Professional Documents
Culture Documents
Internship JSW Report
Internship JSW Report
Submitted by
Anubhav Jain#
Enrolment no.: Mett 32/13
National Institute of Technology – Srinagar
Guided by
Mr. Neel Kant*
Research and Development Department
Jindal Steel Works – Dolvi
Head of Department
Mr. Pardip Kumar Patra*
Research and Development Department
Jindal Steel Works – Dolvi
* #
1
2
Acknowledgement
During this industrial internship in JSW (Jindal Steel Works) Dolvi, Maharashtra, in
Research and Development Department was a memorable one for me as it was rich in
experience sharing and helped me to discover my potential. I had so many rich experiences
and opportunities that I personally believe will forever shape and influence my professional
life while fostering personal growth and development.
In this report, I hope to highlight the work that I have performed and learned. Working here
not only given me the industrial experiences, but also teaches me how to sustain in tough
environment. Good working conditions and friendly behaviour of everyone inspires me to
be productive in work.
These few details lead me to realize that, like all human endeavours, this report is not perfect
and may contain errors and shortcomings.
Thus, I remain open to all criticisms and suggestions which could present me with new
sources of inspiration as I develop in my ability to research and learn.
This report would not have been possible without the contribution and collaboration of
others. My sincere gratitude:
To all of you, I extend my deepest gratitude and always owe my respect to them.
3
History
JSW was set up as Nippon Denro Ispat Limited in May 1984 by founding Chairman Mr M.
L. Mittal. The company have operations in iron, steel, cement, energy and infrastructure. It is
an integrated steel plant, located at Dolvi in the state of Maharashtra.
The 1,200 acres (4.9 km2) Dolvi complex houses the 3.3 million tonnes per annum HR Coils
plant, and 1.5 million tonne per annum TMT Bar Mill (Newly established) which combines
the latest technologies the Compact Strip Process (CSP) introduced in Asia. It is
headquartered at Mumbai and employs about 3000 people.
On 21 December 2010 it was declared that JSW Steel will buy this industry at $3 billion to
emerge as India's largest private producer of the steel. On April 2013, the complete merger
has been completed. Currently this industry is owned by Mr. Sajjan Jindal.
The Dolvi unit features a sponge iron plant (1.6 million tonnes per annum), a blast furnace, a
sinter plant, a hot strip mill (3.3 million tonnes), an oxygen plant and a lime calcining plant.
The plant uses a combination of ConArc and CSP processes to produce hot rolled coils.
4
List of Abbreviation
5
Contents
1. Introduction .............................................................................................7
1.1 Safety awareness ...............................................................................7
2. Literature Review ...................................................................................8
2.1 Compact Strip Process (CSP)…………………………………...….8
2.2 ConArc Process (Converter & Arcing) .............................................8
2.3 Quenched & Tempered Bars (QTB) .................................................8
2.4 Standards of TMT and HR Coil ........................................................9
2.4.1 TMT Bar Chemical Composition ...............................................9
2.4.2 TMT Bar Mechanical Standards .................................................9
2.4.3 HR Coil Chemical Composition .................................................9
2.4.4 HR Coil Mechanical Standards...................................................9
2.5 Testing.................................................................................................10
2.5.1 Chemical Analysis ........................................................................10
2.5.2 Mechanical analysis .....................................................................10
2.5.3 Microstructure ..............................................................................10
3. Projects ..................................................................................................12
3.1 TMT Bars: .......................................................................................12
3.1.2 Observation: ..............................................................................13
3.1.3 Inference: ..................................................................................13
3.2 HR Coil:...........................................................................................15
3.2.1 Observation: ..............................................................................15
3.2.2 Inference: ..................................................................................16
Appendix A: IS:1786:2008…..……………………………………….…18
Appendix B: Mechanical Properties…………………………………….19
Reference………………………………………………………………..20
6
1. Introduction
Industrial Training in Research and Development, Deartment of Jindal Steel Works, Dolvi,
Maharastra has given chance to work in their newly established TMT Bar Mill installed by
'Danieli Italy', with capacity of 1.5 MTPA (Million tonnes per annum) which produces TMT
bars of different diameters from 8 MM to 40MM and HR Coil Mill with capacity of 3.3
MTPA (Million tonnes per annum), which produces Coils of thickness from 1.2 MM to
25MM and 25 tonn.
