Professional Documents
Culture Documents
Salem Steel Plant Report
Salem Steel Plant Report
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4.10 Slitting line 45
4.11 Tension Leveling Line 46
4.12 Rotary Polisher 47
4.13 Re-squaring Shear 48
4.14 Coil Packing & Dispatch 49
4.15 Coin Blanking line 49
4.16 CRM Cranes 51
5 UTILITIES
5.1 Introduction 52
5.2 Boilers 52
5.3 Feed water treatment 53
5.4 Air Compressors 53
5.5 Liquefied Petroleum Gas 54
6 SERVICES
6.1 General Administration 55
6.2 Public Relation 55
6.3 Material Management 55
6.4 Marketing 55
6.5 Finance & Accounts 56
6.6 Safety Engineering & Fire Services 56
6.7 Water Supply 57
6.8 Medical and Health Services 57
6.9 Corporate Social Responsibility 57
6.10 Central Engineering Shop 58
6.11 Electrical Repair Shop 58
6.12 Production Planning and Control 58
6.13 Metallurgical Services 58
6.14 Centralized MechanicalMaintenance 59
6.15 Auto Garage 59
6.16 Centralized Electrical Maintenance 59
6.17 Total Quality Management 59
6.18 Technical Bureau 60
6.19 Computer & Information Technology 60
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1. OVERVIEW OF SALEM STEEL PLANT
INTRODUCTION:
Salem Steel Plant is one of India’s leading producers of quality Stainless
Steel. The Plant was commissioned in 1981. “Salem Stainless” has become a
house hold name in India. SSP products are also widely exported.
The entire Salem Steel Plant is certified with ISO 9001:2008 for Quality
Management System (QMS), ISO 14001:2004 for Environment Management
System (EMS), OHSAS 18001: 2007 for Health Services, SA 8000:2008 for Social
Accountability, ISO 14001:2004 EMS for Township also.
Hi-tech industries like atomic power stations prefer ‘Salem Stainless Steel’.
The products from SSP are widely used in industrial sectors like Dairy and food
processing, Chemical and fertilizer, Heavy engineering, Railways, Automobiles,
Bulk solid handling, Power etc. The building and architecture segment which is
growing at a rapid pace, sees ‘Salem Stainless’ as the most dependable
companion.
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Capacity (Tonnes)
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2.STEEL MELTING SHOP
2.1INTRODUCTION:
400 Series 18,000 10% of which 409M is 45%,430 is 45% & others is 10%
Total 1,80,000 100%
Table 2.1 Capacity of Steel Melting Shop for Various Grades
EAF is a batch process producing batches of molten steel called “heats”. Furnace
operating cycle is called tap to tap cycle.
In Furnace, roof & electrodes are raised to allow scrap charging (MS Scrap /
SS Scrap and Ferro-alloys). After scrap charging roof & electrodes are
lowered.
Melting process is the heart of EAF. First intermediate voltage tap is
selected until electrodes bore into scrap. After 15% of scrap is melt, voltage
is increased so as to have long arc.
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Once scrap is melted, both temperature and samples are taken to analyze
path chemistry & to determine oxygen to be blown for refining.
In refining, oxygen is lanced at the end of meltdown to lower path carbon
content to desired level of tapping.
Deslagging process is done to remove impurities from the furnace & finally
tapping is done once desired steel composition & temperature is achieved.
Liquid Steel is then poured into Laddle placed on transfer car and taken to
AOD by means of EOT Crane.
In EAF power consumption is 390 kWh/T. Tap to Tap time is 72 minutes and
Electrode consumption is 2.2 Kg/T. EAF also has a fume extraction system.
Purpose of Laddle furnace is for heating, alloy addition for final adjustment
& desulphurization. Rate of temperature rise is 4o C/min & the electrodes used
here is graphite. LF has Inert gas stirring system, twin transfer car. LF has also
fume extraction system.
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The mould is straight type with copper plates & has a length of 700 mm.
Strand guide system is of 10 segments. At the end, Torch cutting is done to get the
slab of required size.
Average Casting speed is 1.0 - 1.4 m/min. Maximum machine speed is 2.0
m/min. Secondary cooling system is Spray water. Laddle turrets maximum lifting
capacity is 120 T.
Slab caster is equipped to cast slabs of dimensions shown in Table 2.2.
Width 600-1300 mm
Thickness 145 & 175 mm
Length 5.0-10.5 m
Table 2.2 Slab Dimensions
Its main purpose is to grind slabs, if required for removing defects from surface.
Both plant return scrap & purchased scrap will be used as melting stock.
Both categories of scrap will be stored in scrap aisle & material storage aisle.
Purchased scrap will be brought either by rail or road & stored in open yard & then
transferred by trucks to storage aisle as required. Plant return scrap wil l also be
transported by in-plant trucks to this aisle & stored in segregated manner.
