HOSPET STEELS LIMITED

INTRODUCTION

Steel is an alloy of iron and carbon, and sometimes other elements like chromium.
Because of its high tensile strength and low cost, it is a major component used
in buildings, infrastructure, tools, ships, trains, automobiles, machines, appliances, weapons.
Iron is the base metal of steel. Iron is able to take on two crystalline forms (allotropic forms),
body centered cubic and face-centered cubic, depending on its temperature. In the body-
centered cubic arrangement, there is an iron atom in the center and eight atoms at the vertices
of each cubic unit cell; in the face-centered cubic, there is one atom at the center of each of
the six faces of the cubic unit cell and eight atom satisifaction . It is the interaction of the
allotropes of iron with the alloying elements, primarily carbon, that gives steel and cast iron
their range of unique properties. Steel is crucial to the development of any modern economy
and is considered to be the backbone of human civilization. The level of per capital
consumption of steel is treated as an important index of the level of socioeconomic
development and living standards of the people in any country. It is a product of a large and
technologically complex industry having strong forward and backward linkages in terms of
material flows and income generation. All major industrial economies are characterized by
the existence of a strong steel industry and the growth of many of these economies has
beenlargely shaped by the strength of their steel industries in their initial stages of
development. Steel industry was in the vanguard in the liberalization of the industrial Sector
and has maderapid strides since then. The new Greenfield plants represent the latest in
technology. Output has increased, the industry has moved up in n the value chain and exports
have raised consequent to a greater integration with the global economy. The new plants have
also brought about a greater regional dispersion easing the domestic supply position notably
in the western region. At the same time, the domestic steel industry faces new challenges.
Some of these relate to the trade barriers in developed markets and certain structural
problems of the domestic industry notably due to the high cost of commissioning of new
projects . The domestic demand too has not improved to significant levels. The litmus test of
the steel industry will be to surmount these difficulties and remain globally competitive.

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 HOSPET STEELS LIMITED
COMPANY PROFILE

HOSPET STEELS is a world class steel plant setup by way of strategic alliance
between M/s Mukund limited of Mumbai and M/s Kalyani steels limited of pune.

Sri BN Kalyani is the chairman and MD of M/s Kalyani group of companies Sri Niraj
Bajaj is the chairman for M/s Mukund limited. Sri Rajesh V Shah is the co-chairman and MD
and Sri Suketu V Shah is the Jt.MD for M/s Mukund Limited.

This plant is located at Ginigera in Koppal district Karnataka. This plant is near to
Hospet. The World heritage centre Hampi and Tungabhadra are situated near to this plant.

Hospet Steels Limited consists of Iron making division, Steel making division and
Rolling mill division. It is one of the largest manufacturers of alloy steels and special steels
in India and renowned for its quality worldwide.

 Established in 1998,Hospet Road , Ginigera , koppal.

 Strategic Alliance between “Mukand” & “Kalyani” groups to produce world class
Alloy steel.
 It is an Integrated steel mill spread across 375 acres of greenery
 Both the groups are Leaders in Alloy & Special Steels.
 Capacity:7,00,000MT/Annum.
 HSL product ranges are - Bloom-Billet
-Rolled products.
 Equipped with state – of – the –art technology in steel – making, finishing and
testing facilities.
 They produce steel through ore route, ensuring low trampelements ,low gas content
and thus , high control on chemical and mechanical properties as per customers
requirements.
 Unit ensures maximum energy efficiency and cost efficiency through in – house
power generation and complete waste re-utilization.

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ORGANISATION CHART

CHIEF EXECUTIVE OFFICER

(CEO)

VICE PRESIDENT (VP)

Sr.GM– Mech.Maint.

GM–Mech.Maint.

MANAGER– Mech.Maint.

DY.MANAGER–Mech.Maint.

EXECUTIVE–Mech.Maint

Shift I/C Shift I/C Shift I/C Shift I/C Shift I/C Shift I/C

Technician

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 HOSPET STEELS LIMITED
The Growth Profile

(i) Steel: The liberalization of industrial policy and other initiatives taken by the
Government have given a definite impetus for entry , participation and growth of the
private sector in the steel industry .While the existing units are being modernized /
expanded, a large number of new steel plants have also come up in different parts of
the country based on modern, cost effective, state of – the-art technologies. In the last
few years, the rapid andstable growth of the demand side has also prompted domestic
entrepreneurs to set up fresh green field projects in different states of the country.

Crude steel capacity was 142.24 mt in 2018-19, up by 3.1% over 2017-18 and India,
whichemerged as the 2nd largest producer of crude steel in the world in 2018, as per data
releasedby the World Steel Association, has to its credit, the capability to produce a variety of
grades and that too, of international quality standards.

(ii) Pig Iron: India is also an important producer of pig iron. Post-liberalization, with
setting up several units in the private sector, not only imports have drastically reduced
butalso India has turned out to be a net exporter of pig iron. The private sector
accounted for 91% of total production of pig iron(6.414 mt) in the country in2018-19.

