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Sunvik Steels PVT LTD Pre-Feasibility Report: 2.5.5. Raw Materials
Sunvik Steels PVT LTD Pre-Feasibility Report: 2.5.5. Raw Materials
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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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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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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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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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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3.
Sl. No
Quantity in MT
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
12,00,000
14
Slag
21,000
4.
Sl no
Quantity in KLD
60
Induction Furnace
220
Rolling Mill
30
120
Blast Furnace
400
Tunnel Kiln
60
40
50
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Pre-feasibility Report
10
10
10
5.
Sl no
Particulars
Quantity in MW
0.4
Induction Furnace
22.0
Rolling Mill
3.0
1.5
Blast Furnace
4.0
Tunnel Kiln
0.5
15
0.6
0.5
10
0.2
Particulars
Quantity in Acres
6.0
Induction Furnace
10.0
Rolling Mill
3.0
5.0
Blast Furnace
5.0
Tunnel Kiln
5.0
5.0
5.0
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Pre-feasibility Report
3.0
10
3.0
7.
Sl no
Particulars
Amount in Crores
30.00
Induction Furnace
08.00
Rolling Mill
12.00
50.00
Blast Furnace
140.00
Tunnel Kiln
45.00
207.00
06.00
07.00
10
04.00
11
Land Cost
02.50
TOTAL
550.00
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