TMT Bar from Scrap

TMT BAR FROM SCRAP

[EIRI/EDPR/4713] J.C.: 2933XL

MS Billets

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, and 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            300 MT/Day

Land & Building (16,000 sq.mt.)    Rs. 8.70 Cr

Plant & Machinery                    Rs. 20.90 Cr

Working Capital for 1 Month    Rs. 28.40 Cr

Total Capital Investment          Rs. 59.31 Cr

Rate of Return                          45%

Break Even Point                      56%

CONTENTS

MS BILLETS

THE AVAILABLE SIZES OF THE STEEL BILLETS ARE

IMPORTANT ASPECTS OF CONTINUOUS CASTING OF BILLETS

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

FOR MORE INFORMATION CONTACT AT:

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)

BEND TEST

REBEND TEST

WEIGHT DETAILS

MARKET OVERVIEW OF BILLETS AND BAR

MS BILLETS

GROWTH FACTORS OF MILD STEEL BILLET MARKET:

TMT BARS

APPLICATION INSIGHTS:

REGIONAL ANALYSIS

GROWTH FACTORS:

STAGES IN TMT BAR MANUFACTURING

STAGE 1 – SOURCING MATERIALS AND PROCESSING

THE FOLLOWING PROCESSES CAN BE USED:

STAGE 2 – MAKING STEEL BILLETS

STAGE 3 – MAKING TMT REINFORCEMENT BAR (REBARS) FROM STEEL BILLETS

THIS IS FINAL MANUFACTURING PROCESS THAT PRODUCES THE TMT STEEL REBARS.

CONVERSION OF BILLETS INTO STEEL

CONVERSION OF BILLETS TO STEEL:

THERMO MECHANICAL TREATMENT:

THESE THREE ESSENTIAL STEPS ARE:

QUENCHING:

SELF-TEMPERING:

ATMOSPHERIC COOLING:

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 FURNACE

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

TMT BAR

THE THERMO MECHANICAL TREATMENT INVOLVES 3 ESSENTIAL STEPS

THAT ARE:

THE QUALITY OF TMT BAR DEPENDS ON THREE MAJOR FACTORS

PRIMARY STEEL MAKING

THERMO MECHANICAL TREATMENT

QUENCHING –

THIS COOLING TECHNOLOGY IS KNOWN AS QUENCHING.

SELF TEMPERING –

ATMOSPHERIC COOLING –

PROCESS FLOW DIAGRAM OF TMT BAR FROM SCRAP

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

ROLLING MILL - TMT

TYPICAL LAYOUT OF 3-DRIVE CROSS COUNTRY TYPE ROLLING MILL

MAJOR EQUIPMENTS/PARTS OF STANDARD CROSS COUNTRY TYPE ROLLING

MILL

A STANDARD CROSS COUNTRY TYPE ROLLING MILL IN THE SME-SRRM

SECTOR HAS THE FOLLOWING MAJOR EQUIPMENTS/PARTS:

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

BILLET PREPARATION

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

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

POWER SUPPLY & DISTRIBUTION SYSTEM

CONTROL PANELS

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

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

RAW MATERIAL SUPPLIERS

SUPPLIERS OF STEEL SCRAP

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)

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)