ABSTRACT/ LIST OF THE PROJECT DONE:

ABSTRACT/ LIST OF THE PROJECT DONE:

Automation means to do a job by using various automatic machines to reduce the difficulties in operations and to increase the quality of the product and to reduce the wastage. Billets which are formed form other sides of plant (Con Casting furnace) are used for making required amount of solid pipes to be supplied to the customer. The steel manufacturing process at our bhushan begins when ferrous scrap metal arrives by rail car or truck and is unloaded by large overhead cranes. Scrap metal is loaded into a "charge bucket" and brought into the melt shop where it will go through our two-step melting process. The first melting step begins when the scrap is unloaded from the charge bucket into our electric arc furnace (EAF). The EAF uses electric power to heat the scrap to over 3,000 degrees Fahrenheit and melt it into liquid form. In the process, slag forms and floats to the top of the molten steel with oxidized impurities and discarded. The molten steel is transferred to the Ladle Refining Furnace, the second step in our melting process. Here, the steel is tested and fine adjustments are made to the composition and temperature to ensure the right characteristics for the desired grade of steel to be produced. the steel is poured into molds, cooled and shaped into the desired cross section, essentially forming a long bar called a billet. As the billets move through the continuous caster, they are cut by torches into desired lengths. The completed billets are used as the feedstock for our rolling mill or sold on the world market for use by other mills. The hot rolling process begins by reheating the previously created billets in our reheat furnace until they turn into a "plastic" state. In this photo, the billets are entering the reheat furnace. The reheated billets exit the reheat furnace and proceed to one of our two rolling mills. Each rolling mill consists of a series of "stands", each containing a set of rollers that compress and lengthen the billets and then finish them into the desired shape. The formed product is transferred to the cooling bed where it is allowed to cool before it is cut and bundled. In this photo, you can see straight lengths of reinforcing bar cooling. Hot rebar arrives on the right from the rolling mill stands and cools as it progresses to the left. The final bundled product is placed in our warehouse.

ACKNOWLEDGEMENT

An acknowledgement is something one owes to people he is indebted to.Therefore it is a great honor for me to acknowledge these people who have given me support in every sphere of my training period.With great pleasure and deep sense of gratitude, I wish to express my heartiest appreciation and gratitude to our training officer for giving us an opportunity to work as trainee in a reputed industry like Bhushan Power and Steel. I also wish to thank Mr. V.P. Kakkar (Training In charge of Bhushan Power and Steel) for the keen interest, guidance, inspiration, encouragement and thorough advice given during the training period. I want to thanks the entire staff of Bhushan Power and Steel for being so supportive and helpful.

COMPANY PROFILE

Brij Bhushan Singal, the Prime Mover, a visionary entrepreneur founded the Bhushan Group more than 20 years ago in Chandigarh. Making a moderate start with manufacture of hinges & rail tracks fasteners in the early 70s with a capital less than a lakh of rupees, the group has continuously grown by modernizing, expanding & integrating its facilities/operations.Joined by his young and dynamic sons Sanjay & Neeraj in the 80s & taking advantage of the liberalized environment in the steel sector, Brij Bhushan Singal has propelled the group to the success earning it a permanent place among the large players of the steel industry. Bhushan Power & Steel Limited, a fully integrated 2.3 Million TPA Steel making Company with turnover of INR 4217 Crores (USD 937 Million) and 7 World Class ISO 9000 Certified State of the Art Plants at Chandigarh, Derabassi, Kolkata and Orissa in India.

Bhushan Limited is an integrated mini steel plant, located at Chandigarh, with facilities for manufacturing 1.5 lac tones of steel billets and rolled products like rolled bars, rcs and tore per annum. From a modest start in 1973, it has gone through expansion, backward integration, up gradation of its facilities and has reached annual turnover of 167 crores with cash profits of about 5 crores. The industry has net worth of about 19.5 crores.

PRODUCT EXPORTERSBhushan's products are being exported toChina, Singapore, Malaysia, Hong Kong, Indonesia, Philippines, Dubai, Oman, Saudi Arabia, South Africa, Thailand, Korea, Myanmar, Sri Lanka, Bhutan, Nepal, Bangladesh, Vietnam, USA, Nepal, England, Belgium, Turkey, Angola, Monrovia, Nigeria, Beinhoa City, Belgium, Kuwait, Switzerland, and a host of African countries.

PROGRESS

1970- Started with very small initial outlay for manufacturing Door Hinges & later on, Rail Track Fasteners.1973- Manufacturing facilities set up for Tor Steel and Wire Rod in Chandigarh.1981- Rolling Mill Project commissioned at Chandigarh for Round and Narrow Strips.1985- Backward Integration Project for Steel Melting facilities.1986- Upgrading of Mini Steel Plant with continuous casting and ladle furnace facilities. 1997 - Commissioning of Narrow Width Cold Rolling Project at Chandigarh.1998- Commissioning of Precision Pipe Project at Chandigarh.2001- Commissioning of Cold Rolling & Galvanizing Complex at Kolkata.2002- Addition of narrow width Cold Rolling facilities at Kolkata.2003- Expansion of wide width Cold Rolling facilities, ERW Water Pipes & Tubes down stream facilities at Kolkata.2004- Further expansion of Cold Rolling facilities at Kolkata.2005- Commissioning of Orissa Project consisting of 4 DRI Kilns, Steel Making Facilities, Coal Washery and 100 MW Power Plant.2007- Commissioning of further expansion of Orissa Project consisting of HR Coil Mill, Steel making, Blast Furnance, Sinter plant, Coke oven plant, Oxygen plant and Lime & Calcining Plant.2009- Commissioning of 3.5 million tpa Coal Washery, 146 MW Power Plant and 0.3 million tpa Sponge Iron under Phase III of Orissa Project.2010- Commissioning of 130 MW Power Plant and Electric Arc Furnace under Phase III of Orissa Project and further expansion of Orissa Project under Phase IV consisting of 6 DRI Kilns, 130 MW Power Plant, Steel Making Facilities, 6th strand, 2nd CSP Caster & Tunnel Furnace, Oxygen Plant, Lime Calcining with downstream facilities - Cold Rolling, Galvanizing, Galvalume, Colour Coating, Precision Tube & Black Pipe/GI Pipe.

