the indian cold rolling industry

7/27/2019 The Indian Cold Rolling Industry

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An Overview

old-rolled

coils, stripsC and sheets are versatilesteel products that are used as

critical inputs in various

sophisticated industries which

demand very stringent qualityspecifications, high level of

surface finish and close

tolerances in dimensions.

Important

applications of cold-

rolled steel products

are found in the

manufacture of

automotive body,

auto components,

petroleum tankers,

lube grease barrels,bitumen drums,

agricultural and

electrical

appliances, earth

moving equipment, furniture, off ice

equipment, precision tubes, bicycle

components, fabricated parts of

engineering machinery, railway

coaches, locomotives, wagons,

elevators, containers, trucks, coldformed sections etc. Beside these,

the construction sector uses

narrow CR Sheets for cable

armouring tapes, press

formed components and

wided CR Sheets for

building industrial

construction tanks and

containers.

Major consumers of cold-

rolled steel products are the

automobile sector, whitegoods sector, galvanized /

coated steel manufacturers

and the oil sector.


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Cold Rolling of SteelThe method of cold rolling points at

the process of metal forming in which

the shape and structure of steel is being

changed by drawing, extruding,

hammering, pressing, spinning or

stretching at temperatures below thesteel's recrystallisation temperature.

These actions create alterations in the

metal's work which increase its

hardness and tensile strength while

enhancing the surface f in ish,

decreasing ductility and impact

resistance.

Cold Rolling is termed as a process by

which the sheet metal or strip stock is

being introduced among rollers

fol lowed by compressing and

squeezing. The rollers rotate in

opposite directions at a steady space

and they are set apart so that their

width is smaller than the metal sheetingthat is passed through. When the metal

goes through the cold mill process, it is

pressed into a pre-ordered gauge for

finishing.

Advantages of Cold RollingThe major advantages of cold-

rolling operation are as follows :

lCold-rolling refines the metal and

goes on to develop the surface

condition of the strips. It makes steel

more strong.

lThe metal-on-metal procedure

helps to stiffen and reinforces the

properties of steel itself. While thesteel thickness decreases most of the

break down or variable patches that

take place in the heating process are

built-up or annealed by cold rolling.

Cold Rolling Steel Industry inIndia

Leading Indian producers of cold-

rolled steel are now capable of

producing high quality products

comparable to global standards for

high-end applications. They are

con t i nuous ly upgrad ing the i r

technologies with the help of world

majors in their eagerness to face thechallenges of global competition.

New Application AreasIn the new application areas, cold

formed sections are being successfully

produced in India. Tailored blanks for

automobiles and high tensile cold-

Industry Group% Share in Total

Consumption

Auto / Tractor / Cycle 24.0

Drums / Barrels /

Containers12.0

Galvanized/Coated Sheets 12.5

Tube Makers

Furniture Makers

Consumer Durables

5.0

6.5

6.2

Agricultural Implements 4.0

Other Eng. Units 3.0

Machinery Manufacturers 2.6

Electrical Manufacturers

CR Units

Oil Sector

Total

2.4

3.0

12.8

100.0

INDUSTRY GROUPWISE CONSUMPTIONOF CR PRODUCTS

rolled products are being produced by

many leading producers. Many Indian

cold-rolled producers have installed

s ta te-of- the-ar t wor ld-c lass

technologies and are now capable of

producing DD/EDD and other stringent

grades / specifications for high-end

applications.

Major Grade / Specif ications

Applications of CR Products Major

Grade / Specificationwise of CR

Products are Shown in Table 1.

Production for Sale of CR Sheet/ Coils in India

Production for sale is arrived at

after deducting Inter-plant Transfers

(IPTs) and producers own consumptionfrom gross production.

Production for sale of CR Sheets /

Coils in India between 2007-08 and

2011-12 are shown in Table-2.

