| | Reference Document on Best Available Techniques in the |
| | 5,32 | | MB | Ferrous Metals Processing Industry (adopted Dec 2001) |
| | 538 | | stron |
| | 1103 | | ID | JRC-IPTS Instituto de Prospectiva Tecnológica (IPTS) |
| | 2002 | | rok |
| | Executive Summary. i |
| | Preface xxi |
| | A.1 General Information on Hot and Cold Forming 1 |
| | A.1.1 Hot Rolled Flat Products2 |
| | A.1.2 Hot Rolled Long Products3 |
| | A.1.3 Tubes.4 |
| | A.1.4 Cold Rolled Flat Products 5 |
| | A.1.5 Cold Drawn Long Products/ Bright Steel Bars 8 |
| | A.1.6 Wire 8 |
| | A.2 Applied Processes and Techniques in Hot and Cold Forming.11 |
| | A.2.1 Hot Rolling Mills .11 |
| | A.2.1.1 Process Overview.11 |
| | A.2.1.1.1 Blooming/Slabbing Mills.13 |
| | A.2.1.1.2 Hot Strip Mills .13 |
| | A.2.1.1.3 Plate Mills16 |
| | A.2.1.1.4 Bar and Rod Mills17 |
| | A.2.1.1.5 Structural/Section Mills .19 |
| | A.2.1.1.6 Tube Mill .22 |
| | A.2.1.2 Surface Rectification and Conditioning of Input25 |
| | A.2.1.3 Reheating- and Heat Treatment Furnaces 26 |
| | A.2.1.3.1 Batch Furnaces.26 |
| | A.2.1.3.2 Continuous Furnaces27 |
| | A.2.1.4 Descaling.29 |
| | A.2.1.5 Edging 30 |
| | A.2.1.6 Roughing 30 |
| | A.2.1.7 Strip Rolling/Finishing Train .30 |
| | A.2.1.8 Rod Rolling/Finishing Train 30 |
| | A.2.1.9 Plate Rolling.31 |
| | A.2.1.10 Transport of Roll Stock between Rolling Stands .31 |
| | A.2.1.11 Cooling Lines .31 |
| | A.2.1.12 Sheet and Plate Production.32 |
| | A.2.1.13 Plate Heat Treatment 32 |
| | A.2.1.14 Roll Shop33 |
| | A.2.1.15 Water Circuits / Water Management in Hot Rolling Mills.33 |
| | A.2.1.16 Waste and By-product Management in Hot Rolling Mills .36 |
| | A.2.2 Cold Rolling Mills .38 |
| | A.2.2.1 Process Overview.38 |
| | A.2.2.2 Pickling of Low Alloy and Alloy HR Steel40 |
| | A.2.2.3 Annealing (I) and Pickling (I) of High Alloy HR Steel41 |
| | A.2.2.4 Cold Rolling of the Pickled Hot Rolled Strip.43 |
| | A.2.2.4.1 Low Alloy and Alloy Steel 43 |
| | A.2.2.4.2 High Alloy Steel 44 |
| | A.2.2.5 Annealing of Low Alloy and Alloy Steel.45 |
| | A.2.2.5.1 Batch Annealing.45 |
| | A.2.2.5.2 Continuous Annealing .46 |
| | A.2.2.6 Annealing (II) and Pickling (II) of High Alloy Steel .47 |
| | A.2.2.7 Tempering of Cold Rolled Strip .48 |
| | A.2.2.7.1 Low Alloy and Alloy Steel 48 |
| | A.2.2.7.2 High Alloy Steel 48 |
| | A.2.2.8 Finishing49 |
| | A.2.2.9 Roll Shop49 |
| | A.2.2.10 Water and Process Baths Management in Cold Rolling Mills .50 |
| | A.2.2.10.1 Emulsion System .50 |
| | A.2.2.10.2 Degreasing Solution System51 |
| | A.2.2.10.3 Cooling Water Systems51 |
| | A.2.2.10.4 Waste Water Treatment .53 |
| | A.2.2.11 Waste and By-product Management in Cold Rolling Mills .53 |
| | A.2.3 WIRE PLANTS .54 |
| | A.2.3.1 Wire Drawing Process Overview. 54 |
| | A.2.3.2 Wire Rod Preparation 55 |
| | A.2.3.2.1 Mechanical Descaling of Wire Rod. 56 |
| | A.2.3.2.2 Chemical Descaling (Pickling) of Wire Rod. 56 |
| | A.2.3.2.3 Application of Soap (Lubricant) Carrier . 56 |
| | A.2.3.3 Drawing . 57 |
| | A.2.3.3.1 Dry Drawing of Wire 57 |
| | A.2.3.4 Heat Treatment of Wire . 57 |
| | A.2.3.4.1 Batch Annealing of Low Carbon Steel Wire. 57 |
| | A.2.3.4.2 Continuous (In-Line) Annealing of Low Carbon Steel Wire 58 |
| | A.2.3.4.3 Continuous (In-Line) Annealing of Stainless Steel Wire 58 |
| | A.2.3.4.4 Patenting 58 |
| | A.2.3.4.5 Oil Hardening and Tempering (Oil Tempering) 59 |
| | A.2.3.4.6 Stress-relieving 59 |
| | A.2.3.5 In-line Pickling 60 |
| | A.3 Present Consumption and Emission Levels for Hot and Cold Forming 61 |
| | A.3.1 Hot Rolling Mills. 61 |
