The development and progress of China's cold rolling engineering technology

   
1 Overview of Cold Rolling Project
Cold -rolled projects are the projects built by the production of cold -rolled products (cold -rolled board rolls, galvanized plate rolls, tin plating rolls, color coating rolls, etc.), including the main crew (such as the pickled pour machine joint unit, continuous continuous units, continuous continuous groups Hot -galvanized units, continuous annealing units, etc.) and public auxiliary systems serving the main crew.
The construction of the cold -rolled project covers the entire process from the early planning to the creation of the crew to the unit of production, assessment and inspection, and received the entire process of engineering warranty. Construction and installation technology, trial operation and debugging technology, unit production technology, unit equipment maintenance technology, etc.
2 Current status of domestic cold rolling projects and equipment matching capacity
2.1 The construction of the domestic cold rolling unit
There are many varieties of cold rolling, and this article only explains the cold -rolled project of carbon steel. According to incomplete statistics, the situation of major broadband steel cold rolling and post -processing units has been built in China.

Table 1 The status of the main broadband steel cold rolling and post -processing units has been built in China
Unit name	Number of domestic crews, entries	Total production capacity, 10,000 tons	Foreign businessmen	Major domestic engineering companies
Cold rolling and pickled pour machine joint unit	> 90	> 1200	Mitsubishi Hitachi (Prett), SMS, etc.	China Metallurgical Sai, Zhongye Jingcheng, Yizhong, etc.
Continuous hot -dip galvanized units	> 580	> 9500	CMI, SMS, VAI, Danieli, etc.	China Metallurgical Sidi, Southern Metallurgical Southern, Zhongye Jingcheng, Huangshi Shanli, Gangyan Xinye, etc.
Continuous annealing unit	> 40	> 2500	New Railway, SMS, VAI, Danieli, etc.	China Metallurgical Sidi, Southern Metallurgical Southern, Zhongye Jingcheng
Continuous color coating unit	> 360	> 3920	FATA, New Railway, etc.	China Metallurgical Sai, Zhongye Jingcheng, Gangyan Xinye, etc.

The acid rolling unit of the domestic 1700mm level or above in the car board market is basically monopolized by SMS and Prite (Mitsubishi Hitachi). The SMS rolling machine uses CVC technology, while Priit mainly uses UCM or UCMW technology.
Under 1700mm, especially the 1450mm -level cold rolling or acid rolling unit, most of them are borne by domestic engineering companies and one heavy. Foreign business has basically abandoned the competition in this field. The same is true in the field of continuous retirement and galvanized units.
The construction of the introduction units responsible for the technology of foreign companies, the domestic design institutes mainly undertake the work of factory design. Domestic heavy machinery factories undertake the cooperation and manufacturing work of some equipment, and the construction is borne by domestic metallurgical construction units.
The construction of the cold -rolled localization unit project is mainly due to the recent more than 10 years from the recent 10 years from a factory design institute from digestive and transplant foreign advanced technology equipment to domestic research, to independent innovation of technical equipment, through research and development Get your own core technology and solidify it into a complete set of equipment, and then use the complete set of equipment to drive the general contracting.
At present, domestic equipment manufacturers mainly include one heavy, duet, upper, Changbao Ling, Shaanxi pressure, etc.; Domestic electrical vendors include Baoxin, China Metallurgical Sidi, etc. These companies have more engineering performance in the industry and reach a higher level of industry.
2.2 Practice of Cold Rolling Project
Each engineering company has its unique engineering practice. Here is only the crew of Cydie's production in recent years, such as the first set of pickles of the first cleaning machine joint crew in China Cold rolling implementation, the first set of ultra -high -intensity (780MPa) continuous retirement units are put into production in Xunhui (China), and the recent production of the original 3#acid rolling unit reconstruction project, Angang (aluminum) zinc unit , Purtle Steel thickness specifications (8.0mm) continuous pickling units and other projects have a large impact in the industry. The construction cycle of these projects is about 12-20 months.
China Metallurgical Sidi has done a lot of work in the aspects of pickling models, secondary setting models of rolling machines, plate -shaped closed -loop control systems, annealing furnace models, and units production big data analysis. The results have been put into industrial applications.
Through continuous progress and deep integration of core processes and core equipment, various large -scale advanced cold rolling equipment of domestic engineering companies have gradually been recognized and adopted by large domestic steel companies. Its market share, equipment level, and product quality have reached the international advanced level. And complete equipment.
2.3 The gap between domestic engineering companies and world benchmark companies
2.3.1 The gap between the design field and the world benchmarking enterprises
The factory design technology of domestic engineering companies is the world's leading leading, but there is still a certain gap between the unit design technology and the world benchmarking enterprises. In terms of units, continuous color coating units, etc., especially in the field of units above 1700mm, world benchmark companies have brand and performance advantages, core equipment and technical advantages, and independent design capabilities. Domestic engineering companies are mainly digestive transplantation and technology. Enter.
However, the competition between domestic engineering companies and foreign benchmark companies has completely changed from running from the 20th century to compete with them. Especially in the past 10 years, various processing units of cold -rolled carbon steel fields, hot -dip galvanized units, electro -galvanized units, continuous annealing units, and cold -rolled silicon steel are widely used in Baosteel, Anshan Iron and Steel, Martang, Tai Iron Large state -owned enterprises such as Steel and Shougang have been recognized.
In the field of high -end cold -rolling projects above 1700mm in China, the Zhanjiang Cold Rolling Project independently integrated by Baosteel BSEE has been successfully put into production, but the construction of these units is more or less shadow of foreign businessmen.
Compared with the world's benchmark companies, domestic engineering companies have a certain gap in terms of brand or technology and performance, but it can be said that the gap is gradually narrowing.
2.3.2 The gap between core equipment and world benchmark companies
The supplier of the cold -rolled unit's main electromechanical products or core equipment is shown in Table 2.

