Detailed Project Report on steel rolling mill (m.s.rod)

STEEL ROLLING MILL (M.S. ROD)
[CODE NO.3412]  

Steel reinforcement bar is also known as rebar, reinforcing bar, reinforcing steel and reinforcement steel. It is a versatile constructional material which is widely used in the construction industry for making of the reinforced concrete. Reinforcement concrete (RC) is a composite material made up of concrete and some form of reinforcement – most commonly steel rods, bars, wires or mesh of steel rods and steel wires. The steel reinforcement bars usually consists of such shape and size that they may easily be bent and placed in the concrete so as to form a monolithic structure.

The properties of thermal expansion for both steel and concrete are approximately the same. This along with excellent bendability property makes steel the best material as reinforcement in concrete structures. Another reason steel works effectively as reinforcement is that it bonds well with concrete. When passive reinforcement (steel bars) is employed, the structure is known as reinforced concrete structure. In pre-stressed concrete structure, the reinforcement (steel wire) is stressed prior to subjecting the structure to loading, which may be viewed as active reinforcement. Passive steel reinforcing bars, also known as rebars, should necessarily be strong in tension and, at the same time, be ductile enough to be shaped or bent.

Steel rebar is most commonly used as a tensioning devise to reinforce concrete to help hold the concrete in a compressed state. Concrete is a material that is very strong in compression, but virtually without strength in tension. To compensate for this imbalance in a concrete slab behavior, reinforcement bar is cast into it to carry the tensile loads. The surface of the reinforcement bar may be patterned to form a better bond with the concrete.

Reinforced concrete gets its strength from the two materials, steel and concrete, working together. To get them working together, it is critical that the steel be adequately bonded to the concrete. Achieving this bond is called developing the bar, and many aspects of reinforcement design are geared toward achieving development.

Steel rebars are the time proven match for reinforcing concrete structures. RC structures are designed on the principle that steel and concrete act together to withstand induced forces. The aim of the reinforced concrete designer is to combine the reinforcement with the concrete in such a manner that sufficient of the relatively expensive reinforcement is incorporated to resist tensile and shear forces, whilst utilizing the comparatively inexpensive concrete to resist the compressive forces.

To achieve this aim, the designer needs to determine, not only the amount of reinforcement to be used, but how it is to be distributed and where it is to be positioned. These decisions of the designer are critical to the successful performance of reinforced concrete and it is imperative that, during construction, reinforcement be positioned exactly as specified by the designer.

Originally concrete structures were made without reinforcement. The use of rebars has started in construction since at least the 18th century. Earlier cast iron was the materials for the rebars. This was because cast iron rebars were of high quality, and there was no corrosion on them for the life of the structure. Later the technique was refined by embedding the steel bars in the reinforced concrete structures. Plain mild steel rebars of strength 250 MPa were used widely till about 1960s. Square twisted steel bars (deformed bars) were introduced in 1960s. But these were phased out due to their inherent inadequacies.


COST ESTIMATION

Plant  Capacity                                               :       100.00 MT./day
land & Building (12,000 sq.mt)                   :       Rs.  10.32 Cr
Plant & Machinery                                          :        Rs.  19.13 Cr
Working Capital for 2 Months                      :        Rs.  13.96 Cr
Total Capital Investment                               :       Rs.  45.65 Cr
Rate of Return                                                 :       39%
Break Even Point                                            :        53%

