Industry Overview
Mild steel (M.S.) ingots are basic raw materials used in the manufacture of re-rolled products such as rounds, flats, channels, and equal and unequal angles. A significant portion of these products is further processed into cold-twisted deformed bars used as reinforcement in building construction.
An ingot is produced by pouring liquid steel into a cast iron mould of a shape suitable for subsequent hot rolling or forging into semi-finished or finished products. Ingots generally have the form of a truncated pyramid or truncated cone, with side surfaces that may be corrugated and corners that may be rounded. Depending on subsequent processing requirements, ingots may be dressed, hot scarred, or cropped.
Ingot cross-sections may be square, rectangular, round, oval, or polygonal. Square ingots are commonly used for rolling into billets, rails, and structural sections, while rectangular ingots are generally used for flat products. Round ingots are used in seamless pipe production, and polygonal ingots can be used for tyres and wheels. Low-capacity steel melting shops using induction furnaces produce very small cross-section ingots, commonly known as pencil ingots.
Cost Estimation
| Plant Capacity | 30 MT/Day |
|---|---|
| Land & Building (6000 sq.mt.) | Rs. 3.40 Cr |
| Plant & Machinery | Rs. 2.07 Cr |
| Working Capital for 1 Month | Rs. 10.73 Cr |
| Total Capital Investment | Rs. 16.57 Cr |
| Rate of Return | 50% |
| Break Even Point | 43% |
Content Index
Appendix
Frequently Asked Questions
Mild steel ingots are primarily used as raw material for producing re-rolled steel products. These products include rounds, flats, channels, and equal and unequal angles, among other structural sections. A significant downstream application is the production of cold-twisted deformed bars used as reinforcement in building construction. The suitability of an ingot for a particular application depends on its composition, dimensions, quality, and the subsequent rolling or forging process used to convert it into semi-finished or finished steel products.
A steel ingot is a solidified mass of steel produced by pouring liquid steel into a mould for subsequent processing. The mould provides a shape suitable for later hot rolling or forging operations. Ingots commonly resemble truncated pyramids or truncated cones, although their cross-sections can be square, rectangular, round, oval, or polygonal. Depending on the intended conversion route, an ingot may undergo dressing, hot scarring, or cropping before further processing.
An induction furnace produces mild steel by electrically heating and melting a metallic charge through electromagnetic induction. The process generally involves preparing and charging steel scrap or other metallic inputs, melting the charge, removing slag, refining the molten metal as required, and tapping the steel for casting. Furnace operation also requires appropriate refractory lining, power control, temperature management, process supervision, and safety practices. The molten steel is subsequently cast into ingots or other forms according to the intended product and process route.
The main stages include preparation of steel scrap, melting, slag removal, refining, tapping, and casting. Scrap preparation can involve sorting and separation processes designed to improve charge quality and remove unwanted materials. During melting, the metallic charge is converted into liquid steel in an induction furnace. Slag is removed and the melt may undergo refining before tapping. The molten steel is then transferred for casting into ingot moulds, followed by solidification and subsequent handling or processing.
Steel scrap preparation is important because charge quality directly influences melting operations and the quality of the resulting steel. Preparation can include mechanical sorting, magnetic separation, eddy current separation, heavy media separation, and separation based on physical or chemical characteristics. Additional treatments such as decoating, dezincing, detinning, and decopperization may be used where appropriate. Modern approaches can also include portable optical emission spectrometers, colour sorting, and laser-induced breakdown spectroscopy to improve identification and sorting of scrap.
Segregation in steel ingots results from the redistribution of alloying elements and impurities during solidification. Micro-segregation occurs on a relatively small scale, particularly between dendritic and interdendritic regions, while macro-segregation involves composition differences over larger regions of the ingot. Solidification conditions, molten steel composition, thermal gradients, fluid movement, and the development of the solidification structure can influence segregation. Understanding these mechanisms is important for controlling ingot quality and minimizing defects that could affect subsequent rolling, forging, or other processing operations.
Quality and safety in induction furnace steelmaking require controlled raw materials, reliable process monitoring, suitable refractory systems, effective temperature and composition control, and disciplined handling of molten metal. Quality control should address the chemical and physical characteristics required for the intended steel product, as well as casting and solidification-related defects. Safety measures are essential around high electrical power, hot metal, slag, furnace equipment, and material handling systems. Environmental controls should also address emissions and other operational impacts associated with melting and casting activities.
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