Amreli Steel-Internship Report-Yaseen Raza

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2012
Yaseen Raza
NED University of
Engineering and Technology
INTERNSHIP REPORT

YASEEN RAZA NED University of Engineering And Technology | 2
INTERNSHIP
REPORT
SUBMITTED TO
MR. Abdul Latif Bhano
MANAGER PRODUCTION
SUBMITTED BY
YASEEN RAZA (MY-50)
NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY
BATCH: 2009~2010
DURATION: 05TH
DECEMBER 2012 TO22ND
DECEMBER 2012

ACKNOWLEDGMENT
Starting with the name of Allah who is the most merciful and
beneficent
My report work has accomplished under excellent guidance and
supervision of production and management team of Amreli
Steels Limited, SMS Dhabeji. I offer my heartiest gratefulness
to ASL team for its step to step guidance and close supervision
during the conduct of all the period of internship at ASL.
No acknowledgement could ever adequately express my
obligations to my affectionate parentsfor their all inspirations
and guidance which always motivated us to carry ourselves
through the noblest ideas of life and solving all troubles and
boosted my moral to fly high to accomplish our goals.
I convey special thanks to my dear class adviser MR
IFTIKHAR AHMED CHANNA, NED Universityfor his
excellent, efficient, accurate and reliable help to completion of
this internship as well as completed our report.

I also convey special thanks to
SMS plant Planning & production team
MR Noman Sajjad (Executive Manager)
MR Inayat Ullah Baig (Maintenance Manager)
MR Abdul Latif Bhano (Production Manager)
MR Hammad Ali (Manager Planning& Development)
MR Sohail Mumtaz(Deputy Manager, Mechanical)
MR Abdul Majeed Jagirani (Deputy Manager, Electrical
MR Muhammad Farooq (Assistant Engineer,Mechanical)
MR Zaigham Masood (Shift Incharge IF)
MR Kamran Memon (Shift Incharge LRF)
MR Adnan (Asst Engg Ref)
MR Alam (AsstEnggIF)
MR Naeem Khatti (Shift Incharge CCM)
MR Said Haneef (Incharge QC)
MR Qadeer (Incharge QC)
MR Zubair (InchargeUtility)
MR Sarfaraz (Trainee Engg)
MR Ammar (Trainee Engg)
Mr Zeeshan Moeen (Ass. Engg Vezzani)
Mr Noman Amjad (Trainee. Vezzani)

INDEX
Sr. No Plant Description PG.NO
1 ASL Process flow chart 6
2 Introduction 7
3 Raw Material
 Types
 Vezzani
8
4 Steel Melt shop (SMS) 9
5 Induction Furnace
 Furnace specification
 Furnace Operation
 Furnace Lining
 Furnace Crucible
 Furnace Control
 Furnace Slag
10-14
6 Ladle Furnace
 Ladle lining
15-16
7 Continuous casting
 Process
 Mold Body
 Operation modes
 Metallurgical Length
 Calculations
 Cooling zones
 Liquidus Temp
 Carbon equivalent
16-20

8 ASL Grades and Composition 21
9 Slag Processing Area 22
10 Quality Control
 Spectro lab
 Wet Lab
24-25
11 Logistic and Stores 25
12 FES (Fume Exhaust System) 25
13 Reverse Osmosis Plant (RO) 26

Scrap
Scrap Yard
Vibratory Feeder
Scrap Area
Charging
Vessani Shear
LRF
Transfer trolley
Melting
Spectro Lab
Deslagging
Continuous casting
Billets
Induction Furnace
Shearing of
Oversize scrap
Quality Control
Heat taping
Wet Lab
Slag processing
area
Temperature
check
Billets stock
area

