Detailed Project Report (DPR) on Integrated Unit on MS Pipe, Rod, Sariya, Plates, Channels and Girders

INTEGRATED UNIT ON MS PIPE, ROD, SARIYA, PLATES, CHANNELS AND GIRDERS

[EIRI/EDPR/4465]

The pre-determined cooling of the bar periphery transforms the peripheral structure to martensite and then annealed through the heat available at the core. The peripheral and core temperature difference finally equalizes at around 600 degree C and the resultant bar structure is of tempered martensite at the periphery and of fine-grained ferritepearlite at the core. Generally speaking, the resultant soft core forms about 65-75 per cent of the area (depending upon the desired minimum yield strength) and the rest is the hardened periphery. The equalizing temperature together with the final rolling temperature is the most important parameter to achieve the required mechanical properties. Finally, when the bar is discharged on to the Cooling Beds, the remaining austenite transforms into a very fine-grained pearlite structure.

After this process of thermo mechanical treatment, a dark etched peripheral rim of tempered martensite and a grey core of ferrite pearlite get formed. The tempered martensite surface layer is very hard while the microstructure of the core is a very fine-grained ferrite and pearlite which is quite soft. The result is a structure withigh yield strength combined with high ductility. 

Hence from the above data it is seen that the sudden quenching is the key role in hardening the steel bars. The pressure of the water jets on the hot molten bars determines the thickness of the martensite structure and is controlled for the required hardness.

COST ESTIMATION

Plant Capacity            200 MT/Day  

Land & Building (20,000 sq.mt.)    Rs. 17.52 Cr    

Plant & Machinery                    Rs. 19.29 Cr 

Working Capital for 2 Months    Rs. 49.30 Cr 

Total Capital Investment          Rs. 88.36 Cr 

Rate of Return                          50%

Break Even Point                      47%

CONTENTS

INTRODUCTION

(A) STEEL BARS

ROLLED STEEL BARS

TMT STEEL BARS

FEATURES OF TMT BARS

ADVANTAGES OF TMT BARS:

PROPERTIES OF TMT BARS

PHYSCIAL PROPERTY

CHEMICAL PROPERTY

SIZE OF TMT BAR

SPECIFICATION OF ROUND BAR

SPECIFICATION OF HEXAGONAL BAR

SPECIFICATION OF SQUIRE BAR

SPECIFICATION OF REACTANGULAR BAR

RECTANGULAR BAR SIZES

USES AND APPLICATIONS

(B) STEEL SECTIONS

TYPES OF ROLLED STRUCTURAL STEEL SECTIONS

1. ROLLED I-SECTION (BEAM)

HERE ARE SOME COMMON STEEL BEAM SHAPES LISTED BELOW:

I-BEAM:

W-BEAM:

H-BEAM:

2. ROLLED CHANNEL SECTIONS

3. ROLLED T- SECTIONS

4. ROLLED ANGLE SECTIONS

HOT ROLLING

HOT ROLLING

ADVANTAGES:

DISADVANTAGES:

PROPERTIES

USES AND APPLICATION

STRUCTURAL STEEL

ISMB (INDIAN STANDARD MEDIUM WEIGHT BEAMS):

ISMC (INDIAN STANDARD MEDIUM CHANNEL):

ISA (INDIAN STANDARD ANGLE):

B.I.S. SPECIFICATION

PROCESS FLOW CHART

(A) FOR BILLET

(B) FOR TMT BARS

FOR STEEL SECTIONS

MANUFACTURING PROCESS

PRODUCTION OF BILLET

(A) SCRAP MELTING PROCESS

1. PREPARATIOON OF SCRAP

PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP

MECHANICAL PROCESSES

BALING:

BRIQUETTING:

SHEARING:

SHREDDING:

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

INDUCTION CHANNEL FURNACE:

INDUCTION CRUCIBLE 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

(B) CASTING PROCESS

CONTINUOUS CASTING OF STEEL BILLETS

FIG 1: SINGLE STRAND BILLET CASTER

FIG 2: EIGHT STRAND BILLET CASTING MACHINES

THE PROCESS OF THE CONTINUOUS CASTING OF STEEL BILLETS

IS DESCRIBED BELOW

STEEL LADLE

TUNDISH

MOULD

THE IMPORTANT ASPECTS WITH RESPECT TO THE MOULD OF A

BILLET CASTING MACHINE IS AS FOLLOWS.

