Training Course Seminar Workshop Provider

Training Overview

A rolling mill is a machine or factory for shaping metal by passing it between a pair of work rolls.

Rolling mills are often incorporated into integrated steelworks, but also exist as separate plants and can be used for other metals, and other materials.

Rolling mills historically have been of several kinds:

Depending on the temperature of the metal being rolled, rolling mills are typically hot or cold rolling mills. A slitting mill was used to cut flat bar iron into rods for nail-making. A tinplate works normally contained at least two rolling mills, one for hot rolling and the other for cold rolling single plates, prior to tinning. Puddled iron, after consolidation with a powered hammer (shingling), was rolled into bar iron using a rolling mill with grooved rolls. The grooves provided were progressively smaller, so that on successive passes through the rolls, the cross-section of the bar became smaller and the bar itself longer. By designing the rolls appropriately, it is possible to obtain iron or steel with various cross-sections, including I-shaped girders and railway rails.

For silversmithing mainly two types are used, a flat one (with two cylindrical rolls) for rolling sheet and one with grooved rolls for rolling octagonal wire. The rolls are made of hardened steel.

You can imagine how this might be used in the process of making aluminum foil. An aluminum ingot enters the rolling mill with a thickness of 45 cm. after passing through a hot rolling mill 12 to 16 times it is reduced to a thickness of just 5 cm. The aluminum then goes to the cold rolling mill to reduce it to its final thickness of less than 0.20320 mm.

Kilns are thermally insulated chambers, or ovens, in which controlled temperature regimes are produced. They are used to harden, burn or dry materials. Specific uses include:

To dry green lumber so that the lumber can be used immediately Drying wood for use as firewood Heating wood to the point of pyrolysis to produce charcoal For annealing, fusing and deforming glass, or fusing metallic oxide paints to the surface of glass For cremation (at high temperature) Drying of tobacco leaves Firing of material, such as clay, to form ceramics Drying malted barley for brewing Smelting ore to extract metal Heating limestone with clay to make cement

Training Objectives

To provide a clear understanding of the key aspects of rolling mills and kiln, its advantages and limitations. To demonstrate how to develop a successful operational program at your organisation and to provide you with the practical and effective methods you need to perform an analysis.

Training Methodology

The proposed course will combine presentation of the key principles, methods, and best practices and enforces the learning with case studies and Question & Answer workshops to maximize the benefits to the participants. The comprehensive course notes and presentation material will provide valuable reference.

Training Contents

Day 1

Introduction to Roll Mills

Theory Application

Session 1

Hot Rolling Cold Rolling Slitting Coiling

Session 2

Rolling Mill Components and Control Systems Mill Management Tools Overview of Advanced Control Benefits Roughing and Plate Mill Control Simulation of Rolling Mills Gauge Control for Single Stands Roll Eccentricity Control Flatness Control

Session 3

Supervisory Control Multivariable and Model-Based Mill Controls Predictive Control for Finishing Mills

Session 4

Control Benchmarking Fault Monitoring

Day 2

Introduction to Kiln Burning

Theory Application

Types of Kilns

Wet Process Kilns Long Dry Kilns Travelling Grate Preheater Kilns Cyclone Preheater Kilns Cyclone Preheater Kilns with Riser Duct Firing Precalciner Kilns

Kiln Operational Parameters

Material Residence Time Kiln Degree of Fill Kiln Slope Kiln Capacity

Kiln Design Parameters

Burning zone heat loading Secondary air velocity Burning zone gas velocity Kiln exit gas velocity Kiln exit gas temperature Preheater tower gas velocities Preheater tower pressure drops Preheater tower exit gas temperature Volatile concentrations Material residence time Cooler grate loading Cooler air supply Kiln dust cycles

Training Outcomes/Objectives

At the end of the program, participants will be able to:

Develop a working knowledge of the various typesof rolling mills and kilns; Enhance their knowledge and skills to identify and address the problems associated with rolling mills and kilns; Implement plans that are cost effective and aligned to strategic goals; Improve performance by developing detailed specifications with service partners;

Who Should Attend

Plant Engineers and managers, Maintenance Engineers, production managers and engineers, manufacturing managers and engineers etc

Instructor FOCUS's Team Expert Schedule On Request 2 days Venue - - Tuition Fee  Rp. 3.600.000,-   per participant, excluding accommodation & tax. Registration Send by email -or- fax to:

PT. FOCUS TRACO INDONESIA Wisma Pakuan, Jl. Pakuan 12 BOGOR – 16143

(021) 7009-9943   (0251) 2169-150 (0251) 7534-984 training@focustraco.com  

Training Overview

A rolling mill is a machine or factory for shaping metal by passing it between a pair of work rolls.