MISSION AND VALUES

Our Mission is to achieve clear identity and leadership globally in Steel production and distribution by integration of complete chain of production starting from captive iron ore to end user Steel products.Our revolution in Steel production has helped us to carve a niche unique only to a market leader. Every year passes by with new value additions and more accolades from our customers - Locally and Globally. Our rising chart in respect of all-important parameters of production and finance is a testimony to our claim.In pursuing ourmission, we at Bhushan Power & Steel Ltd. are guided by the followingvalues- Quality- To be the best in quality. We aim and achieve excellence. Technology- State of the art technology and product enrichment by continuous Research and Development. Customer Friendly- Our products are world class and more and more clients are appreciating and using our products. We also undertake customized products with values addition and enhancement. Corporate Governance- We comply with all applicable laws and regulations. We believe in maintaining clean environment and conservation of natural resources. We contribute towards betterment of our staff and provide them with best of facilities. Environment Protection and Practice- We are adopting and implementing pollution control measures as a matter of policy. Our Commitments

To improve the quality of our products and complete integration of various stages of production. To be conscious towards quality and pricing of our products. We strive by continuous research and development to make our products world class, having distinct identity and uniqueness. Our customers get best value for their money. To run the company profitably year after year. A workforce motivated, skilled and well looked after. A workplace safe, secure and hygienic.

To make our Environment Clean, Healthy and Hospitable

PRODUCTS

Bhushan Power & Steel Ltd., produces a number of steel products for domestic users, Industrial concerns etc. for infrastructure development at its manufacturing bases at Chandigarh, Derabassi (Punjab), Kolkata and Orissa.

ALL OUR PRODUCTS CONFORM TO INDIAN AND INTERNATIONAL SPECIFICATION

HR COILSTEEL BILLETSALLOY STEEL ROUNDSTOR STEEL

WIRE RODS PIG IRONSPONGE IRONPOWER

CR COILSNARROW CR COILSCR SHEETS PRECISION TUBES (ERW and CEW)

CABLE TAPESBLACK PIPE GI PIPESGP COILS / SHEETS

FACTORY LAYOUT

There are nine sections in this factory. This whole process goes through these sections only, from melting to rolling. These are following sections:(A) Melting shop(B) Casting shop(C) Rolling shop(D) Physical strength testing section(E) Spectro and chemical Lab(F) Microscopic lab(G) Machine shop(H) Electic lab Finishing Section

PROCESS

Starting from melting shop, steel caps and raw materials are charged in the furnace with the help of overhead crane 60 ton. The crane lifts the charged bucket, which is then tilted in the furnace. Then after 45 to 90 minutes, molten metal is tapped in the preheated ladle. Then its ladle is transferred to the ladle refining furnace, where the metal is refined by adding some additives. After 30 to 40 minutes the ladle is transferred to the continuous casting machine section, before this some metal in solid state is taken from continuous casting machine section, before this some metal in solid state is taken from ladle refining furnace for testing its chemical composition, physical strength and the structure.

After this casting process goes on and casting of billets of size 4 sq inches, 5 sq inches, 5.5 sq inches is done. Then from casting sections, billets are cut into the required pieces and size, and they are heated in oil furnace at suitable temperature. After heating billets they are frequently passed through rolling mill, where required shape is given to the billets by hot rolling process. After that, marking is done on different grades.

MACHINE SECTIONIn machine section, rolls of rolling mills are designed for the production of different shapes.

Machine section consists of following things: Lathe Milling Machine Shaper Grinders Tools and gas welding set

ELECTRICAL SELECTION

Here the whole supply to the factory and machine are controlled. It is a prohibited area because it consists of huge transformer which can cause hazards.

FINISHING SECTION

In finishing section the round bars are stretched in sulphuric of hydrochloric acid in diluted form to remove dust and layers of oxide from the surface. Some irregularities on the surface of the bar are removed with the help of pneumatic grinder, which works at the pressure of 7 to 8 Kg/sq cm.

RAW MATERIAL

The factory uses scrap as raw material. A big electromagnet is used to separate iron from big heaps of scrap an overhead crane is used to drive this electromagnet. The material picked up by electromagnet is collected in a charging basket having a capability of 32 tones. The material goes into the furnace by the use of this charging basket. The raw materials used in the industry along with their sources are explained as:

S.No. MATERIAL SOURCES

A) Sponge IronJindal Factory, RaigarhB)Shredded SteelRussia, U.S.AC)GranularJindal Factory, RaigarhD)Granular 2Cheap ProductE)Mill HeavyFrom plant itselfF)Tin TupperFrom local marketG)Heavy melting scrap From Middle EastH)Nickel Trojan Nickel, Zimbabwe

TRAINING REPORT

CLASSIFICATION OF STEEL

Steel can be grouped into following four categories: - Plain carbon steel Alloy steels Special alloy steels Cast steels

PLAIN CARBON STEELS: -

These steel contain only carbon and iron. Si, Mn, S and P exist as Impurities. These have negligible effect on steels when their extent does not exceed: 0.3-0.4% Si, 0.5-0.8% Mn, 0.08% P and 0.04% S

Plain carbon steel can be classified according to their carbon content:

1. Low carbon or mild steel0.05-0.30% C2. Medium carbon steel0.30-0.60%C3. High carbon steel0.60-1.50% C

EFFECT OF IMPURITIES

Sulphur combines with iron chemically to produce iron, which forms the grain boundaries. Iron sulphide, because of its melting point, produces red shortness in steels, cause brittleness at forging temperatures. Phosphorous is also a harmful impurity in steels, because it causes brittleness. Silicon is a very good oxidizer. It removes the gases and oxides, prevents blowholes and thereby makes the steel tougher and harder. Manganese also serves as a good deoxidizing and purifying agent. It also combines with sulphur to form manganese sulphide and thereby reduces the harmful effects of sulphur remaining in the steel; it makes metal ductile and have good bending qualities.