INTRODUCTION
Company`s Profile
The Company was incorporated in Pakistan as a private limited company under Companies
Ordinance 1984, to take over from partnership firm doing business in the name of Amreliwala
Hardware Industries. Prior to 1984, the Sponsors were operating manual re-rolling mills to
manufacture mild steel bars. These rolling mills were dependent for raw material on sponsor-
owned ship breaking business.
The Sponsors are in steel business for many decades; because of this exposure and experience
the family was able to foresee the advent of strong demand in quantity and quality of steel bars.
To cater to this, all manual rolling mills were scraped in 1984 and fully automatic plant of
Danieli brand was imported and installed with production capacity of 35,000 tons, the capacity
of which over the years was increased to 75,000 tons.
Amreli Steels has been in steel business for decades and have earned a respectable name in the
business world through commitment to its customer by providing the best quality product and
adherence to the corporate and ethical principals in conducting business operations. Amreli
Steels is one of the few steel bar manufacturers that used billets of Pakistan Steel Mills as raw
material for its hot rolling process. Good quality billets and advanced automatic manufacturing
facility with professional and motivated team has given Amreli a competitive edge over its
fellow manufacturers.
This report will cover the areas of
 Induction furnaces (IF)
 Ladle Refining Furnace (LRF)
 Continuous Casting Plant
 Refractory Shop
 Utilities
 QC
Which I learned during the internship.
Amreli steels limited produce
 High strength Xtreme bars conforming to BS 4449:2005
 Hot rolled deformed bars conforming to ASTM A615
Above grade reinforcedsteel bars from high quality billets. These billets are produce through
continuous casting process. Induction furnace is used to melt the scrap, which is the prime raw
material for producing desire melt.

RAW MATERIAL
Scrap is the prime raw material used for producing quality melt. This scrap is imported from
UAE and India. It is then transferred to scrap yard through containers from port. As per
requirements, different types of scrap are used. They are classifies as
 HMS
Heavy Melting Scrap is a designation for recycled steels. Its size is above 600mm. It is
divided in two categories
HMS-1: Consists of non-galvanized parts, engine blocks, some Aluminum and Copper
parts
HMS-2: Consists of galvanized parts etc.
HMS: Soft scrap like sheets, pipes etc.
 SHREDDED
Consist of small parts, crushed scrap. Size is below 600mm
 BUNDLED
LMS: Light Metal Scrap
UBC: Used Beverages Canes etc
GI: Galvanized sheets or parts are Bundled scrap
20% HMS, 30% shredded, 25% bundled and remaining 25% mix scrap is used. As per
requirement, scrap is transferred from yard to scrap bay through dumpers. Scrap size more than
600m is first shifted to Vezzani shear for shearing than to melt shop.
VEZZANI SHEAR
Vessani shear is used to perform shearing of oversized scrap. Crane is operated manually. Scrap
is charged over a taper plate of vezzani at the end of which there is a ram. Scrap is compressed
first by horizontal ram then by vertical ram and shearing blade shear the scrap to size of
600mmthen the gate is opened. it is then passed over a vibrating conveyer, it consist of a
magnetic drum. It is 1/3rd
magnetic so it attract ferrous scrap and nonferrous scrap like
aluminum, copper etc fell down on debris conveyer belt.
From scrap car it is transferred to furnace floor i.e. vibratory feeder. Vibratory feeder is used to
feed scrap to the furnace crucible at a rate of about 400kg/min. its surface is slightly tapper so as
to allow easy feeding

SMS- STEEL MELTING SHOP
Steel melt shop consist of:
 Two induction furnaces (IF) each with 2 crucibles
 Ladle Refining Furnace (LRF)
 Continuous Casting Plant
 Ladle Preheating area
 Refractory Shop
 Slag processing Area
INDUCTION FURNACE
Induction furnace is an electrical furnace which utilizes electricity as fuel. Electromagnetic
heating is used to melt the scrap in the crucible. Copper coils are used which acts as primary and
generate low voltage high current in secondary (scrap). Alternating current(A.C) passes through
it and magnetic flux is generated within conductor.The magnetic flux generated eddy current that
enables the heating andmelting process in the crucible.

