STEEL + TECHNOLOGY 01/2020 EXTRACT

STEEL TECHNOLOGY | 47
and GA. The rolls’ pre-heater structure can
be gas-fired or electrically heated. Properly
designed maintenance buggies and
tools for easy and fast maintenance
improve equipment change over and setup
efficiency.
Operating costs. Submerged rolls with
3-rolls/2-beams configuration for the fastest
handling time reduce downtime for
submerged equipment changeover. The
maximum flexibility for using different
types of bushings given by the CapEx, to
meet customer and process requirements,
optimizes OpEx for consumables.
Equipment productivity and flexibility.
Quick and precise fixing system for roll rigs
on mounts guarantees repeatability and reliability
in re-positioning roll rigs. The possibility
to switch from air to nitrogen wiping
gives maximum flexibility in case of final
product coating type (GI, GA, Al55%-Zn)
Pre-heating, set-up, transport and storage
stands can be configured for all possible
plant layouts.
Wide-open pot design for easy skimming,
process observation and maintenance
access and roll diameters sized
appropriately for the chosen product mix
also are part of the Danieli Kohler package.
Integrated technological packages.
Closed-loop control for coating weight,
including a sophisticated coating model,
long-term adaptation functions, as well as
precise controllers for air-knives distance
and pressure, supports a tight coating
weight accuracy and fast adjustment in
case of flying product changes.
In a galvanizing line, human operation is
most challenging in the zinc pot area. To
reduce human intervention and health
risks, Danieli-developed robotic systems
designed to skim the surface of the zinc
bath remove dross and place it in a dross
container, or handle the zinc ingot feeding.
The Q-Robot Zinc can be fully integrated
to the Level 1 automation system and
automatically follows the bath level, optimizing
the skimming action.
Main benefits
The features of the Danieli Kohler X-Jet
air-knife wiping equipment offer the following
benefits, proven by the feedback
collected from our customers in 35 installations
put into operation since 2009:
• easy and rapid handling during equipment
change,
• minimal and simple setup, maintenance
and operation,
• heavy-duty construction for minimum
vibration and maximum strip stability, to
improve the coating control,
• un-driven rolls turn easily under the
most critical conditions,
• precise and repeatable pass-line position,
• excellent control of strip crossbow,
• zinc-resistant materials, for extended
lifetime,
• increased line speed of +20 to +25% for
the same coating weight,
• improved coating uniformity up to 10%.
• drastically reduced strip edge over coating
problems,
• reduced splashing, which means less
dross generation and improved quality
(with less lip cleaning required),
• reduced surface defects and improved
surface aspect,
• easier lip cleaning thanks to proven
design of automatic lip cleaner and easy
access for operators,
• reduced manpower requirements and
improved operator health and safety,
• reduced dross skimming, up to 10% for
the same operating conditions,
• reduction of nitrogen/blowers power
consumption up to 20%, for the same
operative conditions,
• further reduction of nitrogen/blowers
power consumption, up to 35%, with
width adjustment,
• reduced noise, by 1 to 4 dB(A) for the
same operating conditions (with width
adjustment),
• capability to produce challenging and
high value-added products.
Automation and on-site services
The Danieli Automation (DA) system allows
the complete control by operators with detailed
diagnostic capability. All critical parameters can
be monitored and adjusted from the HMI.
Automatic set-up of process parameters is
implemented according to material PDI.
Danieli supports customers with process
know-how for the complete galvanizing
process. This is presented by operators
with years of experience in both actual
production and in teaching users of Danieli
Kohler equipment. Users are ensured a
quick start-up, an efficient learning curve
and continuous technical support.
Figure 6. Main dimensional comparison
between compact and normal X-JET
(Picture: Danieli)
Figure 7. Danieli Automation (DA) system
allows the complete control by operators
with detailed diagnostic capability
(Picture: Danieli)
Conclusion
Danieli is a leading company in the field
of cold rolling and cold-processing lines
through the Danieli Wean United (DWU)
division. The Kohler Coating Machinery
Corporation (KCMC) was integrated into
DWU in 2001, establishing Danieli
Kohler to bring outstanding experience
in coating technology into the Danieli
Group.
KCMC’s long experience together
with Danieli’s facilities worldwide gave
Danieli Kohler first-class capability in
technology, research, design, manufacturing,
logistics, flexibility and local customer
support, as well as integrating
their equipment into complete coating
lines. The unique and wide-ranging
expertise of the Danieli Kohler team
was gained over 50 years and more
than 200 installations, with feedback
from market-leading galvanizers worldwide.
STEEL + TECHNOLOGY 2 (2020) No. 1