LOW CARBON STEELS These steels are used extensively in

Industrial products Construction industryThe product application includes: pipes, tubes, storage tanks, railroad, cars, automobile frames, nuts, automobile bodies and galvanized steel sheet. These steels are soft, very ductile, easily welded and unresponsive to heat treatment due to low carbon content.

MEDIUM CARBON STEELS These steels can be hardened and tempered. Thus, these steels can be used for products requiring greater strength and wear resistance. Typical product application include: forging, casting, axles, shafts, crankshafts, connecting rods, etc.

HIGH CARBON STEEL

This type of steel responds better to heat treatment as compared to medium carbon steel. So, these have high strength, hardness and good resistance to wear. Typical product applications include: forging and wide varieties of tools such as drills, taps, reamers, dies, hand tools, cutlery, chisel, shear, spring wire, cable and wire rope. These are not so ductile in higher carbon ranges; the extreme hardness is accompanied by excessive brittleness.

ALLOY STEEL

Steel is said to be alloyed when its composition incorporates specially introduced alloying elements or when the silicon or manganese content exceeds the usual percentage. The aims of alloying are following:

To produce fine grained steel To improve wear resistance, corrosion resistance. To improve harden ability and hardness. To improve merchantability. To improve weld ability. To improve electrical properties. To improve physical properties at high temperatures. To improve tensile strength, ductility, elastic properties etc.The most frequently employed elements for alloying steels are: Cr, Ni, Mn, Si, Mo, Va, W, Cu and Al.

ELECTRICAL FURNACES HISTORY

In 1878, Siemens made use of electric current for melting iron. French metallurgist, Paul Lois Toussaint Heroult, placed the first direct electric arc steel making furnace in operation in 1899. Initial are furnaces were of very low capacity i.e less than 4 tones. The one installed at the Bhushan Power and Steel Ltd is of 30 ton capacity which takes 3 hours to affect the melt. The first arc furnace was introduced in USA in 1904 with 4 ton capacity and utilized two electrodes.

INDRODUCTION

Originally the electric arc furnace was used for the manufacture of relatively small amounts of high grade tool steels and alloy steels. Modern electric arc furnaces produce a wide range of steels and no longer arc considered suitable only for making a limited range of high quality steels of special compositions.

ELECTRIC ARC FURNACE

Construction

A schematic cross-section through an EAF. Three electrodes (black), molten bath (red), tapping spout at left, refractory brick movable roof, brick shell, and a refractory-lined bowl-shaped hearth.An electric arc furnace used for steelmaking consists of a refractory-lined vessel, usually water-cooled in larger sizes, covered with a retractable roof, and through which one or more graphite electrodes enter the furnace. The furnace is primarily split into three sections: the shell, which consists of the sidewalls and lower steel 'bowl'; the hearth, which consists of the refractory that lines the lower bowl; the roof, which may be refractory-lined or water-cooled, and can be shaped as a section of sphere, or as a frustum (conical section).The hearth may be hemispherical in shape. In modern meltshops, the furnace is often raised off the ground floor, so that ladles and slag pots can easily be maneuvered under either end of the furnace. Separate from the furnace structure is the electrode support and electrical system, and the tilting platform on which the furnace rests. A typical alternating current furnace has three electrodes. Electrodes are round in section, and typically in segments with threaded couplings, so that as the electrodes wear, new segments can be added. The arc forms between the charged material and the electrode, the charge is heated both by current passing through the charge and by the radiant energy evolved by the arc. The electrodes are automatically raised and lowered by a positioning system. The regulating system maintains approximately constant current and power input during the melting of the charge, even though scrap may move under the electrodes as it melts. Since the electrodes move up and down automatically for regulation of the arc, and are raised to allow removal of the furnace roof, heavy water-cooled cables connect the bus tubes/arms with the transformer located adjacent to the furnace. The furnace is built on a tilting platform so that the liquid steel can be poured into another vessel for transport. The operation of tilting the furnace to pour molten steel is called "tapping". Originally, all steelmaking furnaces had a tapping spout closed with refractory that washed out when the furnace was tilted, but often modern furnaces have an eccentric bottom tap-hole (EBT) to reduce inclusion of nitrogen and slag in the liquid steel.

DSP-200 steel-smelting arc furnace, with a capacity of 200 tons: (1) graphited electrode 710 mm in diameter, (2) electrode holder, (3) roof, (4) water-cooled roof ring, (5) cylindrical shell, (6) water-cooled auxiliary door, (7) electromechanical mechanism for rotating furnace about vertical axis, (8) electromechanical mechanism for tilting furnace, (9) casting spout, (10) movable current lead from flexible water-cooled cables, (11) stem for vertical movement of stand-sleeve-electrode-holder-electrode system, (12) current lead from water-cooled copper tubes A mid-sized modern steelmaking furnace would have a transformer rated about 60,000,000 volt-amperes (60 MVA), with a secondary voltage between 400 and 900 volts and a secondary current in excess of 44,000 amperes. Enormous variations exist in furnace design details and operation, depending on the end product and local conditions, as well as ongoing research to improve furnace efficiency. To produce a ton of steel in an electric arc furnace requires approximately 400 kilowatt-hours per short ton of electricity, or about 440kWh per metric tonne; the theoretical minimum amount of energy required to melt a tonne of scrap steel is 300kWh (melting point 1520C/2768F). Electric arc steelmaking is only economical where there is plentiful electricity, with a well-developed electrical grid.

