MS BILLETS (1,20,000 TPA) & TMT BARS (1,45,000 TPA)
[EIRI/EDPR/4542] J.C.:2759NPR, 2759INR
INTRODUCTION
MS Billets
The Project profile envisages to set up Con-cast plant for manufacturing of M.S Billet which is the main raw material of Iron & Steel finished products, e.g., T.M.T Bars, angles, channels and sections etc. used in construction activities. Con-cast plant can be simply defined as a mill that carries con-cast process in which the molten steel is poured into laddle mould to perform the gradual solidification of metal into desired forms and shapes. Swiftly, the molten metal is solidified and is drawn down the caster. This gradually gets transformed into a solid steel billet, bloom or slab.
The Induction furnace based on mini steel plant is a versatile installation where provisions are available for producing a range of steel products by Alloying and casting into various shape. The products of steel plants are in the form of Ingots, Billets, Sheets etc. These Induction furnace-based steel casting units are suitable for small scale industries and medium scale industries and yet have the capability to complete in the internal as well as international market at all counts. In mini steel plant operating under Indian conditions small Billets are Cast for rolling into structural sections, Mild steel billets are manufacturing by different types of furnaces such as Blast Furnace, Electric Arc furnace, Induction Furnace, Basic oxygen furnace etc.
The available sizes of the steel billets are
100 x 100 mm2
110 x 110 mm2
130 x 130 mm2
160 x 160 mm2
200 x 200 mm2
Billets are the basic products of steel from which different types of steel products are made such as sheets, Angles, Channels, Rods, etc. Mild steel Billets are the basic raw material for manufacturing various types of re-rolled products.
Important Aspects of Continuous Casting of Billets
Continuous casting of steel billets is an operation which is sensitive to a number of factors. It is to be performed with adequate controls and with steadiness and in such a way so as to produce safe casting product with sound steel mechanical properties, and to ensure a continuous process with limited delays. The process requires good control of operating parameters in order to produce sound and continuous billets.
Important aspects of the continuous casting of billets are (i) quality of the billets, (ii) productivity of the machine, and (iii) cost of production. There is necessity to optimize the performance parameters to achieve high productivity and required billet quality with decreasing operating costs. The machine availability and the process reliability are the important factors during the continuous casting of the billets.
The continuous casting of billet is a highly flexible process in which the operator is to react to changing requirements extremely quickly. The steel qualities needed from a billet continuous casting machine range from simple construction steel (rebar) to state-of-the-art ‘special bar quality’ (SBQ) for the automotive industry and other engineering applications, as well as high grade wire products such as soft-steel wires, pre-stressed concrete reinforcing wire, and tire cord.
During the continuous casting, the quality of cast steel billets, thermal stress, surface defects and cracks formation are highly dependent on the temperature distribution along the entire continuously cast billet. The main attention is usually paid to the surface temperatures and particularly to the corner temperature distributions.
COST ESTIMATION
Plant Capacity 803.64 MT/Day
Land & Building (26,475 sq.mt.) Rs. 29.87 Cr
Plant & Machinery Rs. 89.22 Cr
Working Capital for 0.25 Months Rs. 29.47 Cr
Total Capital Investment Rs. 152.11 Cr
Rate of Return 56%
Break Even Point 58%
CONTENTS
INTRODUCTION
MS BILLETS
THE AVAILABLE SIZES OF THE STEEL BILLETS ARE
IMPORTANT ASPECTS OF CONTINUOUS CASTING OF BILLETS
FACTORS AFFECTING CASTING SPEED AND MACHINE PRODUCTIVITY
MECHANICAL PROPERTIES OF STEEL AT ELEVATED TEMPERATURES
TEMPERATURE ZONES OF REDUCED HOT DUCTILITY OF STEEL AND MECHANICAL PROPERTIES
SOLIDIFICATION OF THE STRAND
AXIAL PROFILE OF SHELL THICKNESS AND MID-FACE TEMPERATURE
CAST STRUCTURE
SHELL GROWTH
MACRO-SEGREGATION
TMT BARS
WHAT ARE TMT STEEL BARS?