(iii) Sponge Iron: India, world‟s largest producer of sponge iron (2018), has a host of
coalbased units located in the mineral -rich states of the country. Over the years, the
coal based route has emerged as a key contribute or and accounted for 79%of total
Sponge Iron production in the country . Capacity in Sponge Iron making too has
increased over the years and stood at 46.56 mt (2018-19).

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CUSTOMERS & PRODUCTS
Kalyani Steel Ltd. (KSL) is a leading manufacturer off oreing and engineering quality
carbon and alloy steels using the blast furnace route. KSL caters to engineering, automotive,
seamless tube, foundry and casting industries and the primary aluminum industry . KSL is a
quality supplier steel to engine components like Crankshaft, Camshaft, Connecting Rods,
Axle Beams, Steering Knuckles , & Bearings . In the Energy space it caters to players which
manufacture seamless Tube applications for High Pressure Boilers, Oil Lines,Casing and
Tubing Pipes for Oil Exploration. It is also a certified supplier to the Indian Defence and
supplies steel for bomb shells and barrel applications & components for heavy vehicles. KSL
has earned the status of preferred steelsupplier for engineering, automotive, seamless tube
and primary aluminium industry.
The company has national and international clients like Alcan Iceland, Caterpillar Inc,
Ford, Volvo, Ashok Leyland, Jindal Saw, Automobile Axles, Indian Railway and Tata
Motors ,among others . Major clients are Maruti Suzuki , Hyundai , M&M etc…

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SAFETY DEPARTMENT;
This department is further divided into:
 Health department
 Environment department
 Fire department.
 Doctor & all medical facility is provided at HSL.
FUNCTION
1. To follow general safety rules.
2. To conduct safety induction training after medical test of an employee.
3. To provide protective equipments.
Safety equipment provided at HSL
 Safety shoes
 Helmets
 Goggles
 Dust mask
 Ear plug & ear muffs.
 Chemical & heat protection
VISION
To be come the preferred producer globally for long products specially steels by
2014.
MISSION
 Achieve sustainable & Profitable growth in Steel Business.
 Delight our customers through Product Quality.
 Continuous focus on Business Process & Technologies.
 Facilitate the Growth of Employees& Key Community.
CORE VALUES
 Ul most concern to wards customer needs.
 Concern for environment and safety.
 Respect for dignity and potential of all employees.
 Transparency, integrity and development.

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HOSPET STEEL – PROCESS FLOW DIAGRAM

IRON ORE COKE LIMESTONE

IRON & STEEL FLUX

SCRAP MINI BLAST FURNACES
(LIME &
(15-30%)

HOT MOLTEN IRON

ENERGY OPTIMISING FURNACE

FERRO FERRO
ALLOYS ALLOYS

LIQUID STEEL

REFINING REFINING

VACUUM DEGASSING
CLOSED STREAM CLOSED STREAM
VD
CASTING CASTING

COMPUTERISED COMPUTERISED
CONTROL CONTROL
BLOOM CASTER BILLET CASTER
10/18 m Radius 9/16 m Radius

ROLLING MILL

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SINTER PLANT

Sintering process is developed mainly to utilize under size of lump ore called iron ore
fines ; which other wise , could not be charged directly in blast furnace. In order to conserve
these, other wise waste material, they are compacted to gatherand made into lumps by a
process known as sintering.Sintering is defined as the agglomeration of the Iron ore fines
(generally <8 mm) by incipient fusion of fine mineral particles with heat produced by burning
of coke breeze , uniformly distributed in raw mix bed. During the sintering process, iron ore
fine particles agglomerate into a porous compact heterogeneous lumpy mass called
SINTERby incipient fusion caused by the heat produced during the combustion of the solid
fuel within the moving bed of loosely particles.

The coke at the top of the blend is ignited by gas burners, that can be fueled bycoke
oven gas, blast furnace gas, or natural gas. As the sinter bed moves, air issucked from the top
through the mixture, enabling combustion through the entire layer and complete sintering–
where the temperatures may reach 1300–1480oC. At the end of the strand, the material is
cooled by air and finished sinterissize-screened.

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As per given burden, raw materialsare collected on a common conveyor fromthe
respective bunkers through weigh feeders and then mixed homogeneously in mixing drums
(primary & secondary mixing drums) by adding required water(7to 8 %) and then feed on
sinter machine. Generally, raw mix bed height is 550mm and is adjusted based on quality of
the raw material. The bed in running(motion) condition is taken to ignition front. The raw
mix undergoes through the ignition furnace and there is a negative suction from bottom .As
soon as suction

takes place, hot products of combustion are sucked through the bed and transferits
heat to the next layer of the bed keeping it ready for the combustion. These flue gases are let
out from chimney through ESP . After completion of the sintering process, sinter cake will be
crushed and screened after discharge from the machine. Sinter having size > 5 mm will go to
the cooler and then it will go to BF. Sinter with size <5 mm size fines will be recycled in the
process.

