Industry Overview
M.S. billets are semi-finished steel products that serve as the primary raw material for manufacturing a wide range of finished steel products, including TMT bars, angles, channels, rods, sections, and sheets used extensively in construction and engineering applications. This project proposes the establishment of a continuous casting (con-cast) plant for the production of M.S. billets, where molten steel is continuously poured into a mould, gradually solidified, and withdrawn to produce billets, blooms, or slabs with consistent quality.
The proposed manufacturing facility is based on an induction furnace mini steel plant, offering the flexibility to produce different grades of steel through alloying and continuous casting. Such plants are suitable for both small- and medium-scale industries while remaining competitive in domestic as well as international markets. Mild steel billets may be produced using various steelmaking routes, including blast furnaces, electric arc furnaces, induction furnaces, and basic oxygen furnaces.
Standard billet sizes include 100 × 100 mm², 110 × 110 mm², 130 × 130 mm², 160 × 160 mm², and 200 × 200 mm². Continuous casting is a critical process that requires precise control of operating parameters to achieve high productivity, reliable machine performance, low production costs, and superior billet quality. Temperature distribution, thermal stresses, and surface conditions significantly influence the mechanical properties of billets and the occurrence of defects such as cracks. Modern billet casting facilities are capable of producing steel grades ranging from conventional construction steel to special bar quality (SBQ) steels and high-grade wire products for automotive and engineering applications.
Cost Estimation
| Particular | Value |
|---|---|
| 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% |
Content Index
- 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
- ...
- CONCLUSIONS
Appendix
- 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)
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