India has been growing rapidly when it comes to the steel industry. In comparison to other countries, India rightfully caters to the world’s needs with its high-quality steel solutions. Nowadays, manufacturers have only one goal in mind, which is to provide only superior quality products to their customers.
But how can one achieve that level of quality? It is simply to install state-of-the-art machinery to give attention to detail and produce better quality products. However, what often stops multiple companies from doing so is the cost of operation. Let us find out how we can reduce the operating cost of rolling mills.
What is the main purpose of a rolling mill? It is to form metal. Depending on the client’s demands and the goal they want to achieve, the thickness will vary. Now there are various categories of rolling mills, and they are differentiated based on the temperature. For instance, if the temperature is above the level of recrystallisation, i.e., hot, then it will be considered hot rolling but if it remains below the recrystallisation temperature, then it shall be regarded as cold rolling.
One of the biggest concerns of manufacturers worldwide is the operating cost. Luckily, with a few alterations to the operating process, the manufacturers can drastically decrease the cost without altering the end product.
Here are a few steps with which you can reduce rolling mill costs-
1. Energy Consumption
The first thing that needs to be done is the reduction of energy consumption. On a daily basis, there is a lot of energy waste during operation, and there is no track of it. Our priority is to reduce the energy cost of the unit. How should we do that?
There is a dire need for high-quality machinery in daily operation. The main reason is that advanced machinery and its mechanism will reduce rejects. If there is a reduction of rejects from 1.5% to 2%, this small shift can decrease fuel use up to 9%.
The electricity used during the rolling process can also be decreased significantly if motors are used in conjunction. This process is highly efficient and reduces nearly 1%-2% energy consumption.
A decrease in oxygen levels by even 1.5% in the heating furnace effectively reduces the cost. Energy consumption reduces down to 2.4% once the oxygen reduction is implemented.
2. Process Optimization
Process optimisation is a key way to control and reduce the operating costs of rolling mills. Multiple components work in sync to utilise state of the art rolling mill. There needs to be constant analysis, evaluation, and improvisation for the best output. The most essential is to reduce downtime and accurate interconnection of the production stages.
This method effectively increases the productivity of the operation. One can also accurately measure the energy used per unit. In general, optimisation reduces the risk of scale loss and heightens efficiency. This is a practice that can be adopted by steel plant consultants and multiple different metal manufacturers.
3. The Right Equipment
High-quality rolling mill equipment plays a major role in the operating cost and impacts the overall value in many ways. Good quality equipment reduces maintenance costs as you will omit the need for regular maintenance as these are much more reliable.
It also reduces system downtime significantly and improves operation costs. High-quality equipment also has replacement parts readily available, making replacing much smoother.
4. Leverage Automation
When it comes to reducing the cost of the rolling mill, leveraging automation can be incredibly useful. Making any production process efficient requires advanced mechanical equipment, process technology, and automation functions. These three together can transform the overall cost of operation.
The more suitable software and electrical equipment used will allow more accurate information to be received by mill operators to automate and unify mill setup. This process improves overall operating practices and reduces costs.
Find The Most Reliable Partner in Steel Forming
The Steefo Group is your reliable partner in steel forming when it comes to steel forming. They provide the most high-quality products and turnkey solutions from concept to commissioning. Advanced machinery, highly skilled engineers, state-of-the-art manufacturing facilities, and undisputed quality make the Steefo Group an eminent steel rolling mill manufacturing company in India.