FURNACE SPECIFICATION
 Power requirement: 10MW
 Melting transformer: 12 MW
 Sintering transformer: 1.2 MW
 Capacity: 25-30 MT
 Current: 2000A
 Voltage :3670V
 Frequency : 192Hz
 Temperature :960-1620o
c
There are two crucibles for each furnace. One crucible is on melting operation and another is on
sintering operation. Crucible is changed after 12-15 heats
FURNACE LINING
Lining of If is acidic because of acidic slag formed. Quartzite lining also called acid ramming
mass is used as lining material and boric acid as binder.
It consist of
a) SiO2 -98.5%
b) Al2O3 – 0.02%
c) Fe2O3 – 0.02%
d) Boric acid ((H3BO3) 1-1.2%
Preheating is done to 90o
c for removing moisture. 70% grain and 30% powder is mixedin mixing
mill, 1.2% boric acid is added then transferred to bin then to floor. Cooling of furnace is carried
out through blower for about 6 hrs and then lining is breakout in 3 hrs. Pneumatic drills are used
for this purpose, after breaking the lining, furnace is tilt and waste is thrown down in pot.
Mixture is heated to about 90°c.
Former is used to prepare efficient lining. Two types of former are used.
 ASL Former: It is consumable former made of low carbon steel sheet. Lining is
placed layer by layer and rammed through pneumatic hammer. In ASL former 11 layers
of lining are placed because former is melt able and after melting a fine lining surface is
obtained.
 Chinese Former: It is non-consumable former. In Chinese former 24 layers of lining
are placed because former is removed after lining and close accuracy of lining is
required. When it is removed, patching is done.

Sintering
Sintering is performed after lining so that the binder get hold strongly the acid riming mass and
to induce strength in lining. The greater the time greater will be the strength.
Sintering time (hrs.) Power (KWH) Crucible state
2 125-175 Empty crucible
1 300-450 Filled with scrap
1 500-600
1 650-800
1 850-900
1 900 or above
FURNACE CRUCIBLE
Induction furnace crucibles are made of highly conductive hollow, rectangular copper tubes. 12
pairs of copper coils i.e. 24 coils are mounted rigidly. Also there are 3 SS coils at the top and 4
SS coils at the bottom to facilitate cooling. SS is used because it has high oxidation-resistance,
corrosion resistance and wears resistance.
Induction Furnace Coil

This coil is coated with AH60 refractory material in order to protect from moisture etc.
First coil is painted with a special paint. Each copper tube is then wounded with glass tape.
Scandium blocks are place with the gap between the copper tubes. Then finally it is painted with
resin and aluminum coating.It is then dried in air.
FURNACE CONTROL
Total power supplied to ASL is 63MVA
Total power consumption of both furnaces is 25MVA
Generator room, Crucible room and operating room control all operations on IF.
Generator room consists of:
 DC chock: converts AC to DC. Input is 600V x 4 = 2400V, four Converters are used.
Output is 3600V. Inverter convert DC to AC, in this way we can control (inc/dec)
Frequency
 DM unit:
 Capacitor unit: Capacitor bank is usedto maintainpower factor. Eight capacitor are used,
each consistof 2,4 capacitors respectively. if p.f increases above 1, first 8th
capacitor trip
then 7th
and so on to maintain p.f 0.98-0.85
 ITC-control inverter
 Turnover voltage cct – detect problem and trip furnace in case of problem
 Earthling cct, ET-SL, PLC etc. are other controlling units
 Hydraulic power pack: Provide pressure of 6 bar, (single acting cylinders) used for tilting
furnace
 RTT sensor – Shows temperature
 ELC machine: Filters magnetic particles from hydraulic oil.
Operating room controls power flow, current voltage, etc.
FURNACE OPERATION
Initially shredded scrap is charged because it can melt easily, quickly and efficiently and forms a
conductive molten pool of metal. About 15 tons is added initially, after melting of this first
sample is taken from furnace and analyzed for composition. On the basis of this result, further
scrap is added to control compositions of elements. On this basis HMS or bundled etc are added.
If composition is not accurate different alloying additions are made.
SiMn - added to control % of Mnand Si
FeMn- added to control % of Mn
FeSi- added to control % of Si
Main elements in the melt are carbon, silicon, phosphorous, manganese and iron.
Silicon increases fluidity and facilitate for ease of flow in casting.