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2.9 LIST OF EOT CRANES IN STEEL MELTING SHOP:
Coolant
EAF Fluxes Ferro-alloys
LF
LIQUID STEEL
SLAB
CASTER
LIQUID STEEL
CONDITIONING
SLAB
TO EXISTING
CONDITIONED SLAB HRM
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2.11 STEEL MELTING SHOP LAYOUT:
FES of AOD
(A)
Scrap/Ferro Scrap/Ferro
Alloy Storage Alloy Storage
(B)
(C)
(D)
50T EAF
60T Refining
Converter
60T Laddle furnace
(E)
Slab Caster
(F)
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3. HOT ROLLING MILL
3.1 INTRODUCTION:
3.2 PROCESS:
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The head end and tail end of the T-bar from Roughing Mill are cut in rotary
Drum Shear before further rolling in Steckel Mill. Having achieved the required final
thickness in 3, 5 or 7 passes as per the pass schedule, the strip is cooled by
laminar cooling system in RORT and wound in Down Coiler mandrel. After
strapping, weighing and marking, the coils are taken out from conveyor and
dispatched to CRM or customers.
3.3REHEATING FURNACE:
The furnace section consists of Slab Yard and Re-Heating Furnace. The
walking beam type Reheating furnace is hydraulically operated, top and bottom
fired and has a flat roof. The combustion system is of recuperative type designed
for firing LPG or natural gas. The Reheating furnace has been designed and
supplied by M/S Italiampianti, Italy and Erected by M/S Wellman Incandescent,
India.
Furnace capacity:
For Stainless Steel : 55 T/hr (For a reference slab of 170 mm thick)
For Carbon Steel : 70 T/hr (For a reference slab of 170 mm thick)
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The different types of material that can be processed are:
Stainless Steel : AISI 200 & 300 Series (Austenitic)
AISI 400 Series (Ferritic & Martensitic)
Carbon Steel : IS 1079 D, IS 1079 DD, IS 1079 EDD, IS 6240.
IS 2062B, IS 10748, E38, E34, SAILCOR.
The slabs are uniformly heated in the Re-heating furnace so that they are brought
to the discharge temperature of 1150 ˚C to 1250˚C.
No of burners installed 56
Fuel used : LPG
Calorific value : 22,000 Kcal/N m
No. of combustion blowers installed 2
Recuperator : Metallic type to recover the waste heat
from flue gases.
Automation system supplier : M/S Siemens India, Mumbai
Distributed Control System supplier : M/S Yokogawa Blue Star, Bangalore.
In Roughing Mill the thickness of Reheated and Descaled (Primary scales) slab is
reduced to 20 – 32 mm by rolling process in 5,7,9 passes depending on the input
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slab size by controlling the width during rolling in Edger. The complete rolling and
edging operation is carried out as per the proper selection of pass schedule.
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c. Systems:
Hydraulic system
Booster pump system (Centralized for Steckel Mill and Roughing Mill)
High pressure water system
Morgoil system (Centralized for Roughing Mill and Steckel Mill)
Oil lubrication system (Centralized for Roughing Mill and Steckel Mill areas)
Pneumatic system
Grease systems
Type: Single stand, 4 Hi reversible Mill, provided with one coiler furnace on each
side to wind the hot strip just after rolling in each pass and also to maintain the
strip temperature suitable for hot rolling.
Steckel Mill is built with sophisticated facilities & control systems to obtain
high quality flat product such as
HGC - Hydraulic gap control
AGC - Automatic Gap Control
MON - (Thickness monitoring system)
RAC - Roll alignment control
CVC and Work Roll Bending system
PGM - Profile Gauge Meter
Model Server
The state-of-the-art automatic pass schedule calculation facility (model server) is
installed to have trouble free rolling.
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Automatic work roll change facility is provided for quick and easy changing of work
rolls.
Main drive capacity : 4500 kW each for top and bottom work
rolls Back up roll is friction driven.
Maximum roll force : 30,000 kN
Maximum rolling speed : 10 metre/sec
Maximum bending force : 3,000 kN
COILER FURNACE:
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SYSTEMS:
Auxiliary hydraulic system
Servo hydraulic system
Booster pump system (Centralised for Steckel Mill and Roughing Mill)
High pressure water system
Morgoil system (Centralised for Steckel Mill and Roughing Mill)
Oil lubrication system (Centralised for Steckel Mill and Roughing Mill)
Laminar cooling system
Pneumatic system
Grease systems
Re-circulating water system
b. AIR COMPRESSORS:
4 Nos. of air compressors are installed to meet compressed air requirement
for the Hot Rolling Mill complex.
c. MODEL SERVER:
The Model Server is the Level 2 automation system consisting of a mill
process computer. The mill process computer based on mathematical models and
strategies, calculates the set up values for the mill like roll gap, roll force, CVC
position, bending values etc., (in association with the slab data and transfer bar
data). Finally the set up values allow for an accurate control of strip thickness,
profile and flatness.
The area of the model server is restricted to the Steckel Mill stand and coiler
furnace. The primary data is transmitted by the production control PC to furnace
PLC. When a slab is discharged from the furnace, furnace PLC transmits the
primary data of this slab and the next slab to Roughing Mill PLC. After
acknowledgement from Roughing Mill operator, Roughing Mill PLC transmits the
primary data to model server. With the completion of the last pass in the Roughing
Mill, Roughing Mill PLC transmits the actual values of the last pass in the Roughing
Mill, (Width, last pass roll force, roll gap, temperature and speed) to model server.
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The availability of primary data and T-bar data enable the model server to
calculate the pass schedule. After the calculation, the set up values are transmitted
to the Steckel Mill PLC. The Steckel Mill PLC will do the sequence control of the
process in Steckel Mill. During the pass in Steckel Mill, actual values like roll force
and strip temperature are measured by Steckel Mill PLC and sent to Model server.