Working of Electric arc furnace Scrap metal is loaded into a "charge bucket" and brought into the melt shop. Scrap metal is delivered to a scrap bay, located next to the melt shop. Scrap generally comes from shred and heavy melt along with some direct reduced iron or pig iron for chemical balance. The scrap is loaded into large buckets. Care is taken to layer the scrap in the basket to ensure good furnace operation; heavy melt is placed on top of a light layer of protective shred, on top of which is placed more shred. These layers should be present in the furnace after charging. After loading, the basket may pass to a scrap pre-heater, which uses hot furnace off-gases to heat the scrap and recover energy, increasing plant efficiency. The first melting step begins when the scrap is unloaded from the charge bucket into our electric arc furnace (EAF) and a lot of energy generated by multiple tonnes of falling metal; any liquid metal in the furnace is often displaced upwards and outwards by the solid scrap, and the grease and dust on the scrap is ignited if the furnace is hot, resulting in a fireball erupting.

After charging, the roof is swung back over the furnace and meltdown commences. The electrodes are lowered onto the scrap, an arc is struck and the electrodes are then set to bore into the layer of shred at the top of the furnace. Lower voltages are selected for this first part of the operation to protect the roof and walls from excessive heat and damage from the arcs. Once the electrodes have reached the heavy melt at the base of the furnace and the arcs are shielded by the scrap, the voltage can be increased and the electrodes raised slightly. The EAF uses electric power to heat the scrap to over 3,000 degrees Fahrenheit and melt it into liquid form. This enables a molten pool to form more rapidly. Oxygen is also supersonically blown into the scrap, combusting or cutting the steel, and extra chemical heat is provided by wall-mounted oxygen-fuel burners. Both processes accelerate scrap meltdown. An important part of steelmaking is the formation of slag, which floats on the surface of the molten steel. In the process, slag forms and floats to the top of the molten steel with oxidized impurities and discarded. Slag usually consists of metal oxides. For a furnace, the usual slag formers are calcium oxide (CaO, in the form of burnt lime) and magnesium oxide. These slag formers are either charged with the scrap, or blown into the furnace during meltdown. Another major component of EAF slag is iron oxide from steel combusting with the injected oxygen. Later in the heat, carbon (in the form of coke or coal) is injected into this slag layer, reacting with the iron oxide to form metallic iron and carbon monoxide gas, which then causes the slag to foam, allowing greater thermal efficiency, and better arc stability and electrical efficiency. The slag blanket also covers the arcs, preventing damage to the furnace roof and sidewalls from radiant heat. Once flat bath conditions are reached, i.e. the scrap has been completely melted down, another bucket of scrap can be charged into the furnace and melted down. After the second charge is completely melted, refining operations take place to check and correct the steel chemistry and superheat the melt above its freezing temperature in preparation for tapping. More slag formers are introduced and more oxygen is blown into the bath, burning out impurities such as silicon, sulfur, phosphorus, manganese and calcium and removing their oxides to the slag. Removal of carbon takes place after these elements have burnt out first, as they have a greater affinity for oxygen. Metals that have a poorer affinity for oxygen than iron, such as nickel and copper, cannot be removed through oxidation and must be controlled through scrap chemistry alone. Once the temperature and chemistry are correct, the steel is tapped out into a preheated ladle through tilting the furnace. For plain-carbon steel furnaces, as soon as slag is detected during tapping the furnace is rapidly tilted back towards the deslagging side, minimising slag carryover into the ladle. For some special steel grades, including stainless steel, the slag is poured into the ladle as well, to be treated at the ladle furnace to recover valuable alloying elements. During tapping some alloy additions are introduced into the metal stream, and some more lime is added on top of the ladle to begin building a new slag layer. Often, a few tonnes of liquid steel and slag is left in the furnace in order to form a 'hot heel', which helps preheat the next charge of scrap and accelerate its meltdown. During and after tapping, the furnace is 'turned around': the slag door is cleaned of solidified slag, repairs may take place, and electrodes are inspected for damage or lengthened through the addition of new segments; the taphole is filled with sand at the completion of tapping. Environmental issuesMuch of the capital cost of a new installation will be devoted to systems intended to reduce these effects, which include:enclosures to reduce high sound levelsDust collectorfor furnace off-gasSlag productionCooling water demandHeavy truck traffic for scrap, materials handling, and productsEnvironmental effects of electricity generationADVANTAGES:

1. POLLUTION-Electric arc furnaces are pollution free and have outstanding metallurgical control.2. HEATING-The advantage of a electric metal casting furnace is that temperature can go up to 1800 Celsius. Large reduction in specific energy (energy per unit weight) required to produce the steel.3. FLEXIBILITY: EAFs can be rapidly started and stopped. A typical steelmaking arc furnace is the source of steel for a mini-mill, which may make bars or strip product. Mini-mills can be sited relatively near to the markets for steel products, and the transport requirements are less than for an integrated mill.

DISADVANTAGES:

1.Sound levels- Lost of sound levels.2. Energy It can be produced only in place energy is available in a large scale3. flicker and harmonic distortion: They are common side-effects of arc furnace operation on a power system.4. Health hazards- movement of scrap through the locality can cause health hazards. Electric arc steelmaking is only economical where there is plentiful electricity, with a well-developed electrical grid.

Ladle (metallurgy)

A ladle of molten iron is poured into an open hearth furnace for conversion into steel at Allegheny Ludlum Steel Corp., 1941In foundry work a ladle is a container used to transport and pour out molten metals. It needs to be: Strong enough to contain a heavy load of metal. Heat-resistant like a furnace. Heat-insulated as much as can be managed, to avoid losing heat and overheating its surroundings. LADLE CASTING For foundries making small castings, a hand-held ladle somewhat resembling a kitchen ladle for soup is enough, with a long handle to keep the heat of the metal away from the person holding it. For bigger castings and in steel mills, it can run on wheels, a purpose-built carrying car or be slung from an overhead crane. Ladles are most commonly made of fabricated steel. The most common shape is a vertical cylinder, but other shapes are possible: the most common of these is known as a 'torpedo' ladle, is shaped as a horizontal cylinder suspended between two bogies, and is commonly used to transport liquid iron from a blast furnace.

