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Sunvik Steels Pvt Ltd

Pre-feasibility Report

raw material closer to the final product and any miscalculation in any stage or occurrence of
breakdown will result in loss of raw materials, wastage of power and delay in production. Hence
every process is equally important. Now let us have a brief insight stage wise.
Now the first stage is handling the ingots and billets. They are the raw materials for the TMT bars.
They are unloaded from the truck and placed in stacks and are in line with the next batch ready
to be processed further. Various color coding is already done based on their type. They are always
placed in order as to reduce lead time. There are few minor differences between ingots and
billets which will be later discussed in greater detail. The ingots then fed into the furnace and are
softened to a red hot ingot which is later on fed into the roughing mill which considerably
decreases the diameter of the ingot and gradually brings it closer to the final required diameter
and then leading its way to the intermediate mill to further decrease the diameter. Finally the
finishing mill comes into play where the final dimensions are obtained. Note that the rod is still
red hot after emerging from the finishing mill and enters into the TMT quenching box where the
pressure of water is set and the rod is hardened. In the final stage the rod is placed on the cooling
bed and then at last they are stacked together and are ready for dispatch. Thus this brief
summary gives us a proper foundation how the TMT bars are manufactured.
2.5.5. RAW MATERIALS
The raw materials used in production of TMT bars is in-house Billets.
The ingots and billets are almost similar but billets have better finish and there is less chance of
blow holes being present inside within. The final product obtained by using billets have better
finish when compared to the ingots.
Billets are more refined raw material which has less chance of blow holes and smooth surface
finish.

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Sunvik Steels Pvt Ltd

Pre-feasibility Report

Billets have no standard color coding or a standard ratio. They are entirely made as on order. But
after manufacturing the billets are supplied with a Heat number (a test certificate) which
elaborates the ratios of metals used and order size. The dimensions of billets are almost similar
to the ingot. The cross section area of a billet is: 125.Average mass per length 3.1kg per inch in
length
After quality testing, the ingots are ready to be fed in the furnace. It is necessary for the ingots
to have a high temperature for the rolling process through the rollers. This is where the furnace
comes to play. The ingots are fed into the furnace wherein they are constantly heated for 4 hours.
The material, on exit is suitable to undergo Rolling. The furnace generates heat energy by the
combustion of coal gas, which is produced in a coal gas plant located nearby.
The furnace has three processes:

Feeding

Heating

Ejection

The feeding of the raw material into the furnace is done with the help of conveyer rollers. The
ingots are placed on the conveyer rollers manually; tongs are used in the positioning onto the
conveyor system, which transports the raw material to the feeding bed. Once the ingots are
stacked one after the other on the feeding bed, they are pushed into the pre-heating chamber of
the furnace with a mechanism which consists of a worm gear pushing the ingots into the furnace.
This mechanism is also controlled manually by a person due to discontinuity in feeding.
The Heating Chamber or furnace is the chamber where the ingots are made molten, which makes
it feasible to pass it through the rollers. The furnace is a fuel consuming chamber which works on
coal gas. The furnace has a total of 8 burners. There is a pre- heating zone, which leads to the
intermediate zone ultimately leading to the final zone.
The gas plant is where the coal gas is produced. There is a pipeline system which leads the gas to
the burners. The peak temperature in the furnace goes up to 1200C. The gas is streamlined to

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Sunvik Steels Pvt Ltd

Pre-feasibility Report

vary the temperature. Lot of precaution is taken as there is immense heat in proximity to the
furnace.
The furnace interior is made of refractory bricks to withstand the high temperatures. There are
also certain doors at the side for inspection during maintenance. There is another controller near
the exit of the furnace to guide the red hot ingots outside of the furnace and position them onto
the rollers; leading them to the rolling mill.
After heating, the ingot is ready for the roughing mill. Authorized personnel are stationed at
various nodal points to navigate the heated raw material from the Furnace to the Roughing
mill. The exit door is opened by the person who removes the ingot.
Just after the ingot comes out of the furnace it is slowly led to the roughing mill. The roughing
mill is the first mill among the three mills present there. The mills are operated with a high
capacity motor. There is a gear reduction of ratio 1:6 to provide the necessary torque required
for rolling. The roughing mill is where there is very slight elongation and gradually decreases in
diameter and this is the main function of the roughing mill. There are three sets of rollers present
in the roughing mill.
The single motor shaft is transmitted to three shafts through the distributer. The sequence of the
alignment of the motor, couplings, bearings are as shown in the figure below.