After 35-50% of that pass length is rolled the model server will process the
measured values sent by Steckel Mill PLC. Based on this feedback, the models will
re-calculate an improved set up for the remaining passes. However, the thickness
distribution, speed, tension values will not be changed. This process will be
repeated pass by pass until the last pass is reached.
The used work rolls, Back up rolls of Roughing Mill and Steckel Mill, Edger
rolls and Pinch rolls of Steckel Mill and Down Coiler are reground in the Roll
grinding machine. Roll grinding m/c is supplied by M/S Toshiba machine company,
Japan. State – of –the- art CNC roll grinder is working on Level -3 automation
which ensures fully automatic grinding where special functions like wheel quick
approach, Automatic roll alignment and wheel surface speed control are done by
machine itself.
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Overhauling and maintenance of all Work roll and Back up roll bearings are
taken up on a regular basis. The chocks earmarked for overhauling are
dismounted from rolls. Then the bearings, seals and chock internals are taken out,
cleaned and checked for any mark or wear and tear. Based on the condition, the
bearings and chock internals are either replaced with new or are put back after
thorough cleaning and removal of marks.
3.7ROLL GRINDING MACHINE (RGC 1400 X 5000 CNC GRINDING MACHINE) hot
Rolling Mill (HRM) of Salem Steel Plant have different rolls like Backup
Rolls, Work rolls, Edger Rolls and Pinch Rolls. All these Rolls in HRM need
grinding after a stipulated tonnage of rolling for better surface finish. So, these rolls
are being ground by CNC grinding machines.
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Special features of RGC 1400 x 5000 CNC grinding machine:
The roll grinding machine RGC 1400 x 5000 CNC type performs
grinding, measuring and testing E.C cylindrical surfaces, Plane or
Cambered (concave or convex).
Highly productivity output ranges, optimal machine accuracy and
decreasing preparation period.
All types of profile can be ground Viz. Straight, Taper, Concave, Convex,
Radius, CVC etc.
Backup Rolls and Edger Rolls can be ground with chocks
Roll diameter can be measured during grinding
Grinding accuracy
- Roundness : 0.002 mm
- Cylindricity : 0.002 mm
- Crown profile : 0.0025 mm
- CVC profile : 0.0025 mm
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b. SIDE GUIDES: Side guides are provided for guiding the strip straight into
the Coiler.
c. HOLD DOWN ROLL: The main function of the hold down roll (Roll dia: 300
mm) is to avoid fluttering in the strip. This roll will be in the up position when the
strip is coming and will get down when the strip enters the pinch roll.
d. PINCH ROLL: The function of the pinch roll is to guide the strip into the
mandrel
Max Min
Top Roll : 900 mm 880 mm
Bottom Roll : 400 mm 370 mm
e. STRIP Switch: The strip switch guides the strip to the mandrel. During
coiling it opens and it allows the strip to the mandrel and afterwards it closes
the way to the mandrel.
f. CHUTE PLATE: The chute plate feed the strip to wrapper roll 1 which
makes the strip to wind on the coiler
g. WRAPPER ROLLS: Three wrapper rolls are provided for wrapping the
head end of the strip into the mandrel. The wrapper rolls will get retracted after
the mandrel expanded and tension built.
h. MANDREL: The finished strip from Steckel Mill winds on the mandrel
The diameter of the mandrel:
Collapsed : 727 mm Pre-
expanded : 738 mm Fully
expanded : 762 mm
i. OUTBOARD SUPPORT BEARING: Two support bearings are provided ,
one in right and the other in the left side to hold the mandrel during rolling.
j. COIL CAR: The coil car transports the finished coil from the mandrel to the
walking beam conveyor. It has a lifting table which is provided with two rollers
and locking provision for the rollers.
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3.9 HRM – Crane Details
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4. COLD ROLLING MILL
4.1 INTRODUCTION:
Capacity:
Phase 1 : Installed capacity 32,000 Tonnes / Annum
Phase 2 : Installed capacity of CRM is 70,000 Tonnes / Annum.
S. No Package Supplier
1 Coil Preparation Line Andritz, Austria
2 Annealing & Pickling Line Andritz, Austria
3 Z-Mill-3 Waterbury Farrel, Canada
4 Up gradation of Existing Z-Mill T Sendzimir, USA
5 Skin Pass Mill SMS Demag, Germany
6 Slitting Line Fagor, Spain
7 Tension Leveling Line REDEX, France
8 Roll Grinder WMW, Romania
9 Acid recovery system Andrtiz, Austria
Table 4.1 Machines in NEW-CRM and their Supplier
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Expansion of cold rolling mill capacity together with value adding facilities to
enhance cold rolled stainless steel (CRSS) production from 70,000 tpa to 1,46,000
tpa.
GRADES PRODUCED :
STAINLESS STEEL - Austenitic, Ferritic & Martensitic Grades
301, 304, 304L, 304M, 316, 321, 409, 409M, 410S,
430 , 201, SSLN1,SSLN4, SSLNQ , 204 Cu
Major Equipments to be installed in Cold Rolling Mill are:-
Annealing and Pickling Line
Mixed Acid Recovery System
Coil Build up line
Coil Preparation Line
20 High Sendzimir Mills
Skin pass Mill
Tension Leveling Line
Slitting Line
Roll Grinders for CRM (2 nos)
Rotary Polisher
Associated auxiliary facilities
Online shape control
New wiping system (For improvement of quality and productivity)
The line is equipped with a MIG welding m/c and has a speed of 50 m/min.