Table 2 Cold -rolled mechanical all -in -one product or core equipment supplier
Device name	Major foreign merchant	Major domestic supplier
Laser welding machine	Miebach, TMEIC	Wuhan Cage, Bao Welding, Southern Metallurgical South
Narrow welding machine	Miebach, TMEIC	Wuhan Cage, Treasure Welding
Pierced phosphorus	Sms, Misubishi, Yi	China Metallurgical Sai, Boya, China Metallurgical South, etc.
Purmurn slot and pickled circulation system	Sms, Misubishi, Y, Almightz	Albert, Jiangsu Xinglong, etc.
Disk shear	Sms, Misubishi, Yi	China Metallurgical Sai, Boya, China Metallurgical South, etc.
Extent	Drever, stein heurtery, ef	Sidi Industrial Furnace, Southern Whiskey Furnace, Beijing Phoenix Furnace, Huangshishan Li, Gangyan Xinye, etc.
Zinc pot	AJAX,Inductotherm	Xi'an Zhongwei et al.
Air knife	Foen, Duma, Kolher, Visit	Nerride, Tianjin Shuoyan, Zhongye Sidi
Plate	ABB, BFI	Yanshan University
Static oil removal machine	Dima, GFG, Trion	Wuhan University of Science and Technology, Odaik, etc.
Disassembling bundle and automatic bundle machine	Since Ichi G, Lake Lake Lake, Episode 1 CK	Big Workers, Beijing Machine Sciences, Lean of Zhejiang
Burn your mouth and control unit	BLOOM,IBE	Shi Neng, Guangzhou
Online detection instrument, such as tension, etc.	ABB, Chalice	-
Electrical transmission device	Siemens, ABB, TMEIC	-

After years of hard work, the localization of cold -rolled equipment and spare parts has achieved remarkable results, which fully reflects the improvement of my country's independent equipment manufacturing capabilities.
Cold rolling practitioners really thank these domestic core equipment suppliers. Through their unremitting efforts, some core devices can completely replace imports. For example, domestic laser welding machines are only one fi of the import price, which has greatly reduced project construction investment. With the continuous improvement and innovation of these domestic suppliers, domestic brands have made great progress in terms of performance, operating stability, automation level, product quality control, and product service life. Accept, the market share is getting higher and higher.
The main transmission devices, auxiliary transmission devices, electrical system software, and online detector instruments in electrical engineering are basically foreign equipment. In terms of product quality online monitoring technology, performance prediction methods, and quality diagnosis technology, domestic companies and foreign companies also have a big gap. All of these need cold -rolled relevant personnel to work hard together.
3 The construction model and market environment of cold -rolled projects
3.1 Construction mode of cold -rolled project
See Table 3 for the construction mode of the cold -rolled project. The construction model in the table is adopted in China. The usual construction mode is: the main unit or the device generally adopts an EP mode. The owner selects a factory design unit, and the purchase order is purchased. There are also a few cold -rolled projects in China that are built in EPC models. There are two main cases:
1) The contractor undertakes the design, supply, installation, and commissioning of the host group.
2) The contractor undertakes the general contracting of the entire project, including unit equipment, installation, commissioning, civil construction, etc., that is, the large total contract mode.

