MS Ingot (TMT Bar, Angle Channel, Round) (Capacity: 60 MT/Day)

MS INGOT (TMT BAR, ANGLE CHANNEL, ROUND)

[EIRI/EDPR/4688] J.C.: 2905XL

Mild steel Ingots are the basic raw material for the manufacture of various types of re-rolled products, for e.g. rounds, flats, channels equal and unequal angles etc. A major part of this re-rolled products in the form of cold-twisted deformed bars are used in building construction as reinforcement.

Ingot is the product obtained by pouring liquid steel into cast iron mould of a shape appropriate for the subsequent processing generally by hot rolling or forging into semi-finished or finished products. The shape generally resembles a truncated pyramid or truncated cone. The side surfaces can be corrugated and the corners are more or less rounded. Depending on its subsequent conversion requirements, ingot can be dressed and/or hot scarred or cropped.

The usual cross section of ingot is square, rectangular, round, oval, or polygon. Ingots with square cross section are used for rolling into billets, rails and other structural sections, whereas, ingots with rectangular cross section, are generally used for rolling into flat products. These ingots usually have a width which is two times or higher than the thickness. Round ingots are used for the production of seamless pipes. Polygonal ingots are used to produce tyres, and wheels etc. Low capacity steel melting shops with induction furnaces produce very small cross section ingots which are called as pencil ingots.

Typically ingots used for the production of rolled products have weights in the range of 5 tons to 35 tons. Pencil ingots are used for the rolling of merchant long products and reinforcement bars and have weights typically in the range of 100 kg to 200 kg. Ingots used for the production by forging of the heavy equipment/components can be extremely large ingots weighing even 600 tons and more.

Ingot is a conventional crude steel product, but presently it constitutes a very small percentage of global crude steel production. However, ingots are still fundamental for specific low-alloy steel grades and for special forging applications, where products of large dimension, high quality or small lot size are needed. These large dimension ingots are being used these days in the power engineering industry (e.g. shafts for power generation plants, turbine blades), the oil and gas industry (conveying equipment, seamless tubes), the aerospace industry (shafts, turbines, engine parts), ship building (shafts for engines and drives), tool making and mechanical engineering (heavy forgings, cold, hot and high-speed steels, bearing, drive gears) as well as automotive engineering (shafts, axes).

As the demand of heavy ingot increases nowadays, especially from the power engineering industry and ship industry, there is a tendency of producing extremely large ingots, which are mainly applied for pressure retaining components such as reaction vessels for nuclear power plant and rotating components like drive shafts of gas turbines and generator rotors.

As the demand of heavy ingot increases nowadays, especially from the power engineering industry and ship industry, there is a tendency of producing extreme large ingots over 600 t and continuous cast strands with thickness over 450 mm and rounds with diameter up to 800 mm, which are mainly applied for pressure retaining components such as reaction vessels for nuclear power plant and rotating components like drive shafts of gas turbines and generator rotors.

COST ESTIMATION

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%

CONTENTS

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 – 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)