Between the molten metal and the steel shape is a refractory material that may be from 1mm (0.04") to 150mm (6") thick or more. The refractory material protects the steel shell and acts as a thermal barrier to contain the heat. Ladles can be either open-topped or covered. Covered ladles have a (sometimes removable) dome-shaped lid to contain radiant heat; they lose heat slower than open-topped ladles Medium and large ladles which are suspended from a crane have a bale which holds the ladle on bearings, called trunnions. To tilt the ladle a worm gear mechanism is used, which tilts the cylindrical shell while the bale carries the weight. The gear mechanism may be hand operated with a large wheel or may be operated by an electric motor or pneumatic motor. Internal friction brakes are used to regulate the tilting speed of the ladle. The largest ladles are poured using a special, two-winch crane, where the main winch carries the ladle while the second winch engages a lug at the bottom of the ladle. Raising the second winch then rotates the ladle on its trunnions.Some ladles are designed for special purposes such as adding alloys to the molten metal. Ladles may also have porous plugs inserted into the base, so gases can be bubbled through the ladle to enhance alloying or metallic treatment practices.

CONTINUOUS CASTING

The casting process employed in the industry is continuous casting arrangement commonly known as con cast carries it out. In this casting process, the ladle from ladle roof furnace containing 30 tons of molten charge is held at the top of the con cast arrangement.Continuous casting, also called strand casting, is the process whereby molten metal is solidified into a "semifinished" billet, bloom, or slab for subsequent rolling in the finishing mills. Prior to the introduction of continuous casting in the 1950s, steel was poured into stationary molds to form ingots. Since then, "continuous casting" has evolved to achieve improved yield, quality, productivity and cost efficiency. It allows lower-cost production of metal sections with better quality, due to the inherently lower costs of continuous, standardised production of a product, as well as providing increased control over the process through automation. Section such as: round, rectangular, square, hexagonal, fear toothed, and the process can produce many other forms. The process is mainly employed for copper, brass, etc. and increasingly with cast iron and steel. Since the mould is an open cylinder of the required cross-section, a metal block must be placed at the lower end of the mould to support the steady state of thermal equilibrium that the casting solidifies before leaving the mould. The mould is cooled by circulating water.

CONTINOUS CASTING IN DETAIL

The casting process employed in the industry is continuous casting process. It is carried out by using continuous casting arrangement commonly known as cone cast. In this casting process, the ladle from ladle roof furnace containing 30 tons of molten steel is held at the top of the billet casting machine. The tundish allows a reservoir of metal to feed the casting machine while ladles are switched, thus acting as a buffer of hot metal, as well as smoothing out flow, regulating metal feed to the molds and cleaning the metal Metal is drained from the tundish through another shroud into the top of an open-base copper mold. The depth of the mold can range from 0.5 to 2 metres (20 to 79 in), depending on the casting speed and section size. The mold is water-cooled to solidify the hot metal directly in contact with it; this is the primary cooling process.

1. Ladle 2. Stopper 3. Tundish 4. Shroud 5. Mold 6. Roll support 7. Turning zone 8. Shroud 9. Bath level 10. Meniscus 11. Withdrawal unit 12. Slab

A. Liquid metal B. Solidified metal C. Slag D. Water-cooled copper plates E. Refractory material

A lubricant can also be added to the metal in the mold to prevent sticking bring them to the top of the pool to form a floating layer of slag. Often, the shroud is set so the hot metal exits it below the surface of the slag layer in the mold and is thus called a submerged entry nozzle (SEN). In the mold, a thin shell of metal next to the mold walls solidifies before the middle section, now called a strand, exits the base of the mold into a spray-chamber; the bulk of metal within the walls of the strand is still molten. The strand is immediately supported by closely spaced, water cooled rollers; these act to support the walls of the strand against the ferrostatic pressure of the still-solidifying liquid within the strand. To increase the rate of solidification, the strand is also sprayed with large amounts of water as it passes through the spray-chamber; this is the secondary cooling process. Final solidification of the strand may take place after the strand has exited the spray-chamber. After exiting the spray-chamber, the strand passes through straightening rolls (if cast on other than a vertical machine) and withdrawal rolls. There may be a hot rolling stand after withdrawal, in order to take advantage of the metal's hot condition to pre-shape the final strand. Finally, the strand is cut into predetermined lengths by mechanical shears or by travelling oxyacetylene torches, is marked for identification and either taken to a stockpile or the next forming process.

In many cases the strand may continue through additional rollers and other mechanisms which might flatten, roll or extrude the metal into its final shape. Aluminium and copper can be cast horizontally and can be more easily cast into near net shape, especially strip, due to their lower melting temperatures. The refined molten steel is then transferred to continuous caster. Here, the steel is poured into molds, cooled and shaped into the desired cross section, essentially forming a long bar called a billet.

Billets at warehouse

The completed billets are used as the feedstock for our rolling mill or sold on the world market for use by other mills.

BILLETS AT BHUSHANBillets refer to a cast semi finished product. A Billet is typically cast to a rectangular, hexagonal or round cross-section compatible with secondary processing, e.g. Forging. It can be produced either as coil or cut lengths.

FURNANCEGRADETHICKNESS(mm)WIDTH(mm)LENGTH(mm)

ARCAS(Alloy Steel)

MS(Mild Steel)

CS(Cold Steel)

SS(Spring Steel)100/125/160/200

100/125/160/200

100/125/160/200

100/125/160/200100/125/160/200

100/125/160/200

100/125/160/200

100/125/160/200

1000-12000

1000-12000

1000-12000

1.75 to 50.40 to 0.50

INDAS(Alloy Steel)

MS(Mild Steel)

CS(Cold Steel)

100/125/160/200

100/125/160/200

100/125/160/200

100/125/160/200

100/125/160/200

100/125/160/200

1000-12000

1000-12000

1000-12000

ADVANTAGES:

High quality metal can be produced because it is protected from contamination while melting and being poured.Its yield in rolled shapes is about 10% more as compared to that from ingots. The physical properties and surface qualities are comparable to those obtained in other permanent mould processes.