The growth of 3.22 percent in the

production for sale of CR products in

2011-12 over the previous year is acommendable performance in view of adismal growth of 2.9 percent in themanufacturing sector over 8.9 percenin the above comparative periods.Leading Producers of CRProducts in IndiaThe gross production of CR Sheets Coils by leading Indian producer

between 2009-10 and 2011-12 areshown in Table 3.In 2011-12, the above fineproducers had a share of 42.02 percenin the total gross production of CRproducts in India.ImportsImports of CR products by Indiabetween 2007-08 and 2011-12 arefurnished in Table 4.The drop in imports of 14.49percent in 2008-09 was due to theadverse effect of the global crisis tha

started from October, 2008.The higher imports of CR Sheets coils between 2009-10 and 2011-12was due to a robust demand from

automobile, white goods, galvanisedsteel and oil sectors.Exports of CR Sheets / Coils byIndiaExports of CR Sheets / Coils byIndia between 2007-08 and 2011-12are shown in Table 5.

Year Production for Sale % Change

2007-08

2008-09

2009-10

2010-11

2011-12(P)

4439

4602

5914

6717

6933

==

3.67

28.51

13.58

3.22

TABLE 2 : PRODUCTION FOR SALE OFCR SHEETS / COILS : 2007-08 AND

2011-12 ('000 TONNES)

Grades / Specifications Applications

Full Hard IS:513 Grade O Coated Sheets

Packaging, Household Appliances, Precision Tubes

IS:513 Grades D/DD/EDD

IS:513 Grades O(SK) ID(K)

Automobiles

IRSM 41 Railway Coaches, Wagons

IS:513 O/D with Cu Corrosion Resistant Applications

HSCR 26/35Load Bearing Components of Automobiles, Rolled-formed

Sections, Industrial Storage System, Drums and Barrels.

TABLE 1 : MAJOR GRADE / SPECIFICATION APPLICATIONS OF CR PRODUCTS


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Gross Production DuringProducers

2009-10 2010-11 2011-12 (P)

SAIL

Tata SteelEssar Steel

JSW Ispat

JSWSL

720

1041954

238

1498

683

1095907

209

2496

574

1084820

359

1625

TABLE 3 : THE GROSS PRODUCTION OF CR SHEETS / COILS BY LEADING INDIANPRODUCERS : 2009-10 TO 2011-12 ('000 TONNES)

Year Imports % Change

TABLE 4 : IMPORTS OF CR SHEET / COILSBY INDIA : 2007-08 TO 2011-12

('000 TONNES)

2007-08

2008-09

2009-10

2010-11

2011-12 (P)

821

702

892

1148

1442

==

(-) 14.49

27.07

28.70

25.61

Year Exports % Change

TABLE 5 : EXPORTS OF CR SHEETS / COILSBY INDIA 2007-08 TO 2011-12

('000 TONNES)

2007-08

2008-09

2009-10

2010-11

2011-12 (P)

510

327

345

283

285

==

(-) 35.88

5.50

(-) 17.97

0.71

The negative growth in exports of35.88 percent in 2008-09 was due tothe global crisis that started in October,2008. The negative growth of 17.97percent in 2010-11 and the marginalgrowth in 2011-12 was as a result ofthe Eurozone financial crisis and lack ofdemand in the global market in general.Apparent ConsumptionThe apparent consumption of CRSheets / Coils in India between 2007-08 and 2011-12 are shown in Table 6.The high growth in apparentconsumption of cold-rolled products in

India in 2009-10 and 2010-11 was dueto robust growths and higher demandf rom the consum ing sec torsparticularly the automotive sector.India's automotive sector posted highgrowth of 25.7 percent in production,26.41 percent in domestic sales and17.90 percent in exports in 2009-10

Year Exports % Change

TABLE 6 : APPARENT CONSUMPTIONCR SHEETS / COILS IN INDIA : 2007-08 TO

2011-12 ('000 TONNES)

2007-08

2008-09

2009-10

2010-112011-12 (P)

4730

4966

6344

76148063

==

4.99

27.75

20.025.90

over the previous year. In 2010-11, the

respective growths in production,

domestic sales and exports were 27.45

percent, 26.17 percent and 29.64

percent over the previous year.