Production
 The blend (including return fines) along with burnt lime and coke are mixed together
andweighed.
 Mixed
 Transferred from one area to another container
 Pelletised (processed)
 Weighed (processed)
 Wetted (treatment)
 Added to the strand at high temperature to form a cake.
 Transferred from one area to another container

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 HOSPET STEELS LIMITED
 Processed at High temperature
 Cake broken down on crash deck & or with crusher.
 Broken or crushed (processed)
 Optional Hot screening
 Transferred from one area to another container

Cooling and Screening

 Cooled at coolers.
 Cooled (treatment)
 Transferred from one area to another container
 Screened to remove over and under size sinter.
 Mechanical screening(processed)
 Transferred from one area to another container

Blast Furnace
 Transfer and Storage
 Transferred from one area to another container
 Transfer from sinter plant to blast furnace
e.g.viawheelloader,wagon,conveyorbeltetc.
 Stored in bunkers
 Stored in open air stock piles
 Transfer from stock pile to blast furnace
e.g.viaw heel loader ,bucket etc
 Charging ofsinter
 Transferred from one area to another container
 Bunker to charging bucket
 Consumed by blast furnace as feed stock

Other Activities Maintenance

 Maintenance activities on several parts of the plant.
 Bunkers
 Conveyors
 Screens

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 Crusher
 Precipitators/bagfilters
 Windboxes/mains
 General cleaning operations

Sampling
 Sampling activities at the sinter plant.
 Sinter Sampler
 Hearth layer over size
 Hearth layer under size
 Coal/Coke crushing plant
 Precipitator dust
 Return fines sampling
 Sampling activities at the blast furnaces.
 Sinter fines
 Bottom bunkers sinter

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Raw materials :-

Iron ore:
The iron ore using is Hematite (Fe2O3). Ore contains Fe > 63%, SiO2 : 2.2% - 2.3%,
Al2O3 : 2 – 3%, P : 0.04%, S : 0.01%, Moisture : 2 – 2.50% and density of about
2.20gm/cm3.The size of the iron ore using for MBF is above 15mm, generally 40 – 50mm.
Iron ore density is in the range of 2.20gm/cm3 .
IRON MAKING DIVISION (MBF)
This division is invested by Kalyani Ltd,
In this process Iron is manufactured through MBF. Iron ore & coke are the basic material
consumed in MBF. The output of this process is solid pig iron & liquid pig iron or melts iron.
Raw materials used in manufacturing pig iron are:
Iron ore casually hematite
Coke
Lime stone
Dolomite Fluxes
Manganese ore
BHQ
Coke:
Coke is used as a fuel in MBF. This contains 84 – 90% fixed carbon, 4 – 7% moisture,
0.40 – 0.70% sulphur with low ash content. The size of coke used in the MBF is above 20
mm. The density is in the range of 0.60 – 0.65 gm/cm3. Coke provides the following in the
MBF.
 Heat for endothermic reactions, melting of slag and metal.

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 Reducing gasses for the reduction of iron oxides.
 Permeable bed through which slag and metal pass down into the hearth and hot reducing
gasses pass upwards.

Flux:
A flux is a substance added during smelting to bring down the softening point of the
gangue materials, to reduce the viscosity of the slag and to decrease the activity of some of its
components to make them stable or unstable in the slag phase. Flux materials used in the
Mini blast furnace are lime stone, dolomite, banded hematite quartzite.

Lime stone: It contains CaO: 45 – 48%, MgO: 2.5 – 3.5%, Al2O3 :1% max, SiO2:5– 7%, and
loss on ignition is in the range of 45 – 50%. Limestone density is around 1.70 gm/cm3;
Limestone size used in MBF is in the range of 20 -25 mm.
Dolomite:It contains CaO: 30 – 35%, MgO: 18 – 22%, SiO2: 2 – 3% Al2O3 :1% max and loss
on ignition is in the range of 45 - 50%. Dolomite density is around 1.70 gm/cm3; size used in
MBF is in the range of 20 – 25 mm.
Quartzite:It contains Fe: 38 – 45%, SiO2: 35 – 40%, Al2O3 :3% max, moisture <1.5%.
Density is around 2 gm/cm3; size used in MBF is in the range of
Manganese ore: It contains 26% manganese content. It protects the lining of hearth area. The
consumption is 50 Kg/ THM.
Product and by products of the mini blast furnace are,
1) Pig Iron (Hot metal).
2) Slag .
3) B.F. Gas.

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MINI BLAST FURNACE (MBF-1, MBF-2, MBF-3)

Important features of a MBF :-

MBF is a shaft type furnace with a vertical stack superimposed over a crucible like
hearth. MBF complex is composed of BF proper, hot blast stoves, MBF top and charging
system, Several maintenance platforms, stock house system with several bins for burden
materials, tuy ere platform and cast house, slag granulation system, gas system,
The bosh, belly and partially stack area is lined normally with alumina bricks. High
density fireclay bricks are used in the upper stack area for the lining. Furnace inner shell is
usually sprayed with alumina cast ables to have a thickness of 70 mm. For the BF throat and
top cover inner lining, welding of anchors and one layer of heat-resistant and wear resistant
cast ables are used. Depending on the furnace lining design, the expected campaign life of
MBF varies in the range between 5 years to more than 10 years.
Increase of the hot blast temperature is one of the major measures for increasing the
volume of pulverized coal injection in the MBF and reducing the coke rate in the MBF. The
hot blast system design is done normally in such a way so that the hot blast temperature can
be maintained at 1200 deg C by using the BF gas as fuel. These days, MBFs are equipped
with 3 numbers hot blast stoves with rotary tangential dome combustion design.

