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Consulting - Save Money with Better Tech

In producing high strength grades such as linepipe steel X80 - X120, the rolling and cooling processes need to achieve process targets (temperature, draft, cooling rate etc.). The processes also involve strip/plate shapes under certain roll profiles, together with the equipment capacity limits and energy saving issues. Metal Pass helps you in improving mill models and automation software, with also metallurgical knowhow integrated to the models. This will not only ensure you can successfully produce the high strength grades, but also let you achieve a yearly return of millions of dollars (e.g. in a steckle plate mill). Many clients of Metal Pass, though already possess technologies to produce high grades, still hire Metal Pass to improve their draft schedule. After upgrading the level 2 model, a plant usually is expected to increase earning of about a million US dollars per month!

In general, Metal Pass consulting covers a variety areas for steel mills on model improvement and software development, such as Level 2 model, mill software, Automation System, Mill Improvement, Roll Pass Design and FEM/FDM Analysis. In flat rolling, we improve yield and product quality (shape/property) by accurate prediction of force, temperature and roll deformation, etc. for Level 2 model. In rod, bar and section rolling, we have accurate models for spread, forward slip and tension effects, etc. to achieve high quality roll pass design. In either case, we improve existing mill software and/or develop new software system.

Level 2 Model Improvement  (Ask a question)

Steel mill Level 2 system is considered as the nerve system of a steel mill and is usually referred to as the Production Execution System, in which mill Level 2 model contains most of the mill system intelligences.

Most product defects, such as the poor geometry and low properties, are directly or indirectly related to a poor Level 2 model. The center buckle and edge wave, for example, are caused by unequal drafts in the middle and the sides of the plate/strip due to a draft schedule not fit to roll profile. The problem of low mechanical properties is often caused by inaccurate Level 2 model in which the preferred parameters (temperatures, etc.) missed metallurgical targets. See Level 2 Model Performance Issues such as Product Defects and Level 2 Model Error.

Even a slight improvement of a Level 2 model can add significant economic value to the steel mill. See Significance of the Level 2 Model Improvement. For example, 1% reduction in the Level 2 force error may have a value of 1 million US dollar per year! (See Significance of Accurate Level 2 Force Prediction).

Metal Pass Level 2 Model Improvement can significantly increase your system accuracy, by making very few , often only several lines of, source code change, or by simple modification of the Level 2 input data without any source code modification. Improvement can be performed in the modules such as

For more significant improvement, usually by more modifications to the existing system, Metal Pass can perform System Further Development for you. Metallurgical models and other thermal and mechanical models can be integrated into your system, as showed below:

Please see the consulting section Level 2 Model Improvement for details.

Mill Software Development and Improvement  (Ask a question)

Metal Pass' expertise exists in the development of model-based steel mill software, especially those used in the rolling mills. We have consultants (e.g. Dr. Benjamin Li) who are both the mill model experts and the highly-skilled software engineers.

Metal Pass' software consulting and developments are primarily in the following areas:

See details on Metal Pass' Model-based Mill Software Development and Improvement.

Mill Automation System Development and Improvement  (Ask a question)

We develop new and improve existing Level 2 systems. We apply our accurate rolling process models and metallurgical models to develop new production scheduling system or to improve the existing ones. In addition, we develop various software applications to satisfy steel mill needs.

For details, see the consulting section Mill Automation System Development and Improvement.

Rolling Mill Plant  (Ask a question)

Metal Pass provides steel wire rod rolling mill machinery and automation equipment. with the state-of-the-art development of mill technological parameters, process models and automation systems, the mill is, however, with very competitive price. For detailed information on the wire rod mill plant, see the Rolling Mill Plant section.

Roll Pass Design  (Ask a question)

Metal Pass provides consulting services to improve both your roll pass schedule and roll pass software. There are dozens of influence factors on a roll pass schedule, together with issues of robustness and accuracy. Metal Pass' strength exists in the unique combination of the theory (accurate process models) and field practice. Example of our consulting areas are:
  • Wire rod rolling: a list of roll pass design programs, with accurate process models

  • Bar rolling: models, advanced analytical tools and a good collection of existing pass schedules

  • Section rolling: good understanding of metal deformation, with the Ph.D. research on the subject and a book published.

  • Pipe/tube rolling: work on tension-reducing mill roll pass, good understanding of related metal deformation; many classes in the field and mill practices, etc.

  • Flat rolling: both online and offline models available, with sophisticated Level 2 models.

See detailed description of Metal Pass Roll Pass Design consulting.

Mill Performance Improvement  (Ask a question)

This is to apply our mill models and mill knowledge in the daily operation of the steel plants, to improve productivity, yield and product quality, etc. It is under unique combination of the mill theory and mill practice. Examples of our consulting areas include:

  • Mechanical properties improvement: such as increasing reductions in certain temperature range and application of roll bending schedules.

  • Shape and yield improvement: change of mill operation to reduce all kinds of defects such as camber, hooking, edge wave, center buckle, missed slots, kinks, knuckles, etc.

  • Productivity improvement: improvement of mill operation, such as decreasing the number of passes, slab line up and firing, flow analysis, etc. to increase productivity.

  • Energy saving and cost reducing: such as improvement of reheating process, optimization of slab size and slab grade.

See details on Mill Operation Improvement with a list of work areas and solutions.

FEM/FDM Analysis  (Ask a question)

We are one of the earliest successful researchers in the industry applications of finite elements method (FEM) for the steel rolling. Our work area focuses on the application of FEM to solve real industry problems. We can use our expertise to help you. Besides FEM, we have also developed software with finite differential method (FDM), see an online demo.

FEM is an universal tool to provide information on local deformation such as roll deflection and roll flattening, and to do product defects analysis. The information is very useful in improving forming process and reducing defects. FDM is an efficient tool for temperature profile determination. See FEM/FDM Application Areas.

Metal Pass consulting utilizes FEM and FDM to improve your rolling mill operation and forming processes, to achieve accurate roll pass schedule, improved Level 2 model, and to reduce defects, etc. Metal Pass can guide you to improve your production process in a very wide range with application of FEM/FDM. See detailed Metal Pass Work Areas in this aspect.

Please refer to the Metal Pass Consulting in the section FEM/FDM Analysis for details.

Model Training  (Ask a question)

Based on the large number of web-based software programs, Metal Pass provides hands-on training on mill model and mill design/development. The training schedule consists of 20 modules. Every module has technical discussion and lab excise, etc. Hands-on lab is an effective way for students to quickly gain experience on mill parameter calculation and mill design/development. The training schedule can be customized based on each company's practice. For more details, see "Model Training: Steel Rolling Process Modeling and Mill Design ".

Metal Pass Resources Available for Consulting  (Ask a question)

As an industrial expert, Metal Pass has rich resources for mill consulting, especially in the steel mill process modeling and computer application. Detailed listing for the resources is described in a separate file, which covers following topics:

See the profile for the primary consultant Dr. Benjamin Li. You may also view our company profiles. Please contact us via email admin@metalpass.com or by phone (001) 503 516 9625 for top quality consulting services.

Metal Pass has dozens of research reports and some software applications available at no charge for the Metal Pass Consulting clients (under approval by Dr. Benjamin Li).

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