
9
9
9
9

9.96 Lt/min
12.64 Lt./min
12.64 Lt./min
12.64, 1.96 Lt/ m

The input water having quality parameter as Temp, pH & its chloride to be maintained. The
chloride norms for input water in rinse tank#4 is the 5.0 PPM (max.) and for pickled surface
5.0 PPM (max.). Excess chloride in pickled surface leads to rust formation as chloride ion
has tendency of salt formation which cause moisture absorption from atmosphere.

Tank #4

Tank #3

Tank #2

Tank #1

Weak Acid tank

To avoid carry-over strip goes through a pair of squeezer roll after each rinse tank to
maintain the water quality of each tank. The pressure maintained is 6 kg in each squeezer
roll. Finally after rinse tank#4 the strip goes through 2 pair of squeezer roll before dryer.
24. The Dryer Section: Two dryers are provided to dry the water from the strip. Both dryers

are similar in construction .Fresh air addition can be adjusted manually by damper .V

type headers are provided for the wiping of the water from the strip .The normal
temperature of the dryer air will be around 120 0 C as the air is re circulated. Due to re
circulation the initial heat up is less, thereby reducing the energy consumption .Air is
blown at 110 m3/minute. For each dryer the one blower is given for suction of air & and
another for discharge
Side trimming Process
25. Slitter facility is available in Pickling line to give the width as per customer requirement.
Both edges can be trimmed by cutter given of diameter. This cutter does not have any
drive. The configuration of cutter explained in figure below
Top cutter

Horizontal gap

Vertical Overlap/ Gap

Bottom cutter
Cutter allowable diameter is 400-430mm. Diameter reduces after grinding of the
cutter. Thickness of the cutter is 25-30mm. The Horizontal gap and vertical overlap is
adjusted as per thickness & grade of the coil.
The Vertical Overlap: (-0.35 mm) for
Horizontal Gap:

Thickness 2.00-3.9 mm

(-0.25 mm) for

Thickness >4.00 mm

(+0.23 mm) for

Thickness 2.00-2.4 mm

(+0.27 mm) for

Thickness 2.50-3.00 mm

(+0.33 mm) for

Thickness 3.0-3.40 mm

26. ARP (Acid regeneration plant) & Utilities are also an subject for study in pickling line.
ARP provides regenerated acid from WPL of a concentration 18%. Boiler used to
maintain temperature in varies processes parameter.
Roll Grinding shop
Diameter difference of SPM work Roll pair=0.60micron (Max)
Diameter difference of SPM work Roll pair=0.70micron (Max)