Together
to success
since 1997
INTECH GmbH
We are interested in cooperation with the manufacturers of equipment for billet roughing (reduction), who are looking for an official and reliable distributor that deals with supply & delivery of their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your roughing stands. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative in Russia, our marketing staff will carry out a market research in order to check the demand for billet roughing (reduction) mills, will submit a market overview for billet roughing stands that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your billet roughing (reduction) plants and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods, for various types of billet roughing (reduction) plants in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for billet roughing (reduction) mills as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your billet roughing (reduction) mills into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of roughing stands. They will also provide necessary training and guidance for the customer’s personnel.
Cogging stands play an important role in section rolling production. These stands ensure high performance drawing within the restricted space to make the best use of the heat generated by a continuous cast billet and extending the overall length of a billet. This facilitates the pouring process and production of high-quality billets. High-reduction roughing mills can be of different designs such as planetary mills, screw-rolling mills and small-scale quick-change two-hi alternating horizontal and vertical cogging stands.
The variety of cogging machines designed and implemented by the leading companies shows an intensive search for the most efficient process solutions in this area.
The main feature of planetary rolling is that metal deformation is performed using a large number of operating rolls with a fair small contact area determined by the billet’s low-speed feeding. A facilitative stress pattern, small widening and lack of tensile stress on the major part of the cogging area make it possible to perform deformation without disturbing continuity of low-plasticity alloys.
Forces generated by the operating rolls of small diameter are relatively low, thus enabling to roll materials with high deformation resistance. Significant drafting of a billet performed at a high deformation speed in one stand intensively increases the temperature of the metal that comes out of the stand. It is especially important when rolling hard-to-deform steels and alloys that have a narrow deformation temperature range.
Planetary rolling allows drawing up to 50 billets using one stand, thus making it possible to replace 18-20 standard two-hi stands. Finishing rolling is performed in a small train of compact rolling stands. The equipment requires small area to be arranged. These mills are the most reasonable to be used when rolling high-alloy and special steels with the performance of up to 100 thousand tons per hour.
High drafting rate (≥ 80%) is achieved using screw-rolling planetary stands.
Rolls in screw-rolling planetary stands are located in a rotating rotor, and the billet moves in the axial direction without any rotation. Performance depends on the standard size of a mill and on the drawing degree of a stand and can vary from 11-36 t/h for small units (a billet is a circle of 80 mm in diameter) to 266-820 t/h for large units (a circle of 320 mm in diameter).
During deformation process while performing screw-rolling, metal is heated up to 80-100°С due to intense drafting, thus enabling to reduce the temperature difference along the length of a billet and decrease the heating temperature of the billet as well. Hence, planetary screw-rolling has the following advantages: it is possible to perform a wide-range adjustment of the rolling speed as well as of billet and feed diameters by changing the rolls’ sizes and continuously regulating the rolls’ rotation speed.
Performance depends on the standard size of a mill and on the drawing degree of a stand and can vary from 11 to 850 t/h. Possible mismatch of pouring and rolling speeds is compensated by slipping of metal relatively to the rolls.
Another type of rolling with intense drafting is transverse screw-rolling using a stationary three-hi stand.
A rotating billet with a round cross section is deformed by three conical tilted mill rolls. During screw-rolling, the structure of all the metal being deformed is intensively worked out. Using one three-hi screw-rolling stand, the billets with the drawing of 6-8 can be drafted, which is equivalent to installation of 6-8 longitudinal-rolling stands.
Two forming two-hi stands are additionally installed before a screw-rolling stand when processing square billets to roll a hot billet without any rotation into a round rolled product, which is then transferred to a screw-rolling stand.
The low speed of the rolled product coming out of a screw-rolling stand allows cutting the product using flying shears into specific cut lengths. This makes possible to exclude cutting the rolled product twice, decrease the length and weight of a cooling rack.
High drawing coefficients per one pass and intense shift movements ensure efficient deformation of the metal structure, increase its physical and mechanical properties by 1.5-2.5 times and ensure long lifetime of the parts in operation.
However, the surface defects of a billet are not removed, but enhanced instead. Transverse screw-rolling is reasonable to apply in billet production of machine building enterprises to make the best use of existing billets and to widen their grade schedule.
The feature of combining metal deformation procedures using both screw- and longitudinal-rolling stands is that in the of a screw-rolling stand, the billet is moved axially and rotary, and in the deformation zone of a longitudinal-rolling stand, the billet is moved axially only. Therefore, when combining these two procedures, additional twisting deformation of metal occurs in the space between the stands due to rotary movement, without any alteration of the dimensions of the billet’s section
Billet twisting between stands is taken into account when calculating the force parameters of the rolling procedure.
Forming two-hi stands are additionally installed before a screw-rolling stand when processing square billets in order to give them a round shape.
It is the most reasonable to use these stands in the production of rolled products with a restricted length (4-6 m) and billets for further rolling of grinding rods and balls.
Based on many years of experience, one can conclude that section rolling production is being developed to increase rolling speed, extend geometrical and grade schedule, and increase operating time by reducing the time needed for auxiliary operations that are related to transfer of stands and readjustment for another type of products.
Recently there has been a tendency to use hot charge and combine casting and rolling, rolling-and-splitting technology and continuous welding-and-rolling procedures.
Using rolling mills as a part of combined casting units requires compactness, flexibility and operational readiness.
A small cogging train ensures increased drafting due to forced feeding of the rolled product by an additional support.
Due to increase of drafting intensity in each stand and decrease of inter-stand spaces, the number of operational stands is reduced, thus the longitudinal size is decreased. A small train consists of four alternating horizontal and vertical stands and is designed for billet rolling.
When rolling in the first stand, a billet is freely fed with a gripping angle of up to 21° and drafting of approximately 11%; while in the following stands, the metal is forced from the previous stands with a gripping angle of up to 45° and drafting of up to 48%. When the metal is gripped by the next stand, the drive control system automatically changes the ratio of rolling speeds in the stands, thus excluding additional dragging and ensuring further rolling with low strain. The system is activated by sensors installed in the gaps of housings, sensing horizontal dragging power or strain.
The length of a train along the rolling line is decreased due to the fact that the rolls with cushions are installed on the common housing where the racks that take roll forces are common for nearly located stands. Hence, there are no inter-stand spaces and the distance between the axes of nearly located stands is approximately 1 m.
When rolls are being changed, the rolls and cushions are pulled out of the base openings towards the transfer direction on special cars with a hydraulic drive. The overall time of transfer does not exceed 15 minutes.
This small four-stand train with the structure described above has a size of 3 m by the axes of last stands and replaces a train of six standard stands with a size of 16 m.
Rolling is performed with strain in all inter-stand spaces. Changing is carried out by previously assembled stands with special mechanisms, and the roll opening is adjusted by rotation of eccentric bushings.
This design has high radial rigidness, compactness and relatively low metal consumption; however, it has a number of disadvantages as well. It is feasible to be used for production of 70-200 thousand tons per year.
Upon becoming the official distributer of roughing stands, our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (roughing stands) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!