In this period of training, I worked on the Microstructure of TMT bars & HR Coil,
Mechanical properties of Fe500D Grade of bar of diameters 25MM & 40MM and TR34Al Z
of HR Coil.
In TMT Bar, I figure out the Microstructures, Tensile test and Chemical composition.
Due to trial of TMT bar mill it become difficult to go further, so they suggested me to also
work on HR Coil also.
In HR Coil, I worked on the Microstructures of Coils with excess of Nitrogen and normal
Nitrogen coil and find correlations with the YS, UTS and Grain Size of Microstructures in
both of them. I used two samples of Excess Nitrogen and one sample of normal Nitrogen.
TMT Bars are used for General reinforcement of high rise building, bridges and other
concert constructions; it is highly used in earthquake prone areas.
HR Coils are used for fabrications like automobiles, pipes, gas cylinders, etc.
7
2. Literature Review
It is essential to understand some basic process and terms used in this report, I refer some
papers. Hence brief ideas of these processes are as follows.
ConArc combines two traditional methods – making steel using solid charge like
steel scrap, pig iron or sponge iron as well as making steel through the blast furnace route.
This provides the unit with the flexibility of using any combination of solid charge and liquid
hot metal. It chooses feed mix depending on market demands.
QTB plus is a recently established model by ‘Danieli Italy’ in TMT bar mill, which is
used for the better control for mechanical properties of quenched & tempered bars. This
gives an accurate estimation of YS, UTS and Hardness at different points across the section
of the bars. It calculates the thermal histories of different segments, finally the system uses
these histories to estimate the final microstructures.
This system is useful in producing the desired mechanical properties through proper process
control. It can be used to design new grades of bars with superior quality such as improves
elongation and bend ability.
An Additional Neural Network (ANN) model is set up to considered uncertainties of
processing in the plant.
8
2.4 Standards of TMT and HR Coil
Followings are the standards used by the JSW Dolvi, for the manufacturing of the
above products.
Grade used for TMT Bars is: FE500D
Grade used for HR Coil is: TR34AL Z
9
2.5 Testing
Different types of techniques are used to determine mechanical, chemical and microstructure
of the sample. These techniques are described as follows:
Mechanical analysis is done to obtain the YS, UTS and %Elongation of the sample.
For this purpose, Universal testing machine is used, in which a certain length of sample is
taken in the account for e.g. 300 MM length is used for HR Coil and 600 MM length is used
for TMT Bar. In this machine, sample is tightened properly at the ends and gradually load is
increased continuously until breaking is done. Each and every data is recorded
computationally.
2.5.3 Microstructure
Mounting: It is done when the sample is not in the proper shape to hold during
grinding and polishing, I have done cold mounting for the HR Coil sample. Cold
mounting epoxy resin is used to mount the HR Coil sample with the Benzene
Solution.
Grinding: Rough grinding is done to provide excellent surface finish to the sample
in order to make it suitable for the further grinding. First we use 220 grit size emery
papers, and then we go for 320, then 600. Then 1200 by changing orientation of
sample by 90º to erase the pervious scratches.
10
Polishing: Now samples get polished by the velvet paper, with aerosol spray and
diamond paste to give it a mirror finish to its surface.
11
3. Projects
During this internship, I have performed my work on TMT Bars and HR Coil,
information on the experimental procedures and inference are as follows:
12
3.1.2 Observation:
3.1.3 Inference:
1. The mechanical properties depend on the thickness and the distribution of the
different phases.
2. The rim formation depends on the quenching operations.
3. The control property is therefore, achieved through desired rim thickness and corrects
combination of microstructure across section.
4. Microstructure formed can be characterized in three different sections namely Ferrite
and Pearlite (core), Banite (Middle ring), and Tempered martensite (outermost ring).