Rolling mills are often incorporated into integrated steelworks, but also exist as separate plants and can be used for other metals, and other materials.

Rolling mills historically have been of several kinds:

Depending on the temperature of the metal being rolled, rolling mills are typically hot or cold rolling mills. A slitting mill was used to cut flat bar iron into rods for nail-making. A tinplate works normally contained at least two rolling mills, one for hot rolling and the other for cold rolling single plates, prior to tinning. Puddled iron, after consolidation with a powered hammer (shingling), was rolled into bar iron using a rolling mill with grooved rolls. The grooves provided were progressively smaller, so that on successive passes through the rolls, the cross-section of the bar became smaller and the bar itself longer. By designing the rolls appropriately, it is possible to obtain iron or steel with various cross-sections, including I-shaped girders and railway rails.

For silversmithing mainly two types are used, a flat one (with two cylindrical rolls) for rolling sheet and one with grooved rolls for rolling octagonal wire. The rolls are made of hardened steel.

You can imagine how this might be used in the process of making aluminum foil. An aluminum ingot enters the rolling mill with a thickness of 45 cm. after passing through a hot rolling mill 12 to 16 times it is reduced to a thickness of just 5 cm. The aluminum then goes to the cold rolling mill to reduce it to its final thickness of less than 0.20320 mm.

Kilns are thermally insulated chambers, or ovens, in which controlled temperature regimes are produced. They are used to harden, burn or dry materials. Specific uses include:

To dry green lumber so that the lumber can be used immediately Drying wood for use as firewood Heating wood to the point of pyrolysis to produce charcoal For annealing, fusing and deforming glass, or fusing metallic oxide paints to the surface of glass For cremation (at high temperature) Drying of tobacco leaves Firing of material, such as clay, to form ceramics Drying malted barley for brewing Smelting ore to extract metal Heating limestone with clay to make cement

Training Objectives

To provide a clear understanding of the key aspects of rolling mills and kiln, its advantages and limitations. To demonstrate how to develop a successful operational program at your organisation and to provide you with the practical and effective methods you need to perform an analysis.

Training Methodology

The proposed course will combine presentation of the key principles, methods, and best practices and enforces the learning with case studies and Question & Answer workshops to maximize the benefits to the participants. The comprehensive course notes and presentation material will provide valuable reference.

Training Contents

Day 1

Introduction to Roll Mills

Theory Application

Session 1

Hot Rolling Cold Rolling Slitting Coiling

Session 2

Rolling Mill Components and Control Systems Mill Management Tools Overview of Advanced Control Benefits Roughing and Plate Mill Control Simulation of Rolling Mills Gauge Control for Single Stands Roll Eccentricity Control Flatness Control

Session 3

Supervisory Control Multivariable and Model-Based Mill Controls Predictive Control for Finishing Mills

Session 4

Control Benchmarking Fault Monitoring

Day 2

Introduction to Kiln Burning

Theory Application

Types of Kilns

Wet Process Kilns Long Dry Kilns Travelling Grate Preheater Kilns Cyclone Preheater Kilns Cyclone Preheater Kilns with Riser Duct Firing Precalciner Kilns

Kiln Operational Parameters

Material Residence Time Kiln Degree of Fill Kiln Slope Kiln Capacity

Kiln Design Parameters

Burning zone heat loading Secondary air velocity Burning zone gas velocity Kiln exit gas velocity Kiln exit gas temperature Preheater tower gas velocities Preheater tower pressure drops Preheater tower exit gas temperature Volatile concentrations Material residence time Cooler grate loading Cooler air supply Kiln dust cycles

