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EPS vs. Acid Pickling Capital Cost Comparison
We recently completed a detailed evaluation of EPS pickling and acid pickling capital costs and are sharing the results with you in this EPS Update. When examining all components of capital costs – equipment, facility and installation – the evaluation shows that a tension-leveling EPS Coil Line project costs approximately 30% less than a push-pull, tension-leveling acid pickling line project of comparable capacity.
COMPARISON BASIS: OUTPUT
A valid comparison of EPS and acid pickling capital costs rests on the assumption of comparable output. For EPS, we can accurately model output using both the EPS Operating Cost Calulator and experience from our own EPS production line. However, we have no such tool to model acid pickling – we needed actual operating data from an acid pickler. Fortunately, some acid picklers were willing to share such data with us in the context of their evaluating EPS technology as a better solution for pickling AHSS grades.
In reviewing the data, a specific acid pickle line utilizing four acid tanks and running low carbon strip offered the most detailed cost information. We characterize this line as ‘service center duty’ because, among other reasons, it does not include a tension leveler. This acid pickle line is located in North America and was supplied from a very reputable acid pickle line equipment manufacturer. Using the data on average product (thickness and width) and tons this acid line actually processes, we found, based on our experience operating our own EPS tension level coil line, that a 2 Cell EPS Coil Line is a close match in output. This gave us the solid basis for the comparison we were seeking.
COST FACTOR 1: EQUIPMENT
While the selected four tank acid pickling line does not include a tension leveler, it is, nonetheless, a full-featured line. Like the standard EPS Coil Line, it does not use an in-line welder or stitcher to join coil ends. The cost data revealed that its total equipment cost is roughly comparable to the 2 Cell EPS Coil Line, however, that lack of tension leveling is an important difference that keeps this from being an ‘apples-to-apples’ comparison.
The EPS Coil Line is a full tension line with a tension leveler: EPS is a ‘tight line’ process so its uncoiler and recoiler provide the same overall tension as the entry and exit bridle rolls of the tension leveler found in acid pickling lines. By contrast, the four tank acid pickling line of this study featured just a basic flattener with no tension leveling at all. Therefore, to keep the lines on an equal footing, the cost of a bridle roll tension leveling system (customary for a line like this) was added to the cost of the acid pickling line. That adjustment escalates the total cost of the acid pickling line such that the 2 Cell EPS Coil Line equipment cost is 25% less than the adjusted
acid pickling line equipment cost.
COST FACTOR 2: BUILDING
This factor is straightforward: it’s simply the footprint of each pickling line. The drawing of the acid pickling line indicates the crane-served area of the line is 313 ft. x 80 ft. for a total area of 25,040 sq.ft. The comparable numbers for the two cell EPS Coil Line are 165 ft. X 75 ft. = 12,375 sq.ft. Yes, there is more to the building than the uncoiler-to-recoiler sections of the lines. There are line services that do not have to be ‘under crane ’ like acid regeneration and EPS water filtration. But such areas are essentially equivalent in size since the two lines have equivalent output.
So the important difference is 25,040 sq.ft. for acid and 12,375 sq.ft. for EPS: the acid pickling line requires 2X the under crane space as the EPS line does, so it has 2X the building cost. At a building cost of $100/sq.ft. (a reasonable number for an industrial building with foundations, columns and rails to support 50 ton cranes), that is a difference of $1,266,500 more for an acid pickling line.
COST FACTOR 3: INSTALLATION
When it comes to installation costs, we are very confident of the EPS Coil Line cost data. After all, we’ve just recently installed a tension leveled EPS coil line in our own facility and have been involved in many more installations at customer sites.
We were not as confident about the acid pickling line scope, but we got valuable help from those same acid picklers. Bottom Line: an EPS line costs approximately 30% less to install than an acid pickling line of comparable output. That difference is easy to understand, because the acid pickling line simply has more components to be installed and connected plus the acid pickling line is almost twice as long. The acid line has separate pre-wash and post-wash systems that the EPS line doesn’t, plus the bridle rolls for tension leveling. The acid line has heaters, scrubbers, fume extraction systems, plus many more sets of pinch rolls that are not needed for EPS. And finally, there is just more plumbing – valves, piping, filters, etc. – needed for an acid pickling line. The cost of installing all this additional acid pickling equipment really adds up.