CUTTING OF BILLET

Billets are cut in the required lengths by using the weight phenomena which is described as under:We know, weight= Vol. X DensityAlsoVol= Area X LengthNow as the weight of the product required would be known its volume and density are known, so we can cut the required length of billet of. Equivalent weight of the billet = Weight of product + 10% losses.

Billets proceeding to rolling millsREHEATING FURNACE

After the billets are marked and cut according to required length, the temperature of the billets falls below the rolling temperature. The hot rolling process begins by reheating the previously created billets in our reheat furnace until they turn into a "plastic" state.

Reheating furnance

Now to attain the higher temperature, the billets are made to pass through the reheating furnace. Reheating furnace has two zones namely Preheating in zone and Heating zone.

The billet continuously runs through these two zones along the bed. The preheating zone has one burner (oil and air charged) inclined position providing a temperature of 1000C. Now after this preheating, the billet passes to the heating zone which has two burners in horizontal position outside the other end of the furnace. This helps to attain a maximum temperature of 1250C. Finally the temperature of the billet length leaving the reheating furnace is 115C.

The oils used to produce heat in the burners can be of many types but in the said industry we particularly use: Furnace oil (FO) Refined Furnace Oil (RFO)

Cooling of billets

The burners used are A type West man. These are self proportional burners which makes air and oil in the required definite proportions themselves. Its height is very small as compared to its length.

The reheated billets exit the reheat furnace and proceed to one of our two rolling mills. Each rolling mill consists of a series of "stands", each containing a set of rollers that compress and lengthen the billets and then finish them into the desired shape (i.e., reinforcing bar, wire rod, one of the merchant shapes, etc). Water is used to keep the equipment from overheating.

Billets lying on cooling bed

The formed product is transferred to the cooling bed where it is allowed to cool before it is cut and bundled. In this photo, you can see straight lengths of reinforcing bar cooling. Hot rebar arrives on the right from the rolling mill stands and cools as it progresses to the left.

Billets at warehouse

The final bundled product is placed in warehouse or prepared for shipping. Most products are delivered as straight bars, however reinforcing bar can be delivered as straight bundles or coiled bundles.

LIFTING MECHANISM

Introduction

Overhead cranes are used in many industries to move heavy and oversized objects that other material handling methods cannot. These cranes have a railed support structure called a bridge, and a wheeled trolley that travels across the bridge horizontally. Several varieties of overhead cranes exist including gantry, semi-gantry, cantilever gantry, storage bridge and wall crane.

Design RequirementsAll overhead cranes are required to have characteristics to promote their safe use. The OSHA regulation specifies design requirements on the construction of the cab and its controls; footwalks, ladders and stairways; bridge and trolley bumpers; hoist. Holsing Trolley and bridge brakes, electrical components, hoisting equipment, and warning devices.

Inspection RequirementsDue to the large and heavy objects often being transported by overhead cranes, routine inspections are necessary to ensure continued operation of the crane and the safety of the employees around the crane. An initial inspection of the crane prior to initial use of new and altered cranes is necessary. Once placed into service, overhead cranes will require two different types of inspections. Frequent inspections are done at daily to monthly intervals. While periodic inspections are completed an monthly to annual intervals.

Initial inspection

Items to be inspected Hoisting and lowering Trolley travel Bridge travel Limit switches, locking and safety devices Load test of not more than 125% of rated load.

Periodic Inspections

Deformed, Cracked or corroded members Loose bolts or rivets Cracked or worn sheaves and drums Worn, cracked or distorted parts such as bearings, gears, rollers, etc. Excessive wear on brake system parts Inaccuracies in load, wind and other indicators Electric of fossil-fuel motors Excessive wear of chain drive sprockets and chain Deteriorated electrical components such as pushbuttons, limit switches or contactors.

Frequent Inspections

Items to be inspectedFrequency

Operating mechanisms for maladjustmentDaily

Deterioration or leakage in pneumatic and hydraulic partsDaily

Hooks with deformation or cracks (visual)Daily

Hooks with deformation of racks (written record with signature of inspector and date)Monthly

Hoist chains and end connections for wear, twist of distortion (visual)Daily

Hoist chains and end connections for wear, twist, or distortion (written record with signature of inspector and date)Monthly

Running Rope and end connections for wear, broken strands, etc. (written record with signature of inspector, rope identity and date)Monthly

Functional operating mechanisms for excessive wear As needed

Rope reeving according to manufacturers recommendationsAs recommended

Operations

The manufacturers instructions must be followed when operation the crane. Attach the load to the block hook by means of slings or other approved devices; making sure the sling is clear of all obstacles. Once the load is properly secured and balanced in the untwisted sling, slowly raise the load. Horizontal movements must also begin slowly to prevent the load from swinging or coming into contact with other.The crane warning signal or horn must be sounded when the load or hook comes near or over personnel. Carrying loads over personnel is not recommended. A load should not be left suspended. Audible and discernible voice communication should be kept with the operator at all times. If this cannot be accomplished, a signal system should be used. Standard signals as shown on the next page; however, it may be necessary to create special signals in certain circumstances. In these circumstances, the signals must be understood and agreed upon by all individuals using the crane.

OXYGEN PLANT

The oxygen gas which is required for oxidation, cutting and other purposes is produced in the factory itself. For this purpose, there is a separate installation in the factory called OXYGEN PLANT. The oxygen produced in this plant is not only for in house use but it is also sold in the market in the form of oxygen cylinder used in hospitals. In addition to oxygen, nitrogen gas is also produced which is also used in hospitals. In addition to oxygen, nitrogen gas is also produced which is also used in house as well as is sols in the market.Oxygen plant is a much planed section. It has four main elements namely:(a) Air compressor(b) Cooling section(c) Air separation unit(d) Oxygen and nitrogen bank

AIR COMPRESSOR:It is an electrically operative, five stage reciprocating air compressor. Water cooling system is used for its cooling. Servo press oil is used as lubricant is each stage. At the end of the last stage, a drain valve is present which separates water from the compressed air. It works on the principle of Boyles Law i.e., temperature through out the system. The atmosphere air is sucked in the compressor and is compressed to a pressure of about 85 times more than the atmospheric pressure. Before passing air through the compressor, it is first of all filtered for removing dust particles and other impurities.