Projected Consumption of CRSteel Products upto 2019-20

The projections of World Steel

Associat ion (WSA) on India 's

consumption of CR products up to

2019-20 are shown below :

lCurrent Consumption ('000tonnes) 5.2

lProjected Consumption in 2011-

12 ('000 tonnes) 8.0

lProjected Consumption in 2019-

20 ('000 tonnes) 17.0

lCAGR (%) 2007-08 to 2019-20

10.4

Source : Article by Sushim Banerjee,

Presently Director General, INSDAG, in ISR,

December 2008

Configuration of A Modern ColdRolling Mill

Tata Steel's world-class CR Mill

based at Jamshedpur, Jharkhand

produces Tata Steelium which has been

claimed as world's first branded Cold

Rolled Steel. The Tata Steel CR Mill has

the following facilities for the

manufacture of cold-rolled steel.

(i) 5-Stand 6-Hi Tandem Mill

Supplied by Hitachi of Japan. Its main

features are :

lTandem Mill

l6 Hi UCM

lAutomated Gauge and Shape

Method

lThickness Tolerance + 0.percent

lFlatness 10 / units in blanking

The input material, HR Coils ge

picked and are rolled to Cold Rolle

Steel of desired thickness in a single

continuous automotive operation. Th

Tandem Mill ensures guarantee

number of components per tonne, clea

surface and high productivity.

(ii) Bell Annealing Facilitie

Supplied by LOI of Germany. Its main

features are :

lSuperior and uniform mechanica

properties

lSuperior surface cleanliness

lDehumidated chamber for cooling

and storage of annealed coils (rust-

free surface)

lHydrogen Annealing

The Bell Annealing facilitie

guarantee :

(a) Superior formabilities for end-

products

(b) Even point rust spots are

avoided

In the annealing process, the coil

are imparted the desired properties tosuit varying end applications rangin

from auto appliance to drums and

furniture.

(iii) Single Stand 4-Hi Skin Pas

Mill & Electro Discharge Texturing

Machine, supplied by IHI of Japan an

U.K.

Annealed coils are given a smal

reduction (Less than 1%) in the Skin

Pass Mill. The operation results in the

desired surface roughness imparted in

the strip surface as per custome

specifications. Also, flatness of the

strip is improved.

Its main features are :

l4-Hi Configuration

lWide range of surface finishe

with precise control

lControl of surface, sharpness in

narrow band


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Skin Pass Mill Its main purposes :lTo suppress yield point elongationlTo impart roughness on striplFor better paintabilitylFor improve the followingmechanical properties :- Hardness- Yield Strength- Ultimate Tensile Strength

- To improve shape (Removingwaviness and centre buckle)Performance of Indian CRIndustry, in H1 of 2012-13The performance of the Indian Cold Rolling industry between April, 2012and September, 2012 (H1 of 2012-13)are shown below :Production for SaleProduction for sale of CR Sheets /

Coils in India during H1 of 2012-13 areshown below :Products

Production for Sale ('000 tonnes)% Change

H1 of 2011-12 H1 of 2012-13

CR Sheets / Coils 3490 (P) 4348 (P) 24.58

Despite various constraints, theIndian Cold Rolling industry hasrecorded a robust growth of 24.58percent in production for sale during H1of 2012-13 over H1 of 2011-12.ImportsImports of CR products during H1 of2012-13 over H1 of 2011-12 are

shown below :Products % Change

H1 of 2011-12 H1 of 2012-13

Imports ('000 tonnes)

CR Sheets / Coils 716 776 8.38

ExportsExports of CR production during H1 of 2012-13

vis--vis of 2011-12 are shown below :

Products % ChangeH1 of 2011-12 H1 of 2012-13

Exports ('000 tonnes)

CR Sheets / Coils 152 199 30.92

Apparent Consumption

Apparent Consumption of CR products by India during H1 of 2012-13 vis--visH1 of 2011-12 are presented below :

Products % ChangeH1 of 2011-12 H1 of 2012-13

CR Sheets / Coils

Apparent Consumption ('000 tonnes)