Here is the order of the layout of the roughing mill. C stands for coupling and B stands for
bearing. While entering the first set of the roughing mill it roles at about seven times at the same
roller in different slots.

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Sunvik Steels Pvt Ltd

Pre-feasibility Report

The different slots are shown in diag.2 which are the gray parts and the molten ingot passes
through these slots and then manually put back into the next slot and after 7 times in the first
set of rollers it moves through the guide way which leads it to the second set of rollers and again
leading it through the third roller and then the roughing mill is over.

The roughing mill is where most of the elongation is done and the area cross section gradually
decreases and the length increases. But the ingot is still in the molten state and it continuously
moves on to the next rollers through the guide ways.

The motor used for the roughing mill has a capacity of 800HP. Enough power has to be produced
to as the shaft power has to be divided among three shafts.
After passing through the roughing mill, the rod is led into the Intermediate mill. It should be
observed that, there is a considerable decrease of the size of the rod after passing through the
Roughing mill. The main function of the Intermediate mill is to prepare the specimen for the
finishing mill.

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Sunvik Steels Pvt Ltd

Pre-feasibility Report

This is the sequence of the intermediate mill. There is a speed increaser placed as shown. This
facilitates for the smooth movement of the rod as the motor is incapable of giving the entire push
to the rod. The speed increaser is placed wherever more thrust is required.

The finishing mill is the main roller where the required dimension is obtained. The rollers are
made with precision and in such a way that the exact dimension can be obtained. Quality is of
great importance, since the manufactured products are graded and approved by the ISI. This
gives the company an edge over its competitors. The finishing mill also facilitates for the brand
imprint to be put onto the rod.

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Sunvik Steels Pvt Ltd

Pre-feasibility Report

2.9.3. Recovered fuel value of high-carbon fly-ash


In addition to the production of a controlled-LOI fly-ash for use in ready-mixed concrete, this
process also recovers a stream enriched in carbon. The reburning of high-LOI fly ash in utility
boiler is a relatively simple method of utilizing this concentrated unburned carbon(UBC).
Furthermore, recovery of residual energy contained in the high-carbon fly ash increased the value
of the beneficiation process directly to the power plant operation in the form of reduced fuel
costs.

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Sunvik Steels Pvt Ltd

Pre-feasibility Report

2.10. Slag Crusher & Beneficiation Plant


2.10.1. Brief introduction of steel slag processing production line:
Steel slag iron separation equipment researched and developed by our company is of high
efficiency. Steelmaking in steel works, the residue flowing out contains iron, the second recycling
uses crane to pour the liquid slag of slag ladle with layering onto the slag bed ( or slag pit ), spray
a proper amount of water to make the high-temperature slag quench fragmentate and accelerate
cooling, and then excavate and loading with loading machine, electric shovel and other
equipment mining loading, then ship it to the residue field. Those needs processing and
utilization is transported to the steel slag treatment room for fabrication processing such as
crushing, grinding, grading, magnetic separation.

2.10.2. Steel slag iron separation processes:


Disc splash water ( ISC method)
In a steel slag workshop, set elevated splash slag plate, use the crane to splash liquid steel slag
inside slag ladle into the slag plate. The slag layer is generally 30-120mm thick, then sprayed with
proper amount of water to quench cracking.
Overturn the slag in the slag car, drive the car to the pool water cooling, unload the slag to the
tank for further cooling. Residual particle size is generally 5 - 100mm, finally grab it out with grab
bucket and then load in the car, send to slag processing workshop, crush from large to small
pieces, get into the ball mill for grinding, when up to a certain degree, with mortar pump beat
them into the high-frequency screen, sieve, sieved material gets into the magnetic separator for
magnetic separation, those not on the magnetic into the re-election, shaker and the spiral chute
separate, the grade can reach above 64%, three times of recycle into steel steelmaking.