THE SPECIFICATIONS OF THE ARIR COMPRESSOR ARE: -

Speed:510 rpmMaximum air pressure :210 kg/cmPower:325 hpCylinder bore:370 mmNumber of stages:5Compression ratio:85:1Capacity:155m/hr

COOLING UNIT:

The purpose of this unit is to reduce the temperature of compressed air coming out from the air compressor. This unit is connected to the outlet of the air compressor. The temperature of the compressed air leaving the compressor is 35 degree Celsius. To reduce this temperature, heat exchanger is used in which frozen gas acts as a cooling agent. The Freon gas acts on this compressed air to maintain a constant temperature of 25 degree Celsius. After further cooling, the temperature of air finally discharged from this unit is 4 C.

BATTERY OR DRIER:

Two batteries are used in the arrangement. Each battery works for 12 hours and is charged for the remaining time. So we see that the two batteries work alternatively. The function of using battery is to remove moisture and carbon dioxide gas from the cooled air. Two chemicals namely molecular seap and caustic soda may be used in batteries but in the said plant we use molecular seap.

AIR SEPARATING UNIT:

Ideally, it is said that carbon dioxide has been completely removed by the battery. But actually a small amount of it is left in the air. Now this dry air with small part of carbon dioxide enters the air separating units. The principle on which this unit works is known as Throttling Law. It states that if a gas is allowed to pass through a small hole, the temperature of it gets reduced immediately by sudden expansion through this opening.

THE VARIOUS PRESSURES PRESENT INSIDE THIS COLUMN ARE:

(I) Pressure at top column top:1.875 kg/cm(II) Pressure at top column bottom:0.38 kg/cm(III) Pressure at bottom of column:9.4 kg/cm(IV) Pressure of oxygen outlet:120 kg/cm

THE TEMPERATURE AT WHICH THE GASES LIKE OXYGEN, NITROGEN ARE OBTAINED IS STATED AS:

(A) Carbon dioxide:-78 C(B) Oxygen:-182.5 C(C) Argon:- 185 C(D) Nitrogen:-196.5 C

OXYGEN AND NITROGEN BANK

The oxygen, nitrogen and other gases obtained at the specific temperatures are collected in this bank. It consist of three valves namely as Oxygen valves-It is is operative to charge oxygen gas in the cylinder. Nitrogen valves- It is is operated to charge nitrogen gas in the cylinders. Main expansion valve-It is operated to discharge carbon dioxide, argon etc. gases from the plant into the atmosphere.

THE ROLLING PROCESS

The process of plastically deforming metal by passing it between two rolls is known as rolling. The two rolls revolving in opposite direction i.e. clockwise and anticlockwise are spaced such that the distance between them is somewhat less than the height of the section entering them. The work piece is subjected to high compressive stresses (pressures) squeezed into the gap between the rolls (roll gap). Surface shear stresses develop due to friction between the rotating rolls and the work piece. The frictional forces help in dragging the metal into rolls. The work piece is delivered out with reduced cross sectional area and increased length.

Hot and cold rolling: -

All processes of plastic deformation can be classified as hot or cold working. This refers directly to the temperature but to the temperature relative to recrystallisation temperature (tr) of the metal hot refers to the processes about (tr) and cold to processes below (tr).The recrystallisation temperature of metal is estimated by Tr = 0.6 tmWhere tm = absolute melting temperature Tm = C melting point + 273 C

HOT ROLLING PROCESS

Forces in rolling:

Radial forceThe radial force Pr acts outwards to radius. It is caused by rotation of rolls.

Friction forceThe friction force F acts tangentially to the rolls.

Rolling loadRolling load (P) is the vertical component of the radial force Pr and it is the compressive force for rolling deformation.

Roll separating forceThe roll separating force is the reaction of work piece of the rolling load. It is equal and opposite of the rolling load. Thus, as opposed to compressing the work piece, it causes separation of the rolls. The angle of bite is the angle between entrance plane and center lines of roll. Hence higher frictional force allows bigger angle of bite.

Advantage of high temperatures(1) Lesser resistance of deformation lesser rolling load(2) More rolling passes are possible as matter remains hot for more time.

Disadvantage of high temperature(1) Higher scale loss in furnace and roughing stand.(2) Higher fuel consumption in the furnace to achieve higher temperature.(3) Chances of grain boundary oxidation of steel i.e. burning.(4) Normally higher temperature is preferred for alloy steels rolling or for high rolling speeds.

Rolling defects causes and remedies

Fins and overfills: -These are protrusions formed when the section is too large for the pass it is entering, or when proper allowance has not been made for lateral spreading in the rolls. Overfills are broad and less sharp than fins. As per rule, overfills occur more frequently than fins and in many cases are associated on the same bar with under fills. To avoid fins and overfills proper proportioning of section and pass hence to be done. Proper allowance for lateral spreading should be given.

Underfills: -These are the reverse of overfills. Underfills appear most frequently on round and channels. To avoid underfills proper proportioning of the section with respect to the size of pass should be done.

Seams: -There are crevices in the steel that have been closed but are not welded. They are type of defect very difficult to detect on certain type of steel product. Blow holes or cracks in the original ingot or cause seams by faulty methods of rolling in both semi-finishing and finishing mills. To avoid these only internally sound ingots, which are free from blow holes or crevices should be used.

Laps: -These can be said to be rolled- over condition caused by a bar having been given a pass through the rolls after a sharp overfill or fin has been formed, causing the protrusion to be rolled into the surface of the product, Best remedy to these is to avoid fine and over fills.

Fire creck:-These are impressions in the product, of varying degree and pattern, caused by mill rolls becoming overheated, and cracking or spalling. Proper cooling of rolls at proper water pressure etc should be provided.