| | A.3.1.1 Mass Stream Overview 61 |
| | A.3.1.2 Surface Rectification and Conditioning of Input . 62 |
| | A.3.1.3 Reheating and Heat Treatment Furnaces . 63 |
| | A.3.1.4 Descaling . 65 |
| | A.3.1.5 Hot Rolling 67 |
| | A.3.1.6 Roll Shop . 67 |
| | A.3.1.7 Oil, Grease and Hydraulic Oil Flow 67 |
| | A.3.1.8 Hot Rolling Mill Waste Water Treatment Plant 69 |
| | A.3.1.9 Waste and Recycling . 70 |
| | A.3.1.10 Noise Issues in Hot Rolling . 71 |
| | A.3.1.11 Commissioning and Decommissioning . 71 |
| | A.3.2 Cold Rolling Mills. 73 |
| | A.3.2.1 Mass Stream Overview 73 |
| | A.3.2.2 Pickling of Low Alloy, Alloy and High Alloy Steel 74 |
| | A.3.2.2.1 Hydrochloric Acid Pickling Line and Regeneration Plant 75 |
| | A.3.2.2.2 Sulphuric Acid Pickling Line and Regeneration Plant 77 |
| | A.3.2.2.3 Mixed (HNO3-HF) Acid Pickling Line and Acid Recovery 79 |
| | A.3.2.3 Cold Rolling. 80 |
| | A.3.2.3.1 Low Alloy . 80 |
| | A.3.2.3.2 High Alloy/Reversing Mill 82 |
| | A.3.2.4 Annealing of Low Alloy and Alloy Steel 83 |
| | A.3.2.4.1 Batch Annealing 83 |
| | A.3.2.4.2 Continuous Annealing. 84 |
| | A.3.2.5 Annealing and Pickling of High Alloy Steel 85 |
| | A.3.2.6 Tempering (Low alloy/High Alloy). 87 |
| | A.3.2.7 Finishing (Cutting, Inspection, Packing) . 87 |
| | A.3.2.8 Roll Shop . 88 |
| | A.3.2.9 Hydraulic Fluids and Lubricants Management 88 |
| | A.3.2.10 Cold Rolling Mill Waste Water Treatment Plant. 89 |
| | A.3.2.11 Waste and Recycling . 91 |
| | A.3.2.12 Noise Issues in Cold Rolling 91 |
| | A.3.3 Wire Plant. 93 |
| | A.3.3.1 Mass Stream Overview 93 |
| | A.3.3.2 Wire Rod Preparation 94 |
| | A.3.3.2.1 Mechanical Descaling of Wire Rod. 94 |
| | A.3.3.2.2 Chemical Descaling/Pickling of Wire Rod . 94 |
| | A.3.3.2.3 Application of Soap Carrier. 95 |
| | A.3.3.3 Drawing of Wire 96 |
| | A.3.3.3.1 Dry Drawing 96 |
| | A.3.3.3.2 Wet Drawing . 97 |
| | A.3.3.4 Heat Treatment of Wire . 99 |
| | A.3.3.4.1 Batch Annealing/Bell and Pot Furnaces 99 |
| | A.3.3.4.2 Continuous Annealing/Molten Lead Bath. 99 |
| | A.3.3.4.3 Patenting 100 |
| | A.3.3.4.4 Oil Hardening & Tempering . 101 |
| | A.3.3.4.5 Annealing of Stainless Steel Wire .102 |
| | A.3.3.4.6 Stress Relieving .102 |
| | A.3.3.5 Noise Issues in a Wire Plant.102 |
| | A.4 Techniques to Consider in the Determination of BAT for Hot and Cold Forming105 |
| | A.4.1 HOT ROLLING MILL 105 |
| | A.4.1.1 Storage and Handling of Raw Materials and Auxiliaries .105 |
| | A.4.1.2 Surface Rectification and Conditioning of Input105 |
| | A.4.1.2.1 Enclosed Scarfing Operation with Wastegas Cleaning105 |
| | A.4.1.2.2 Enclosed Grinding Operation with Waste Gas Cleaning .107 |
| | A.4.1.2.3 CAQC - Computer Aided Quality Control 109 |
| | A.4.1.2.4 Rolling of Wedge-type Slabs .110 |
| | A.4.1.2.5 Slab Slitting110 |
| | A.4.1.3 Reheating and Heat Treatment Furnaces111 |
| | A.4.1.3.1 General Measures for Energy Efficiency and Low Emission Operation .111 |
| | A.4.1.3.2 Furnace Automation / Furnace Control113 |
| | A.4.1.3.3 Optimised Furnace Door Design114 |
| | A.4.1.3.4 Regenerative Burner System115 |
| | A.4.1.3.5 Recuperator and Recuperative Burners117 |
| | A.4.1.3.6 Oxy-fuel Technology .117 |
| | A.4.1.3.7 Low-NOx Burners .118 |
| | A.4.1.3.8 Selective Catalytic Reduction (SCR) .119 |
| | A.4.1.3.9 Selective Non-Catalytic Reduction (SNCR) 121 |
| | A.4.1.3.10 External Flue Gas Recirculation (FGR).123 |
| | A.4.1.3.11 Waste Heat Boiler123 |
| | A.4.1.3.12 Optimised Skid Design to Reduce Skid Marks125 |
| | A.4.1.3.13 Reduction of Energy Loss through Stock Transportation Device126 |