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Sunvik Steels Pvt Ltd

Pre-feasibility Report

Steel slag water quenching process


Hot melt slag in the outflow, falling process, segment and shatter by pressure water. Slag meets
water and rupture because of stress concentration from quenching shrinkage, and granulate the
slag. As slag has higher basicity and viscosity than blast furnace slag, difficulty of water quenching
is big. In order to prevent the explosion, some use slag pot hole, adopt method of water
quenching of the water slag groove and limit the maximum flow rate through the aperture of slag
ladle slag.

Wind quenching method


Slag ladle receives slag and transport it to the air quenching device, tip slag ladle, slag flows out
via intermediate tank, blown and scattered by the air a special nozzle blows, crushed into
particles, in bell type boiler recycle high-temperature air and the heat slag particles emit and trap
slag particles. After air quenching particles turn into the converter slag can be used as building
materials; the medium temperature steam generated by the boiler can be used for drying and
oxidizing the iron sheet.

2.10.3. Steel slag powder processing


As slag contains free CaO of no tables, when processing converter steel slag with steam of l00
and 0.2-0.3MPa pressure, its volume increases by 23% to 87%, powder ratio of steel slag less than
0.3mm is up to 50% -80%.Without changing the main mineral phase composition in the slag, it
eliminates uncombined CaO, improves the stability of the steel slag. This treatment process can
significantly reduce broken steel slag processing capacity as well as reducing the wear of the
equipment.

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Sunvik Steels Pvt Ltd

Pre-feasibility Report

3.

Annual requirement of Raw Materials for Entire Project

Sl. No

Raw materials Description

Quantity in MT

Iron Ore Lumps

4,90,000

Coal

4,50,000

Coke

1,00,000

Limestone

5,00,000

Dolomite

14,000

Sponge Iron

1,00,000

Pig Iron

75,000

Steel Scrap

21,000

MS Billets

2,31,000

10

Fly-Ash

26,520

11

Processed Slag

8,750

12

Cement

4,900

13

Low Grade Iron Ore Fines

12,00,000

14

Slag

21,000

4.

Overall water requirement

Sl no

Details of water requirement

Quantity in KLD

DRI Based Sponge Iron Kiln

60

Induction Furnace

220

Rolling Mill

30

Captive Power Plant

120

Blast Furnace

400

Tunnel Kiln

60

Iron ore Pelletization & Beneficiation

40

Fly-Ash Brick Plant

50
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Sunvik Steels Pvt Ltd

Pre-feasibility Report

Fly-Ash Beneficiation Plant

10

10

Slag Crushing & Beneficiation Plant

10

5.

Overall Power Requirement

Sl no

Particulars

Quantity in MW

DRI Based Sponge Iron Kiln

0.4

Induction Furnace

22.0

Rolling Mill

3.0

Captive Power Plant

1.5

Blast Furnace

4.0

Tunnel Kiln

0.5

Iron ore Pelletization & Beneficiation

15

Fly-Ash Brick Plant

0.6

Fly-Ash Beneficiation Plant

0.5

10

Slag Crushing & Beneficiation Plant

0.2

6. Overall Land utilization pattern


Sl no

Particulars

Quantity in Acres

DRI Based Sponge Iron Kiln

6.0

Induction Furnace

10.0

Rolling Mill

3.0

Captive Power Plant

5.0

Blast Furnace

5.0

Tunnel Kiln

5.0

Iron ore Pelletization & Beneficiation

5.0

Fly-Ash Brick Plant

5.0
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Sunvik Steels Pvt Ltd

Pre-feasibility Report

Fly-Ash Beneficiation Plant

3.0

10

Slag Crushing & Beneficiation Plant

3.0

7.

OVERALL PROJECT COST

Sl no

Particulars

Amount in Crores

DRI Based Sponge Iron Kiln

30.00

Induction Furnace

08.00

Rolling Mill

12.00

Captive Power Plant

50.00

Blast Furnace

140.00

Tunnel Kiln

45.00

Iron ore Pelletization & Beneficiation

207.00

Fly-Ash Brick Plant

06.00

Fly-Ash Beneficiation Plant

07.00

10

Slag Crushing & Beneficiation Plant

04.00

11

Land Cost

02.50

TOTAL

550.00

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