MS Billets (1,20,000 TPA) & TMT Bars (1,45,000 TPA)

MS BILLETS (1,20,000 TPA) & TMT BARS (1,45,000 TPA)

[EIRI/EDPR/4542] J.C.:2759NPR, 2759INR 

INTRODUCTION

MS Billets

The Project profile envisages to set up Con-cast plant for manufacturing of M.S Billet which is the main raw material of Iron & Steel finished products, e.g., T.M.T Bars, angles, channels and sections etc. used in construction activities. Con-cast plant can be simply defined as a mill that carries con-cast process in which the molten steel is poured into laddle mould to perform the gradual solidification of metal into desired forms and shapes. Swiftly, the molten metal is solidified and is drawn down the caster. This gradually gets transformed into a solid steel billet, bloom or slab.

The Induction furnace based on mini steel plant is a versatile installation where provisions are available for producing a range of steel products by Alloying and casting into various shape. The products of steel plants are in the form of Ingots, Billets, Sheets etc. These Induction furnace-based steel casting units are suitable for small scale industries and medium scale industries and yet have the capability to complete in the internal as well as international market at all counts. In mini steel plant operating under Indian conditions small Billets are Cast for rolling into structural sections, Mild steel billets are manufacturing by different types of furnaces such as Blast Furnace, Electric Arc furnace, Induction Furnace, Basic oxygen furnace etc. 

The available sizes of the steel billets are

100 x 100 mm2

110 x 110 mm2 

130 x 130 mm2

160 x 160 mm2

200 x 200 mm2

Billets are the basic products of steel from which different types of steel products are made such as sheets, Angles, Channels, Rods, etc. Mild steel Billets are the basic raw material for manufacturing various types of re-rolled products.

Important Aspects of Continuous Casting of Billets

Continuous casting of steel billets is an operation which is sensitive to a number of factors. It is to be performed with adequate controls and with steadiness and in such a way so as to produce safe casting product with sound steel mechanical properties, and to ensure a continuous process with limited delays. The process requires good control of operating parameters in order to produce sound and continuous billets.

Important aspects of the continuous casting of billets are (i) quality of the billets, (ii) productivity of the machine, and (iii) cost of production. There is necessity to optimize the performance parameters to achieve high productivity and required billet quality with decreasing operating costs. The machine availability and the process reliability are the important factors during the continuous casting of the billets.

The continuous casting of billet is a highly flexible process in which the operator is to react to changing requirements extremely quickly. The steel qualities needed from a billet continuous casting machine range from simple construction steel (rebar) to state-of-the-art ‘special bar quality’ (SBQ) for the automotive industry and other engineering applications, as well as high grade wire products such as soft-steel wires, pre-stressed concrete reinforcing wire, and tire cord.

During the continuous casting, the quality of cast steel billets, thermal stress, surface defects and cracks formation are highly dependent on the temperature distribution along the entire continuously cast billet. The main attention is usually paid to the surface temperatures and particularly to the corner temperature distributions. 

COST ESTIMATION

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%

CONTENTS

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

TYPICAL LAYOUT OF 3-DRIVE CROSS COUNTRY TYPE ROLLING MILL

MAJOR EQUIPMENTS/PARTS OF STANDARD CROSS COUNTRY TYPE ROLLING MILL

GRADES OF INPUT MATERIAL & FORM

THE PROMINENT GRADES OF ALLOY STEELS BEING ROLLED INCLUDE:

TYPICAL MILL PRODUCT RANGE

STANDARD OPERATING PRACTICES IN ROLLING MILL - TMT

RAW MATERIAL SECTION

RECEIVING, TESTING & STACKING OF INGOTS/BILLETS

INGOT PREPARATION

BILLET PREPARATION

PRODUCT PLANNING AND SCHEDULING

PRODUCTION PLANNING IS DEPENDENT ON SEVERAL FACTORS LIKE:

SELLING PRICE-GRADE C

FORMAT OF WEEKLY PRODUCT PLANNING SHEET

HEAT CARD FORMAT –INGOT/BILLET PROCESSING

SETTING OF ROLLING MILL BEFORE OPERATION

THE ROLL PASS DESIGN FOR ANY PRODUCT DEPENDS ON THE FOLLOWING:

TYPICALLY, A PASS DESIGN CALCULATION HAS THREE PARTS:

PASS DESIGN AND GROOVE DETAILS: THIS CALCULATION GIVES THE FOLLOWING PARAMETERS FOR EACH PASS:

PASS SCHEDULES: PASS SCHEDULE CONSISTS OF THE FOLLOWING FOR EACH PASS:

POWER CALCULATION: POWER CALCULATION WORKS OUT FOR EACH PASS:

THE VARIOUS SHAPES OF GROVES ARE:

AFTER BREAKDOWN PASSES THE SEQUENCE CAN BE:

DRAFT ADJUSTMENT

HORIZONTAL AND VERTICAL/EDGING ROLLS ASSEMBLIES

ROLL CHANGING

STEPS IN ROLL CHANGING

CRITICAL PARTS OF ROLL LIFTING SYSTEM

SCHEMATIC DIAGRAM FOR DISMOUNTING OF ROLL ANTIFRICTION BEARINGS

ROLL SETTING

PASS BURNING

TYPICAL INSTRUCTIONS TO BE FOLLOWED FOR ADJUSTMENT OF RM DURING PASS BURNING FOR ROLLING OF ROUNDS ARE PROVIDED BELOW:

BEFORE ROTATING THE ROLLS AFTER SETTING, THE FOLLOWING SHOULD BE ENSURED:

STANDARD OPERATING PROCEDURES FOR ROLLING MILL

ROLLING SUPERVISION & SECTION CONTROL

THE IMPORTANT ASPECTS TO BE KEPT IN MIND DURING ROLLING SUPERVISION ARE:

EMERGENCY STOPPING OF MILL

ACTION TAKEN IN THE EVENT OF COBBLE

MEASURES TO BE ADOPTED FOR INCREASING MILL UTILIZATION

STANDARD OPERATING PARAMETERS & INSTRUCTIONS FOR CRITICAL MILL

EQUIPMENTS/PARTS 

GEAR BOX & PINION STAND

SPINDLES

MILL HOUSING

ROLLER TABLES, TILTING, Y-ROLLER TABLES

WALL –TILTERS

FRONT & BACK END CROPPING SHEARS

THERMO-MECHANICAL TREATMENT OF STEEL (TMT) SYSTEM

COOLING BEDS

HYDRAULIC & PNEUMATIC SYSTEMS

IN THE HYDRAULIC SYSTEMS THE IMPORTANT PARAMETERS TO BE OBSERVED ARE:

MILL ELECTRICS; POWER SUPPLY & DISTRIBUTION SYSTEM

MILL ELECTRICS INCLUDES THE FOLLOWING MAIN MILL DRIVE MOTORS FOR 15 TPH CAPACITIES RM:

POWER SUPPLY & DISTRIBUTION SYSTEM

CONTROL PANELS

PROCESS CONTROL/PROGRAMMABLE LOGIC CONTROL (PC/PLC) FOR ROLLING MILLS

THERE ARE THREE LOCATIONS WHERE AUTOMATION IS INTRODUCED IN THE TMT ROLLING MILLS:

CENTRALISED OIL LUBRICATION & GREASING SYSTEM

CENTRALIZED OIL LUBRICATION SYSTEM (COLS)

CENTRALIZED GREASE LUBRICATION SYSTEMS (CGLS)

MILL COOLING WATER SYSTEM

MANUFACTURING PROCESS/PROCESS FLOW–TMT BAR

PROCESS FLOW

RAW MATERIAL SUPPLIERS

SUPPLIERS OF PLANT AND EQUIPMENTS

CONCASTING MACHINE

INDUCTION FURNACE

METAL TESTING MACHINE

PRECISION MEASURING TOOLS

NDT INSPECTION EQUIPMENT

ELECTRICAL MEASURING INSTRUMENTS

EOT CRANES

ELECTRICAL PANEL

COOLING TOWER

ROLLING MILL

SHAPING MACHINE 

SUPPLIERS OF INDUCTION FURNACE

SHEARING MACHINE

DRILLING MACHINE

LATHE MACHINE 

GRINDING MACHINE

ARC WELDING MACHINE 

POWER TRANSFORMERS

SUPPLIERS OF ETP PLANTS

CRUSHING PLANT

BALL MILL

ELECTRICAL PANEL

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSOR

PLATFORM WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE FIGHTING EQUIPMENTS

HDPE BAGS

MATERIAL HANDLING EQUIPMENTS

UTILITIES REQUIREMENT (ESTIMATED - MONTH) 

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT 

STP FLOW DIAGRAM (TYPICAL)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WATER (ESTIMATED)

WASTE (ESTIMATED)

FLUE GAS (ESTIMATED)

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY LAYOUT

CONCLUSIONS

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)