An Industrial Visit to Amreli Steels .docx

UNDERGRADUATE THIRD YEAR PROJECT REPORT
Department of Mechanical Engineering
NED University of Engineering and Technology
“A Visit to Amreli Steels”
Batch: 2021
Group Member Names:
Muhammad Huzaifa [ME-21189]
Huzaifa Rizwanullah [ME-21176]
Anas Ahmed [ME-21254]
Furqan Akhtar [ME-21314]
Approved by
……………………………………………………………………………………………...
Prof. MUHAMMAD SAEED
Lecturer
Project Advisor
© NED University of Engineering & Technology. All Rights Reserved – [Dec 2023]

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AMRELI STEELS LIMITED
Introduction:
Amreli steels is Pakistan’s largest selling brand of steel bars. They
operate steel billet and rebar manufacturing facilities that are the
largest in the country in terms of output and capacity.
Their competitive advantages include economies of scale, cost,
leadership, brand preference and country-wide distribution network.
A Brief History:
Amreli Steels roots can be traced back to the migration of the Akber Ali family to Pakistan after
partition from India. After settling in Karachi and entering the steel trade, the Akber Ali family
founded Amreli Steels and took a bold step to import and install Pakistan's first automatic re-
rolling mill to produce steel bars. The journey from thereon has been one of continuous
investment in technology, capacity and manpower to transform Amreli Steels from a small
family business to Pakistan's leading steel manufacturing entity
Amreli’s Major Projects:
 Jinnah International Airport, Karachi
 Allama Iqbal International Airport, Lahore
 Lucky One Mall, Karachi
 Benazir Bhutto International Airport, Islamabad/Rawalpindi
 Chashma Nuclear Power Plant, Kundian
 Fish Harbor, Karachi
 FTC Flyover, Karachi
 Gwadar Deep Sea Port, Karachi
 Hub Power Station, Balochistan
 Jinnah Bridge, Karachi
 Lucky Cement, Khyber Pakhtunkhwa
 Lucky Textile Mills, Karachi
 Lyari Expressway, Karachi

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 MCB Tower, Karachi
 Meezan Bank, Headquarters, Karachi
 Mirani Dam, Baluchistan
 National Refinery Limited, Karachi
 Northern Bypass, Karachi
 Ocean Tower & Mall, Karachi
 Port Grand, Karachi
 Serena Hotel, Islamabad
 Shaheed-e-Millat Flyover, Karachi
 Shaukat Khanum Memorial Hospital, Lahore
 US Embassy, Afghanistan
 National Stadium, Karachi
Maxima:
PRODUCT SPECIFICATIONS
Strength: 60,000 PSI
Ultimate Tensile Strength: 90,000 PSI
Size Designation: 10
Type of Steel: S 60 = Carbon Steel (A615/A615M)
Usage: Construction Reinforcement
Benefit: Earthquake Resistant
The composition of steel as per the standards of A615 grade 60 is
No Vanadium added (A) Vanadium Added (B) Niobium Added (C)
Cast Temp- Cast Temp- Cast Temp-
Superheat- Superheat- Superheat-
Element Wt.% Elem
ent
Wt.% Elem
ent
Wt.%
C 0.40 C 0.37 C 0.30
Mn 1.06 Mn 0.99 Mn 1.10
S 0.033 S 0.029 S 0.037
P 0.017 P 0.024 P 0.012
Si 0.18 Si 0.18 Si 0.24
Cu 0.48 Cu 0.31 Cu 0.36
Cr 0.22 Cr 0.23 Cr 0.16
Mo 0.06 Mo 0.08 Mo 0.05
Sn 0.013 Sn 0.011 Sn 0.018
Ni 0.21 Ni 0.17 Ni 0.15
Nb 0.000 Nb 0.000 Nb 0.012
V 0.005 V 0.025 V 0.003
Pb 0.000 Pb 0.000 Pb 0.004

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Ultima:
Ultimate Tensile Strength: 80,000 PSI
Tensile to Yield Strength Ratio > 1.25
Type of Steel: W60=Low Alloy Steel (A706)
Size Designation
Usage: Construction Reinforcement
Benefit: Earthquake Resistant in all Seismic Zone
The composition of steel as per the standards of A706 grade 60 is
Standards Grade Carbon Silicon Manganese Phosphorous Sulphur C.E.(%)
ASTM 706 60 0.3 max 0.5 max 1.5 max 0.060 max 0.045 max 0.055 max
C.E. (%) =C+(Mn/6) +(Cu/40) +(Ni/20) +(Cr/20) -(Mo/50) -(V/10)

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Xtreme:
Benefit: Up to 15% Consumption Saving as
Compared to ASTM 615 Grade 60 Bars*
Usage: Safely Weldable
Benefit: Earthquake Resistant**
Standard: Revised British Standard 2016
Type of Steel: G500 = British Standard, W = Weldable
Standards Carbon Manganese Phosphorous Sulphur
BS4449
G500 W
0.20
max
1.2 max 0.040 max 0.03 max

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Scrap Bay:
It can be defined as the facility to store the scrap metal that is used for melting and
manufacturing of steel. Scrap metal of large quantity are stored at pre-hand in these
warehouses or sheds. The scrap metal is of three types that are
Shredded scrap:
It is defined as the chunks of ferrous material that
has been shredded by the shredded that mainly
include shredded vehicle body and appliances and
other objects it is relatively smaller in size and is
easy to transport.
Balers Scrap:
These are the form of scrap that has been
compressed by the machines in a cube form these
balers scrap cubes mostly include pieces of sheets
and large metals objects that have been compressed.
Heavy Metal scrap:
This scrap is relatively larger than the other two
types of scrap and normally include ship metal and
ship blade and casing of the engines and other large
objects.