Table 3 Construction mode of cold rolling project
Contract mode	consult	design	Purchasing/supply	Construction/installation	Cold tone	Hot test/trial operation	Production operation
Owner self -built	owner
PMC/EPCM	PM	owner
AND	Pum/cum	Designer	owner
EP	Pum/cum	contractor		owner
EPC	Consultant	EPC				owner
Turnkey	Consultant	EPC					owner
BOT	Consultant	EPC
Note: The debugging of EP and EPC's crew is borne by electrical vendors.

3.2 The market environment of cold -rolled engineering
3.2.1 Excess capacity of cold rolling, less and less projects
At present, in addition to a few domestic cold rolling products that still need to be imported due to various reasons, the capacity of almost all cold rolling varieties is surplus, and the existing production lines are seriously under started. According to analysis, the current operating rate of color coating units is less than 30%. Due to excess cold rolling capacity, there are fewer and fewer new projects.
3.2.2 Engineering investment is getting lower and lower
Cold-rolling projects have declined significantly. In 2007, investment and construction of a cold rolling factory with domestic equipment-based equipment-oriented 1.2 million T/A. About 1,000 yuan.
Reasons for decline in investment: design optimization, localization of equipment, reduction of price reduction of foreign equipment, manufacturing costs, technical service fees, and contractors' profits are declining. Although labor costs have risen, the total investment has declined significantly.
3.2.3 Engineering project competition is fierce
Now the project is getting less and less. Once there is project information, each family is desperately fighting. The final result is the fierce competition. The contractor's profit is very thin. If you are not careful, it will cause the project to lose money.
Because the project generally uses a low -cost winning standard, the contractor of the winning bid will try to optimize the design during the implementation process. Its goal is to reduce weight, reduce allocation, reduce costs and sacrifice some functions. This only recognizes the price and does not pay attention to the quality and service of the product. In the end, the production plant itself is not conducive to the continuous and effective technical improvement and improvement of the engineering company.
3.2.4 Engineering risk is large
Some projects were originally low in contract, but the owners were still trying to delay payment, or the payment was not timely. At present, domestic engineering companies have more or less triangular bonds. On the one hand, there are a lot of arrears that cannot be collected. On the other hand, there are a large number of subcontracting models that cannot be paid, resulting in some of them. Money pays the salary of migrant workers and causes social instability.
According to the project practice, the final payment for assessment and acceptance and project quality guarantee deposit is generally 5% - 10%, and the highest is more than 20%. Even if some contractors have passed the assessment, the final payment is very difficult to collect.
4 The development of cold rolling technology
Cold -rolled technology must be implemented through specific projects to achieve industrialized applications in order to be transformed into real productivity. In the past two decades, cold rolling has not yet appeared in a disruptive and revolutionary new production technology, such as similar acid rolling production technology and continuous annealing production technology. However, there are many technologies worthy of attention in the cold rolling field. These technologies are likely to get more engineering applications in the future.
4.1 New process technology
1) Environmental protection type -based acid -free washing unit technology: For example Some engineering applications, but currently cannot completely replace conventional carbon steel hydrochloride technology;
2) Powder coating technology;
3) Tibette steel continuous coating technology (PVD).
4.2 Core equipment efficient and reliable improvement technology, new functional product development, product quality improvement technology, high -precision control technology, production process energy conservation and environmental protection technology, new process technology, etc.
The more representative are:
1) Mitsubishi's IBOX pickling slot heating technology;
2) The core technology of the edge of the cold rolling machine;
3) Advanced high-strength steel manufacturing technology: such as pre oxidation to produce high-strength galvanized sheet technology; The super steel produced by the cooperation of Beijing, Hong Kong and Taiwan has a yield strength of 2200MPa and a uniform elongation of 16%, which has the best combination of strength and ductility.
4) Rapid heating and cooling technology;
5) Development of new products: For example, OA uses high -guide electrical electroplating products, zinc and aluminum -magnesium products, etc.;
6) Quality improvement technology: such as zinc gray ash and furnace nose removal technology, etc.;
7) Electrical control technology: such as the full -machine plate -shaped control technology of the acid rolling unit, the entire machine frame second traffic control technology, etc.;
8) Unit environmental protection technology: such as wastewater treatment technology, sour, alkaline fog high purification technology, etc.;
9) Green coating technology: such as fingerprint coating, self -cleaning coating, self -healing coating, self -lubricating coating, antibacterial coating, etc.;