Equipment was Supplied by M/S Sundwig, Germany in association with HEC, India.
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Coil preparation line is used to attach header & leader end to the coil before it
is sent to Sendzimir mill. It is done so as to have effective utilization of the coil.
Capacity of Coil Preparation Line is 50,000 tpa.
Coil preparation line will be located at the place where currently Bell
Annealing furnace is located i.e. in CD bay. Bell annealing furnace will be
relocated behind APL-3.
Technical Data:
Material :Hot and cold rolled Stainless steel strips of AISI 200,300 & 400 Series.
Strip dimensions :
Hot rolled : 630 mm to 1300 mm wide and
2.5 mm to 8 mm thick.
Coil Dimensions :
Coil Inside diameter : 610/762 mm at the uncoiler
610 mm at the Coiler
Coil preparation line is mainly used for Leader end attachment and saleable
steel production of sheets and coils.
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Technical Data:
Main equipment:
LINE CHARACTERISTICS:
Phase I Phase II
Supplier : Wesman Wellman
Heating furnace : 1 No 2 No
Furnace bases : 3 5
Inner cover : 3 5
Coil Size (mm) : 610 610/760
Outside dia : 1830 mm 1900 mm
Strip width (mm) : 600/1300 600/1300
Maximum furnace temperature : 900 ˚C 1000˚C
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Maximum operating temperature : 870 ˚C 870˚C
Coil Weight : 15 T max 15 T max
Hot rolled strip thickness : 3.0 to 6.0 mm 2.5 – 7.0 mm
Cold rolled strip thickness : 0.3 to 4.0 mm 0.3 to 4.0 mm
Cooling hood :1 2
Expected base output : 0.9-1.0 T/hr 1.0-1.1 T/hr
Entry Section- Unwinding of coils, cutting of head/tail ends, welding two coils
to maintain continuous feeding of strip. Tension bridles are used maintain strip
tension. Strip centering is done through correcting rolls.
Annealing Furnace- Relieving of stresses & for new grain formation. After
heating strip will be cooled by air jet & water spray followed by drier unit. In
Annealing furnace dual fuel fired burners (LPG / Natural gas) have been
envisaged.
Pickling Tank- Pre-rinsing of scales by spraying of water. First part of tank will
have electrolytic pickling where 80% of scales will be Removed & remaining
20% will be removed by mixed acid having a mix of HNO3 & various % of HF
depending upon grade.
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Exit Section- Its purpose is to shear the coil at welded joints & winding on
coiler.
Suppliers:
Entry & Exit Sections – M/S Dujardin Montbard Somenor (DMS)
Furnace - M/S Drever International, Belgium
Pickling - M/S Ruthner, Austria.
The entire electrics of these lines were supplied by M/S BHEL of India.
The lines are equipped with latest ‘Neutral Electrolytic Process’ (Ruthner Process)
for pickling. The process has many advantages like reduced cost of operation,
more consistent quality, less environmental pollution and better safety.
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Fig 4.2 Process Flow in Annealing and Pickling Line
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PROCESS CONTROL AND INSTRUMENTATION:
In APL 1 & 2 proper process parameter should be maintained like process
temperature, gas flow rate, % oxygen in side furnace, proper speed, direction and
tension of strip etc. For this control and Instrumentation is very important. Inside
furnace temperature measurement and control we are using PTRH (Platinum +
Rhodium) R-type thermocouples, which operating at a temperature range of 0-
1400˚ C and Output is 4-20 mA. With the help of temperature controller and relay
assembly we can maintain temperature in a required range. Similarly for pickling
tank we are using RTD. K-Type thermocouples operating range is 0 to 100˚ C
using material (Cr-Al).
Annealing is done to relieve the stresses & formation of new grain. Pickling is done
to remove the scales which are formed during annealing. Annealing &Pickling Line
consists of different important sections which are:
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1. Entry Section
2. Process section.
3. Exit Section.
Entry Section-
Unwinding of coils, cutting of head/tail ends, welding two coils to maintain
continuous feeding of strip. Tension bridles are used maintain strip Tension. Strip
centering is done through Steering roll Mechanism. Entry section consists of POR,
Leveller, Crop shear, Welding Machine and Entry looper.
Welding Machine:
Supplier : Supplied by M/S Guild, USA.
Welding Process : MIG
Welding Machine : RCM 500-54 (Rotary cutting Machine)
Process Section
Annealing Furnace:
Annealing is done to Relieving of stresses formed during hot rolling or cold
rolling & for new grain formation. After heating strip will be cooled by air jet, air
&water jets followed by water cooling. Furnace chambers are divided in to 1,2,3
and 4.Chamber 1 is preheating chamber where no nurners.Furnace chamber 2,3
and 4 will be heated by special Nox type hot air burners suitable for 500º
preheated air operation.Burners are suitable for operation with both LPG AND
Natural gas.