SUMMARY
For pickling of low carbon coils up to 0.250”, EPS has the cost advantage over a tension-leveling push-pull acid pickling line of comparable capacity in each category:
- 25% lower equipment cost
- 30% lower installation cost
- A $1.27 million savings in building cost
Combining these factors together, the EPS line capital cost is roughly 70% of the acid pickling line costs. If you introduce high carbon, alloy steels, AHSS and silicon steels into the mix, the EPS capital cost advantage becomes even greater. Why? Because while the EPS line’s output would be lowered modestly for these grades, the acid pickling line’s output would drop dramatically (see details). To raise the acid line’s output back to parity would necessitate additional acid tanks, more building space and greater installation costs, while the EPS’s equipment cost would increase only marginally.
For more details of the study, please contact Chris Liefer at 618-282-4200 xt 103 or by email.
EPS’d Stay Flat Dry Plate Production Line
Users of large plate – up to 25mm (1″) thick – would absolutely love a dry, scale-free, stay flat product. TMW has developed a new Cut-to-Length (CTL) line configuration that will deliver exactly that at an affordable price.
ConAg equipment, rail car, tank/vessel manufacturers and other users of large plate sections can really appreciate a dry, scale-free product. It would simplify their paint prep, keep their shops much cleaner and eliminate blasting operations. But it’s a product that is very difficult to source because there are few acid pickling lines that can run material over 12.5mm (0.50″) thick and few CTL processors who can turn coils of 12.5mm – 25mm (1/2″ – 1″) material into sheets.
Why not combine the pickling and CTL operations into a single processing line? That’s exactly what our new patent-pending** development does. Integrating a smaller EPS Cell into a heavy gage Stretcher Leveling or Temper Pass CTL line creates an efficient, compact CTL line that produces ‘stay flat’, dry, rust-resistance plate up to 25mm (1″) thick. The illustration below depicts this system and you can watch a short video animation of the concept by clicking here.
An Integrated EPS CTL Line for Plate Up to 25mm (1″) (click to enlarge)
As the illustration shows, the EPS Cell extends the length of the heavy gage CTL line by a small amount. Better yet, it presents only a modest increase in the line’s capital cost because it uses the Version 6 EPS Cell with only 4 Slurry Turbines – two above the plate and two below – instead of the normal 8. Fewer Slurry Turbines can still achieve the needed scale removal at attractive line speeds for a CTL line handling 12.5mm to 25mm (1/2″ to 1″) material. If the plate only needs to be ‘cleaned up’, rather than thoroughly pickled, the speed can be increased up to 3X. And for orders that require no descaling, the EPS Cell is simply turned off and the line operates as a normal CTL line.
While our depictions of this CTL show the 4 Turbine EPS Cell paired with a Heavy Gage Stretcher Leveler (a combination which produces the popular EPS Unlimited product), the concept also applies to a Temper Pass CTL line. Either way, the product is a thoroughly pickled, dry, rust-resistant plate product with an optimized surface that provides superior paint performance and appearance. The EPS surface also eliminates or minimizes many typical mill defects, giving you a uniform, lustrous finish that you just won’t find on other plate products.
If you’d like to learn more about this innovative concept, please contact Chris Liefer at 618 282-4200 ext. 103 or chris.liefer@thematerialworks.com.
** US Patent App. No. 15/968,107
EPS Direct and EPS Operating Costs – An Update
Sixteen months ago we announced the EPS Direct program – complete EPS Coil Lines, both EPS Cells and the terminal equipment – sold, serviced and guaranteed by TMW. EPS Direct takes the high-performance Generation 3 EPS Cell, matches it with optimized terminal equipment and introduces advanced controls and automation. This brings the entire EPS processing line to a higher level of throughput and lower operating costs. Another important goal of EPS Direct is to simplify operation and maintenance of this environmentally friendly pickling line to a level typical of a cut-to-length or slitting line.
The first installation of an EPS Direct line has been running for 12 months in the TMW Technology Center. We have carefully collected operation and performance data, tested the line’s new features and controls, and painstakingly analyzed its total costs of operation. This update is a summary report of that work.
EPS OPERATING COSTS
For quite some time the EPS Cost Calculator has been available to provide projected EPS Cell operation costs for different configurations and materials. It was recently updated to reflect the latest results from our Generation 3 Cell. However, the Cost Calculator, while very useful, tells only part of the story because it doesn’t include terminal equipment operating costs which, of course, will vary by manufacturer.
