AISTech 2019 — Proceedings of the Iron & Steel Technology Conference

6–9 May 2019, Pittsburgh, Pa., USA

DOI 10.1000.377.162

Induction Bar and Edge Heating Technology in the Hot Strip Mill

Gary Gepitulan 1, Hiroyuki Imanari 2, Eiji Hashimoto2, Tetsuji Doizaki2

1
TMEIC Corporation
2060 Cook Drive Salem, VA 24153, USA
Phone: 540-283-2132
Email: [email protected]
2
Toshiba Mitsubishi-Electric Industrial Systems Corporation (TMEIC)
Tokyo Square Garden, 3-1-1, Kyobashi, Chuo-ku, Tokyo 104-0031
Phone:+81-3-3277-4950
Email: [email protected], [email protected], [email protected]

Keywords: Steel Plant, Induction Heating, Edge Heater, Bar Heater

INTRODUCTION
Induction Heating (IH) technology has been in constant evolution following industrial and technological advancement since
the end of the 19th century. The principle of induction heating was discovered by Michael Faraday when he experimented on
induced currents by a magnet. James C. Maxwell developed later the unified theory of electromagnetism and James Pl Joule
described the heat produced by a current in a conductor, establishing the fundamental principles of induction heating [1].
Induction heating application has long been associated with the metals industry. It started when Sebastian Z. de Ferranti, who
in 1887 proposed IH furnace for melting metals [3]. That was the first filing of a patent on industrial application of IH. Later,
in 1891, F.A. Kjellin presented the first fully functional induction furnace. The first major advancement came when Edwin F.
Northrup implemented the first high-frequency induction furnace at Princeton in 1916 [1].
Induction heating provides contactless, fast and efficient heating of conductive materials. It is becoming one of the preferred
heating technologies in the industrial, domestic, and medical applications, among other applications, owing to its advantages
when compared to other classical heating techniques such as flame heating, resistance heating or traditional ovens or furnaces
[1].

Figure 1. Basic components induction heating system

Figure 1 shows the basic components of an induction heating system [1] in a longitudinal flux configuration. The basic
components of an induction heating system are an induction coil, an AC power supply, and the work-piece [3]. An AC
generator is used to supply an alternating voltage to an induction heating coil. As AC flows through the coil, the coil
generates an alternating magnetic field which cuts through the work-piece. Current moving inside the coil results in changing
magnetic field around the coil. Similar to a transformer the coil is the primary while the work-piece is the secondary. Due to
the changing magnetic field, the flow of current results in the work-piece called eddy currents. The effect of the eddy current
dissipates energy and bring about heating.

© 2019 by the Association for Iron & Steel Technology. 1579

 BAR HEATER AND EDGE HEATER APPLICATION
For much modern manufacturing processes, induction heating finds its greatest application in the metal-processing industries.
It is fast, consistent and ease of automation and control. Among the major categories are heat treating, welding, and metal
melting. Bar Heater (BH) and Edge Heater (EH) are the applications of industrial induction heating technology in the hot
strip mill. Figure 2 shows the mill layout.

Reheating Furnace Roughing Mill RDT FET Finishing Mill FDT CT

Run Out Down Coiler
HSB FSB Table
Edger

Slab
Strip

Coil

Figure 2. – Edge and Bar Heater equipment layout in the Hot Strip Mill
Figure 3 shows a more detail arrangement of the Edge and Bar Heater equipment at the entry side of the Finishing Mill (FM).
The transfer bar after it is being rolled at the Roughing Mill (RM) is sent down through the delay and FM entry tables. It first
enters the Hot Leveler. The hot leveler corrects any up bend or down bend of the strip head before entering the Edge and Bar
Heaters. Then the strip will proceed through Bar Heater delivery side-guide in front of the Crop Shear (C/S). There are up
and down bend detectors in cases the limits are exceeded then the FM entry initiates an emergency stop.

Hot Bar Edge Crop Finishing Finishing

Roughing
Leveler Heater Heater Shear Scale Mills
Mills
Breaker

Figure 3. – Edge and Bar Heater equipment layout in the Hot Strip Mill

1580 © 2019 by the Association for Iron & Steel Technology.