Training Outcomes/Objectives

At the end of the program, participants will be able to:

Develop a working knowledge of the various typesof rolling mills and kilns; Enhance their knowledge and skills to identify and address the problems associated with rolling mills and kilns; Implement plans that are cost effective and aligned to strategic goals; Improve performance by developing detailed specifications with service partners;

Who Should Attend

Plant Engineers and managers, Maintenance Engineers, production managers and engineers, manufacturing managers and engineers etc

Instructor FOCUS's Team Expert Schedule On Request 2 days Venue - - Tuition Fee  Rp. 3.600.000,-   per participant, excluding accommodation & tax. Registration Send by email -or- fax to:

PT. FOCUS TRACO INDONESIA Wisma Pakuan, Jl. Pakuan 12 BOGOR – 16143

(021) 7009-9943   (0251) 2169-150 (0251) 7534-984 training@focustraco.com  

Course Overview

A rolling mill is a machine or factory for shaping metal by passing it between a pair of work rolls.

Rolling mills are often incorporated into integrated steelworks, but also exist as separate plants and can be used for other metals, and other materials.

Rolling mills historically have been of several kinds:

Depending on the temperature of the metal being rolled, rolling mills are typically hot or cold rolling mills. A slitting mill was used to cut flat bar iron into rods for nail-making. A tinplate works normally contained at least two rolling mills, one for hot rolling and the other for cold rolling single plates, prior to tinning. Puddled iron, after consolidation with a powered hammer (shingling), was rolled into bar iron using a rolling mill with grooved rolls. The grooves provided were progressively smaller, so that on successive passes through the rolls, the cross-section of the bar became smaller and the bar itself longer. By designing the rolls appropriately, it is possible to obtain iron or steel with various cross-sections, including I-shaped girders and railway rails.

For silversmithing mainly two types are used, a flat one (with two cylindrical rolls) for rolling sheet and one with grooved rolls for rolling octagonal wire. The rolls are made of hardened steel.

You can imagine how this might be used in the process of making aluminum foil. An aluminum ingot enters the rolling mill with a thickness of 45 cm. after passing through a hot rolling mill 12 to 16 times it is reduced to a thickness of just 5 cm. The aluminum then goes to the cold rolling mill to reduce it to its final thickness of less than 0.20320 mm.

Course Objectives

To provide a clear understanding of the key aspects of rolling mills and kiln, its advantages and limitations. To demonstrate how to develop a successful operational program at your organisation and to provide you with the practical and effective methods you need to perform an analysis.

Course Methodology

The proposed course will combine presentation of the key principles, methods, and best practices and enforces the learning with case studies and Question & Answer workshops to maximize the benefits to the participants. The comprehensive course notes and presentation material will provide valuable reference.

Course Contents

Day 1

Introduction to Roll Mills

Theory Application

Session 1- Hot Rolling

Hot Rolling Process Hot Rolling Applications Types of Hot Rolling Mills

Session 2- Cold Rolling

Physical Metallurgy of Cold Rolling Degree of Cold Work Cold Rolling as a Manufacuring Process

Session 3- Other Rolling Processes

Tube Beading Skin Pass Foil Rolling Plate Roll Bending Progressive Roll Forming

Day 1

Session 4

Rolling Mill Components and Control Systems Mill Management Tools Overview of Advanced Control Benefits Roughing and Plate Mill Control Simulation of Rolling Mills Gauge Control for Single Stands Roll Eccentricity Control Flatness Control

Session 5

Supervisory Control Multivariable and Model-Based Mill Controls Predictive Control for Finishing Mills

Session 6

Control Benchmarking Fault Monitoring

Learning Outcomes/Objectives

At the end of the program, participants will be able to:

Develop a working knowledge of the various typesof rolling mills; Enhance their knowledge and skills to identify and address the problems associated with rolling mills; Implement plans that are cost effective and aligned to strategic goals; Improve performance by developing detailed specifications with service partners;

Who Should Attend

Plant Engineers and managers, Maintenance Engineers, production managers and engineers, manufacturing managers and engineers etc

Instructor FOCUS's Team Expert Schedule On Request 2 days Venue - - Tuition Fee  Rp. 3.600.000,-   per participant, excluding accommodation & tax. Registration Send by email -or- fax to:

PT. FOCUS TRACO INDONESIA Wisma Pakuan, Jl. Pakuan 12 BOGOR – 16143

(021) 7009-9943   (0251) 2169-150 (0251) 7534-984 training@focustraco.com  

Course Overview

A rolling mill is a machine or factory for shaping metal by passing it between a pair of work rolls.