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Other auxiliary equipment for blast furnace proper are (i) 2 stage throat armour, (ii)
„throat infrared imagery camera‟ installed near throat stock line to detect the stock
distribution in the throat area, and (iii) top water spraying and cooling device which is used
when top temperature goes very high.

The cast house is usually of rectangle shape with the steel roofing with slope of 1:12
and RCC column. Ventilation windows are normally provided in the roofing design. The cast
house is equipped with the hydraulically operated mud gun and hydraulic/pneumatic operated
tap hole drilling machine.
The operation of MBF is similar to the conventional large BFs. When the burden
materials, namely iron burden (sinter/pellets and lump ore), reducing agent (charcoal or BF
coke) and flux (limestone and dolomite), charged into the top of the blast furnace, descend
through the stack, they are preheated by the hot gases ascending from the hearth and by the
hot blast introduced through the tuyeres located at the bottom of the shaft, just above the
hearth.
The heated air burns most of the BF coke charged from the top to produce the heat
required by the process and provide reducing gas that removes oxygen from the ore burden.
The reduced iron melts and runs down to the bottom in the hearth. The flux combines with
the impurities in the ore to produce a slag, which also melts and accumulates on top of the
liquid iron in the hearth. From time to time, the liquid iron and liquid slag are drained out of
the furnace through tapping hole.

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 Operating parameters of MBFs

Sl.No. Parameter Unit Value
1 Furnace availability number of days 330 – 350
2 Sinter in burden % Around 80
3 Ore rate kg/t HM 1600-1700
4 Fuel rate kg/t HM 550-600
5 BF coke rate kg/t HM 420-450
6 PCI rate kg/t HM 120-150
7 Blast temperature Deg C 1100-1200
8 Top pressure kg/sq cm 0.3 -1.0
9 Slag rate kg/tHM 300-380
10 BF productivity tons/cum/day 2-3
11 Oxygen enrichment of Air blast % Around

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 Typical consumption of utilities in MBFs
Sl.No. Parameter Unit Value
1 Air blast N cum/t HM Around 1800
2 BF gas generation N cum/t HM Around 900
3 Steam kg/t HM Around 50
4 Electricity kWh/t HM Around 120
5 Nitrogen N cum/t HM Around 2
6 Compressed air N cum/t HM Around 0.3

The MBF control room which is located usually near the MBF working platform. The
control system normally consists of supervisory stations, main PLC, alarms, interlocks and
protections. One remote station is also generally installed at the raw material handling control
room. The system is linked through a network. A supervisory system is usually used for
controlling process parameters, trend recording and alarm logging. A number of field
instruments are installed to measure and control all process parameters. Some of the
important measurements include (i) pressure measurements, (ii) temperature measurements,
(iii) flow measurements, (iv) BF gas dust level measurements, (v) measurements of stock
level, chute angle and throttle valve opening degree, and (vi) weight measurement of burden
materials and many more. Control cabin for the operation of cast house equipment is located
in cast house itself at a safe place from where the operator can view the equipment.

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Water cooling system of the MBF normally requires industrial water on a continuous
basis in the areas which include (i) blast furnace shell cooling, (ii) cooling of tuyeres and
tuyere coolers, (iii) gas cleaning system in case of wet gas cleaning, (iv) slag granulation, (v)
BF top hydraulic system cooling, (vi) mud gun/drilling machine hydraulic system cooling.
All the water is recirculated. An overhead water tank is normally provided to take care of
emergency requirements during power failure. The main parameters related to all water
systems are monitored through the supervisory system from the control room.

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STEEL MELTING SHOP (SMS)

1. Energy Optimizing Furnace (EOF)

2. Ladle Refining Furnace (LRF)
3. Vaccum Degassing (VD)

Energy optimizing furnace (EOF)

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Main parts of EOF
A. Oxygen Lancing

B. EBT

C. Slag Door

D. Coke Injection System

E. Charging Door

F. Furnace Exhaust System

A. Oxygen Lancing:-
For oxygen lancing three co-jet systems is arranged in EOF. In each co-jet system coherent jet
blow by different nozzle . For oxygen gas one hole is used and diameter of the hole 22.4mm,oxygen
gas penetration depth is 1.4 mm and the purity of oxygen is 99.9%,blowing pressure is 22kg/square
centimeter and oxygen consumption 2200nm^3/heat

Propane (C3H8) gas used for producing the cloud over the oxygen jet which prevent the
reaction of oxygen with refractory walland also prevent the wear of refractory wallas well as to help for
deep penetration , the propane gas pressure 8kg /cm2 and the diameter is 4mm. Shroud oxygen used due to
high utilization of main oxygen gas and deep penetration of main oxygen and pressure of shroud oxygen3-
4kg/cm2 and nozzle diameter is 8mm.
The three – oxygen lance are placed at position 120 deg . and two are inclined at 45deg . and one is
inclined at 55deg.

B. EBT:-
The form of the EBT is eccentric bottom tap and their diameter is 130 mm. the main
function of EBT are slag free tapping and good alloy recovery in further process,and tore duce the
process time.