4114 4969 20.78

CR Coils and Sheets recorded highgrowth of consumption in H1 of 2012-13 among major carbon steel products.Special Features of UpcomingCR Mill at Bokaro Steel PlantAmong the features of the 1.2 Mtpy

capacity Cold Rolling Mill at SAIL'sBokaro Steel Plant in Jharkhand to besupplied by Siemens VAI of Austria arethe Siroll CIS CM and PL product line.The first link of the production chainwill be the tandem cold mill coupled to apickling line. For these products, allcore equipment, critical for the lineperformances, are fully engineered,manufactured and tested at SiemensVAI's European plant, located inMontbrison in France. The state-of-the-art PLTCM of 1.2 Mtpy capacity,will be the first of its kind in India,equipped with heavy gauge laserwelder (LW21H), pickling section,horizontal loopers and side trimmer, 5-stand 6-Hi cold rolling mill and a

carrousel coiler. This Cold Rolling atBokaro Steel Plant will meet thehighest Quality standards in terms ofstrip flatness, strip surface, stripcleanliness and dimentional tolerances.It has been designed to produce highstrength automotive grades including,IF, HSLA, HSS And DP Steels as well aslow carbon steel.

The new Cold Rolling Mill at Bokar

has been scheduled to be operation by

2012-13. Downstream of the Bokaro

PLTCM, SAIL has also invested in an

Electrolytic Cleaning Line (ECL) t

remove the remaining iron fines and o

residues from the tandem mill. The

advanced technology of ECL at Bokarwill ensure outstanding coil cleanlines

before the coils reach the downstream

batch annealing furnace.

Recent Innovations in Indian CRMills

Two major innovations that ar

taking place in the configuration o

Indian cold rolling mills are :

lInstallation of PLTCM

lInstallation of Continuou

Annealing Line (CAL)

Pickling Line Coupled withTandem Mill (PLTCM)

Continuous pickling line couplewith tandem mill provides significan

quality improvement, productivity

yield and cost advantages, thereby

eliminating intermediate storages fo

pickled coils and the necessity of strip

threading for each coil entering th

tandem mill. The combination of these

two lines is a mix of highly efficien

features that ensure excellent quality

results in terms of strip's flatness and

thickness control.

The continuous process eliminate

the necessity to thread the strip head

between two consecutive roll

resulting in higher line productivityreduction of off-gauge materials an

reduction of coil handling.

SAIL's Bokaro Steel Plant i

installing a PLTCM to be supplied by

Siemens VAI. The main features o

Bokaro's PLTCM have already been

mentioned earlier.

lJindal South West Steel Ltd

(JSWSL) has placed an order with SMS

Siemag of Germany for the supply of

PLTCM at its Torangall plant. The mil

will have an annual capacity of 2.3 Mt o

cold strips in widths up to 1890 mm and

will be producing high grade cold rolled

products particularly for the auto

sector.

The scope of supply by SMS Siemag

includes entry section, equipped wit

two pay off real groups with a SMS

Siemag welder which enables those

strip of difficult weldability to be joined


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together. A tension leveler preparesthe strip for the pickling process in thethree downstream pickling tanks. Theturbulence pickling technology allowsop t imum desea l i ng w i th l owconsumption of energy and acid as wellas reduced maintenance and operatingcosts. In addition, an integratedtrimming shear sets the desired stripwidth and straightens the strip edges.Altogether, three horizontal stripaccumulators are integrated into theline which ensures continuous striptravel.The 5-mill stands of the tandem millare designed as a 6-high stand and areequipped with Continuous VariableCrown / enhanced shifting system(CVC Plus / Ess) technology. The roll-gap adjustment range made availableby this SMS Siemag technology allowsoptimum results as regards strip gaugeand flatness, even when the productrange is extremely broad.In the exit section, the strips arecoiled by a carrousel reel at minimumfinal gauge of 0.3mm. A particularlycompact design is achieved from theexit section of the tandem cold mill bycombining the carrousel reel and thedownstream in-line inspection system.The PLTCM of JSWSL is likely to beoperational by the year 2013.Continuous Annealing LinesThe continuous annealing processrepresents the ideal solution for