Carbon induces strength and hardness as well as reduces ductility (If added in excess quantity).
Manganese induces ductility and wear resistance in the melt.
Deslagging
FURNACE SLAG
Slag of IF is acidic slag, because our lining is acidic. Basic slag will consume acidic lining very
rapidly. This acidic slag consist of
SiO2,Al2O3, FeO, MnO, P2O5
Fe+O2 ----- FeO
C+O2 ----- CO
Si+O2 ----- SiO2
Mn+O2 ----- MnO
2P+5/2O ----- P2O5
Excess of sulphur and phosphorous causes hot shortness and cold shortness respectively.

LADLE FURNACE
The ladle is a vessel used to transfer and pour molten metal from furnace to desire plant for
casting, refining etc.
Sometimes the ladle acts as a furnace normally used to heat up, and to hold different kinds of
metal melts. Heating is done either by graphite electrodes, Depending on metal, ladle size and
expected heating rate, electrical power of up to several megawatts may be applied.
LADLE FURNACE (top view)
Ladle Refining Furnaces are a proven technology used for producing alloy steel, desulfurizing
liquid steel and for improving the productivity from a steel plant. Ladle Refining is a post-
melting treatment that is after melting in the Induction Melting Furnace Whenever LRF is
installed online, liquid metal is transferred from the main melting source to the LRF at a nominal
tapping temperature and either Argon/Nitrogen is purged from the bottom apart from arcing
(using electrodes) on the top to bring about homogeneity of liquid metal composition and
temperature. Fused lime/CaSi is added to the liquid metal to reduce sulphurup to 0.015% and
bring it within acceptable limits
Ladle Refining of liquid metal is a proven technology to produce high quality steel. Ladle
Refining Furnaces (LRFs) are used to desulphurize steel, remove other impurities and hold the
molten steel for casting operations. Without LRFs, higher tap temperatures are normally required
from steel making furnaces due to heat losses during transfer and casting of liquid metal. LRF
facilitates higher productive time to the melting furnace besides producing better quality of steel
at lower cost.

When alloying is done in the LRF, the main melting furnace is freed from this activity providing
more productive time to the melting equipment and this external treatment has a few distinct
benefits like reduced alloy consumption, better lining life, excellent homogeneity of chemical
composition & temperature and relatively lower energy cost.
LADLE LINING
The total height of ladle is 2900mm and top, bottom dia are 2400mm, 2090mm respectively.
First lining of ladle is broken after 80 heats aprox. Bottom is prepared by Chrome Magnesite
bricks [chromite (40–50 percent or higher)]. QC well block and porous plug well block are also
placed and adjusted. Asbestos sheet (1000x1000x08mm) is placed. Safety lining of side walls is
done by Chrome Magnesite bricks.
There are for zones in ladle lining. Each zone consists of certain layers of refractory bricks
lining.
ZONE 1: Metal Zone 1-4th
layer using High Alumina bricks(175x154/146x100) and
(175x170/130x100) mm with Doloram as back filling mass
ZONE 2: Metal Zone 5-13th
layer using High Alumina bricks(150x154/146x100) and
(150x165/135x100)mm with Doloram as back filling mass
ZONE 3: Slag Zone 14-18th
layer using Carbon Magnesite (150x154/146x100) and
(150x154/146x100) mm with Doloram as back filling mass
ZONE 4: Free Board 19-22nd
layer using High Alumina bricks (250x150x100) mm
Zone
AH-90 paste (90% Al2O3, 4% CaO, SiO2+FeO) and SRA-95H (High % Al2O3) are used to fill gaps
and inner side of well blocks.