C. Slag Door :-

Slag door is used to tap continuously foamy slag to refine the steel.

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 Foamy Slag Practice

Foam has been defined as a medium consisting of gas bubbles in a liquid, e.g. soap bubbles in
water . Principle of foamy slag in steel making he generation of CO during the refining can lead to foam
formation if the slag is viscous enough . Reaction of Foamy Slag Practice-
(FeO)+C=Fe+CO(g)

D. Coke Injection System

For the injection off in coke (3-6mm) two hoppers are used.

Purpose-

1. To safe refractory lining

2. for better foamy slag practice 3. for better recovery of oxygen 4.And also prevent the metal Fe
is not form FeO more.

E. Charging Door
Through the pan feeder the raw material of EOF is charge in charging door of furnace. Mainly
bottom charging is done by pan feeder . Bottom charging used because it prevents the wear of refractory
lining from hot metal charging.
Bottom charging Lime -500 Kg Dolomite - 500 Kg DRIFines-1500Kg Scrap-500Kg

Purpose of charging materials

Lime-use for Slag making
Dolomite –use for slag making as well as refractory lining safety by coating of Mgo DRI –For
temperature maintenance as a coolant.

F. Fume Extraction System (FES)

During the furnace operation large amount of CO gas are generates which are used as main
refining gas but some amount of Co gas is unutilized which are come out through FES, this Co gar ar
every harmful for our environment therefore this CO gar are converted into CO2 by combustion of air
.When the CO gas come out from furnace which are burn in combustion chamber by air . The air suction
amount operates bye lbow duct if the distance of moving sleeve increase air suction is increase.

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After burning of Co gas which are convert into CO2 gas, these CO2 gas goes for cooling in
forced air cooler (FAC) than finally goes in bay house for removal of solid dust and now solid free CO2
gas come out through ID fan.

PROCESS OF ENERGY OPTIMIZING FURNACE

EOF process done in 40T capacity furnace the raw materials are

1.Hotmetal composition C-3.5-4.2%,Si-0.8-1.2% Mn-0.1-0.5%,P-0.12(max)S-0.06%(max),Fe-93-

94%2.Lime3.Dolomite4.Coke5.DRI6.Scrap
 Steel making is a oxidation processs ,In EOF heat generate by exothermic creaction.

 Operating temperature of EOF is1580deg.C and tapping temperature Is1620deg.C.

 Colour of oxidizing slag is black and FeO% in slag20%

 In steel making process the impurities are remove in following sequence Si,Mn,C,P.
 For the removalof„P‟,the temperature maintains between1540

 deg.C-1580 deg.C Because above that temperature bond of P2O5has break and „P‟ again
diffused in hotmetal
 Removal of„P‟and„S‟are very important because it form the non-metallic inclusion which are
create the problem for further processing.
 Phosphorus Create – Cold shortness Sulphur Create–Hot shortness

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 HOSPET STEELS LIMITED
Mainly two processes are done in EOF

 De-carburization- it is a process of removal of carbon by O2 Blowing

 De-phophorisation-it is process of removal of „P‟ by O2 blowing and maintaining basicity.

De-phophorisation condition are-

1. Highbasicity–2.5-32.
2. Lowtemperature-1540C-1580 deg.C
3. Oxidizingatmosphere–oxygenblowing

Basicity
It is a ratio of basic slag and acid slag
Basicity=Basic slag/acid slag,CaO/SiO2=2.5-3

The Principle Reactions of steel making are

1.(FeO)=[Fe]+[O]
Oxygen dissolved in the melt oxidizes carbon, phosphorous , silicon and manganese :

2.[C]+[O] = {CO}
3.[Si]+ {O2}= (SiO2)
4.[Mn]+1/2{O2} =(MnO)
5.2[P]+ 5/2{O2}=(P2O5)
6. [S]+(CaO)=(CaS)+ [O]reducing atmosphere

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LRF (LADLE REFINING FURNACE) ANDVD (VACCUMDEGASSING)

LADLE REFINING FURNACE VACCUM DEGASSING

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A Ladle Furnace is used to relieve the primary Melter of most secondary

refining operations , and its primary functions are:

 Reheating of liquid steel through electric power conducted by graphite electrodes

 Homogenization of steel temperature and chemistry through inert gas stirring
 Formation of a slag layer that protects refractory from arc damage,
concentrates and transfers heat to the liquid steel, trap inclusions and metal
oxides, and providethemeansfor desulphurization.

Secondary functions that can be included with a ladle furnace are:

 Alloy additions to provide bulkor trim chemical control

 Cored wire addition for trimming or morphology control
 Provide a means for deep desulphurization
 Provide a means for dephosphorization
 Act as a buffer for downstream steelmaking equipment the function of the porous
plug is to provide gas stirring of the molten metal to promote homogenization.