Scratches: -These are long nicks or indentations in the product caused by the surface of the bar rubbing against sharp or pointed objects such as guides on the mill, chutes, dead conveyor or rolls, chain hoists or other mechanical equipment. Any sharp or pointed edges of the equipment, which may hinder the movement of the bar, should be avoided.

CHEMICAL TREATMENT

After obtaining the desired sized rolled product by using rolling mill, these products are made to pass through chemical treatment. This process is carried out in two steps:

SULPHURIC ACID TREATMENT:As we know that sulphuric acid is a highly reactive agent, so it may cause decomposition of the rolled product. In order to neutralize its effect, we dip the acid treated roll product in the soda ash solution.

CHEMICAL LABThe chemical lab is an integral part of the industry. It is the heart of the plant. This is used to carry out chemical analysis on the products. The analysis is done by using two apparatus: - WET APPARATUS: This is used to carry out gravimetric analysis making use of burret, pipette, flaks, etc. SPECTROMETER: It is an analytical converter which gives information about the chemical composition of base metals like iron, copper, zinc and lead.It consists of 36 channels thereby giving composition of up to 36 alloying elements of product. It is a modern machine employed having cost of about 50 lakhs imported from a company named Polyvac analytical.In the spectrometer test, the samples taken are first of all super finished by the available equipment. Now this sample is placed on the spark stand of the machine. The sample is covered from all the sides using the cover, now the power supply is given to the machine. The electrode present inside the machine would produce a highly dens spark on the surface of the sample. This extremely dens spark would distort the sample at a very small section. A lens is present in the path of these spark would distort the sample at a very small section. A lens is present in the path of these sparks which would results in rays. Now with the help of grating (diffuser) these rays are differentiated by photo multiplying tools, commonly known as PMT present in the machine. Spectrometer would give the intensity of rays of different colored wavelengths. CHEMICAL RESULTS:- Depending upon the spectrometer analysis and wet analysis,the chemical composition of mild steel is stated as:MILD STEEL: - Carbon = 0.05 to 0.2%Manganese= 0.3 to 0.5%Silicon = 0.1 to 0.35%Impurities (S&P) =>.05% eachVarious alloyed steels are also present having many alloying elements like nickel, chromium, molybdenum, vanadium, tin,etc.AUTOMATION OF ROLLING MILLBRIEF DESCRIPTION:In the rolling mill the billets which are formed on the other side plant (in the furnace portion) are used for making the required amount of solid pipes to be supplied to the customers.Now see that in this rolling mill the layout is as shown:DRIVE MECHANISMFOR THE WORKING OF ROLLING MILL

5 STAGES ROLLINGMILLCOOLING BEDTO QUALITY DEPAERTMENT

LAYOUT OF ROLLING MILLIn this layout as shown above, the strength of the workers is 34 except one head foreman. 4 fitters 1 welder 2 helpers Now in the rolling mill there is total strength of 34 workers at the work place except the skilled work force. Now in this the detailed description of the workers, work and their numbers is as under. workers use to bring the billets, which are being placed there. 2 workers use to pick the billet piece, which is nearly 75-80 kg in weight, and bring it to the pusher bed. Then during this time a lot of time is wasted as the worker brings the billets from outside to the pusher bed. 1 worker is used to operate the mechanical pusher, which pushes the billet placed on the pusher bed into the furnace. The second position is of the place for the exit of the furnace. Here the billet placed on the pusher bed into the furnace, after being red hot is ejected out from the furnace. These workers are called Toun men. Now see there are 3 toun men here and they guide these red-hot billets into the 1 stage of 5 stage of rolling mill. There are 18 workers on this 5 stage rolling mill, the workers for the spray of additional coolant and other 4 to pull the long pipes and to let it to heat, the place called the quality door.

AUTOMATION

The automation of the above described rolling mill is done with the help of the sensor objector pusher, magnetic crane, belt conveyors, automated guided conveyors etc. Now this done on the basis of the time study as described below.Time taken by a worker to bring a bunch of seven billets and to put them on the pusher bed is 15 min. With the help of automation (use of magnetic crane) the time gets reduced on the pusher bed. Now with the introduction of a magnetic crane the number of workers gets reduced from 7 to only 1 (who operates the magnetic crane).Now, the second place where there is 3 workers (toun men) i.e. the outlet place for the furnace, there is placed a sensor ejector pusher. In the pusher when the billet after gets red hot comes in the front of the ejector, then the sensor detects the billet and then automatically pushes the billet out of the furnace and placed it on the guided conveyor. The thrown out billet is then be put on the guided conveyor and this is to guide the billet to the 1 stage of high stage rolling mill. Then again after the billet is worked on at the 1 stage, then the billet is received by chain conveyor and then is as such guided to the different stages. There is a hydraulic riser and pusher required to raise and push the billet by certain height so as to place it into the final finishing roller.Then there is a hydraulic riser and pusher, its working is as such a worker pushes the paddle, then the fluid induces pressure to make the billet to raise and other one to push it to the roller.Then the billet is finally be pushed to the cooling bed where there is a chain conveyor and the coolant sprinkles which are used to cool down the billets this is the methodology with which the rolling mill is automated.

OPERATIONSOLD TIMENEW TIME

Unloading of billets at the15 min4 minPusher end

The time taken by furnace7 min7 minTo make the billets red-hot

The work performed on 6 min4 min5 stage rolling mill

Work on cooling bed5 min2.5 minFor the cooling of pipes

Total time33 min17.5 min

RESULT: -

The number of workers gets reduced from 34 to only 2. The time now required to provide a bunch of 7 solid pipes from the 7 billets is reduced from a time of nearly 33 min to 17.5 min.

BIBLIOGRAPHY1. MANUFACTURING PROCESSVOL: I BY SH. O. P. KHANNA2. ELEMENTS OF WORKSHOP TECHNOLOGY.VOL: II MACHINE TOOLSBY: S.K. HAJRA CHOUDHURY3. COMPANYS WEBSITEwww.bhushan-group.orgwww.google.com Nikhil Sharma, C09133Page 37