Material Strip Speed(m/min) Temp(ºc) Product(T/h) TV value
size(mm)
HR-304 3.0x1250 50.0 1,100 88.9 150
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Principal Dimensions of Furnace Equipment (m)
Length of Heating section 80.2
Inside width of heating chamber 2.4
Inside Height of heating chamber 2.8
Design operating temperature-700-1150 ºC
Maximum allowable operating temperature 1230ºc
The furnace is provided with the following measurement and control functions:
1. Furnace zone control and alarm/safety temperature measured by double
thermocouple (type S) and monitored by separate alarm contacts.
2. Combustion air flow to each zone incl air temperature and air pressure
compensation by differential pressure flow sensor.
3. Gas flow to each zone incl temperature and pressure compensation by
turbine meter.
4. Air gas ration adjustable with range 1.0-1.5.
5. Measurement of the strip temperature at the end of the last two heating
chambers 3 and 4.
After annealing strip will be cooled to immediately by air, air &water and then
water. After annealing and quenching strip will enter scale breaker.
SCALE BREAKER:
To break the scale layer on the strip surface. This will be done by bending
the production material around the working rolls of the scale breaker. The outer
fibres of the strip will be lengthened so that the scale will break. This leads to the
advantage that the access of the pickling fluid to the scale will be improved.
Furthermore the strip can be lengthened by the combination of bending (work rolls)
and tension (bridle rolls).This leads to a better strip shape. The scale breaker
consists of one bending and two flattening rolls set in a welded mono block frame.
Technical Data:
Pass line rolls : 1x entry and 1x exit side.
Diameter : 300 mm
Face length : 1,600 mm
Lining : PU
Bending cartridges : 4 pieces each 2 top/2 bottom
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Bending roll diameter : 70 mm
Face length : 1600 mm
Flattening cartridges : 2 pieces, 1 top/ 1 bottom
Flattening roll diameter : 200 mm
Face length : 1600 mm
Top cartridge adjustment By means of two hydraulic cylinders with integrated
linear sensors, controlled by machine mounted servo
valves.
Cartridge clamping : 2x per catridge,hydraulic cylinder.
After scale breaker strip enters the shot blasting machine where maximum
amount of scale will be removed by blasting with steel shots of S170.After bla sting
with shots removed scale/dust will be collected by separate dust collector.
Technical Data:
Supplier : M/S DISA, Switzerland.
Number of blast wheels 8
Number of throwing blades per wheel 8
Throwing speed : 52-78 m/s.
Abrasive flow per blast wheel : 1200 kg/min
Drive power (frequency controlled) : 8x110 KW
Current of blast wheel motor : by 78 m/s and 1200 kg/min - 141A
Dust collector : 67,000 m3/hr
Low pressure : 1200 pa
Rotary piston blower : 2 Nos (2x2325 m3/hr)
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Differential pressure : 0.8 bar.
PICKLING:
Neutral Electrolytic pickling:
Pickling is used for removing the left scale on the surface. Pickling is divided
into 2. One is Neutral electrolytic pickling and acid pickling.
The type of the pickling tank is an electro-chemical one. That means that
there are anodes and cathodes installed in the tank. As electrolyte sodium -sulfate
(neolyte) can be used.
In the neutral-electrolytic pickling section - NEOLYTE - the strip is de-scaled
with the help of electric current (current density is controll ed by the mathematical
model) at an operating temperature of approx. 80 °C (controlled by the
mathematical model).
The heat requirement for the pickling bath is covered by the Joule effect
(=electricity) and by steam via heat exchanger.The electrolyte is an aqueous
solution of sodium sulphate (Na2SO4). The concentration has to be as high as
possible.
Concentraion: 140 g/lit
Mixed acid Pickling: The mixed acid pickling sections serves to make the strip
free of scale and to brighten the strip surface.
The mixed acid pickling section No. 1 consists of one pickling treatment
tank. 2 circulation pumps (1 as stand by) pump the mixed acid via 2 switch-over
circulation tanks in circuit.
The mixed acid pickling section No. 2 consists of one pickling treatment
tank. 3 circulation pumps (1 as stand by) pump the mixed acid via 2 switch-over
circulation tanks in circuit.
Cooling and heating of the mixed acid is done by means of external heat
exchangers.
3.Exit Section: Exit section is used for separation of the coil and equipped with
Tension reel and exit looper.
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ACID RECOVERY SYSTEM
Acid Recovery system designed to recover free and total acids(hydrofluoric
acid and nitric acid) and metals(iron,chrome,nickel,etc) in form of oxides from
waste acids of 5,00,000 TPA annealing and pickling line 3.
Equipment specification:
1. Reactor: for thermal decomposition of the concentrated waste acid. Reactor is
divided into upper and lower parts. Upper part contains main burners.
3 burners (for heating)
3 Pilot burners
3 Flame detectors.
Capacity of burners: 8,500 MJ/hr/burner
2. Spray system: to spray the waste acid in to the reactor..2 spray booms with
exchangeable nozzles.
3. Rabbling device: 2 rabble rakes to transport the oxide from the upper part of
the reactor to the lower part and to withdraw the oxide form the reactor.
4. Combustion air fan: To cater the burners with the required air for proper
combustion.
Capacity 8,500 m3/hr.
Pressure 12 kpa.
5. Preconcentrator,absorbtion column, jet scrubber ,spray cooler, oxidation column
are installed to help the further process.