Normal stirring operations are performed by per collating argon gas through a purge
plug arrangement in the bottom of the ladle. A top lance mechanism serves as aback-up
means for bath stirring in the event the plug circuit in the ladle is temporarily in operable. The
gas supply connection to the ladle is automatically made when the ladle is placed on the

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transfer car . Fumes and particulates generated during heating and alloying operations at the
LF will exit the water-cooled ladle roof through the various openings in the roof. These
emissions will be captured (i.e. entrained) in ambient airdrawn into a lateral draft type fume
collection hood mounted on supporting structuresabove the ladle roof. The ladle roof is
typically a water-cooled design with a refractory centre or delta section and is configured to
coordinate with existing ladles such that theroof will completely cover the top portion of the
ladle when in the operating (i.e. fullylowered) position.

Vacuum Tank Degasser (“VTD”) is used to reduce the concentrations of dissolved gases
(H2,N2,O2) in the liquid steel ; Homogenize the liquid steel composition and bath
Temperature ; remove oxide inclusion materials from the liquid steel ; and , provide the
means and technical conditions that are favour able for final desulfurization.

The fundamental requirements for the ladle degassing process include:

 Sufficient free board in the ladle to contain the vacuum-induced slagand steelboil;
 An inert gas per collating through the steel bath for stirring ,inclusion
separation ,and enhancement of vacuum degassing performance;
 Sufficient super heat in the steel to avoid skull formation ; and,
 Means to deliver
 Additives while the ladle is inside the vacuum tank.

Ladle Metallurgy Furnace During operations at the VTD, the liquid steel is stirredto
promote homogenization by per colating argon gas through a single refractory stir plug
arrangement in the bottom of the ladle. The argon connection to the ladle is established when

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the ladle is set in place inside the vacuum tank. The vacuum tank is evacuated to the required
operating pressures by one of three ways : steam jet ejector , steam jet ejectors and a water
ring pump, or, mechanical pumps. Emissions are evacuated through a vacuum pumping
system and are collected prior to the pumps or they are discharged under water contained
within a weir wall-equipped concrete hot well. The process gases, including those entrained
in the inter condenser discharge water, are exhausted from the hot well viaa motor driven fan
to a vent stack equipped with a flare burner. Hot wells water is pumped to a cooling tower of
the contact water system.

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CONTINUOUS CASTING MACHINE

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LIST OF EQUIPMENT USED

LADLE TURRET :-

Having turret member supporting a platform which revolve about Its vertical
axis & Is furnished with ladle carrying arms lifted through hydraulic cylinder.
It is a device used for carrying steel ladle from way to other & changing over
the ladle in sequential operations & successive feeding of molten liquid steel to
tundish.

Slew bearing
“slew” means to turn without change of place; a “slewing” bearing is
rotational Rolling element bearing that typically supports a heavy duty but slow
turning or slow oscillating load.
Uses two rows of rolling of rolling elements they often use three race
elements ; such as inner ring and two outer rings “hawls” that clamp to gether axially
Slewing bearings are often made with gear teeth integral with inner or outer race , used to
drive the plat form relative to the base

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TUNDISH CAR

Is mainly used to support the tundish & tundish can travel on Itto change tundish
rapidly.

It‟s a welded steel plate construction, 4 idler wheels are mounted in a car to
support it and tundish can travel vertically along the two rails at a same level by use of
hydraulic cylinders. And it travels right or left by means of gear box driven by electric
motor. Tundish can be moved in forward or backward direction to match the SEN centre
with mould centre.

MOULD OSCILLATOR:-
The oscillating drive is in the form of a cam which moves the follower pivoted
atone end. A transfer element b/w the follower & the mould transmits the oscillation to
mould

FUNCTION
 To maintain stable steel level in the mould.
 To supply sufficient lubrication for steel shell in the mould.
 Provides the necessary movement of the mould to prevent sticking to the strand
shell to copper tube.

ELECTO MAGNETIC STIRRER:-

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 Rotating stirrer acts like the statoro fan electrical AC motor
 It is fed by three phase electrical supply
 Creates rotating magnetic field and induces at or que in the liquid steel of the
billet or bloom
 Liquid steel acts as the rotor of AC motor and rotates around the axis of the
cast product

WITH DRAWAL

 To continuously with draw billets/blooms from the mould at different for

different section.
 Min&Max speed is 0.5m/min to2.95m/min.
 To straighten billets/blooms.

DUMMY BAR :-The dummy bar head serves to seal the mould before start of casting and to
withdraw the initially solidified hot strand out at casting start and send it into the withdrawal
straightening unit

 It includes drive mechanism for with drawing dummy bar by means of winch
system and to park the same after its work.
 It includes hydraulic cylinders to lift the dummy bar storage tilter.

PICKUP BRIDGE

Its function is to lift the bloom / billet and carrying them which are arrived at the
end of the discharge roller table tone of the cooling beds.

