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  1. 1. Group-C
  2. 2. Members NAMES ID Nos. Bhargav Jha 2011B1A8867P Saransh Solanki 2011A2PS547P Tanuj Sen 2011A3PS723P Tanveer Singh Virdi 2011B2A8669P Trishu Dey 2011B1A7689G
  3. 3. Our Project
  4. 4. LD-2 & Slab Caster • concerned with producing different grades of Flat Products • Exs: automobile body application (including exposed) ,sheets for white goods ,LPG cylinders ,Tube Making, High tensile plates etc.
  5. 5. • Has 3 units PSM • Primary Steel Making SSM • Secondary Steel Making Slab Caster • Casts slabs with the material received from SSM
  6. 6. Primary Steel Making  molten steel primary refined steel  Process Description Hot metal from Blast furnaces brought in using torpedoes. unloaded in hot metal ladles (170 T) at the torpedo unloading pit
  7. 7. Desulphurisation  Unit – 3 Nos.  Capacity – 30 heats/DS/day  Co-injection process – CaC2 & Mag97 injection Raking  Unit – 3 Nos.  Slag raked off initially and after the DS Operation
  8. 8. LD Vessel Unit – 3 Nos. (2/3 Vessel in Operation) Capacity – 38 Heats/day/Converter Total Charge (Hot Metal + Scrap) Vessel Blowing The impurities (C, Si, P, Mn) are removed by blowing Oxygen through a Six hole lance at Supersonic speed.
  9. 9.  Online Purging Steel is tapped in a steel ladle capacity 160T, necessary additions are made with argon rinsing from top lance.
  10. 10. Secondary Steel Making Online Purging Caster Ladle Furnace RH Degasser
  11. 11. Slab Caster  Unit – 3 Nos. Capacity –80 heats; with 94 to 98% metal in mould  casting of molten iron into slabs of definite dimensions as required by different customers. Casting Continuous Batch
  12. 12.  Process of casting :  Turrets - To accept full ladle & to hold the ladle above tundish during casting  Driven by means of D.C. Motor  The ladle is equipped with a hydraulically controlled slide gate system.  Refractory tube shrouds - high Alumina graphite.  Mould - open-ended box structure, containing a water-cooled inner lining casted and machined from a high purity copper alloy  Tapered to compensate for the shrinkage of the shell  Oscillator provides necessary movement of the mould to prevent sticking of the strand shell to copper plates .
  13. 13.  Slab Marking – On-line 11 digit aluminium spray marker.
  14. 14. OVERVIEW OF SLAB CASTER  Mould – 900 mm (Copper coated mould, open ended, Indirect Cooling), oscillated by motor driven cams to reduce mould strand adhesion and the risk of breakouts.  RAM – Width change online 10 mm/min/side. The adjustment could be made either by electromechanically or hydraulically. The mould taper adjusted by gear mechanism.  Sec. Cooling – Spray type (Air Mist)  Section size – 950-1550 mm Wide;  210 mm Thick  Slab Length – 8-11 m  Slab Cutting – TCM (uses propane gas)  PINCH ROLL – Inserting dummy  bar and withdrawal during casting.  DUMMY BAR – Provides base in the  Mould Before casting & withdraw slab.
  15. 15. SYMS  Slab Yard Management System  automatic tracking of the slab  inspection of slab is done and surface defects if any, removed by scarfing
  16. 16. Entire Process : R-H Degasser O.L.P. (3)
  17. 17. Hot Strip Mill  a part of FP division  converts slabs supplied by LD2 & Slab Caster into Hot Rolled Coils, Sheets and Plates  Reduces the thickness of coils from 210 mm to about 1.2-16 mm
  18. 18. Process Flow Walking Beam Furnace  Re-heating the slabs  Mixed gas – coke oven+ BF gas+ LD gas  Calorific value 2700
  19. 19.  Slab support and movement inside the furnace through skids.  Four different zones of Heating Designed to heat till 1250oC.
  20. 20. High Pressure Descalers • High pressure water jets applied to remove scale formed on the metal surface during heating and rolling process.