10) Artificial Intelligence Technology: For example, the automatic control solution of the artificial intelligence galvanized layer of Pu Xiang.
5 cold -rolled engineering development direction
The production process and the development of new products will put forward new requirements for the construction of the project, and the future construction direction of the cold -rolled project will mainly face the following aspects.
5.1 Intelligent manufacturing will get more and more widely used
In order to reduce the intensity of workers, the intelligent manufacturing technology of cold -rolled in production safety and operation level mainly includes: 1) smart library pipes and unmanned cranes; 2) automatic rolls and automatic rolls; 3) automatic disassembly tied; 4) Automatic surface quality inspection and mechanical performance online inspection; 5) fully automatic roll; 6) fully automatic bundle and packaging; 7) automatic upper and unloading sleeves; 8) automatic zinc residue; 9) Equipment operation status online Monitoring, etc.
Using the remote VPN technology of the Internet +, engineers can remotely perform fault diagnosis and can maintain remote system maintenance, which greatly reduces the processing time of fault shutdown.
Use big data analysis technology to collect, store, dig, and analyze the various parameters of the production process to provide technical support for energy conservation, emission reduction, improve product quality, reduce production costs, optimize production operations, etc. Process product quality interaction analysis and abnormal diagnosis, comprehensive monitoring and early warning of process process, traceability analysis of process parameters, comprehensive evaluation of product quality, and research and development of new products based on big data.
Using the mobile app, managers can also master production trends anytime, anywhere, so as to facilitate production management.
5.2 Domesticization of core technology and core equipment
Through continuous digestion, absorption, and re -innovation, the localization of core technologies and core equipment will be better and better.
5.3 Upgrade and renovation of existing units
In response to the upgrading and transformation of the existing units, owners can get a small amount of investment to obtain new technologies, new products, new equipment, new processes, improvement of production capacity, etc. and win greater economic benefits.
5.4 Cold -rolled project overseas
There are some common problems in the domestic cold -rolled project overseas:
1) No brand advantage;
2) The maturity of technology is not high: one is that some technical performance is too small; the other is that the original technology is not enough, and the traces of the retaining original technology are too obvious; the third is that the essence of the technology has not really understood. When designing, the place where it changes is prone to problems;
3) The quality control capacity of equipment manufacturing and weak quality monitoring capacity on the spot;
4) The prices of local laws, regulations, standards, customs, customs, various materials and labor prices will cause the quotation to be false and project management risks. These are all ways we must face and try to solve them when we go abroad.
In recent years, although the exports of cold -rolled equipment in my country have made great progress, in general: the scale is not large and large equipment is small, and small and medium -sized equipment is small; there are few advanced equipment and more ordinary equipment; There are fewer products, and there are many products; more effort is made by prices, and less projects are won by technology.
Improving independent design and manufacturing capabilities, and improving the quality of equipment is the fundamental way to improve my country's cold -rolled equipment engineering level and technical exports. At the same time, it is necessary to restrain the disorderly competition of domestic engineering companies overseas. In addition, it is necessary to make full use of the “Belt and Road” strategic opportunities with Chinese companies to invest in factories overseas to expand the technology export of cold -rolled equipment. Especially in the current situation of excess steel production capacity in my country, it is necessary to create conditions to strive to relocate domestic cold -rolled factories overseas.
6 conclusion
1) After years of hard work, the localization of cold -rolled equipment and spare parts has achieved significant results, which fully reflects the improvement of my country's independent equipment manufacturing capabilities. Domestic equipment has been widely used in cold -rolled engineering.
2) There is still a certain gap between domestic engineering companies and world benchmark companies in terms of brand or technology and performance, but the gap is gradually narrowing.
3) Call for the market environment of the cold -rolled engineering, and in strict accordance with the contract to avoid vicious competition.
4) The new technology must be closely integrated with the project to achieve industrial application and transform into productivity.
5) Improving independent design and manufacturing capabilities, and improving the quality of equipment is the fundamental way to improve my country's cold -rolled equipment engineering level and technical export.