 SYSTEM COMPONENTS AND EQUIPMENT ASSEMBLY
Four main technologies are driving the application of Edge and Bar Heaters in the hot strip mill. Power electronics, micro-
processor, and control algorithm, and the inductor coil design.
Electrically the Bar Heater single line diagram is illustrated in Figure 4. The rectifier power element is thyristor-based, while
the high-frequency inverter is a high-speed thyristor. The rectifier transformer is fed via Medium Voltage (MV) switchgear
with primary typically 34.5 kV. Between the inverter and Bar Heater coil, is a matching panel. The matching panel provides
the impedance matching compensation required by the system. Commonly known as the tank circuit. Similarly, the Edge
Heater has the rectifier, inverter, and induction coil assembly.

Figure 4. Bar Heater Single Line Diagram

Figure 5 shows the Bar Heater induction coil components. It can move in (online position) and out (maintenance position)
approximately 4-meter travel. At the retracted position, maintenance will have easy access to the equipment for repairs and
routine maintenance activities. When a product campaign, a sequence of production, does not require bar heating, it can be
retracted automatically offline until the next time it will be used. Since starting is so quick induction heating can be turn off
when not in use, saving energy.
The refractory plate guards the coil and iron core against hot scales and heat. Water cooling system cools the refractory
plates. This tremendously helps absorb the heat energy from the transfer bar, thus prolonging the life of the inductor and
reduce maintenance cost.

Figure 5. Bar Heater induction coil

© 2019 by the Association for Iron & Steel Technology. 1581

Figure 6 shows the Edge Heater induction coil components. The Edge Heater car assembly can move in and out
approximately 4 meters from online and offline positions. Unlike Bar Heater, Edge Heater has drive side and work side cars
each.

Figure 6. Edge heater induction coil

HEATING CHARACTERISTIC
Generally, the Bar Heater can be used to achieve more stable rolling operations in finishing mills and to get a higher quality
of hot rolled products by;
1. Improving the longitudinal and lateral temperature in the transfer bars,
2. Expanding the temperature range at the finishing mill entry individually and with flexibility.
The advantages of the use of Bar Heater can be categorized as follows.

1. Preventing troubles in finishing mills

A quick stop by excess roll force near strip tail sometimes occurs because of thermal run down, especially for hard materials.
Strip steering and chewing occur near strip tail because of low temperature. Tail chew damages work rolls and production
loss due to the stoppage. Bar heaters are effective to prevent such trouble when the bar temperature is increase near the tail.

2. More flexible heating in furnaces

Slabs in a reheating furnace are sometimes limited to heat up because of melting specific chemical compositions under high
temperature. The low-temperature slabs due to limited heat up, by the above reason, may cause unstable operation and lower
quality.
In such case, the furnace temperature can be set lower, and the bar temperature can be increased by Bar Heater after rolling in
roughing mill. Bar Heater can heat up individual slabs to their target temperature with flexibility before entering the finishing
mills.

3. Improving product quality

The high temperature in a reheating furnace may cause product surface quality problems. Also, large skid marks will cause
lower performance of product thickness, width, etc.
The slab can be discharged at a lower temperature and heated up by Bar Heater before finishing mills to prevent the surface
issues. Bar Heater can compensate and reduce the temperature variation by the skid marks along the bar length.
The purpose of the Edge Heater is to compensate for temperature around the width edge of the strip. Temperature distribution
across the width at the 25mm point from the edge is typically lower by about 50°C compared to near the center. Edge Heater
will raise this temperature by 50°C. When the edges are cold, edge crack can result when rolled at the Finishing Mill.
Edge heating also improves the unit consumption of work rolls. Cold edge of bar width easily brings a cat ear shape along
work roll barrel direction. Heat up by Edge Heater will prevent the growth of the cat ear and keep the roll contour well which
helps to make the strip crown and flatness better. Figure 7 shows an example of an Edge Heater longitudinal heating
characteristic.

1582 © 2019 by the Association for Iron & Steel Technology.

 Figure 7. Edge Heater Longitudinal heating characteristic

MODEL AND CONTROL FUNCTIONS

The model and control functions for BH decide how much power to be used in BH to increase the bar temperature at FM
entry pyrometer (FET) based on BH entry temperature predicted by measured RM Delivery pyrometer (RDT), bar transfer
speed, steel grade, bar size, etc.
Figure 8 shows an overview of BH and EH control. Also, the model and control functions for EH decide how much power to
be used in EH to increase the edge temperature at the Scan Pyro-A based on EH entry temperature predicted by measured
Scan Pyro-B and the other information. Usually, the target point of heat-up along the bar width by EH is at 25mm position
from the edge.
Note that the arrangement of BH, EH, and pyrometers showed in the figure is an example.

