Detailed Project Report on Hot Rolling Mill for Producing TMT Bars (100 TPD)

HOT ROLLING MILL FOR PRODUCING TMT BARS (100 TPD)

[EIRI/EDPR/1285] J.C.9948

INTRODUCTION

What is TMT

Thermo mechanically treated (TMT) steel, can be described as a new-generation-high-strength steel having superior properties such as weldability, strength, ductility and tensility, which meet the highest international quality standards.

Features:

Resists fire: Withstands temperatures up to 5,000 degree C.

Resists corrosion: The TMT process gives the bar superior strength and anti-corrosive properties.

Earthquake resistance: The soft ferrite-pearlite core enables the bar to bear dynamic and seismic loading.

Malleability: TMT bars are most preferred because of  their flexible nature

Enables welding: They have fine welding features.

Bonding strength: External ribs running across the entire length of the TMT bar give superior bonding strength between the bar and the concrete.

Cost-effective: A high tensile strength and better elongation value gives you great savings

How TMT steel is prepared:

Under thermo mechanical treatment (TMT) the steel bars are passed through a specially designed water-cooling system where they are kept till the outer surface of the bars becomes colder while the core remains hot. This creates a temperature gradient n the bars.

When the bars are taken out of the cooling system, the heat flows from the core to the outer surface, further tempering of the bars, which helps them attain a higher yield strength. The resulting heat-treated structure imparts superior strength and toughness to the bars. The microstructure of the core is a very fine-grained ferrite and pearlite. TMT bars are also known as 'quenched and tempered rebars', because of the quenching and tempering processes involved in making the bars.

The production of quality TMT bar depends on three major factors - quality raw materials, a properly designed and automated mill and a well-designed quenching and tempering technology. All rebars must be purchased based on the properties of yield strength, tensile strength and elongation values.

Deciding the percentage of carbon content in steel has been a major challenge for engineers. While a minimum level of carbon content in steel is essential to achieve the required strength, excess carbon threatens its weldability. In TMT bars, this problem has been eliminated by restricting the carbon content to 0.2 per cent to attain weldability and ensuring that its strength is not lost. The joints can be welded by ordinary electrodes and no extra precautions are required.

The bars come in different lengths, in sizes of 11 to 12 metres and can be customized to the required specifications. TMT bars that have uniform and concentrated hardened periphery and the softer core will have the desired tensile strengths coupled with high elongation as required in seismic zones. Depending on the size and grade, rebars with hardened periphery of about 15 to 30 per cent of the cross sectional area of the bar are ideal for civil constructions (constructions of houses, offices etc.)

COST ESTIMATION

Plant Capacity            100 MT/Day  

Land & Building (8000 sq.mt.)    Rs. 5.40 Cr    

Plant & Machinery                    Rs. 14.85 Cr 

Working Capital for 2 Months    Rs. 17.42 Cr 

Total Capital Investment          Rs. 38.21 Cr 

Rate of Return                          69%

Break Even Point                      31%

CONTENTS

INTRODUCTION

WHAT IS TMT

FEATURES:

HOW TMT STEEL IS PREPARED:

USES & APPLICATIONS

PROPERTIES

BIS- SPECIFICATIONS

QUALITY STANDARDS

MARKET POSITION OF TMT STEEL BARS (SARIYA)

INDIAN STEEL INDUSTRY

PRODUCTION

CONSUMPTION

EXPORTS

INVESTMENT

A SHOWER OF STEEL PLANTS

GLOBAL FORAYS

INDIAN STEEL REQUIREMENT

STEEL - BASIC GLOBAL NORMS

WHAT DO THESE FIGURES CONVEY ABOUT INDIA?

"TMT" BARS IN INDIA

THERMO-MECHANICAL TREATMENT (TMT):

BASIC OBJECTIVES OF DEVELOPING TEMPCORE & THERMEX TECHNOLOGIES:

SUB-STANDARD & DEFECTIVE “TMT” REBARS

FEATURES:

MANUFACTURERS AND SUPPLIERS OF TMT STEEL BARS

MANUFACTURING PROCESS

PROCESS FLOW DIAGRAM

PLANT LAYOUT

TMT BARS

SUPPLIERS OF RAW MATERIALS

STEEL SCRAP

CHEMICALS

LIME

CUTTING OILS

SUPPLIERS OF PLANT AND EQUIPMENTS

ROLLING MILL

SHAPING MACHINE

INDUCTION FURNACE

SHEARING MACHINE

DRILLING MACHINE

LATHE MACHINE

GRINDING MACHINE

ARC WELDING MACHINE

POWER TRANSFORMERS

D.G. SETS

ETP PLANTS

EOT CRANES

WEIGHING MACHINE

COOLING TOWERS

COMPLETE PLANT AND MACHINERY SUPPLIERS FOR TMT STEEL BARS

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)