Scope and opportunities of energy conservation and monitoring in rolling mills

Efficient control, monitoring and energy conservation plays important role in the assessment of annual investment on electricity consumption in every industry. In central India there are few industries who invest approx. one third from their profit on electricity bills on every month. Out of several loads the one which is considered as most energy intensive load is process where to reduce the thickness of the cold rolling coils as per requirement. Here the power requirement is fulfilled by a distribution transformer which is used to drive the mill motors, entry tension reel, dispatch tension reel and auxiliaries. The data available in an industry can be used to reduce the power consumption and ultimately which may lead to lessen the electricity bill of an industry. To reduce the thickness of the sheet is limited and in order to reduce the power consumption, the constraints such as grade of coil, number of passes and mill reduction capacity has to be taken into consideration. The data such as weight of the coil, number of existing passes, the starting thickness and ending thickness is available in industry and can be used to calculate length of coil and further using the length average speed and total time can be calculated using simple mathematics. In order to monitor and control the several physical quantities such as flow, pressures, temperatures, liquid levels and their detection, several transducers are used in an industry. Proper selection of these devices and the knowledge associated with them are necessary for their implementation and figure out the faults associated with it. Thus, the overall measuring processes are improved and cost of future expansion is reduced by proper knowledge and ratings of the transducers.