Scan Scan
RDT Pyro-B Pyro-A FET
RM F1
EH C/S FSB
BH

BH
Bar data Control
- temperature
- speed, etc. EH
Control

Figure 8. Overview of BH and EH control

Configuration of model and control functions

Figure 9 shows the model and control functions for BH.
• Dynamic feed-forward type control based on the measured temperature at RDT, bar speed, etc. This is the main
control function.
• Dynamic feed-back type control based on the measured temperature at FET etc. Dead time compensation is applied.
• Model learning is applied to modify the temperature model accuracy.

© 2019 by the Association for Iron & Steel Technology. 1583

 • Measured temperature at the center of the width is used.
• Measured temperature by scan pyrometers is used.

Scan Scan
RDT Pyro-B Pyro-A FET
RM F1
BH EH C/S FSB

BH Control
- Initial setup
- Feed Forward control
Bar data
- Feed Back control
- temperature - Model learning function
- speed, etc.

Figure 9. Model functions for BH control

Figure 10 shows the model and control functions for EH.
• Dynamic feed-forward type control based on the measured temperature at Scan Pyro-B, bar speed, etc. This is the
main control function.
• Dynamic feed-back type control based on the measured temperature at Scan Pyro-A etc. Dead time compensation is
applied.
• Model learning is applied to modify the temperature model accuracy.
• Measured temperature at 25mm position from the width edge by scan pyrometers is used.

Scan Scan
RDT Pyro-B FET
Pyro-A

RM F1
EH C/S FSB
BH

2D temperature calculation

EH Control
- Initial setup
- Feed Forward control
Bar data - Feed Back control
- temperature - Model learning function
- speed, etc.

Figure 10. Model functions for EH control

Heat-up patterns
Heat up patterns by BH are prepared for the heating situation. There are four basic heat up patterns:
Mode A: Uniform heat up,
Mode B: Ramp up to compensate for thermal run-down,
Mode C: Head & Tail heat up,

1584 © 2019 by the Association for Iron & Steel Technology.

 Mode D: Skid mark compensation.
Any modes can be selected to build a heat-up pattern. Figure 11 shows the prepared BH heat up pattern and their combination.

Heat up Temperature
Heat up Temperature <Mode A > < Mode B >
at FET
at FET

Bar Length
Bar Length

Combination of
any mode
Heat up Temperature Heat up Temperature
at FET < Mode C > at FET < Mode D >

Bar Length Bar Length

Heat up Temperature
at FET

Any combination of each mode

is available such as A+B, A+C,
A+B+C, A+B+C+ D, etc.

Bar Length

Figure 11. Prepared Bar Heater Heat up pattern

CONCLUSIONS
With Bar Heater and Edge Heater brings rolling stabilization to the Finishing Mill. With the ability now to reduce reheat
furnace temperature, this can lower fuel cost and prolong the life of the refractories. It will keep the temperature within the
target temperature, thus improving the quality of high-performance steel.

REFERENCES
1. O. Lucia, P. Maussion, and D. E. J. Burdio, Induction Heating Technology and its Applications: Past developments,
current technology, and future challenges, IEEE Trans. Ind. Electron., vol. 61, no. 5, May 2014.
2. Joseph E. Goodwill and Thomas J. Donahue, Induction heating for the steel industry, Iron and Steel Engineer August
1999.
3. Alfred Muhlbauer, History of Induction Heating and Melting, 2008 Vulcan-Verlag GmbH.
4. N. L. Samways: Developments in the North American Iron Steel Industry-1998, pp. 50-51, Iron and Steel Engineer,
February 1999.
5. Katsuro Ito, Yasutomo Moriura, and Tetsuji Doizaki, 9,000kW Frequency Converter for Hot Bar Heater, pp. 47-50,
Toshiba Review, Vol. 57 No. 7 2002 (Japanese Version)
6. Frank E. Fonner, Dofasco’s Hot Band Improvement Program, pp31-32, AISE steel Technology, May 2003.

© 2019 by the Association for Iron & Steel Technology. 1585