PROCESS EQUIPMENT UPDATE
throughput posed a particular challenge for the wear protection of the two machines. Tis challenge was met by fabricating the blast chamber from manganese steel and lining it with 10mm thick, easily replaceable, wear plates – also made from manganese steel. For shot blasting operations, where a
higher surface roughness is specified, each machine can be run separately. In such cases the transport speed of the steel plates is reduced to 4m/minute. To prevent media spillage, each machine is equipped with a high-performance blow-off system.
to vertical position before entering the shot blast machine.
TWO MACHINES COMBINED INTO ONE OVERALL SYSTEM To meet the customer’s surface quality demands within the specified timeframe, the Rösler engineers developed an innovative equipment concept. It combines two identical shot blast machines into one system, where the stainless steel plates are passing through the two machines sequentially, and each machine uses a different blast media. Te individual machines are equipped with 12 Gamma 400G turbines with an installed power of 37kW per turbine. On each side of the blast chamber six turbines are mounted at an angle. Tis turbine arrangement ensures that the plates are evenly covered by the blast media across their entire width. Te total blast media throughput per machine amounts to 12,000kg/minute – a huge quantity compared to the throughput of between 2,000 and 3,000kg in standard shot blast machines. Te high media
EXTREMELY STURDY DESIGN FACILITATES MAINTENANCE Te large size of the steel plates and their high weight demanded an extremely sturdy design of the two shot blast machines. For example, the maximum load per running meter amounts to four tons. Te overall machine dimensions are also impressive: Te entire system is 17m long and 14m high. It was placed in a pit with a depth of 2.5m. Te blast media cleaning system and media hopper were placed on the roof of each shot blast machine. For quick and easy maintenance the machines are equipped with four inspection platforms on different levels that can be easily reached by suitable stairways. Tis enhances the already impressive appearance of the shot blast system, designed for processing 315,000 tons of stainless steel plates.
CONTROL SYSTEM DESIGNED FOR FULLY AUTOMATIC OPERATION Te production unit consisting of the two Rosler shot blast machines and the pickling line is equipped with a level 2 control system. Tis upper- level system provides all the data required for the process, for example, the plate type and the required surface roughness. Te information also specifies whether a special plate type must pass through both shot blast machines or just one. Tis ensures that the required surface roughness and finish values are achieved without any manual intervention whatsoever.
21 SHIPPING CONTAINERS Te entire vertical shot blasting system was designed and built in
Germany. It was shipped to China by sea in 21 containers. Rösler service engineers, some of them from Germany, installed the system at the customer’s location. Another challenge was that the installation had to take place during a time of strict Chinese travel restrictions and quarantine regulations. In addition, the installation had to be carefully coordinated with the service engineers of the company supplying the pickling line. Vasili Schaermann at Rösler reports: “Only after the installation at TISCO could we test the entire system. Because of the extraordinary size of the shot blast system, such a test was not possible during the production phase at our plant in Germany. Fortunately, the commissioning at the customer location was successful. Actually, the entire project went very well. In the future we will build other vertical shot blast machines, and I would like to point out that we are pleased with the cooperation between TISCO and Rösler.” Te customer was very satisfied with
how the project was handled and the achieved shot blasting results. Te customer’s employees were particularly impressed by the ability of the Rösler experts to fully satisfy the TISCO demands. Te big, sophisticated shot blasting system from Germany will certainly help TISCO to strengthen its position as one of the leading stainless manufacturers in the world.
ABOVE: Directly in front of the shot blasting system the stainless steel plates are moved into a vertical position. They are then passing through the shot blast system and pickling line on special roller conveyors
TOP LEFT: The vertical shot blasting system is 14m high and is placed in a pit with a depth of 2.5m
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