Our one-cell EPS Coil Line has run thousands of coils of a wide variety of sizes and grades, from low carbon to AHSS, stainless to silicon steel. Our production mix even includes EPS’ing high strength coils for acid picklers.
We generally run a single shift with a two man crew who operate and maintain the line 5 days a week. Each month, all variable costs of operation are captured and allocated over the tons processed that month. This approach captures the costs of the EPS Cell and the terminal equipment. Here’s what we found with the material we processed over the last several months:
- Average thickness: 0.130″ (3.30 mm)
- Average coil width: 53″ (1346 mm)
- Average $/ton revenue: $26.40/ton
- Average EPS Cell variable cost: $9.89/ton
- Average Terminal Equipment variable cost: $3.20/ton
- Total EPS Coil Line variable costs: $13.09/ton
These cost rollups, which reflect running a majority of low carbon steel coils, capture everything: grit, water, electricity (pretty expensive for us at $.12/kw-hr), labor – even maintenance, consumable parts and paper wrapping of finished coils. But beyond these numbers are some important developments that we want to share . . .
– EPS CELL COSTS –
While the Generation 3 EPS Cell does not (yet) process material any faster than its predecessor Generation 2 Cell, it does have enhancements that both reduce maintenance costs and extend the period between maintenance points (see “Armour-Plated EPS“).
In addition, we had upgraded the Slurry Turbine motors from 150 to 190 horsepower hoping it would allow us to use a smaller grit size and achieve a slightly better distribution across the strip width. However, there was no meaningful difference, and we are returning to the 150 horsepower motors in order to minimize electricity consumption.
Our Generation 3 EPS Coil Line features the simplified Filtration System that eliminated the magnetic separator section and all of the maintenance it entailed. We upgraded the filter media we use and now our rinse water is so clean that a $220,000 ‘Post Brush/Rinse’ at the end of the line is no longer needed. In another respect, the new filtration media works too well – it actually traps some of the slurry additive and carries it out with the scale sludge. However, we found a way to extract that additive from the filter media and keep it in the system, so there’s no net cost increase for additive.
The new filter media is more expensive than its predecessor and that is reflected in the updated EPS Cost Calculator. The good news is we believe we’ll be able to cycle the new filter media through the system twice, thereby achieving a net savings. (Note that the $13.09/ton total line operating cost includes the 150 horsepower turbine motors and conserving the additive, but does not include running the new filter media through twice).
– COIL LINE AUTOMATION –
Part of the EPS Direct package is a state-of-the art Siemens control and monitoring system that automates many tasks that were traditionally managed by line operators. This system has exceeded expectations: a level of automation has been achieved that it takes just two workers to run the line and they have time to perform the material handling chores and most of the regular maintenance inspections as well.
In fact, as one coil finishes and the next coil is staged on the coil car, the new control system performs entire coil change process in as little as 3 minutes with no operator involvement. The operators band and move coils in and out of inventory and check logs, while coils are loaded and processed nearly unattended. The coil more quickly ramps up to optimum speed and runs that optimum speed automatically. This all makes for higher net run time than was possible before which is reflected in the EPS Cost Calculator.
And to conserve energy, the new controls also power off virtually every pump and motor in the system any time there is not material moving through the cell.
SUMMARY
EPS Direct and the Generation 3 EPS Coil Line brought together ideas, equipment and automation to optimize performance of the entire EPS processing line. The last 12 months of operation have refined those factors and captured the actual operating costs of an entire Generation 3 EPS line. We’ve found that it continues to compare favorably with acid pickling costs, plus we see opportunities for further cost savings that we intend to share in future updates.
If you would like to schedule trial coils or a visit to watch our EPS Generation 3 Coil Line in operation, please contact Chris Liefer at 618 282-4200 ext. 103 or chris.liefer@thematerialworks.com.
New EPS Installations Around The World
The last months of 2017 and beginning of 2018 saw new EPS production lines begin operation, while orders were placed for additional systems that will bring worldwide EPS capacity to 4 million tonnes per year. A summary of the new capacity is provided below. To see all EPS installations visit the EPS web site.
NEW EPS PRODUCTION LINES ENTER OPERATION
The two-cell EPS Coil Line at the new Talleres y Aceros (TYASA) steel mill in Mexico completed commissioning in October 2017. This line can descale up to 350,000 tonnes annually, most of which is Castrip – produced on-site and poured from the world’s first Simetal EAF Quantum electric arc furnace.