13
FOR 25MM
Centre
Bainite
Tempered
Martensite
For 40MM
Centre
Bainite
Tempered
Martensite
14
3.2 HR Coil:
Three different samples are chosen, two are the excess nitrogen sample and the one is
the normal nitrogen sample. In this experiment, comparison between these samples is plotted
in graph v/s YS, UTS, %EL and ASTM Grain Size.
Terminologies:
1. Strain-aging: The changes in ductility, hardness, yield point, and tensile strength that
occur when a metal or alloy that has been cold worked are stored for some time. In
steel, strain aging is characterized by a loss of ductility and a corresponding increase
in hardness, yield point, and tensile strength. This happens due to presence of excess
Nitrogen in the material.
2. Ductility: It is a solid material's ability to deform under tensile stress; this is often
characterized by the material's ability to be stretched into a wire.
3. ASTM Grain Size: Standard Test Methods for Determining Average Grain Size.
ASTM E112 is used as standard for the same, in this method we take microstructures
at 100X magnification, and apply different methods such as grain interaction method
and grain plain-metric method to obtain the grain size. Under this experiment of
finding the grain size we use ‘Grain plain- metric’ method. It should be noted that, as
the ASTM Grain size increase with the decrease in grain size.
3.2.1 Observation:
Grain Grain
ASTM ASTM Size Mid Size
Grain Grain Thick Edge
Sample N(ppm) YS(MPa) UTS(MPa) %El size(Edge) size(Centre) (Micron) (Micron)
Normal* 75 370 460 35 10.15 10.08 10.90 10.67
B** 150 400 475 34 10.26 10.07 10.95 10.26
C*** 265 450 520 32 10.37 10.30 10.11 9.87
15
600 10.4
10.35
500
10.3
400
10.25
Strength
300
10.2
YS
200
UTS 10.15
GS Subsurface
100
10.1
GS Mid
Thickness
0 10.05
50 100 150 200 250 300
Nitrogen (ppm)
Plot between Nitrogen (ppm) v/s Grain size (secondary axis) v/s Strength (Primary axis)
3.2.2 Inference:
1. With the increase in Nitrogen concentration the grain size decreases and ASTM grain size
increase.
2. With increase in Nitrogen concentration the YS and UTS increase and Elongation
decreases, which confirms the strain aging effect.
3. The grain size in mid thickness (centre) is more as comparative to subsurface (edge), it is
because of the cooling process, edge cools faster than the mid hence centre get sufficient
time to expand its grain size.
16
HR COIL (N-75 ppm) HR COIL (N-150 ppm) HR COIL (N-256 ppm)
SAMPLE Normal B C
Subsurface
GRADE-
E34
(TR34AL^)
Mid
thickness
GRADE-
E34
(TR34Al^)
Magnificati NORMAL B C
on
AT 200x
AT 500x
17
Appendix A: IS 1786:2008
IS No. Title
18
Appendix B: Mechanical Properties
%EL: Elongation: The increase in length of a tensile test piece under stress. The
elongation at fracture is conventionally expressed as a percentage of the original
gauge length of a standard test piece.
YS: Yield Stress: The stress at which a specific amount of plastic deformation is
produced. Stress (that is, load per unit cross-sectional area) at which elongation first
occurs in the test piece without increasing the load during the tensile test. In the case
of steels with no such definite yield point, proof stress shall be applicable.
0.2 Percent Proof Stress: The stress at which a non-proportional elongation equal to
0.2 percent of the original gauge length takes place.
19
References
1. Shyam Steel, Hand Book On TMT Bars.
2. A. Mukhopadhyay, L. M. Galasso, M. Ena, G. Buzzi, Technological
Papers, Danieli Automation.
3. IS:1786:2008, Fourth Revision, Bureau Of Indian Standards, 2008.
4. K Priyesh, Studies on Properties of TMT Steels for Structural
Applications, International Journal of Engineering Research &
Technology (IJERT), August – 2013.
20