processing cold-rolled strip with highproduction rates, high yields andsubstantial energy savings ascompared to the batch annealingprocess. These continuous lines ensuretop material qualities and high processflexibility for the broad range of steelgrades and dimensions. Excellentannealing results, especially in theautomotive sector are achieved thanks to the fully automatedtemperature control, specific annealingcycles and rapid cooling system.The present generation ContinuousAnnealing Lines (CALs) for auto bodyquality strip production generallyconsist of coil receiving and entrysection, a double entry pass section forstrip join ing, vert ical looper,electrolytic cleaning section, annealingfurnace, exit vertical looper, skin passand tension leveling section,

horizontal and vertical inspection

station, cooling section followed by coil

delivery section.

Tata Steel has signed a joint venture

agreement with Nippon Steel of Japan

for setting up a Rs. 2300 crore

speciality steelmaking line the

Continuous Annealing Process line to

produce 600,000 tonnes per year of

automotive grade cold rolled steel.

Tata Steel will hold 51 percent share in

the joint venture.

According to Tata Steel sources the

CAL will be located at Jamshedpur in

Jharkhand state and is likely to be

operational in 2013. This will be the

first continuous annealing line to be set

up in India.

Bhushan SteelBhushan Steel is a leading supplier

of auto-grade steel in India. Expanding

the company's current range of flatproducts for the automotive industry. It

has signaled its intention to set up an

advanced pickling line coupled with

tandem cold mill and a continuous

annealing line (PLTCMECAL) facility at

Odisha, with a capacity of 2 Mtpy.

This line will cater to the

requirements of the automotive

industry by increasing the strength of

steel and producing thinner sections,

this reducing weight which will help to

reduce fuel consumption.

The company has already finalized

the technology side and are now

working on the engineering aspect.

Bhushan has planned to start the

construction of the project in January,

2013.

The company expects to complete

the project in Odhisha in two and half

years from the start of physical

construction.

Changing Pattern of CR ProductDemand

In the last decade or so, the demand

for cold-rolled steel, products has

shown an accelerated growth. The

requirement of the products are also

changing fast. The change in the usageof cold-rolled products is evident in the

following two areas in particular :

lGalvanised / Coated Sheets

lNewer sheets like interstitial free

(IF) and brake hardening (BH) steels

for the automobile sector.

In 2010-11 and 2011-12, theautosector in India has posted robusgrowth. The while good sector, whichwas galvanized sheets, a downstreamproduct of cold-rolled steel in theabove two years has also recordedgrowth. In addition to many stringenapplications of cold-rolled productsanother major imporatance of theseproducts is in their downstreamproducts specially the galvanized steesegment including colour coatedsheets. Major galvanized and coloucoated steel producer have nowi n s t a l l e d s t a t e - o f - t h e - a rtechnologies and are producing highesquality products for high endapplication. Despite a difficult markewith lower global demand and loweglobal prices, the Indian Galvanisedsteel industry's export was over 1million tonnes in 2011-12.ConclusionThe Indian Cold Rolling Industry hadeveloped quite significantly in the las5/6 years. It is now capable oproducing high grade products tostringent specifications required fovarious industries. In particular, theleading producers are keen to producehigh grade automotive steels for theIndian automobile industry which hasrecorded robust growth in recenyears.The setting up of PLTCM andContinuous Annealing Lines (CAL) wi

help the production of high gradematerials in a cost-effective and eco-friendly manner. During the periodfrom April, 2012 to September, 2012(H1 of 2012-13), India's cold-rollingindustry's production for sale waabout 4.35 Mt of CR Sheets / Coils ove3.49 Mt during the same period of theprevious year recording a robusgrowth of 24.58 percent.In the above comparative periodsIndia's apparent consumption of CRproducts at about 5 Mt has registered avery high growth of 20.78 percent ove4.11 Mt.Despite a low growth of themanufacturing sector, the performanceof the Indian Cold-Rolling industryduring H1 of 2012-13 is commendableThe industry will grow from strength tostrength in near future.

the indian cold rolling industry

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