Another two-cell EPS Coil Line entered operation just last month in Russia. This line has a capacity of 400,000 tonnes annually and descales product which is first cold reduced. After EPS processing, much of the product goes to different coil coating processes.
Xinyu Bishui Steel Strip Company, Ltd. of China is completing startup of their three-cell EPS Generation 3 Coil Line. This line features the first EPS Cells built by TMW-Jingu, our joint venture company in China. ‘Bishui’ uses acid pickling in their existing plants, but for this new toll processing facility, which also performs cold reduction, they wanted the economic and environmental benefits of EPS. This EPS line has a capacity of 550,000 tonnes annually.
The Xinyu Bishui EPS Coil Line in Final Stage of Startup
NEW EPS PRODUCTION LINE ORDERS
Kama Trade Tatarstan, LLC. is a Russian service center that serves the automotive, railroad, bridge and crane construction and shipbuilding industries. It has opened a new service center focused on EPS processed sheet and plate from 3 to 25mm thick. Their single-cell EPS sheet line, capable of 150,000 tonnes annually, is expected to be operational January 2019.
The Todoaceros Service Center division of Spain’s Network Steel Resources ordered a single Generation 3 EPS Cell which will be integrated into an existing coil processing line manufactured by Red Bud Industries. The line is unique in that the EPS processed material can be produced in either coil form or in sheet form by activating a downstream flying shear. The EPS cell, with capacity for 240,000 tonnes per year, is scheduled for operation in March 2019.
AND CLOSER TO HOME . . .
One year ago we started up the first Generation 3 EPS Cell in our EPS Coil Line at the TMW Technology Center in Red Bud, IL. Since then, hundreds of visitors from steel mills, processors and manufacturers have witnessed this line successfully descale many ‘hard-to-pickle’ grades that confound acid picklers. Recent examples include:
- martensitic AHSS,
- 6150, 4140, Ck75m2,
- grain oriented electrical steel,
- high nickel content alloy steel
We’ve also ‘recovered’ coils by processing them to remove surface issues (like onion skin), including one coil that was accidentally copper plated. And, of course, we have pickled thousands of tons per month of low carbon, high carbon, and HSLA used in every fabrication and manufacturing process you can name
The EPS Coil Line at TMW is the Answer for ‘Hard-to-Pickle” Steels
If you would like to schedule trial coils or a visit to watch our EPS Generation 3 Coil Line in operation, please contact Chris Liefer at 618 282-4200 ext. 103 or chris.liefer@thematerialworks.com.
Castrip is a registered trademark of Castrip LLC.
New Slitter Investment In Response To EPS Demand
Today, we are pleased to announce that we will be expanding our slitting capacity in 2018. A new, state-of-the-art Slitting Line from Red Bud Industries will be installed in TMW Plant #2, near the new Generation 3 EPS Pickling Line. The line will process material from 0.030″ to 0.315″ thick from master coils of up to 60,000 lbs. It is expected to be operational late 3Q 2018.
What’s notable about this Slitting Line investment is that the EPS Coil-to-Coil Line has been the primary catalyst for it. We are now EPS pickling a large number of coils and are on the way to becoming a sizable ‘pickling center’, receiving barge loads of material from mills in the Midwest and Midsouth. Many of our EPS customers want their EPS product to come to them as slit coils ready to use without further processing. It became apparent that this demand would eventually outstrip our current slitting capacity, so the investment case for a new slitter was easily made.
This situation parallels one explained in an earlier EPS Update that prompted our decision to increase capacity of our Stretcher Leveler Cut-to-Length lines. That was done to meet the growing demand for EPS Unlimited sheet product. Although we had produced EPS Unlimited for over 3 years using our EPS Sheet Line, the much higher throughput of the EPS Coil Line foreshadowed a day when we would outstrip our Stretcher Leveling Cut-to-Length capacity. In that case, capacity increases to our two existing Stretcher Leveler CTL line was the stronger investment case than a completely new line.
But here’s the takeaway: investment in EPS production capacity should be considered based on two factors:
- The economics of the EPS line itself, based on providing its premium pickled product to your customers (see EPS Cost Calculator for estimates);
- The additional volume you stand to gain on your other processing lines as a result of offering EPS.