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transmitted from work rolls to the housing through the intermediate rolls and back-
up assemblies. As the design permits the support of work rolls throughout their
barrel length, work roll deflection can be minimized and extremely close gauge
tolerance can be held across the full width of the material being rolled.
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Sendzimir Mill Type : 20-Hi ZR-22B-52
Manufactured by : M/S Hitachi, Japan
Supplied by : M/S Nissho Iwai Co Ltd, Japan.
A ZR-22B-52 type Z-Mill with a capacity of 32,000 tpa in 1st stage & 38,000
tpa in 2nd stage i.e. 1,10,000 tpa in total has been envisaged. Z-Mill will be
capable of processing coil of thickness from 2.0 mm to 7.0 mm & finished strip
thickness will be in the range of 0.3 mm to 4.0 mm. Maximum rolling speed will be
800 mpm. In this mill thickness of the strip is reduced by tension & is done below
recrystallization temperature.
Z-Mill-3 will have Automatic Gauge Control with the help of servo valves. In
order to have better flatness & controlling the shape, support saddles on back-up
rolls are provided. Mineral oil serves as lubricant as well as roll coolant. A
filtration system will ensure supply of clean oil. For obtaining final thickness
between 0.3 to 0.5 mm the rolling cannot be done in one stage & hence has to be
annealed & pickled before 2nd stage of rolling. This is done to overcome
work hardening.
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Main Specification of Sendzimir Mill – I:
Type : ZR-22B-52
Material to be rolled : AISI 200, 300, 400 series of Stainless steel which
Will be annealed and pickled.
Tensile strength : 120 Kg/mm (max)
Coil Size : ID - 610 mm
OD - Max 1830 mm (including sleeve and Interleaving paper).
The third Sendzimir Mill of SSP is Supplied by M/S Waterbury Farell with a
capacity to produce 1,10,000 tons/annum of Stainless Steel of which 22,000 tons
is through second stage rolling. It is designed to roll AISI 200, AISI 300 and AISI
400 series of stainless steel coils. This mill is equipped with level 2 automation.
Supamic type filters are used for rolling oil filtration unlike the other mills which
uses diatomaceous earth as filter aid. As-U-Roll power crown adjustments is
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included on the B&C and F&G backup assemblies in this mill. Oil wiping is by
means of one set of two roll wipers and one set of 3 roll wipers. 3 roll wipers is
equipped with air edge blow off as well as an Air Knife. Electric and controls are by
M/s ABB.
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Motor kW 1 * 600 1 * 4200 1 * 4200 1 * 4200
Capacity
Tensions kN 5 - 125 25 - 500 25 - 500
Equipment m/min 0 - 270 0 – 450 - 800 0 - 800 0 – 450 -
Speed 800
Grinding Section:
There are 9 machines comprising 5 no.of Z Mill roll grinding machines , 1 Skin
pass mill roll grinding machine and 1 rubber roll grinding machine, and 1 surface
grinding machine and 1 HMT Lathe.
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Bearing Section:
Strip grinding line is provided for removing the surface defects of the strip.
The Strip grinding line consists of six grinding heads where the surface of the strip
is ground by moving abrasive belts. The line has a speed of 30 m/min(max) and an
output of 8 to 14 T/hr depending on the stock removal needed.
The line was supplied by M/S Sundwig of Germany and M/S HEC of India.
LINE CHARACTERISTICS:
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The control system originally supplied with analog control is converted into PLC
(Programmable Logic Control) system.
Entry Section- It has Coil car, pay-off reel, snubber roll, peeler blade & pre-
straightener. It has strip edge control device to provide central feeding of
coil.
Exit Section- It consists of tension reel, coil car & swinging table. Paper
winder/ unwinder is provided at two reels for removing/ feeding of
interleaving paper.
The 2-hi Skin pass mill was supplied by M/S MECON (India) Ltd of Ranchi
in collaboration with M/S Wean United, USA. The design of the Skin pass mill has
been made to incorporate many special features such as constant elongation
control, automatic slow down at the end of the strip, constant hydraulic roll force
system with provisions for possible future computerization of the process.
MILL CHARACTERISTICS:
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Outside diameter : 1830 mm
Coil width : 600 mm to 1300 mm
Coil weight : 15 T
Strip thickness : 0.3 mm to 4,0 mm
Tensile strength of the material to be rolled: 70 Kg/mm (normal rolling)
120 Kg/mm (Occasional rolling)
Elongation : up to 0.80 %
Strip speed : 180 m/min at full torque
360 m/min at reduced torque
30 m/min at threading
Tension range of Pay off cum tension reel: 14,000 Kg (max) at 360 m/min
: 700 Kg (min)
Max roll force : 1200 T
Max roll opening : 80 mm
Mill pass line : 1000 mm above floor level
Roll material : Alloy forged steel
The control system originally supplied with analog control is converted into PLC
(Programmable Logic Control ) system.
LINE CHARACTERISTICS:
Materials to be sheared: Cold rolled stainless steel grades
of AISI 200,300 and 400 series
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Width of the initial Coil : 600 mm to 1300 mm.
Sheet Width : 500 mm to 1300 mm
1. Entry Section- It includes pay-off reel with head, peeler cum threading table &
a level. Automatic width & height centering device on pay-off reel. An automatic
strip centering device which facilitates feeling of the strip centrally to the line.