  21. 21.  Roughing Mill  Main mill equipment  Comprises of
  22. 22.  Vertical Edger  A set of vertical rolls installed ahead of roughing mill to control the strip width.
  23. 23.  4 Hi Reversing Roughing Mill  Reduces thickness from 210mm to 20-40mm  Roller Tables  Types:
  24. 24.  Coil Box  an equipment which converts the flat transfer bar into coil and uncoil for feeding into Finishing mills  Temperature – homogenisation.  Reduces loss of heat of transfer bar between roughing and finishing mill.
  25. 25.  Finishing Mill  Roll the strip to a thickness of 1.6mm.
  26. 26.  Run Out Table  To carry the strip to Down Coiler.  Cool the strip to desired temperature at pre-defined cooling rate with Laminar flow of water from top and bottom.
  27. 27.  Downcoilers  serves to centre the strip before it enters the coiler.
  28. 28. Cold Rolling Mill  a part of the FP division  converts hot rolled coils (HR) into cold rolled (CRCA) and Galvanized coils  Reduces the thickness of coils from 2-6mm to about 0.27-3.2mm
  29. 29.  a capacity of 1.2 million tons per annum
  30. 30. Process Flow : After this the material is either coated in continuous galvanizing line (CGL) or to CRCA (cold rolled close annealed). Coupled Pickling and tandem cold mill where HCl pickling is done followed by 5-6HI rolls to reduce the thickness. Hot rolled coil from HSM is brought into CRM for cold rolling. Hot Rolled Coil PLTCM CGL - 1 CGL - 2 CRCA
  31. 31. Skin Pass Mill is for giving shape and surface finish to the product. In BAF the material is heated and then converted to the desired shape. Those which come from ECL are treated with alkali to remove iron fines from the surface. From CRCA the material is sent directly to BAF or via ECL. CRCA BAF SPM Direct dispatch RCL Dispatch ECL
  32. 32.  business objective :  ‘Improve product quality performance as per needs of the customer’.  reduce non compliance on products and improve process capability to meet customer’s expectations
  33. 33. LD#3 & TSCR  is an integrated department in TATA STEEL  has a capacity of 2.4 mtpa.  relatively new plant which was established in Feb 2012.
  34. 34. Process Flow Desulphurization • Sulphur decreases ductility and notch impact toughness especially in the transverse direction. Weldability decreases with increasing sulphur content.For above reasons ‘S’ removal is necessary. Primary Steel Making • Scrap Charging • Hot Metal Charging • Oxygen Blowing and Flux addition • Slag Off • Tapping • Slag Wash • Inspection Secondary Steel Making • Sample and Temperature • Purging: • Arcing • Desulphurization: • Ca-injection
  35. 35.  Twin Ladle furnace  one unit two ladle stands are placed side by side  common arcing facility  bottom purging process is followed
  36. 36. Thin Slab Casting  Continuous Casting  Less cost as  Less number of segments  No slab yard and cross transfer roller table car  No Deburrer and marking machine at caster  No roughing mill  Less equipment so lesser maintenance cost
  37. 37. Rolling  Tunnel Furnace  receive thin slab from respective casters  heat up the thin slab for uniform rolling temperature and conveys it from each caster line exit to the rolling mill entry.  Entry roller table  convey slab from furnace exit to mill entry.  Pendulum Shear  Chopping of the thin slab in case of failures in the finishing mill  Emergency cut
  38. 38.  Descaler  to remove scales from strip before it is rolled  For the descaling process the strip is transported at a constant speed through this box.
  39. 39. Finishing Mill  six four high finishing stands  two work rolls and two back up rolls.  reduced to final thickness  PCFC
  40. 40.  Circumferential strapping machine  Coil marking robot
  41. 41. Safety Guidelines Use Safety Appliances – Safety boots, helmet, fire- proof jacket etc. Beware of overhead cranes moving with load. Maintain safe distance from mobile equipments trucks, cranes, dumpers etc.
  42. 42. Be careful of spilled oil , grease on shop floor. Do not go in furnace area without an escort. Use crossovers for crossing
  43. 43. Thank You !