Growing EPS Unlimited Demand Drives Stretcher Leveler Upgrades
TMW has invested in new equipment to increase its Stretcher Leveling Cut-to-Length capacity to meet the growing demand for the EPS Unlimited product. The work is being carefully staged to be completed by July 2018 with no interruption in service to TMW customers.
We started up our Generation 3 EPS Coil Line in March, knowing there was immediate demand for EPS coils. However, the demand for EPS Unlimited – the Stretcher Leveled EPS sheet product – really took off at the same time. EPS Unlimited is our unique application of EPS Pickling and Stretcher Leveling to produce an ultra-clean, oil-free, ‘stay-flat’ sheet product for which we provide this guarantee:
EPS Unlimited will meet or exceed the performance of:
• Acid Pickled & Oiled • Acid Pickled Dry • Hot Roll Black
• Temper Passed • Roller Leveled
against these criteria:
• Paint Adhesion • Paint Corrosion
• Laser Cutting Speed • Flatness After Lasering
or we buy the steel under our money back guarantee.
With a wider EPS thickness range of 1.2 mm – 9.5 mm and flexibility to EPS in coil, demand is growing quickly..
To meet our increased demand, we are upgrading our heavy gauge Stretcher Leveler with a new roller leveler, shear, threading system, stretcher frames and PLC controls to increase its overall capacity. We will make similar upgrades to our lighter gauge Stretcher Leveler, both increasing its throughput and allowing it to stretch material up to 4.7 5mm”.
If you would like to discuss the advantages of EPS Unlimited, run trial quantities, or receive a processing quote, contact Chris Liefer at 618-282-4200 ext.103, or email Chris now.
EPS Generation 3 Technology Now In Operation
We are pleased to announce that on February 6, 2017, the most advanced EPS technology platform – the EPS Generation 3 Coil Line – processed its first coil at the TMW Technology Center in Red Bud, Illinois. This debut of the integrated, seamless new TMW-supplied EPS Coil line features:
The first coil to be run through the line is shown below. Click on the photo for larger view.
In previous updates, we provided details of how the Generation 3 Coil Line:
The line is now pickling production coils while the many new innovations are being ‘tuned’ for optimum production performance. We are now receiving trial coils and will be accepting visitors at the completion of the startup phase.
If you would like to schedule trial coils or a visit to watch the new EPS Generation 3 Coil Line in operation, please contact Chris Liefer at 618 282-4200 ext. 103 or chris.liefer@thematerialworks.com.
Announcing EPS-Direct – Complete EPS Lines Sold and Guaranteed by TMW
Effective today, The Material Works Ltd. (TMW) is offering complete EPS Coil Lines sold, serviced and guaranteed exclusively by TMW. We call this offering EPS-Direct and it will ensure that the customer gets the very best that EPS has to offer. The EPS-Direct process will also simplify and shorten the process of ordering, installing and commissioning environment-friendly EPS lines around the world.
Highlights of EPS-Direct are a single order placed for the entire EPS line, a single point of contact for startup/commissioning support plus ongoing service, a standard optimized configuration of line equipment and controls – the EPS Version 2.3 Coil Line – and a line performance guarantee by TMW.
Since implementing the first-ever EPS environment-friendly pickling line at TMW in 2007, EPS production line orders were placed with various manufacturers. During that time, TMW has recorded customer preferences, seen opportunities for innovation with terminal equipment and other components, and devised services to help make customers even more successful with EPS. EPS-Direct addresses these findings, plus it leverages our deep experience in operating our own EPS lines to deliver what we believe will be an unsurpassed value.
An EPS-Direct line consists of:
- Quick Setup terminal equipment by Red Bud Industries.
- Mill Duty Scale Breaker/Leveler unit with anti-crossbow station.
- Advanced water filtration system by Filtertech.
- EPS Cells manufactured by Red Bud Industries (except for China and Korea where EPS Cells are manufactured by our joint venture company, TMW Jingu Environmental Protection Equipment Manufacturing Company Limited).
- Seamless, advanced line controls by Applied Industrial Controls.
- Pre-Shipment Line Integration and verification at TMW’s Technology Center.
The advantages of EPS-Direct include:
- Streamlined commercial arrangements with one complete quotation, one contract for the entire line and a single point of contact for sales and project management.
- Critical spare parts – like EPS wear parts and spare scale breaker rolls – are always included.
- EPS Cell water system piping can be included to simplify ordering/installation.