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scrap baler is proved for winding the trimmed edges & compacting in the form of a
ball.
3. Exit Section- Slit coils are fed onto the recoiler mandrel. Provision will be made
in the tension reel to wind coils with inner diameter 406,508 mm as well as 610
mm.
LINE CHARACTERISTICS:
Material : Hot and cold rolled, annealed and pickled and skin
passed/un skin passed coils of AISI 200, 300 and 400 series.
Width of the initial coil : 600 mm to 1300 mm
Width of the slit material : 35 mm to 1300 mm
Material thickness : 0.3 mm to 4 mm- cold rolled
3.0 mm to 4 mm- hot rolled
Coil inside diameter
Entry and recoiling side : 406 mm, 508 mm and 610 mm.
Coil outside diameter : 750 mm (min)
: 1830 mm (max)
Line speed
Threading speed : 15 m/min
Strip speed at Transmission range I : 70 m/min
Strip speed at Transmission range II : 140 m/min
PACKING
The slit coils/baby coils of different width and weight are taken out of Tension Reel
mandrel and packed in packing section as per the customer requirement.
1. Entry Section- It consists of saddle type coil storage, floor mounted coil car,
spool/pup coil ejection, pay off with head, outboard bearing support, paper winder,
peeler cum threading table & a entry decurve roll, deoiler rolls & dirt removal pad.
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Automatic width & height centering device with non-contact sensors are provided
in pay-off to facilitate quick loading. An automatic strip centering device.
3. Exit section- Tension level coils are wound on recoiled head supported by
auto edge guide.
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8. Spindles : 14 Nos per Head
9. Spindle rev (adjustable) : 0 -600 rpm
10. Oscillation Amplitude& Frequency : 0 -235 mm & 0.05 to 8 M/ Min
Production rate & Surface Finish :
The “Rotary Polisher” is designed to produce 1000 tons per year.
Production Rate:
a) 1300 mm wide x 3000 mm long x 2.0 mm thick – 61 Kgs / hour
b) 900 mm wide x 2500 mm long x 1.0 mm thick – 18 Kgs / hour
Surface Finish:
a) Sheet Surface finish: No 8 Finish (Mirror Finish) is guaranteed on the sheets
b) The finished product is free from marks, scratches, lines, patches
(difference in surface colouring), encrustations, gauging and indentations due to
the “Rotary Polishing Line” equipment
LINE CHARACTERISTICS:
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4.14 COIL PACKING & DISPATCH
For Prevention from the dust and defects during storage and transportation,
proper packing should be done. For export and house material different type of
packing is required. Packing also depends on the thickness of the material. For
packing of different grade and thickness material we are using following materials.
PVC Coating, Interleaving paper (ILP) , Bubble sheets, wood and metallic pillers
and Oil sheets. Less than 0.63mm coil should be covered with GI sheets. 1.2 mm
or less coil, inner ring provided and upper coating should be GI Sheet.
For special finishes like No.4 hard boards are used both sides top and
bottom side. Packing strap is used for coils having 0.7mm thickness and widths
are 19mm and 32mm. Other parts of this line are conveyer, weight section and
strip packing section.
The purpose of Blanking line is to produce polished coin blanks and utility
blanks. Blanking facilities supplied by M/S Schuler, Germany has an installed
capacity of producing 3,000 Tonnes of coin blanks or 3,600 Tonnes of utility blanks
per annum. It was commissioned on December 24, 1993. The high speed blanking
press can punch out about 600 Kg of coin blanks per hour at a speed of 600
strokes per minute. These blanks after being de-burred and degreased are rimmed
in a rimming machine.
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The double drum rotary furnace anneals the blanks in a protective nitrogen
atmosphere. The centrifugal pickling and polishing equipment has a rotary drum
where the coin blanks and stainless steel balls are rotated at high speed. The coin
blanks are then counted and packed.
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25 Paise : 3,000 coins per minute
50 Paise : 2,500 coins per minute
1 Rupee : 2,200 coins per minute
Diameter : 14 – 50 mm
Thickness : 1 – 3 mm
Speed : Depending on the diameter.
CAPACITY
S NO LOCATION MAIN AUX SUPPLIER
(TON) (TON)
1 CRANE 11 25 5 M/s BRAITHWAITE, CALCUTTA
2 CRANE 12 25 5 M/s BRAITHWAITE, CALCUTTA
3 CRANE 13 25 5 M/s BRAITHWAITE, CALCUTTA
4 CRANE 21 25 5 M/s BRAITHWAITE, CALCUTTA
5 CRANE 22 25 - M/s BRAITHWAITE, CALCUTTA
6 CRANE 23 25 - M/s BRAITHWAITE, CALCUTTA
7 CRANE 24 25 5 M/s BRAITHWAITE, CALCUTTA
8 CRANE 25 25 5 M/s BRAITHWAITE, CALCUTTA
9 CRANE 31 30 5 M/s BRAITHWAITE, CALCUTTA
10 CRANE 32 25 5 M/s BRAITHWAITE, CALCUTTA
11 CRANE 33 15 - M/s BRAITHWAITE, CALCUTTA
12 CRANE 34 25 5 M/s MUKUND LTD BOMBAY
13 CRANE 41 25 - M/s FAFECO
14 CRANE 42 25 5 M/s FAFECO
15 CRANE 43 25 5 M/s FAFECO
16 CRANE 44 25 5 M/s FAFECO
17 CRANE 51 25 5 M/s FAFECO
18 CRANE 52 30 5 M/s FAFECO
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5. UTILITIES
5.1INTRODUCTION
5.2 BOILERS:
Process steam at a main pressure of 12.5 Kg/cm is required for the following
uses in this plant
- Heating of pickling baths and drying of coil surfaces
- in Annealing andPickling lines.
