MS INGOT (TMT BAR, ANGLE CHANNEL, ROUND)
[EIRI/EDPR/4688] J.C.: 2905XL
Mild steel Ingots are the basic raw material for the manufacture of various types of re-rolled products, for e.g. rounds, flats, channels equal and unequal angles etc. A major part of this re-rolled products in the form of cold-twisted deformed bars are used in building construction as reinforcement.
Ingot is the product obtained by pouring liquid steel into cast iron mould of a shape appropriate for the subsequent processing generally by hot rolling or forging into semi-finished or finished products. The shape generally resembles a truncated pyramid or truncated cone. The side surfaces can be corrugated and the corners are more or less rounded. Depending on its subsequent conversion requirements, ingot can be dressed and/or hot scarred or cropped.
The usual cross section of ingot is square, rectangular, round, oval, or polygon. Ingots with square cross section are used for rolling into billets, rails and other structural sections, whereas, ingots with rectangular cross section, are generally used for rolling into flat products. These ingots usually have a width which is two times or higher than the thickness. Round ingots are used for the production of seamless pipes. Polygonal ingots are used to produce tyres, and wheels etc. Low capacity steel melting shops with induction furnaces produce very small cross section ingots which are called as pencil ingots.
Typically ingots used for the production of rolled products have weights in the range of 5 tons to 35 tons. Pencil ingots are used for the rolling of merchant long products and reinforcement bars and have weights typically in the range of 100 kg to 200 kg. Ingots used for the production by forging of the heavy equipment/components can be extremely large ingots weighing even 600 tons and more.
Ingot is a conventional crude steel product, but presently it constitutes a very small percentage of global crude steel production. However, ingots are still fundamental for specific low-alloy steel grades and for special forging applications, where products of large dimension, high quality or small lot size are needed. These large dimension ingots are being used these days in the power engineering industry (e.g. shafts for power generation plants, turbine blades), the oil and gas industry (conveying equipment, seamless tubes), the aerospace industry (shafts, turbines, engine parts), ship building (shafts for engines and drives), tool making and mechanical engineering (heavy forgings, cold, hot and high-speed steels, bearing, drive gears) as well as automotive engineering (shafts, axes).
As the demand of heavy ingot increases nowadays, especially from the power engineering industry and ship industry, there is a tendency of producing extremely large ingots, which are mainly applied for pressure retaining components such as reaction vessels for nuclear power plant and rotating components like drive shafts of gas turbines and generator rotors.
As the demand of heavy ingot increases nowadays, especially from the power engineering industry and ship industry, there is a tendency of producing extreme large ingots over 600 t and continuous cast strands with thickness over 450 mm and rounds with diameter up to 800 mm, which are mainly applied for pressure retaining components such as reaction vessels for nuclear power plant and rotating components like drive shafts of gas turbines and generator rotors.
COST ESTIMATION
Plant Capacity 60 MT/Day
Land & Building (10 Acres) Rs. 30.00 Lac
Plant & Machinery Rs. 12.08 Cr
Working Capital for 1 Months Rs. 8.05 Cr
Total Capital Investment Rs. 20.96 Cr
Rate of Return 51%
Break Even Point 59%
CONTENTS
INTRODUCTION
SPECIFICATION OF STEEL INGOT
STEEL INGOT SPECIFICATION:
M.S. INGOTS
PROPERTIES
CHEMICAL PROPERTIES OF MILD STEEL
PHYSICAL PROPERTIES OF MILD STEEL
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
CASTING OF INGOT
MECHANISM OF SOLIDIFICATION OF LIQUID STEEL IN INGOT MOULD
MICRO-SEGREGATION AND MACRO-SEGREGATION IN STEEL INGOTS
FIG 1 THREE DISTINCT MACRO-STRUCTURE ZONES IN STEEL INGOTS
FIG 2 MACRO-SEGREGATION PHENOMENON DURING SOLIDIFICATION
IN INGOT MOULD
DEFECTS OF KILLED STEEL INGOTS
FIG 3 PIPE FORMATION DURING SOLIDIFICATION OF LIQUID STEEL
IN INGOT MOULD
MANUFACTURING PROCESS
1. PREPARATION OF SCRAP
PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP
MECHANICAL PROCESSES
FIG 1 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
RECENT STEEL SCRAP SORTING TECHNOLOGIES
PORTABLE OPTICAL EMISSION SPECTROMETERS
COLOUR SORTING PROCESS
PROCESS UTILIZING LASER INDUCED BREAKDOWN SPECTROSCOPY
2. MELTING
OPERATION OF INDUCTION FURNACE
FIG 1 SCHEMATICS OF AN INDUCTION FURNACE
FIG 2 A CORELESS INDUCTION FURNACE
BATH AGITATION MECHANISM
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
THE DISADVANTAGES ARE
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
CASTING OF BILLET
MECHANISM OF SOLIDIFICATION OF LIQUID STEEL IN INGOT MOULD
MICRO-SEGREGATION AND MACRO-SEGREGATION IN STEEL INGOTS
FIG 1 THREE DISTINCT MACRO-STRUCTURE ZONES IN STEEL INGOTS
FIG 2 MACRO-SEGREGATION PHENOMENON DURING SOLIDIFICATION IN INGOT MOULD
DEFECTS OF KILLED STEEL INGOTS
FIG 3 PIPE FORMATION DURING SOLIDIFICATION OF LIQUID STEEL
IN INGOT MOULD
QUALITY CONTROL
MARKET OVERVIEW OF STEEL INDUSTRY
CHART 1: TREND IN GLOBAL STEEL PRICES
CHART 2: TREND IN IMPORT AND EXPORT OF FINISHED STEEL
TABLE 1: INDIA’S STEEL SCENARIO DURING H1FY21 AND H2FY21
SOME OF THE MAJOR INVESTMENTS IN THE INDIAN STEEL
INDUSTRIES ARE AS FOLLOWS:
INDIAN GOVERNMENT ROLE
SOME OF THE OTHER RECENT GOVERNMENT INITIATIVES IN THIS SECTOR ARE AS FOLLOWS:
PLANT LAYOUT
SUPPLIERS OF MS INGOT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF STEEL SCRAPE
SUPPLIERS OF COKE
SUPPLIERS OF LIME
SUPPLIERS OF FERRO ALLOY
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF SHEREDDER
SUPPLIERS OF DE-COATER
SUPPLIERS OF MAGENETIC SEPARATOR
SUPPLIERS OF INDUCTION FURNACE
SUPPLIERS OF INGOT CASTING MACHINE
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
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)