- The option for a turn-key package that incorporates all installation services except facility civil/structural and utility supply work.
- A single point of contact for technical consultation and drawings, including power supply requirements, water quality requirements and component placement/protection that minimizes space and maximizes performance.
- A seamless, integrated control system for the entire line that incorporates performance monitoring and preventative maintenance notifications. The system can keep production logs, track consumables and send alerts ahead of time indicating when wear items will need to be replaced or maintenance performed. TMW will access the system remotely to assist in performance optimization or troubleshooting.
- Customer gets access to the line’s PLC code.
- Extensive pre-startup ‘hands-on’ training of personnel at TMW???s EPS Coil Line in Red Bud, IL.
- Integrated technical documentation – maintenance, operation and startup preparation – for the entire line, presented in a single set of manuals, continuously updated and available online for 24/7 access.
- A guarantee of line speeds and product quality at the completion of commissioning.
- A single point of contact for any warranty or service issues for any part of the EPS line.
We look forward to your inquiries about EPS-Direct and the opportunity to provide you with a competitive quotation for an optimized EPS production line.
Please contact Chris Liefer at 618 282-4200 ext. 103 or send an email to chris.liefer@thematerialworks.com for questions or if you would like to see the new Generation 3 EPS Coil Line in operation.
The EPS-Direct Implementation Team Leaders For Sales, Service and Engineering
EPS Version 2.3 Mill Duty Terminal Equipment + Auxiliaries Boost Performance
We had previously introduced the new EPS Version 2.3 Cell which lowers operating cost by simplifying and reducing maintenance. Today, we share the enhancements to the terminal equipment and the balance of the EPS Cell that complete the picture by
- ramping up to optimum speed more quickly,
- producing an even cleaner surface,
- reducing floor space required for the line,
- improving line efficiency through reduced setup and thread time, and
- reducing maintenance and maintenance checks.
The specific enhancements are detailed below. We are currently implementing them in the new EPS Coil Line at TMW, which will have a pickling capacity in excess of 20,000 monthly tons while occupying just 33 meters of line length. View our progress in this short video:
COIL PREP STATION AND THREADING
Efficiency improvement can begin before the coil is even threaded. The Coil Prep Station, shown below, is designed to let you remove bands, crop the coil head, measure thickness and width and position the coil right next to the uncoiler mandrel. It also includes a special instrument to quickly measure yield strength, eliminating the need to crop off a sample and go perform a conventional off-line yield test.
Once the coil is on the mandrel, improved threading and guiding enhancements allow you to easily feed the coil through the line and have it clamped in the recoiler within three minutes. Part of this is placing the uncoiler at a lower elevation so the material pays off ‘uphill’, which helps prevent occasional reverse bending of the coil head.
MILL DUTY SCALE BREAKER/ROLLER LEVELER
TMW EPS Coil Lines will incorporate a patent pending high-performance combination Scale Breaker and Roller Leveler combined into a single compact machine. This machine was designed specifically for EPS Coil line applications and AHSS grades by Allor Manufacturing, a highly regarded maker of steel mill equipment. It expands capacity up to 6 mm for scale breaking and 10 mm for roller leveling.
The Compact Scale Breaker/Leveler In The New EPS Coil Line At TMW’s Technology Center
It’s well known that a scale breaker placed ahead of the EPS Cell will increase line speed as much as 35% – 40% by removing the looser outer layers of scale. This new machine accomplishes that and brings added benefits of:
- expanding the maximum thickness for scale breaking from 3 mm to 6 mm,
- a space saving footprint versus separate scale breaker and roller leveler units,
- the capability to run thicker strip and AHSS grades,
- an anti-crossbow function that improves flatness, especially for thicknesses > 3mm,
- wet rinsing for cleaner removal of loosened scale,
- automated setup.
This last point provides big efficiency gains by eliminating guesswork and manual setup of the unit. Here’s how it works: the operator enters material thickness and width, but ordinarily would not know yield strength. No problem – the yield strength instrument at the Coil Prep Station measures yield and automatically sends the value to the Scale Breaker/Leveler over the line control. With this information, the Scale Breaker, Anti Cross Bow, and Roller Leveler stations on the unit are all set up and activated or deactivated as needed.