CONTINUOUS CASTING
Continuous casting is a process in which metal is cast in shape of billet, bloom or slab
continuously. Metal ore or scrap is melted in a furnace and then transferred to ladle. Here
refining, alloying additions if required are carried out. Ladle is then transferred to continuous
casting plant. Tundish dummy bar, mold tube, entry and withdrawal rolls, straightener, crop and
pinch, precutting roller table, discharge roller table, cooling belt, pusher, water spray nozzles,etc
are some of the parts of continuous casting mill.
Products obtained from continuous casting are mainly billet, bloom or slab. Heavy, four-piece
plate molds with rigid backing plates are used to cast large, rectangularslabs, (50-250 mm thick
and 0.5–2.2 m wide), which are rolled into plate or sheet. Similarmolds are used for casting
relatively square blooms, which range up to 400 x 600 mm in crosssection. Single-piece tube
molds are used to cast small, square billets, (100 - 200 mm thick)which are rolled into long
products, such as bars, angles, rails, nails, and axles.
Continuous casting

PROCESS
Ladle after metal being taped in it and after refining is placed on a stand above tundish. Bottom
of ladle consist of a slider gate assembly, which is operated hydraulically.
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. Capacity of tundish is 4 tons.
Before starting the casting process, dummy bar is prepared. A bolt is attached along with an
asbestos sheet and metal sheet with the dummy bar. It is used to hold and drawn out cast product
uniformly and accurately from mold. As the mold insert at the bottom, we add steel and iron
chips and some asbestos power for ease of solidification. There is 4 mm gap between mold tube
and jacket of mold for water circulation.
The process is started by plugging the bottom of the mold with a dummy bar. After enough metal
has solidified like a conventional casting onto its head, the dummy bar is then slowly withdrawn
down through the continuous casting machine and steady state conditions evolve. The maximum
casting speed of 1-5 m/min is governed by the allowable length. Once in the mold, the molten
steel freezes against the water-cooled walls of a bottomless copper mold to form a solid shell.
The mold is oscillated vertically in order to discourage sticking of the shell to the mold walls.
Drive rolls lower in the machine continuously withdraw the shell fromthe mold at a rate or
casting speed that matches the flow of incoming metal, so the process ideally runs in steady
state. The liquid flow rate is controlled by restricting the opening in the nozzle according to the
signal fed back from a level sensor in the mold.
Mold Body:-
 B
ase

plate
 Sincere or detector
 Mold jacket
 Mold tube
 Flanges
 Flange
 Cobalt-60
 Water Outlet
 Oil plate
 Water inlet
 Bottom plate
OPERATION MODES
There are four operation modes
 Test mode: in which equipment`s working like oscillation etc is checked out
 Casting mode: oscillation and withdrawal
 DBI: Dummy Bar Insertion
 Run out
The most critical part of the process is the initial solidification at the meniscus, found at
thejunction where the top of the shell meets the mold, and the liquid surface. This is where the
surface of the final product is created, and defects such as surface cracks can form, level
fluctuations can occur. To avoid this, oil or mold powderis added to the steel meniscus, which
flows into the gap between the mold and shell. In addition to lubricating the contact, a mold slag
layer protects the steel from air, provides thermal insulation, and absorbs inclusions.
Water or air mist sprays cool thesurface of the strand between the support rolls. The withdrawal
speed, mold level and water cooling are synchronized. The spray flow rates are adjusted to
control the strand surface temperature with minimal reheating until the molten core is solid.
After the center is completely solid (at the “metallurgical length” of the caster) the strand is cut
with gas torches billets of any desired length.
Gas torches move along the billet and cut at desire length. Fuel gas is LPG along with oxygen at
pressure of 2 bars. Launder pipe is used to open the nozzle, and then tundish is filled metal to
desire level. Tundish has two nozzles for two strands. Dia of nozzle pouring hole is 14mm. it is
made of 95% zirconium to avoid erosion