ADVANTAGES OF TMT BARS
PHYSICAL PROPERTY
CHEMICAL PROPERTY
USES/APPLICATIONS
MS BILLETS
TMT BARS
TMT BARS FIND WIDE APPLICATIONS IN DIFFERENT SPHERES:
SPECIFICATIONS
MS BILLETS
TMT BARS
CHEMICAL TEST - RAW MATERIAL
DETERMINATION OF CARBON:
PRINCIPLE:
PROCEDURE:
DETERMINATION OF SCULPTURE:
PRINCIPLE:
ESTIMATION OF PHOSPHOROUS:
PRINCIPLE:
PROCEDURE:
FURNACE
THE FURNACE HAS THREE PROCESSES: -
FEEDING
HEATING CHAMBER
FURNACE EXIT:
THIS DESCRIBES THE PROCESS INVOLVED IN THE FURNACE
ROUGHING MILL:
CUTTERS
INTERMEDIATE MILL:
FINISHING MILL
TMT QUENCHING BOX:
QUALITY CONTROL
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES OF STEEL (INDIAN STANDARD)
BEND TEST
REBEND TEST
WEIGHT DETAILS
MARKET OVERVIEW
MS BILLETS
GROWTH FACTORS OF MILD STEEL BILLET MARKET:
TMT BARS
APPLICATION INSIGHTS:
REGIONAL ANALYSIS
GROWTH FACTORS:
NEPAL MARKET - A BRIEF OVERVIEW
MANUFACTURING PROCESS – MS BILLETS
PREPARATION OF SCRAP
PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP
MECHANICAL PROCESSES
PROCESSES FOR PREPARATION OF STEEL SCRAP
MAGNETIC SEPARATION PROCESS
EDDY CURRENT SEPARATION PROCESS
HEAVY MEDIA SEPARATION PROCESS
SEPARATION BY PHYSICAL AND CHEMICAL CHARACTERISTICS
DECOATING PROCESSES
DEZINCING PROCESS FOR STEEL SCRAP
DETINNING PROCESS FOR STEEL SCRAP
DECOPPERIZATION PROCESS FOR STEEL SCRAP
INCINERATION
PORTABLE OPTICAL EMISSION SPECTROMETERS
COLOUR SORTING PROCESS
PROCESS UTILIZING LASER INDUCED BREAKDOWN SPECTROSCOPY
MELTING
OPERATION OF INDUCTION FURNACE
SCHEMATICS OF AN INDUCTION FURNACE
A CORELESS INDUCTION FURNACES
BATH AGITATION MECHANISM
THE POWER DISTRIBUTION AND FLOW PATTERN IS SHOWN IN FIG 3.
POWER DISTRIBUTION (LEFT) AND FLOW PATTERN (RIGHT)
REFRACTORY LINING
PRODUCTION OF MILD STEEL BY INDUCTION FURNACE
COMPARISON WITH ELECTRIC ARC FURNACE STEEL MAKING PROCESS
TABLE 1 COMPARISON OF OPERATING PARAMETERS WITH ELECTRIC ARC FURNACE (EAF)
KEY ADVANTAGES OF INDUCTION HEATING
IMPORTANT ASPECTS OF OPERATION
OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING
FIG 1 TYPICAL HEAT BALANCE DIAGRAM OF CRUCIBLE INDUCTION FURNACE
ENVIRONMENTAL EMISSIONS
SAFETY AND INDUCTION FURNACES
CONTINUOUS CASTING OF STEEL BILLETS
SINGLE STRAND BILLET CASTER
EIGHT STRAND BILLET CASTING MACHINES
THE PROCESS OF THE CONTINUOUS CASTING OF STEEL BILLETS IS DESCRIBED BELOW.
STEEL LADLE
TUNDISH
MOULD
SECONDARY COOLING
TUNDISH AND ITS ROLE IN CONTINUOUS CASTING
A TUNDISH IN A CONTINUOUS CASTING MACHINE
TUNDISH-A METALLURGICAL VESSEL
TUNDISH REFRACTORY LINING
BILLET INSPECTION AND CONDITIONING FACILITIES
INSPECTION TECHNIQUES
BILLET INSPECTION TECHNIQUES
EDDY CURRENT TECHNIQUES
FLUX LEAKAGE TECHNIQUES
MICROWAVE TECHNIQUES
OPTICAL TECHNIQUES
THERMAL TECHNIQUES
ULTRASONIC TECHNIQUES
SELECTION OF INSPECTION TECHNIQUES
BILLET CONDITIONING FACILITIES
PROCESS FLOW CHART (MS BILLETS)
ROLLING MILL-TMT
TYPICAL LAYOUT OF 3-DRIVE CROSS COUNTRY TYPE ROLLING MILL
MAJOR EQUIPMENTS/PARTS OF STANDARD CROSS COUNTRY TYPE ROLLING MILL
GRADES OF INPUT MATERIAL & FORM
THE PROMINENT GRADES OF ALLOY STEELS BEING ROLLED INCLUDE:
TYPICAL MILL PRODUCT RANGE
STANDARD OPERATING PRACTICES IN ROLLING MILL - TMT
RAW MATERIAL SECTION
RECEIVING, TESTING & STACKING OF INGOTS/BILLETS
INGOT PREPARATION
BILLET PREPARATION
PRODUCT PLANNING AND SCHEDULING
PRODUCTION PLANNING IS DEPENDENT ON SEVERAL FACTORS LIKE:
SELLING PRICE-GRADE C
FORMAT OF WEEKLY PRODUCT PLANNING SHEET
HEAT CARD FORMAT –INGOT/BILLET PROCESSING
SETTING OF ROLLING MILL BEFORE OPERATION
THE ROLL PASS DESIGN FOR ANY PRODUCT DEPENDS ON THE FOLLOWING:
TYPICALLY, A PASS DESIGN CALCULATION HAS THREE PARTS:
PASS DESIGN AND GROOVE DETAILS: THIS CALCULATION GIVES THE FOLLOWING PARAMETERS FOR EACH PASS:
PASS SCHEDULES: PASS SCHEDULE CONSISTS OF THE FOLLOWING FOR EACH PASS:
POWER CALCULATION: POWER CALCULATION WORKS OUT FOR EACH PASS:
THE VARIOUS SHAPES OF GROVES ARE:
AFTER BREAKDOWN PASSES THE SEQUENCE CAN BE:
DRAFT ADJUSTMENT
HORIZONTAL AND VERTICAL/EDGING ROLLS ASSEMBLIES
ROLL CHANGING
STEPS IN ROLL CHANGING
CRITICAL PARTS OF ROLL LIFTING SYSTEM
SCHEMATIC DIAGRAM FOR DISMOUNTING OF ROLL ANTIFRICTION BEARINGS
ROLL SETTING
PASS BURNING
TYPICAL INSTRUCTIONS TO BE FOLLOWED FOR ADJUSTMENT OF RM DURING PASS BURNING FOR ROLLING OF ROUNDS ARE PROVIDED BELOW:
BEFORE ROTATING THE ROLLS AFTER SETTING, THE FOLLOWING SHOULD BE ENSURED:
STANDARD OPERATING PROCEDURES FOR ROLLING MILL
ROLLING SUPERVISION & SECTION CONTROL
THE IMPORTANT ASPECTS TO BE KEPT IN MIND DURING ROLLING SUPERVISION ARE:
EMERGENCY STOPPING OF MILL
ACTION TAKEN IN THE EVENT OF COBBLE
MEASURES TO BE ADOPTED FOR INCREASING MILL UTILIZATION
STANDARD OPERATING PARAMETERS & INSTRUCTIONS FOR CRITICAL MILL
EQUIPMENTS/PARTS
GEAR BOX & PINION STAND
SPINDLES
MILL HOUSING
ROLLER TABLES, TILTING, Y-ROLLER TABLES
WALL –TILTERS
FRONT & BACK END CROPPING SHEARS
THERMO-MECHANICAL TREATMENT OF STEEL (TMT) SYSTEM
COOLING BEDS
HYDRAULIC & PNEUMATIC SYSTEMS
IN THE HYDRAULIC SYSTEMS THE IMPORTANT PARAMETERS TO BE OBSERVED ARE:
MILL ELECTRICS; POWER SUPPLY & DISTRIBUTION SYSTEM
MILL ELECTRICS INCLUDES THE FOLLOWING MAIN MILL DRIVE MOTORS FOR 15 TPH CAPACITIES RM:
POWER SUPPLY & DISTRIBUTION SYSTEM
CONTROL PANELS
PROCESS CONTROL/PROGRAMMABLE LOGIC CONTROL (PC/PLC) FOR ROLLING MILLS
THERE ARE THREE LOCATIONS WHERE AUTOMATION IS INTRODUCED IN THE TMT ROLLING MILLS:
CENTRALISED OIL LUBRICATION & GREASING SYSTEM
CENTRALIZED OIL LUBRICATION SYSTEM (COLS)
CENTRALIZED GREASE LUBRICATION SYSTEMS (CGLS)
MILL COOLING WATER SYSTEM
MANUFACTURING PROCESS/PROCESS FLOW–TMT BAR
PROCESS FLOW
RAW MATERIAL SUPPLIERS
SUPPLIERS OF PLANT AND EQUIPMENTS
CONCASTING MACHINE
INDUCTION FURNACE
METAL TESTING MACHINE
PRECISION MEASURING TOOLS
NDT INSPECTION EQUIPMENT
ELECTRICAL MEASURING INSTRUMENTS
EOT CRANES
ELECTRICAL PANEL
COOLING TOWER
ROLLING MILL
SHAPING MACHINE
SUPPLIERS OF INDUCTION FURNACE
SHEARING MACHINE
DRILLING MACHINE
LATHE MACHINE
GRINDING MACHINE
ARC WELDING MACHINE
POWER TRANSFORMERS
SUPPLIERS OF ETP PLANTS
CRUSHING PLANT
BALL MILL
ELECTRICAL PANEL
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSOR
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
HDPE BAGS
MATERIAL HANDLING EQUIPMENTS
UTILITIES REQUIREMENT (ESTIMATED - MONTH)
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
ETP FLOW DIAGRAM (TYPICAL)
SEWAGE AND WASTE WATER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
WASTE GENERATION & MANAGEMENT/GREEN BELT
GREEN BELT
WATER (ESTIMATED)
WASTE (ESTIMATED)
FLUE GAS (ESTIMATED)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
PRELIMINARY LAYOUT
CONCLUSIONS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