IMPROVED FILTRATION SYSTEM
The magnetic filter section of the EPS Cell Filtration System has been replaced by an expanded double vacuum filtration section. This provides better performance when pickling HSLA, stainless and silicon steel. This simpler system requires fewer pumps, less piping and it:
- filters scale from the new ‘wet’ Scale Breaker/Leveler, so a separate filtration system is not needed,
- ???fine filters??? 100% of system water for a cleaner EPS surface and extended pump life,
- can be installed outside of the EPS line’s building to significantly reduce overall line space
- eliminates nearly all maintenance since the magnetic separator is no longer used.
The photo below shows this improved Filtration System being installed for the EPS Version 2.3 Coil Line at TMW’s Technology Center. Space has been saved inside the plant by locating the Filtration System in this exterior structure. Additional space saving is accomplished by also placing the line’s heat exchangers in this structure.
Installing The New EPS Version 2.3 Filtration System – click on image to enlarge
At TMW we have also chosen to place the main drive control cabinets in this exterior structure. That isolates them from the dirty, noisy processing plant environment, so they stay cleaner and are easier to access and work on. It’s also makes it easier to cool them, because we can maintain the exterior structure at a lower temperature than the main plant.
POST RINSE BRUSH UNIT
A single-stand high speed rotating roll brush is installed immediately after the final EPS Cell of a Version 2.3 Coil Line. Brushing can be disengaged (normal), set to a light brush to remove traces of smut on the surface, or set to deep brushing to actually reduce Ra for the rare occasions when a smoother surface is required. The post rinse wash is located after this brushing unit to produce an even cleaner EPS surface than before.
EPS VERSION 2.3 IS ALMOST HERE
Installation of these new enhancements on the EPS Version 2.3 Coil Line at TMW’s Technology Center are in their final stages, as shown in the photo below. The line will begin operational testing and commissioning within a month, then it will commence pickling of conventional grades, AHSS, silicon steel and stainless – all on the same line, with no downtime or changeover needed between these different products. Stay tuned for additional updates, including video footage, as progress continues.
EPS Hardware Upgrades Yield Big Speed Increase
A year ago we announced plans to host a new state-of-the-art EPS Coil Line at our processing center in Red Bud, Illinois (see New Features To Debut On The EPS Coil Line at TMW). This ‘combination’ working production line and demonstration/training line, which is currently being installed in one of our Red Bud plants, features many significant enhancements that will result in much faster speeds with lower operating costs, an even cleaner surface, and much less maintenance.
The list of enhancements to the EPS cell is so extensive we are designating this new level of EPS technology as Version 2.3. This month’s update focuses on the Version 2.3 enhancements made to the EPS Turbine Chamber itself. The many further speed and operating cost reduction enhancements that are external to the actual Turbine Chamber will be shared in next month’s newsletter.
SLURRY TURBINE ENHANCEMENT ACHIEVES 20+% SPEED INCREASE
We developed a modified turbine system that more effectively and efficiently directs slurry to the strip. The result: a 23% increase in EPS speeds. This speed increase will result in a proportionate reduction in EPS operating costs!
In addition, Slurry Turbine motor power has been increased from 150 HP to 190 HP which mitigates the effects of electrical supply quality problems that exist in some regions of the world. The vast majority of this additional horsepower will not be used for areas where electricity quality is good.
The First Version 2.3 EPS Cell In Final Assembly
MILL-DUTY TURBINE CHAMBER ENHANCEMENTS
A previous update (see Armour Plated EPS) described innovations that extend the service life of EPS Cell components and reduce maintenance. The Version 2.3 Cell incorporates the following additional enhancements that further extend the time between maintenance:
- Chamber liners: new AR500 liner plates replace rhino hide and increased use of magnetic liners significantly reduces maintenance and better protects the cabinet.
- Strip Guiding: larger cell entry and ‘bash bars’ lower the incidence of threading jams and the top pinch rolls and thread bars have been eliminated to reduce maintenance.
- Quick Change Components: the turbine motors and remaining rolls and thread bars have been made ‘quick change’ to shorten maintenance outages.
A Version 2.2 Turbine Chamber Interior New Version 2.3 Turbine Chamber Interior
SIMPLIFIED TURBINE CHAMBER TANK
This new version 2.3 eliminates the Skim Transfer section which has resulted in one less pump and a reduced footprint.
Next Month: EPS Coil Line Mill Duty Terminal Equipment that results in further increase of EPS speeds, lower maintenance and saves valuable plant space.