Metallurgical length
The length at which core of billet solidifies is called metallurgical length. Metallurgical length
depends upon the rate of cooling and speed of withdrawal or casting speed, temperature and
dimensions of billet. Temperature required for CC is 1510-1550o
c mold level is controlled by
Auto Mold Level Control (AMLC). 6/11 radius ratio is used for this continuous casting. 6 is
bending radius and 11 is unbending radius.
Calculation
Metallurgical length can be calculated by
L= (A2
/4k2
) x V
L = Metallurgical length
A = Crossectional Area
K = Constant
V = Casting Speed
Also it can be calculated by
S = K√ (L/Vc)
For 150 x 150 billet and speed of 1.2 m/min when constant = 30
Metallurgical length = [(150x150)2
/ 4 x (30)2
] x 1.2
Metallurgical length = 8.1 meters
Cooling zones
There are three cooling zones
 Spray ring
 Zone 1: consist of 32 nozzles
 Zone 2
Volume flow rate are different for different nozzles. Nozzle angle is same i.e. 65o
57-65
50-65
35-65
25-65

Liquidus temperature
Temperature at which steel starts to solidify is called Liquidus temperature. Liquidus
temperature is about 1512o
c. For carbon content (For %C < 0.5) it can be calculated by
Tliq (°C) = 1537 - 73.1%C - 4%Mn - 14%Si - 45%S - 30%P - 1.5%Cr - 2.5%Al - 3.5%Ni - 4%V
- 5%Mo
Carbon Equivalent
Carbon equivalent is a value used to predict the process of treatment to be performed on the
specimen, to predict the weldability etc.
Effect on weldability:
Upto 0.35 excellent
0.35-0.40 Very Good
0.40-0.45 Good
0.45-0.50 Fair
Above 0.50 Poor
Carbon equivalent can be calculated by
CE = %C + (Mn + Si)/6 +(Cr + Mo + V)/5 + (Cu + Ni)/15

ASL Grades & Composition
ASL Grade Billet
Chemistry(%)
CE Colour
Coding
Bar size to be
Rolled
Mold
Lubrication
BS 4449-3 C 0.20-0.24
Mn 0.55-0.65
Si 0.15-0.30
S <0.05
P <0.05
Max 0.35
For 3/8
Rolling
Yellow
Cut in 6m
905mm Oil/powder
BS 4449-1 C 0.18-0.26
Mn 0.60-0.80
Si 0.15-0.30
S <0.05
P <0.05
0.36-0.380
For Xtreme
Bars upto
25mm
Green
Cut in 6m
12mm, 16mm Mold powder
BS 4449-2 C 0.26-0.30
Mn0.60-0.80
Si 0.15-0.30
S <0.05
P <0.05
0.39-0.44
G-60 Bars
upto 25mm
Blue
Cut in 3m
19/22/25/28/32mm Mold powder
Special
Grade
C 0.22-0.25
Mn1.05-1.15
Si 0.15-0.30
S <0.05
no tolerance
P <0.05
0.41-0.51 To be
confined
40mm Mold powder
Special
Grade with
High
Carbon
C 0.30-0.34
Mn 0.60-0.80
Si 0.15-0.30
S <0.05
P <0.05
0.48-0.51 To be
confined
40mm Mold powder

Slag Processing Area
The molten oxide by-product obtained during smelting and refining is called slag. Oxides like
SiO2, Al2O3, P2O5 and B2O3 are acidic oxides. They form acidic slag. Oxides like MgO, FeO, and
MnO are basic oxides. They form basic slag
The slag, poured in slag pot is transferred to slag processing area. Here the slag is crushed first
into small size by labours. Then it is transferred to slag crushing area. It is transferred to hopper
then to conveyer belt. It goes to Jaw crusher, from where it goes to 2nd
conveyer belt. A magnetic
screen separates ferrous particles from them. Again it is passed to a roller crusher and crushed
parts are moved on 3rd
conveyer belt. Another magnetic drum separates iron contents and it fell
down. Slag particles transferred to 4th
conveyer belt and at last fell to stock area.
Quality Control
At ASL there are two laboratories for checking the composition of metal and billet, and also the
quality of water, silica sanded. Distilled water also produces here.
 Spectrolab
 Wet lab
Spectroscopy Lab
Spectroscopy is a terms used to refer to the measurement of radiation intensity as a function of
wavelength. Device used to measure the intensity of the radiation emitted is called spectrometer.
The energy of a photon is related to its frequency by
Where is Planck's constant.
Spectroscopy is a method to find out the composition of specimen by generating a spark on the
surface of sample. This spark makes the electrons move in an exited stage as a result they change
their energy. As they move to high energy state they absorb energy and when they come back to
ground state they emit energy in the form of radiations. This principle is used in spectroscopy.
Each element in a sample has its own radiation emission. A magnifying glass is attached which
magnifies these radiations and guide to their respective silts. In this way elements are detected.
Before starting this process, samples grind and polished, Grit size 36 and 60 paper is used.
Sample must be homogenized i.e. no trapped inclusions or slag, and it must be iron base for
proper conductivity.