Heating of LP Gas in LPG vapourizers
Cooking food and sterilizing of dishes in Plant Canteen
Steam ejector to pump out seepage water
Purging of other pipe lines.
In most of the above cases, the pressure of steam will be reduced to around 2.5
Kg/cm or less by means of pressure reducing valves. Average steam
consumption of the plant is about 4 T/hr.
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5.3FEED WATER TREATMENT:
An ion exchange type water softening plant with two numbers of basic softeners of
capacity 18 m /hr each has been installed.
This plant serves for both Coal fired boiler and Oil fired boiler.
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5.5 LIQUIFIED PETROLEUM GAS: (LPG)
This high calorific value fuel is used to fire the continuous annealing
furnaces of the Annealing and Pickling lines. The Liquefied petroleum gas arriving
in special tank wagons is unloaded into the storage spheres using gas
compressors by the indirect displacement method. Thus the compressors will draw
gas from the top of the storage spheres (which is filled to 70 % capacity only) and
pump it under pressure into the top of the tank wagons, creating a lower pressure
in the spheres and a higher pressure in the wagons. Under the differential pressure
the liquid from the wagons will flow into the spheres.
For supplying gas to the furnace, the liquid is piped into the vapourisers
where it is heated by a steam coil . The gas thus produced flows from the top of
vapourisers into the supply mains. The vapourisers are fully automatically
regulated with regard to the level of liquid in the vapouriser and the pressure of
output gas. The LPG storage spheres are guarded against excess temperature by
a special water sprinkler system.(For HRM furnace, AP Lines, Slab Caster torch
cutting, Slab scarfing, Miscellaneous cutting).
SPECIFICATIONS:
Storage: 3 spherical tanks of 500 tonnes capacity each ( i.e. 1070 m each).
- Unloading platform for 60 LPG wagons at a time.
- Unloading compressors (6 No) of the following type:
- Single stage, double acting non lubricated reciprocating compressor of
250m /hr swept volume.
- Vapourisers : Shell and tube type
- Quantity : 3 No
- Heating medium : Steam
- Capacity : 4000 Kg / hr (or) 54,233 Nm3 / day
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6. SERVICES
The Public Relations Department publishes the plant information and co-
ordinate with media. In house and external communication through Stainless
News, Monet is taken care by the department. They takes care of Photo coverage /
Video coverage and keeping records of the events.
6.4 MARKETING:
The Salem Steel Plant Marketing office is merged with Central Marketing
Office(CMO), Head Office located at New Delhi. The product from Salem Steel
Plant are marketed worldwide by its CMO marketing net work with the branches
located in India and world.
Indian Stainless Steel Scenario in the year of 2010
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CATEGORY 2008-09 2009-10 2010-11 .
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6.7 WATER SUPPLY:
The requirement of water for the industrial use and for the Mohan Nagar
Township is drawn from the Cauvery river at Poolampatti and is pumped from the
Head Works at Poolampatti and carried through 28 KM pipe line of 600 mm
diameter and stored in the Balancing Reservoir in the plant. The balancing
Reservoir can store the quantity of water requirement for the Plant and Township
for 10 days.
The following pump houses / plants are installed to meet the water requirement for
various purposes and processes.
1) Make up water Pump house
2) Recirculating water pump house.
3) Water treatment plant
4) IFFS – Independent Fire Fighting System pump house.
ERS carries out the motor rewinding jobs and testing of motors. Adjoining to
ERS, a loco shed is functioning for the maintenance of our loco which transports
the raw materials like slabs, cements, rails etc. from the railway siding yard to the
plant.
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material is given by the Met. Services dept. It also governs the Techno economic
parameters such as Prime, Seconds, Commercial quality etc. They are the
certifying agency of the finished product to the requirement of the customers based
on standards..
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6.18 TECHNICAL BUREAU:
Material Management
Application is running on servers mentioned below:
Application Server: Application is running on two servers. Two servers are sharing the
load of the network & it also takes care of fail over situation.
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Database Server : Oracle is running on primary server, in case of failure of the
primary server secondary server will be automatically
activated.
Make : HP INTEGRITY RX280014 (RISC/EPIC-2 No’s)
Operating System : HP UX 11I V3, HP Service Guard for fail over
Back end : Oracle 11g
RAM : 32 GB
Processor : Itanium
Hard Disk : 300 GB SAS hot pluggable – 2 No’s
SAN Storage : HP PA 6000 (8 TB, After RAID5 3 TB, Active- Active
controller)
Installed disks : 18 numbers of 450 GB SAS Hot pluggable expandable up to
36 disks. Connectivity to servers via FC (Fiber channel)
Backup Server : HP PROLIANT DL 360P GEN8 (XENON based)
Backup Software : HP Data Protector 7 (Magnetic tape drive used for Backup)
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