Detailed Project Report on TMT BAR FROM SCRAP

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.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



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.

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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.

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CONTENTS


MS BILLETS
THE AVAILABLE SIZES OF THE STEEL BILLETS ARE
IMPORTANT ASPECTS OF CONTINUOUS CASTING O F 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

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CHEMICAL COMPOSITION AND MECHANICAL PROPE RTIES OF STEEL (INDIAN
STANDARD)
BEND TEST
REBEND TEST
WEIGHT DETAILS
MARKET OVERVIEW OF B ILLETS 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 A ND PROCESSING
THE FOLLOWING PROCES SES CAN BE USED:
STAGE 2 – MAKING STEEL BILLETS
STAGE 3 – MAKING TMT REINFORCE MENT 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 TR EATMENT:
THESE THREE ESSENTIAL STEPS ARE:
QUENCHING:
SELF-TEMPERING:
ATMOSPHERIC COOLING:
MANUFACTURING PROCES S – MS BILLETS
PREPARATION OF SCRAP
PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP
MECHANICAL PROCESSES

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PROCESSES FOR PREPARATION OF STEEL SCRAP
MAGNETIC SEPARATION PROCESS
EDDY CURRENT SEPARAT ION PROCESS
HEAVY MEDIA SEPARATI ON PROCESS
SEPARATION BY PHYSICAL AND CHEMICAL CHAR ACTERISTICS
DECOATING PROCESSES
DEZINCING PROCESS FOR STEEL SCRAP
DETINNING PROCESS FOR STEEL SCRAP
DECOPPERIZATION PROC ESS FOR STEEL SCRAP
INCINERATION
PORTABLE OPTICAL EMISSION SPECTROMETERS
COLOUR SORTING PROCE SS
PROCESS UTILIZING LASER INDUCED BREAKDOW N SPECTROSCOPY
MELTING
OPERATION OF INDUCTION FURNACE
SCHEMATICS OF AN INDUCTION FURNACE
A CORELESS INDUCTION FURNACES
BATH AGITATION MECHAN ISM
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 ELEC TRIC ARC FURNACE STEEL MAKING PROCESS
TABLE 1 COMPARISON OF OPERATING PARAMETE RS 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 CR UCIBLE INDUCTION FURNACE
ENVIRONMENTAL EMISSI ONS

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SAFETY AND INDUCTION FURNACES
TMT BAR
THE THERMO MECHANICA L TREATMENT INVOLVES 3 ESSENTIAL STEPS
THAT ARE:
THE QUALITY OF TMT BAR DEPENDS ON THREE MAJOR FACTORS
PRIMARY STEEL MAKING
THERMO MECHANICAL TR EATMENT
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 VESS EL
TUNDISH REFRACTORY L INING
BILLET INSPECTION AND CONDITIONING FACIL ITIES
INSPECTION TECHNIQUES
BILLET INSPECTION TECHNIQUES
EDDY CURRENT TECHNIQUES
FLUX LEAKAGE TECHNIQUES

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MICROWAVE TECHNIQUES
OPTICAL TECHNIQUES
THERMAL TECHNIQUES
ULTRASONIC TECHNIQUE S
SELECTION OF INSPECTION TECHNIQUES
BILLET CONDITIONING FACILITIES
ROLLING MILL - TMT
TYPICAL LAYOUT OF 3-DRIVE CROSS COUNTRY TYPE ROLLING MILL
MAJOR EQUIPMENTS/PAR TS OF STANDARD CROSS COUNTRY TYPE ROLLING
MILL
A STANDARD CROSS COUNTRY TYPE ROLLING MI LL IN THE SME- SRRM
SECTOR HAS THE FOLLOWING MAJOR EQUIPMENT S/PARTS:
GRADES OF INPUT MATERIAL & FORM
THE PROMINENT GRADES OF ALLOY STEELS BEING ROLLED INCLUDE:
TYPICAL MILL PRODUCT RANGE
STANDARD OPERATING P RACTICES IN ROLLING MILL - TMT
RAW MATERIAL SECTION
RECEIVING, TESTING & STACKING OF INGOTS/ BILLETS
BILLET PREPARATION
STANDARD OPERATING P ROCEDURES FOR ROLLIN G MILL
ROLLING SUPERVISION & SECTION CONTROL
THE IMPORTANT ASPECT S TO BE KEPT IN MIND DURING ROLLING
SUPERVISION ARE:
EMERGENCY STOPPING OF MILL
ACTION TAKEN IN THE EVENT OF COBBLE
MEASURES TO BE ADOPT ED FOR INCREASING MILL UTILIZATION
SPINDLES
MILL HOUSING
ROLLER TABLES, TILTING, Y-ROLLER TABLES
WALL –TILTERS

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FRONT & BACK END CROPPING SHEARS
THERMO-MECHANICAL TREATMENT OF STEEL (TMT) SYSTEM
COOLING BEDS
HYDRAULIC & PNEUMATI C SYSTEMS
IN THE HYDRAULIC SYSTEMS THE IMPORTANT PARAMETERS TO BE
OBSERVED ARE:
MILL ELECTRICS; POWER SUPPLY & DISTRIBUT ION SYSTEM
POWER SUPPLY & DISTRIBUTION SYSTEM
CONTROL PANELS
PROCESS CONTROL/PROG RAMMABLE 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 PROCES S/PROCESS FLOW – TMT BAR
RAW MATERIAL SUPPLIERS
SUPPLIERS OF STEEL SCRAP
SUPPLIERS OF PLANT AND EQUIPMENTS
CONCASTING MACHINE
INDUCTION FURNACE
METAL TESTING MACHIN E
PRECISION MEASURING TOOLS
NDT INSPECTION EQUIPMENT
ELECTRICAL MEASURING INSTRUMENTS
EOT CRANES
ELECTRICAL PANEL
COOLING TOWER
ROLLING MILL
SHAPING MACHINE

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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 WAT ER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
WASTE GENERATION & M ANAGEMENT / GREEN BELT
GREEN BELT
WATER (ESTIMATED)
WASTE (ESTIMATED)
FLUE GAS (ESTIMATED)
PRINCIPLES OF PLANT LAYOUT

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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 ENVIRONM ENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
PROPOSED IMPLEMENTAT ION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

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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 CAP ITAL
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)

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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%