CONSTRUCTION

1. It is made of steel profile supporting frame on which are installed two racks
and two rails
2. It moves on rails
3. It has bidirectional movement guaranteed by DC motor
4. It has bidirectional movement for lifting and lowering
5. It is equipped with two pneumatic cylinders for finger opening and closing

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AUTO CUTTER
Its function is to cut bloom/billet into pieces as per customer required length by LPG
and oxygen

IRT(INTERMEDIATE ROLLER TABLE)

Supporting ,guiding the hot strand and leaving the with drawal unit & dummy bar
Roller table with chain driven rollers from straightener drive.Fabricated steel frame.Steel
rolls are mounted on roller bearings or bushes. Inter-connecting chains and chaincovers

DISCHARGE ROLLER TABLE(DRT)

They are made using premium-quality raw materials in compliance with industrial
norms and guidelines. They are primarily used for transporting and guiding the hot billets
from cutting area up to cross transfer area. They are located between cutting units and cross
transfer area . Their construction involves roller tables with individually driven common
rollers. They incur low maintenance costs due to individual drives without chains and offer
good heat protection due to cover plates for each drive and bearing. We export them to our
overseas clients through a hassle-free shipment process. They are delivered to clients with in
the stipulated time-period at economical rates.

TAIL PINCH
Tail pieces can be withdrawn by tail pinch

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ROLLING MILL

In metalworking, Rolling is a metal forming process in which metal stock is passed

through one or more pairs of roll stored the thickness and to make the thickness uniform. The
concept is similar to the rolling of dough. Rolling is classified according to the temperature
of the metal rolled. If the temperature ofthe metal is above its recrystallization temperature,
then the process is known as hot rolling. If the temperature of the metal below its
recrystallization temperature ,the process is known as cold rolling.
In terms of usage ,hot rolling processes more tonnage than any other manufacturing
process, and cold rolling processes the most tonnage out of allcold working processes. Roll
stands, holding pairs of rolls, are grouped together into rolling mills that can quickly process
metal, typically steel, into products such as structural steel (I-beams, angle stock, channel
stock, and so on), barstock, and rails. Most steel mills have rolling mill divisions that convert
the semi-finished casting products into finished products.

Types of rolling:
1. Transverse Rolling
2. Thread rolling
3. Shape rolling
4. Ring rolling
5. Tube piercing
6. Skew rolling

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Principle of Rolling:
The rolling is a process which consists of passing the metal through a gap between
rollers rotating in opposite direction. This gap is smaller than the thickness of the part being
worked. Therefore, the rollers compress the metal while simultaneously shifting it forward
because of the friction at the roller-metal interfaces.
When the work piece completely passes through the gap between the rollers,it is
considered fully worked. As a result, the thickness of the work is decreases while its length
and width increases.

The decrease in thickness is called draft, whereas the increase in length istermed as
absolute elongation. The increase in width is known as absolute spread.

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Rolling Mill Process Flow Chart

Receive Plan from PPC

Charging of Billets as per Planning

Re heating of Billets

Recording
Temp of
Zone every
Hour

Hold Billets Till Temp Attainted

Eject the Billets by Ejector after

demand by CP-1

Descaling

Hot Working in Mills

Cut at Hot Saw as per required Length

Transfer From TOT

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Inspection Re-work

OK

Colour Coding
Ok

Colour Coding
Stacking

Stacking as per Dispatch details

Dispatch as
per Market
Transfer For Inspection Requirement

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ROLLING MILL PROCESS (RMS-1&RMS-2)
(Kalyani Steels Limited).
REGENERATIVE PUSHER TYPE FURNACE:

Reheating is an important process of rolling products, it is mainly used forheating the

billets in rolling mill line. And heating temperature control directly affects the quality of
rolled steel products. Here Regenerative pusher type furnace is used which uses Blast
Furnace Gas (BFG) as a fuel for heating. The capacity of the furnace in RMS-1 is 30TPH &in
RMS-2 is 45TPH and the furnace is Top and Bottom fired. The furnace is divided into 3
number of zones (preheating, heating and soaking). Temperature of each zone shall be set as
per different type of steel grade and charged billet temperature and adjust each section air-gas
supply timely. Also in line with BFG quality variation and combustion status, proper
adjustment in practical operation can be done along with observing furnace hearth flame so as
to obtain best proportioning ratio.Furnace operating temperature is 1280°C (max). In 45TPH
capacity furnace total number of Burners are 74 (36BFG&38Air Burners).

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Combustion System Control Panel

1. Billets are charged into the Furnace.

2. Air with massive burners on the side walls of the furnace heat the billets early to its
discharge temperature.
3. Incoming combustion air to is heated before its fired into the furnace using the heating
blowers.
4. Computer models calculate the targate droughing mill exit temperature of the Billet to
obtain a furnace discharge („drop-out‟) aim temperature .Estimating the temperature
profile through the thickness of Billet feeded in the furnace on an ongoing basis, the
computer aids the operator in selecting the production rate and zone set-points that
will maximize production of Billets uniformly heated to as closet the target
temperature as possible
When the Billet reaches the„discharge door‟at the exitend of the furnace, and the
computer has determined that the Billet has been sufficiently heated, the door opens
and the material is drawn out of the furnace with the help of Ejectors. The intensely
hot Billet is placed on a roller table which carries it into the roughing mill

Charging of Billets

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Ejector

Discharge door

DESCALING:

After exiting the reheat furnace, the Billet passes through a descaling unit,
anenclosure employing two pairs of water spray headers that blast the intensely hot Billet
with 200 bar pressurized water to remove the thick layer of oxidized iron (scale) that forms at
the surface of the Billet in the oxygen-rich atmosphere of the re heat furnace.