SECONDARY COOLING

TUNDISH AND ITS ROLE IN CONTINUOUS CASTING

FIG 1: A TUNDISH IN A CONTINUOUS CASTING MACHINE

TUNDISH-A METALLURGICAL VESSEL

TUNDISH REFRACTORY LINING

BRICK LINING:

GUNNABLE LINING PRACTICE:

TUNDISH BOARD LINING:

SPRAYABLE LINING:

TUNDISH DRY LINING:

BILLET INSPECTION AND CONDITIONING FACILITIES

INSPECTION TECHNIQUES

FIG 1: BILLET INSPECTION TECHNIQUES

EDDY CURRENT TECHNIQUES

FLUX LEAKAGE TECHNIQUES

MICROWAVE TECHNIQUES

OPTICAL TECHNIQUES

THERMAL TECHNIQUES

ULTRASONIC TECHNIQUES

SELECTION OF INSPECTION TECHNIQUES

BILLET CONDITIONING FACILITIES

PRODUCTION OF STEEL BARS

INSPECTION OF RAW MATERIALS:-

REHEATING FURNACE

THE FURNACE HAS THREE PROCESSES:-

FEEDING:-

HEATING CHAMBER:-

FURNACE EXIT:-

ROUGHING MILL:

CUTTERS:

INTERMEDIATE MILL:

FINISHING MILL:

TMT QUENCHING BOX:

QUALITY CONTROL

CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES OF STEEL (INDIAN STANDARD)

THINK!- MARYLAND METRICS - THE ONE-STOP SOURCE F

QUALITY CONTROL

CHEMICAL COMPOSITION

MECHANICAL PROPERTIES

BEND TEST

REBEND TEST

WEIGHT DETAILS

FIG-8: THE ROUGHING MILL

FIG-9: THE FINISH MILL

(5) COOLING PROCESS

AIR COOLING BED

(6) SHEARING PROCESS

END SHEARING:

FIG-10: AIR COOLED BED

FIG-11: THE SHEARING MACHINE

(7) STRAIGHTENING PROCESS

STRAIGHTENING:

(8) BUNDLING PROCESS

BUNDLING:

FIG-12: THE STRAIGHTNEER

FIG-13: THE BUNDLE OF STRUCTURE

(11) TESTING PROCESS

FINAL TESTING:

MECHANICAL TEST:

UNIVERSAL TESTING MACHINE:

SPECTROMETER ANALYSIS:

FIG-14: THE UNIVERSAL TESTING MACHINE

FIG-15: THE SPECTROMETER

DESCRIPTION OF HOT ROOLING MILL

UNIVERSAL BEAMS AND ITS ROLLING

FIG 1: COMPARISON OF THE CROSS SECTIONS OF DIFFERENT

TYPE OF BEAMS

ROLLING OF UNIVERSAL BEAMS

CONVENTIONAL UNIVERSAL BEAM MILL

FIG 2: ROLLING OF UNIVERSAL BEAM IN UNIVERSAL STANDAND TYPICAL MILL LAY OUT

MODERN UNIVERSAL BEAM MILL

MAJOR PARAMETERS IN THE THREE STAGES OF MILL PROCESSING

ARE AS FOLLOWS:

REHEATING:

ROLLING:

COOLING:

TAB 1: TYPICAL PARAMETERS AT ROLLING STAGES

FIG 1: MACROSCOPIC & MICROSCOPIC PHENOMENA DURING ROLLING

ROLLS AND ROLL PASS DESIGN

STAND AND ROLL GUIDE SET-UP

TENSION CONTROL

MILL UTILIZATION

YIELD

COBBLE RATE

TECHNOLOGICAL EQUIPMENTS FOR ROLLING MILLS

FIG 1: COMPONENTS OF A ROLL STAND

HOUSING:

ROLLS:

FIG 2: ROLLING MILL ROLLS

CHOCKS AND BEARINGS:

ADJUSTING AND BALANCING EQUIPMENT:

FIG 3: METHODS OF ADJUSTING AND BALANCING OF ROLLS

PINION STAND:

REDUCERS:

COUPLINGS:

MILL MOTORS AND AUXILIARY DRIVES:

SPINDLES AND WOBBLERS:

GUIDE EQUIPMENTS FOR ROLLING

GUIDES:

REPEATERS AND LOOPING CHANNELS:

AUXILIARY EQUIPMENT OF ROLLING MILLS

DESCALING EQUIPMENT:

DEVICES FOR LONGITUDINAL TRANSPORT/HANDLING:

TILTING OR LIFTING TABLES:

DEVICES FOR CROSS TRANSPORT:

MANIPULATORS:

PINCH ROLLS:

SHEARS:

COOLING BED:

STRAIGHTENERS:

COILING MACHINES:

STACKING AND BUNDLING MACHINES:

TYING AND STRAPPING MACHINES:

TRANSPORT OF BUNDLES/PACKS AND COILS:

MILL ELECTRIC SYSTEM:

SAFETY IN ROLLING MILLS

COMMON SAFETY RELATED DEFINITIONS

SAFETY DESIGN PROCEDURE

FIG 1: FUNDAMENTAL APPROACH TO CONTROL HAZARD

DETERMINATION OF THE LIMITS OF THE EQUIPMENT OR SYSTEM

IDENTIFICATION OF THE HAZARDS/RISK ESTIMATION

RISK ESTIMATION

RISK ANALYSIS METHODS

RISK EVALUATION

RISK REDUCTION BY DESIGN

TYPES OF PROTECTIVE DEVICES

SELECTION OF GUARDS AND PROTECTIVE DEVICES

REQUIRED CHARACTERISTICS OF GUARDS AND PROTECTION DEVICES

SIGNALS AND WARNING DEVICES

PERSONAL PROTECTIVE EQUIPMENT (PPE)

MARKET POSITION

KEY POINTS OF STEEL SECTOR

OPPORTUNITY:

STEEL BILLET INDUSTRY OVERVIEWS

INDUSTRY STUDY

SUPPLIERS OF TMT BAR

SUPPLIERS OF MILD STEEL ROUND, HEX AND SQUARE BAR

SUPPLIERS OF STEEL MS ANGLE AND CHANNEL

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF STEEL SCRAP

SUPPLIERS OF FERRO ALLOY

SUPPLIERS OF FLUX

SUPPLIERS OF CARBON ELECTRODE

SUPPLIERS OF GRAPHITE ELECTRODES

SUPPLIERS OF REFRACTORIES

SUPPLIERS OF DEGREASING CHEMICAL

SUPPLIERS OF PICKLING CHEMICALS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF SCRAP BAILING MACHINE

SUPPLIERS OF EAF

SUPPLIERS OF CONTINIOUS BILLET CASTING COMPELETE PLANT

SUPPLIERS OF ROD ROLLING COMPELETE PLANT

SUPPLIERS OF COOLING BED

SUPPLIERS OF DRILLING MACHINE

SUPPLIERS OF MILLING MACHINE

SUPPLIERS OF BOARING MACHINE

SUPPLIERS OF POWER HACKSAW

SUPPLIERS OF GRINDING MACHINE

SUPPLIERS OF POWER PRESS

SUPPLIERS OF WELDING MACHINE

SUPPLIERS OF EOT CRANES

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP 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

SUPPLIERS OF SHOT BLASTING MACHINE

SUPPLIERS OF JIGS AND FIXTURE

SUPPLIERS OF SUBMERSIBLE WATER PUMP

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)