CONTENTS

Introduction

Steel Melting Shop

Vacuum Arc Degassing

Vacuum Oxygen Decarburization

Ladle Furnace

Argon Oxygen Decarburization

Continuous Casting Shop

Blooming and Billet Mill

Forge Shop

Plate Mill

Heat Treatment & Finishing Shop

Conditioning Shop

Mechanical Repair Shop

Boiler House

Conclusion

Steel Melting Shop

The basic function of SMS is to produce hot metal from Ferro scrap

and providing input material to ingot mould and caster for taking a

shape. Slag is also an output of SMS which are used by cement

industries for cement making.

Basic highlights of SMS:

Electric Arc Furnace (EAF)

Transformer rating of this furnace is 25 MVA for stainless steel

furnace and 18.75 MVA for the non stainless steel furnace.

One heat requires 3 hours to complete.

After tapping the molten metal is sent to VOD/VAD/LD directly.

In VAD the molten metal is degassed to removed the Hydrogen or

Oxygen from the metal to reduce their amount to an acceptable

ppm level.

VAD Furnace Ladle Furnace

VOD Furnace AOD Furnace

CONTINUOUS CASTING SHOP(CCS)

Through continuous casting route mainly stailess steel slabs are

produced. In ASP there was a twin caster i.e. slab cum bloom caster

which culd be used either as single strand slab caster or double strand

bloom caster in operation.

For continuous casting there is mould where the liquid metal is to be

poured.Before the ladle comes inside the mould some biscuit and

chocolate size bar is placed to give the shape of the slab.

Casting can be sequential or in batch . In sequential casting 2 or more

then 2 ladles are brought to turret for casting one by one.But in batch

only one ladle is cast.

BLOOMING AND BILLET MILL (BBM)

In ASP, Blooming & Billet Mill plays a major role. Here the

primary rolling mill is use to compress the soaking pits. In this process

the soaking pit is use at temperature 1180-1800 C.

BBM consists of Blooming Mill, Billet Mill & Soaking pits. This

mill produces blooms, billets, squares, rounds, & slabs of various sizes

& can handle all grades of alloy steel produced at SMS. At 1 st in pit

furnace a metal shape is heated and then it passed between two rollers.

In roller operation the crossection of the specimen is gradually

decreased.

CONDITIONING SHOP

COOLING LUD

HOT SAW

BILLET SHEAR

650 mm BILLET MILL 2

700 mm BILLET MILL 1

BLOOM SHEAR

LD SCARFING MACHINE

900 mm TWO HIGH REVERSING MILL

SOAKING PIT FURNACE

FROM SMS & CCS

MAJOR CONTROLLERS IN B.B.M.:

Pit temperature controller.

Fuel controller.

BLOOMING & BILLET MILL

FORGE SHOP

The forge shops have two type of forging presses for producing

compact steel forgings. One is computerized forging press & another

one is manual forging press which have 2 T capacity.

In forging shop there is two heating chamber for heating the

material before forging process. 1st chamber is use for gradually

increasing the temperature of the specimen. Here the specimen doesn’t

reaches the particular temperature which is not suitable for the forging.

And the 2nd chamber is use for reheating the specimen. The total

heating time is 6hrs. After that the specimen is ready for the forging.

USE OF FORGING:

It is use for making a specimen of required shape. By the forging

press we get a final product of good surface finish. In forging process

rectangular shape can be change in circular shape & also vice-versa.

After processing in this shop the material is then sent to Heat Treatment

and Finishing shop.

SECTION:

Press Bay

Hammer Bay

INPUT MATERIAL:

Blooms of various sizes.

CONTROLLING PARAMETERS OF FURNACE:

Metal temperature.

Fuel flow.

Combustion flow.

Compressed air flow.

Furnace pressure.

PRODUCTS:

Rounds, squares, die block, flats, rings etc.

Diagram of Forging Press machine

Forging Hammer Reheating Furnace

Forging Pressure Forging Roll

PLATE MILL

The ingots are rolled at Blooming and Billet Mill for producing blooms, billets,

rounds and slabs in a variety of steel grades & sizes. The rolled slabs are further

rolled in Plate mill to produce plates. Today thermomechanical rolling is the

most important production process for the manufacture of high strength plates.

In this method the temperatures are exactly set for finish rolling and for cooling.

CONDITIONING SHOP

Detection and removal of surface defects like cracks and making

materials ready for further processing a/c to customer’s needs.In

the conditioning shop, the surface defect of the products are

removed prior to shipping further rolling or forging in order to

meet the required quality standard of the finished product. The

further processing is known as conditioning. This shop is equipped

with slow cooling boxes and bogie.Hearth type dispositioning

furnaces for treatment of products received from BBM.Other

facilities include straightening machines,saw and flame cutting

machines elaborate inspection and testing arrangements for spark

and spectro testing for quality control.

INPUT MATERIALS :

Products from-

Forge shop

BBM

Bar mill

There are two types of conditioning shops:

1.CONDITIONING SHOP 1

Normal cooling Box cooling Grinding

Cutting Furnace cooling

2.CONDITIONING SHOP 2:

In this shop materials come from continuous casting shop.

HEAT TREATMENT AND FINISHING SHOP

Here different types of heat treatment arrangements such as for oil

quenching, water quenching are present in order to impart specific

properties to the alloy steel as per customer’s requirement.

BOILER HOUSE

This unit provides steam for the entire plant. Steam is used

in vaccuam creation system consisting of converging and

diverging nozzles. The water to be sent to boiler is first

demineralised by passing it through cation exchanger and

anion exchanger. This is done to prevent scaling by

deposition of minerals on inner surface of boiler which

reduces the life of boiler considerably. The water sent to the

boiler is checked regularly in a chemical laboratory.

MECHANICAL REPAIR SHOP(MRS)

This is the Mechanical repairing shop which is support the

production of the plant as well as looking after breakdown and

preventive maintenance of equipment.

It has Four Sections. Eg; i) Overhauling & Fitting, ii) Winding ,

iii) Testing & iv) Preventive & Breakdown Maintenance.

* Overhauling & Fitting Section :

This section repairs the motor, generator etc, after careful

inspection of all parts & repair it accordingly.

* Welding Section : -

Welding of AC Motor of both Squirrel Cage & Slip Ring upto the

capacity of 225 KW, 415V. 1480 RPM can be done.

* Testing Section :

At Testing section all DC & AC Motors upto the capacity of 100

KW can be Tested.

* Preventive & Breakdown Maintenance : -

Maintains Lathe, Drill, Planning, Copy planning , Welding

etc, for uninterrupted production & to ensure equipment

availability.