Wet lab
Wet lab uses classical method of Volumetric, gravimetric, and instrumental analysis for
analyzing the metal samples, silica samples and water samples. It also produces Demineralize
water by electrical distiller at a rate of 5lit/hr.
Etching is done about 1/2hr for finding defects in billets like pin holes, pipes etc.
Moisture Content is find out by using electrical ovens i.e. %loss in weight after drying.
Loss of ignition (volatile matter, gases) of silica is finding out by using Box furnace. First silica
is heated to about 1000o
c, then cooled about 2-3 min in air then cooled in desigator.
Logistics and stores
At ASL, all the spare parts, extra equipment’s etc. is placed in store. In case of any emergency,
they may be utilized. Different sections are made for each plant. There are Refractory storage,
LRF, IF, FES, CCM etc. sections with their respective spare parts, nuts, bolts, pipes etc.
Whatever the parts are required are first undersigned on a paper by incharge and then give to
store incharge, he then handover the desire part to the worker. All details of store, i.e. item
entered in the inventory, items given, remaining stock, all are managed through ERP- Enterprise
Resource Planning.
Fume Exhaust System (FES)
Fume exhaust system is to exhaust the gases, dust evolving from induction furnaces.Scrubbing
the exhaust air prevents the release of aggressive and harmful vapors into the environmentan
impeller creates suction and transferred to air bags. These bags allow them to pass through but
dust, in which main content is zinc, does not pass through it, it is then transferred to hopper, from
where it is collected in bags.

Reverse Osmosis Plant (RO)
Reverse osmosis (RO) is a filtration method that removes many types of large molecules and
ions from solutions by applying pressure to the solution when it is on one side of a membrane.
The result is that the solute is retained on the pressurized side of the membrane and the pure
solvent is allowed to pass to the other side
Osmosis is a natural process. When two liquids of different concentration are separated by a
semipermeable membrane, the fluid has a tendency to move from low to high solute
concentrations for chemical potential equilibrium.Formally, reverse osmosis is the process of
forcing a solvent from a region of high solute concentration through a semipermeable membrane
to a region of low solute concentration by applying a pressure.
 There are 5 underground bores, among which 3 are in operation.
 Water is extract from here and transferred to pressurized vessel, which holds it. Some
suspended particles settle down and separated. There are 4 pressurized vessels
 Then it is transferred to multimedia filter tank.
 It filters water, suspended particles.
 Filter size is 30 microns.
 VFD – Variable Frequency Distribution: Controls, change frequency.
 This water is then transferred to Cartage filter in which it separates 5 microns
particles.
 Then membrane is used for final filtration of about0.03 microns. It consists of
biosites, anti scalant which kill bacterial effects. Electromagnetic Dosing pump is
attached along with this.
Suggestions
 Safety precautions are not followed. Therefore many accidents have been occurred.
Safety inspector must be appointed in order to check these precautions by workers,
engineers etc
 There are many health hazards because of evolution of gases, dust. Feeding of charge can
be done through vibratory feeder completely, because open feeding through cranes causes
problems like splashes dust evolution etc
 Training period for trainee engineers can be reduced to 4 months instead of 6 months,
along with their initial salary, which is somehow low.
 Scrap feeding can be done fron scrap yard to transfer trolley directly. It saves time,
because first it is transferred to scrap bay, then by EOT cranes to transfer Trolley.

Amreli Steel-Internship Report-Yaseen Raza

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