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3 HI ROLLING MILL:

There are three rolls placed below and parallel to each other . The rolls compress the
material. There are four sections of making the final product they are square section(R1),
diamond(R2), oval(F1) & round(F2) through which thehot material passes in the first region
the hot metal comes from the furnace along with removal of scale from the material by the
descaler and the material is then passed inside the rolling here maximum no. of passes are 4
to 5and the material regain its shape and it is passed to diamond shaped path here also the
same procedure occurs and then passes to oval shaped mould and finally the material passed
into round shaped path here the operator already set there quires size of diameter based on
costumers requirements and the product is ready for cutting into req.length and for finishing.

Pass Design

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2 HI REVERSIBLE BLOOMING MILL:

2 High Rolling Mill Rolling mills consist of two rolls are known as a 2 High rolling
mill. It is used for anything from temper pass to break down of material.The 2 High rolling
mill typically has larger diameter work rolls that are positioned with actuators that are either
Hydraulic or Pneumatic operated.

This Rolling Is of 45TPH. Rounds=90t o160Flats= 80*180 to 100*150RCS=90to180

REVERSIBLE: A reversing mill is a rolling mill in which the work piece Is passed forward
and backward through a pair of rolls. The reversing mill is sonamed because the steel runs
back and forth between the rollers, reducing the thickness incrementally with each pass. A
reversing mill can be used to reduce material to gauge.

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6 STAND HORIZONTAL & VERTICAL CONTINUOUS MILL:

Here there are six stands C1, C2, C3, C4, C5 and C6. Where C1, C3 & C5
arehorizontal stands andC2, C4 & C6 are vertical stands. The milling rolls arearranged in
series with respect to each other one by one. The rolls of horizontal mill are in horizontal
direction and the rolls of vertical mill are in vertical direction.
In the first stand the material is passed through the horizontal stand having a
maximum roll diameter : 580mm motor speed of 0-600-1500mm the material is
compressed the then move toward vertical stand , here the material the compressed
vertically under the motor capacity of 600kw this motor capacity is same for all 6 stands.
And then material passed into horizontal stand here again the material is compressed this
process is continuous for different size of diameters.

Rolls

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COOLING BED:

Used for Cooling and cross transferring the finished product towards the discharged.

HOTSAW:

Hot Saws are used in Hot Rolling to cut desired length and as well as to trim front
&Rear End of the material.

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NON DESTRACTIVE TEST (NTD)

INSPECTIONAND TESTING:
Straightener:

The material is passed through straightener it has 2 rolls, the materials

passesthrough these rolls the bends of the material isremoved by the pressure of therolls.

Shot Blasting:

Shot Blasting is a surface treatment process using high pressure shorts through on the
rolls.

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Ultrasonic Testing Machine (UT):
Velocity steel abrasives. Shot blasting is method through which it is possible to obtain
excellent cleaning and surface preparation for secondary finishing operations . Shot
blasting is commonly used for the cleaning of iron, steel, non-cast parts, forgings
forging ,etc.

Ultrasonic inspection can be used to detect surface flaws, such as cracks,seams, and
internal flaws such as voids or inclusions off reign material.It‟s
material.It‟s also used to measure wall
thickness in tubes and diameters of bars. An ultrasonic wave is a mechanical vibration or
pressure wave similar to audible sound, but with a much higher vibration frequency. For
NDT purposes , the range is usually from 1MHz to 30MHz.Depending on the test
requirements,
equirements, these waves can be highly directional and focused on a small spot orthin line,or
limited to a very short duration.

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Magnetic Particle Inspection (MPI):

Magnetic particle Inspection (MPI) is a non-destructive testing (NDT) process for

detecting surface and shallow sub surface discontinuities in ferro magnetic materials such as
iron, nickel, cobalt, and some of their alloys. The process putsa magnetic field into the part.
The piece can be magnetized by direct or indirect magnetization. Direct magnetization occurs
when the electric current is passed through the test object and a magnetic field is formed in
the material. Indirect magnetization occurs when no electric current is passed through the test
object ,but a magnetic field is applied from an outside source .The presence of a surface or
sub surfaced is continuity.
In the material allows the magnetic flux to leak . To identify leak a magnetic " ink "
composed of iron powder particles in a liquid carrier base is applied to the part .These are
attracted to an area of flux leakage and form what is known as an indication . A technician
then using A UV light torch does the inspection and marks the leak area.

Defects

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COLOUR COADING:

The finished Products are sent for colour coding where coding is done for easy
identification of the material grades.

DISPATCH:

Stacking is done as per Dispatch details and products are Dispatched.

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CONCLUSION

It‟s always a great opportunity to experience the valuable exposure of an industry.

There is a lot of difference between the ories and practices. This training has enabled me to
understand the aspects of professional life . I like the working environment and how more
importance is given for workers Safety at Hospet Steels limited. And come to know how to
deal with our colleagues . The company‟s members are well cultured and well mannered.

An effective process is followed at Hospet Steels limited. But it would be come more
valuable and impressive by implementing certain efficient measures. The company is
constantly focusing onproviding better service, quality and reliability to customers, and
running successfully in this era of competition.

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