INTRODUCTION    
COMMON DEFINITIONS CONNECTED WITH STEEL REINFORCEMENT BARS    
CHEMICAL COMPOSITION    
THEORETICAL WEIGHT    
USES AND APPLICATION    
MARKET SURVEY    
MARKET SIZE    
HISTORICAL BACKGROUND    
COMMODITIZING REBAR MARKETS    
FRAGMENTED MARKETS    
BRANDING IN THE REBAR INDUSTRY    
FRP IN THE FRAY,    
A GLOBAL EXPERIENCE    
OUTLOOK    
MARKET POSITION OF RE-BARS    
LONG STEEL INDUSTRY – A SUNSHINE SECTOR IN INDIA    
THE DEMAND TREND FOR VARIOUS LONG STEEL PRODUCTS
   IS DEPICTED BELOW:    
THE DEMAND BREAK-UP OF BARS AND RODS (NON-ALLOY)
   FOR 2012-13 IS DEPICTED BELOW:    
PRODUCT UPGRADES    
TECHNOLOGY IMPACT    
MARKET OPPORTUNITIES/DEMAND DRIVERS    
CHALLENGES AND RESTRAINTS    
EXPORT DATA OF TMT BARS    
IMPORT DATA OF TMT BARS    
BRITISH STANDARD (B.S)    
MANUFACTURERS/SUPPLIERS OF M.S ROD    
PROCESS FLOW CHART FOR RE-BAR    
MANUFACTURING PROCESS OF M.S BILLET    
INDUCTION FURNACE WITH CCM    
(1) MELTING PROCESS    
(2) CONTINUOUS CASTING PROCESS OF BILLET    
THE MAIN OPERATIONS INVOLVED IN THE WHOLE PROCESS
  OF TURNING OUT BILLETS ARE:    
LUBRICATION    
MOULD    
SECONDARY COOLING    
BILLET CUTTING    
BILLET PROCESSING    
(3) ROLLING PROCESS    
A. ROUGHING MILL    
B. INTERMEDIATE MILL    
C. FINISHING MILL    
(4) FINISHING SECTION    
5. INSPECTION AND TESTING OF BAR    
STAGE WISE INSPECTION DETAILS    
FIGURE 8(A): INCOMING MATERIAL INSPECTION    
FIGURE 8(B): IN PROCESS INSPECTION DATA COLLECTED FOR TMT RODS    
6. DISPATCH:    
WORKING PRINCIPLE OF CONTINIOUS CATING PROCESS    
UNDERSTANDING THE PROCESS OF CONTINUOUS CASTING OF STEEL    
REQUIREMENTS FROM LIQUID STEEL    
TUNDISH APPLICATION    
LIQUID STEEL SHROUDING    
LIQUID STEEL FLOW CONTROL    
MOULD AND HEAT TRANSFER    
SECONDARY COOLING, STRAND CONTAINMENT AND WITHDRAWAL    
CONTINUOUS CASTING OF STEEL BILLETS    
THE PROCESS OF THE CONTINUOUS CASTING
   OF STEEL BILLETS IS DESCRIBED BELOW.    
STEEL LADLE    
TUNDISH    
MOULD    
SECONDARY COOLING    
CONTINUOUS CASTING MACHINE AND ITS EQUIPMENT    
TYPES OF CONTINUOUS CASTING MACHINES    
CONTINUOUS CASTING MACHINE EQUIPMENT    
LADLE TURRET    
TUNDISH    
MOULD    
SECONDARY COOLING    
STRAND CONTAINMENT    
BENDING AND STRAIGHTENING    
DUMMY BAR    
FACILITIES BEYOND BENDING AND STRAIGHTENING SECTION    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERIES    
SCRAP BAILING MACHINE    
INDUCTION FURNACE    
ANNEALING FURNACE    
HEATREATMENT FURNACE    
CONTINIOUS BILLET CASTING COMPELETE PLANT    
COOLING BED    
DRILLING MACHINE    
MILLING MACHINE    
CNC LATHE MACHINE    
BOARING MACHINE    
POWER HACKSAW    
GRINDING MACHINE    
POWER PRESS    
WELDING MACHINE    
EOT CRANE    
POWER TRANSFORMERS    
ELECTRICAL PANEL    
COOLING TOWER    
EFFULENT TREATMENT PLANT    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
PLATFORM WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
SHOT BLASTING MACHINE    
JIGS AND FIXTURE    
SUBMERSIBLE WATER PUMP    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PIG IRON    
SUPPLIERS OF SPONGY IRON    
STEEL SCRAPE    
FERRO SILICON    
COKE    
LIME    
DEGREASING CHEMICAL    
PICKLING CHEMICALS    

APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET