Industry Overview
Mild steel ingots are the primary raw material used in the manufacture of a wide range of re-rolled steel products, including rounds, flats, channels, equal and unequal angles, and reinforcement bars for the construction industry. An ingot is produced by pouring molten steel into cast iron moulds designed for subsequent processing through hot rolling or forging into semi-finished or finished products. Depending on the intended application, ingots may undergo dressing, hot scarfing, or cropping before further processing.
Steel ingots are manufactured in various cross-sectional shapes, including square, rectangular, round, oval, and polygonal, each serving specific downstream applications. Square ingots are commonly rolled into billets and structural sections, rectangular ingots are used for flat products, round ingots are preferred for seamless pipe production, and polygonal ingots are used for components such as tyres and wheels. Small induction furnace steel plants also produce pencil ingots, which are widely used for merchant long products and reinforcement bars.
Ingot sizes vary significantly based on end-use requirements. While smaller ingots may weigh between 100 kg and 200 kg, conventional rolled-product ingots typically range from 5 to 35 tons. Heavy forging applications require exceptionally large ingots that can exceed 600 tons. Although continuous casting has reduced the overall share of ingot production in global crude steel manufacturing, ingots remain indispensable for special alloy grades, large forgings, and limited production runs. They continue to play a critical role in power generation, oil and gas, aerospace, shipbuilding, mechanical engineering, automotive manufacturing, and nuclear power applications, where large, high-quality forged components are required.
Cost Estimation
| Particular | Value |
|---|---|
| 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% |
Content Index
- 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
- 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)
Frequently Asked Questions
Mild steel ingots are primarily used as raw material for manufacturing rolled and forged steel products.
They are further processed into products such as billets, reinforcement bars, flats, channels, angles, seamless pipes, and structural steel sections. Their versatility makes them an essential intermediate product for construction, engineering, automotive, shipbuilding, and heavy industrial applications.
Steel ingots are manufactured by pouring molten steel into specially designed moulds.
After melting and refining, the liquid steel solidifies inside cast iron moulds into the required shape. The ingots may then undergo dressing, cropping, or surface treatment before being rolled or forged into finished or semi-finished steel products.
Different ingot shapes are produced to suit specific downstream manufacturing processes.
Square, rectangular, round, oval, and polygonal ingots are selected based on the type of rolling or forging operation and the final product required. Proper shape selection improves production efficiency, material utilization, and product quality.
Steel ingots remain important for specialized applications that require large or high-quality forgings.
They are widely used where continuous casting is not suitable, particularly for heavy forgings, special alloy grades, limited production quantities, and components used in power generation, aerospace, shipbuilding, and other demanding industries.
Mild steel ingots are widely used across construction and heavy engineering industries.
Major applications include power generation equipment, oil and gas infrastructure, automotive components, aerospace parts, shipbuilding, mechanical engineering, and the production of structural steel products used in commercial and industrial construction.
Steel ingot quality depends on proper melting, casting, solidification, and quality control practices.
Important factors include raw material quality, furnace operation, mould design, solidification behavior, segregation control, and inspection procedures. Effective process control helps reduce defects and ensures the ingots meet the required mechanical and metallurgical properties.
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