Rolling Mill Production
MBC Electric rolling mill stands are manufactured in three distinct groups: Preparation, Intermediate, and Finish Stands. The preparation group varies depending on the specifications of the facility where the rolling stands will be installed. In conventional rolling mill projects, trio preparation stands are used, whereas in continuous rolling mill projects, specially designed cartridge-type preparation stands are utilized.
For a project equipped with a trio preparation stand, the intermediate and finish groups can either continue with classic rolling stands or with a cartridge-type horizontal and vertical stand sequence.
MBC Electric rolling mill stands come with full engineering, manufacturing, and quality assurance. Like all our products, the production of both classic and cartridge-type rolling stands is carried out with precision and computer-aided machines in line with current technological standards. Upon request, a hydraulic clamping system can be implemented in the chassis connection of classic rolling stands. Additionally, if the rolling axis needs to remain fixed during pass changes, a hydraulic pushing system can be added to enable horizontal movement of the stand.
The rolls used in our rolling stands have passed all necessary tests according to material specifications and possess all quality certificates and documentation. Furthermore, the calibers of our rolls are processed with high precision using our computer-aided technological machines.
Types of Rolling Mill Stands We Manufacture
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Trio Preparation Stand
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Duo Rolling Stands (Intermediate and Finish Groups)
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Cartridge-Type Rolling Stand
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Convertible Rolling Stand
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Reversible Rolling Stand
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Universal Rolling Stand
Lifting (Crane) Magnets
Scrap Magnets
These are circular electromagnets. As the name suggests, scrap magnets are electromagnetic equipments designed to carry scrap metals at site. They help reduce operation times. Electromagnets form a magnetic field under the magnet to easily pick even the small pieces that cannot be picked by a grapple.
Scraps magnets are widely used at steel mills and scrap yards. Additionally, they are preferred at scrap yards to collect scrap metals on the ground.
They are most commonly used on overhead cranes and excavators. For underwater applications, bodies with extra IP protection can be preferred.
Body type of the magnet can be determined as per customer's preference as one of the below.
Scrap Magnets with Cast Bodies: The magnet is manufactured as a single-piece cast body. This makes the magnets extremely durable against impact. The prices of these magnets are somewhat higher than others. Available sizes are limited to mold diameters each manufacturer has.
Scrap Magnets with Fabrication Steel Bodies: The body of the magnet is formed by welding bent steel plates. After that, resin-coated coil is placed inside the magnet and sealed. Different diameters are available as per customer's request.
Things to Consider When Choosing Scrap Magnets
- Where the magnet will be used (steel mill, scrap yard, furnace charging, scrap collection, lifting of cut plates, etc.) should be specified.We can then recommend you a magnet with a cast body or a fabrication steel body.
- Magnet's duty cycle should be specified.Duty cycle can range anywhere between 50% and 80%.The higher the duty cycle the more the magnets winding and thus the heavier and more expensive the magnet.
- Lifting capacity of the crane or excavator the magnet will be used on should be specified.
- Type and density of scrap should be specified.
We have 4 types of scrap magnets available for different applications.
- Electric Magnets
- Battery Magnets (for using on excavators or forklifts)
- Hydraulic Magnets (for using on excavators)
- Built-in Battery Magnets
Billet Magnets
These are among the essential equipment for steel mills. Both electro permanent magnets and electromagnets can be used for billet lifting applications. Thanks to specially developed resins, billets with core temperatures up to 600 °C can be handled safely.
They are used initially for transporting the billets from cooling bed which is after tundish at steel mills. After this stage, these magnets are used for stockpiling of billets, loading them on the vehicles and transporting them to furnace feeding units of rolling mills. Electropermanent magnetic systems are designed with a safety factor of 3. Whereas for electomagnetic systems the safety factor is minimum 2 (Relevant Standard: UNI EN 13155: 2003 + A2: 2009 Lifting Appliances - Safety - Non-fixed load lifters). To illustrate, an electromagnetic system to lift :7 nos of 150x150mm, 12m-long billets with a total weight of 15 tons is designed based on a minimum load of 30 tons.
Electropermanent magnetic systems are ideal solutions for billet lifting applications as they operate with a "zero drop" principle. These systems do not drop the load even in case of power failures or damaged magnet cables and just need to initially grab the load. Additionally, these systems do not have backup battery units and hence no maintenance is required. Neodymium or samarium cobalt is used inside these magnets. Having many advantages, electropermanent magnets are costlier than electromagnets.
Due to cost advantage and availability of adding many functions to the systems, electromagnetic systems are commonly preferred for billet lifting applications. Such systems have backup battery units to prevent dropping of load in case of a power failure.
Things to Consider When Choosing Billet Magnets
- Where the magnet is to be used (Cooling bed, stockpiling, vehicle loading, stock yard, etc.),
- Crane lifting capacity,
- Number, cross section, minimum and maximum lengths of billets to be lifted at once
- Maximum temperature of billets
(Electropermanent magnetic systems systems can be used to lift billets with core temperatures up to 600 °C. As they start losing magnetic properties beyond this temperature which makes it impossible for the magnet to catch).
Rebar Magnets
Rebar lifting magnets are used for stockpiling of tightly fastened rebars at the stockyard or loading of them on the vehicles.
Compared to standard applications using chains, this type of magnetic applications can be conducted by a single operator. The load is grabbed and transported either by the controls inside the cranes control cabin or using a remote-control unit. When stockpiling rebar bundles at the stockyard or on vehicles there is no need to leave space between them and this operation does not require an additional operator for lifting strap. Hence, this system works a lot faster. Additionally, using magnetic systems prevents possible damages (scratches, bending, etc.) on the material caused by systems that use hooks or chains.
Power and number of magnets in the magnetic system are determined based on length and weight of rebar bundles to be lifted. These magnetic systems can be designed to lift rebar bundles from 6 to 24 meters long. Fixed or telescopic beam can be used according to the place of application.
Magnetic systems can lift multiple rebar bundles at once. Applications used to lift 3,4 or 5 rebar bundles are commonly seen. Such applications provide significant time savings. Number of rebar bundles that can be lifted is entirely dependent on the crane capacity. Lifting and transporting of multiple rebar bundles ensures the most efficient use of stockyard. Loading of truck, based on carrying capacity and stockyard's availability, can be completed in 5-15 minutes.
Things to Consider When Choosing Rebar Magnets
- Application details (rolling mill, stockyard, truck loading and unloading, etc.),
- Maximum bundle diameter (most common bundle diameters are Ø250mm - Ø300mm,
- Minimum and maximum length of rebar bundles,
- Number of rebar bundles to be lifted at once,
- Crane lifting capacity and number of crane carriages and distance between these carriages,
- Temperature of the material to be lifted,
- Number of ties on bundles and distance between these ties