Rolling mills are often incorporated into integrated steelworks, but also exist as separate plants and can be used for other metals, and other materials.

Rolling mills historically have been of several kinds:

Depending on the temperature of the metal being rolled, rolling mills are typically hot or cold rolling mills. A slitting mill was used to cut flat bar iron into rods for nail-making. A tinplate works normally contained at least two rolling mills, one for hot rolling and the other for cold rolling single plates, prior to tinning. Puddled iron, after consolidation with a powered hammer (shingling), was rolled into bar iron using a rolling mill with grooved rolls. The grooves provided were progressively smaller, so that on successive passes through the rolls, the cross-section of the bar became smaller and the bar itself longer. By designing the rolls appropriately, it is possible to obtain iron or steel with various cross-sections, including I-shaped girders and railway rails.

For silversmithing mainly two types are used, a flat one (with two cylindrical rolls) for rolling sheet and one with grooved rolls for rolling octagonal wire. The rolls are made of hardened steel.

You can imagine how this might be used in the process of making aluminum foil. An aluminum ingot enters the rolling mill with a thickness of 45 cm. after passing through a hot rolling mill 12 to 16 times it is reduced to a thickness of just 5 cm. The aluminum then goes to the cold rolling mill to reduce it to its final thickness of less than 0.20320 mm.

Course Objectives

To provide a clear understanding of the key aspects of rolling mills and kiln, its advantages and limitations. To demonstrate how to develop a successful operational program at your organisation and to provide you with the practical and effective methods you need to perform an analysis.

Course Methodology

The proposed course will combine presentation of the key principles, methods, and best practices and enforces the learning with case studies and Question & Answer workshops to maximize the benefits to the participants. The comprehensive course notes and presentation material will provide valuable reference.

Course Contents

Day 1

Introduction to Roll Mills

Theory Application

Session 1- Hot Rolling

Hot Rolling Process Hot Rolling Applications Types of Hot Rolling Mills

Session 2- Cold Rolling

Physical Metallurgy of Cold Rolling Degree of Cold Work Cold Rolling as a Manufacuring Process

Session 3- Other Rolling Processes

Tube Beading Skin Pass Foil Rolling Plate Roll Bending Progressive Roll Forming

Day 1

Session 4

Rolling Mill Components and Control Systems Mill Management Tools Overview of Advanced Control Benefits Roughing and Plate Mill Control Simulation of Rolling Mills Gauge Control for Single Stands Roll Eccentricity Control Flatness Control

Session 5

Supervisory Control Multivariable and Model-Based Mill Controls Predictive Control for Finishing Mills

Session 6

Control Benchmarking Fault Monitoring

Learning Outcomes/Objectives

At the end of the program, participants will be able to:

Develop a working knowledge of the various typesof rolling mills; Enhance their knowledge and skills to identify and address the problems associated with rolling mills; Implement plans that are cost effective and aligned to strategic goals; Improve performance by developing detailed specifications with service partners;

Who Should Attend

Plant Engineers and managers, Maintenance Engineers, production managers and engineers, manufacturing managers and engineers etc

Instructor FOCUS's Team Expert Schedule On Request 2 days Venue - - Tuition Fee  Rp. 3.600.000,-   per participant, excluding accommodation & tax. Registration Send by email -or- fax to:

PT. FOCUS TRACO INDONESIA Wisma Pakuan, Jl. Pakuan 12 BOGOR – 16143

(021) 7009-9943   (0251) 2169-150 (0251) 7534-984 training@focustraco.com