Roll Coolant Systems: Cold rolling mill

Cold rolling mills filtration system has many functions. It has to remove the scale and scum generated during rolling. The temperature has to be controlled along with flow and pressure.

A cold rolling mill system usually consists of a large tank. The dirty fluid enters into the dirty fluid compartment. Using baffles the complete flow is passed through Magnetic separator into the semi clean compartment. This fluid is then sucked by large pumps and passed through self-cleaning filter and PHE skid to control the temperature. A pressure control valve ensures constant pressure is supplied to the mill.

The tanks have agitators to continuously mix the coolant. Belt skimmers are also mounted on the tank to remove the floating scum. To maintain the temperature of the tank, either electrical heaters are placed in thermic fluid tubes or the coolant is passed through housing heated by electrical heaters or steam. If finer filtration required then a different set of pumps are used to transfer dirty fluid to pneumatic vacuum filters.

Coolant Filtration System

Components

Magnetic coolant separator is device which cleans coolant liquid of very fine particles; it removes chips from the milling or grinding liquid. It has light and compact structure having strong magnetic power which can remove very fine particles. Read more
“Veeraja” has developed a self-cleaning filter, designed to handle large flows, higher pressures & heavy dirt loads. It cleans itself automatically either by sensing pressure drop across the filter, or by timer, whichever occurs earlier. Read more
Standard where the requirements are similar for various customers. This helps us in sizing the product to a standard arrangement, keeping the prices low. Read more
Some application require constant mixing or stirring or agitation. This can be achieved by Veeraja agitators. A geared drive rotates a set of blades at a predetermined speed. The design of the blades and the speed of rotation is determined based on its application. Sizing is done based on tank size, application viscosity. Read more
For finer processes of material removal like grinding and honing, a finer filtration level is required. If the fluid is not filtered to the desired filtration level, the particles leave a mark on the surface. Normal gravity filter does not give the desired filtration level. Also the media consumption is very high. Read more

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Features & Benefits

  • Complete in house design and manufacturing of all products required in the system
  • Tank :
    • Rounded corners to avoid accumulation and rusting in corners.
    • With manholes, inspection hatch, railing and ladders
  • Magnetic Separators :
    • Vertical or horizontal candle
    • Simple and rugged design for 24x7 operation
  • Self-cleaning filter :
    • Modular design
    • Economical design replacing the costly stainless steel wedge wire screens
  • PHE and pressure control skid :
    • Plate type heat exchanger with automatic temperature control valve.
    • Automatic pressure control valve with complete flow back pass arrangement during rolling direction changeover
  • Agitator and Skimmer :
    • Rugged design for 24x7 operation.
    • Option of Individual frame with bottom bearing/bush for added stability
    • Special blade design for proper mixing
  • Heating options :
    • Electrical heaters in tubes with thermic fluid placed inside tanks.
    • Steam heating jackets inside tanks
    • Forced circulation PHE with steam and PRV
    • Forced circulation through heater placed in separate housings.
  • Fine filtration :
    • Separate pumping station
    • Pneumatic Vacuum filter
    • New century design eliminates the blower

Bajaj Auto Ltd

A world class manufacturer in India. They manufacture 2 wheelers and 3 wheelers wide range of products.

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A world class manufacturer in India. They manufacture 2 wheelers and 3 wheelers wide range of products.

Application : Aluminum machining
Process : Machining, Drilling, Tapping, Boring
No of machine : 80 No’s
Fluid : Water based emulsion

Multiple part of a 2 wheeler are made of aluminum die cast. Components are machines, drilled and bored to achieve finished stage. This generates large quantum of chips. Considering the high production requirements multiple machines are working at the same time.

This generates a large quantum of chips. Chips were separated in individual tanks and fluid pumped back to machine. Chips had to be cleaned manually from each tank. This caused significant machine downtime. Customer wanted to reduce this machine down time and if possible completely eliminate it.

Properties of coolant like pH, concentration etc. had to be maintained at each machine. This caused irregularities and required lot of manpower. Due to the space limitation available for individual tanks, filtration level achieved was compromised resulting improper filtration reducing the coolant life and frequent breakdown of machines.

Customer wanted to explore the possibility of adding additional machine in the same shop floor to match the ever increasing production demand

Veeraja proposed a centralized filtration system with large conveyors and mesh drum filters. A layout was prepared with the process planners from Bajaj Auto ltd. Civil trenches were dug in existing machine shop. Advance in civil engineering has made it possible to dig inside the shop floor without disturbing adjacent machines.

Careful coordination with various agencies and technical team Bajaj Auto Ltd ensured that production is hampered the least. A large pit to accommodate a 15000 LPM central filtration which total tank capacity of more than 1,00,000 liters was constructed outside the shop. U shape gutters were fitted in the trenches and a central filtration was installed in the pit. A regularly tracked project execution ensured on time delivery and smooth transition from individual to Centralized filtration system

Individual tanks were removed and dirty fluid outlets of all machines were connected to the U shaped gutters. These carry the fluid and chips to the CFS. Sufficient gradient ensured all is transferred without any blockage and accumulation. Additional flushing nozzles tapped from high pressure supply line are used at regular intervals.

  • Coolant life increased from 3 months to 3 years.
  • New machines were added due to the space saved by removing individual tanks.
  • Manpower was reduced.
  • Lesser breakdown and downtime of machines increased production capacities.
  • Power consumption was reduced by 50%

Industries / Companies Which May Need Centralized Filtration Systems

Our experts will always be happy to help you select proper product / combination of product for your industry application.