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Home scrap: (Jam)
It is the excess or the more steel that has been
generated and is often routed back to the
furnace and is melted again.
Cranes:
In Amreli steels, multiple types of cranes were used for different operations.
Grabber:
This crane is used to pick the scrap metal from the bundles in
front of the furnace and put it in the trolley that is used to hold
the scrap metal.
Magnetic crane:
The magnetic crane then magnetizes the scrap to hold it and
then they transfer it to the buckets.

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Buckets:
The buckets are then held by the hook cranes and the transfer the buckets to the top of the
vibratory feeder.
Vibratory Feeder:
After the sintering process, the metal is then transferred to the vibratory furnace where the
scrap materials are vibrated and poured directly into the freshly prepared induction furnace.
Where the scrap is melted with the outer lining of the furnace.

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Furnace:
The furnaces used in Amreli are the induction furnaces.
In induction furnace a coil carrying alternating current
surrounds the crucible a magnetic field will form due to
the current flowing in the coil due to which eddy
currents are induced in the charge. High frequency of
this current produces high temperature for the metals
which melts the metal inside the crucible.
There were four furnaces in Amreli steels having copper coils with water cooling operating at
the current frequency at 250 to 350 Hz and having the capacity of 30 metric tons. These have a
massive power consumption of 14000 Kilowatts.
In the furnace the metal is first melted and then it is heated to a temperature of 16000C to
16300C that is measured through a device called thermocouple. After melting the scrap, the
slag is removed by tilting the furnace.
A thermocouple is basically a temperature measuring device having two dissimilar conductors
that are in contact with each other at one or more spots. On these spots, temperature
differential is experienced by the different conductors or semi-conductors. After melting the
scrap, the slag is removed by tilting the furnace.
Sintering:
In the process of preparing furnace, copper coils are coated with the refractory material
named as coil coat AH-60. Then the lining process takes place after which the sintering of the
furnace takes place in which six magnets are added as end cuts. Then it is being supplied with
molten metal and a constant power supply of 800 Kilo watts, its temperature is maintained at
1700 o C so that it does not solidify and this state is being held for one hour after which the heat
is tapped.

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Ladle:
Ladle is a device used for the transporting of molten material.
In Amreli industries ladle is pre heated to avoid the sudden
cooling of molten steel by means of natural gas.
Sample testing:
After melting a sample test is conduct to determine the
composition of the molten material using spectroscope
machine, the sample is prepared through cutting, grinding
and polishing before testing on the spectroscopy machine.
Then the 2nd test is conduct after addition of additives.
After which the molten material is transferred into the ladle
using crane where the final test is conducted.
Process in Spectro Lab:
The process of composition testing takes place in the
Spectro lab where a spark of electromagnetic radiations
interacts with the molten metal and emit rays of different
frequencies that is read automatically to detect the
percentages of components present in the sample.
Alloys Used in the Furnace to meet the standards:
After testing the samples and comparing them with the standards, several alloys
are added to do adjustment in order to meet the standards and to fulfill the requirements.

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Alloy recovery Formula:
The addition of alloys is done in a calculated manner and its addition is formulized as under:
Weight % of Alloy = {[ Aim (Standard) – Actual (Sample)] * Tonnage (Capacity of metal
present in furnace)}/ Recovery (*)
Alloys used in Amreli Steels:
To Overcome Deficiency:
1) Ferro-silicate is added to meet the deficiency of Silicon or Iron.
2) Silico-manganese is added to meet the deficiency of Silicon or Manganese.
3) Ferro-manganese is added to meet the deficiency of Iron and Manganese.
4) Petroleum Coke is added to meet the deficiency of Carbon.
1) Ferro-silicate 2) Silico-manganese
3) Ferro-manganese 4) Petroleum Coke

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To Overcome Sufficiency:
To overcome exceeding percentages of the
constituents, Ferrous Oxide is added to decrease their
composition. The Oxygen in Ferrous Oxide oxidize with the
constituents like Carbon, Manganese, Silicon, etc. to form
their oxides in the form of slag that can easily be removed
from the molten material.
2FeO + Mn 2Fe + MnO2
2FeO + Si 2Fe + SiO2
2FeO + C 2Fe + CO2

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Continuous Casting Machine (CCM)

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Tundish:
Molten metal is transferred into tundish through ladle. It
acts as a reservoir. Then the molten metal is transferred into
tundish car for continuous casting purposes.
Mold Bodies:
Mold bodies in Amreli steels are made of copper with
chromium plating having length of 900mm. They are
designed to shape molten materials into the desired
shape of the billets. In Amreli steels the billets have the
constant cross section of 150mmx150mm with a varying
length ranging from 6 meters to 12 meters. There were
three cages each having a mold.
Primary cooling is done through the air in the
atmosphere. It is done to cool the outer surface or edges of
the molten billet while the core is still in the molten form.
After primary cooling the material is transferred to
horizontal table by the help of foot roller.

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Secondary coolingis done through water
to reduce the temperature of the entire billet.
Withdrawal:
Withdrawal has two purposes. Firstly, it pulls the
billets out of the mold bodies and secondly
straightens them. There is a metallurgical length that
is marked up to the point where the strand solidifies.
In Amreli Steels, the metallurgical length is 11 meters
long.
Rigid Dummy Bar Storage
(RDBS):
This mechanism is installed after the cage
system. Its work starts when the CCM machine is
restarted or the billet is supplied for the first time. It
pulls the billets and guides them to the roller ways.

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Pre-Cut Roller Table: (PCRT)
It consists of rollers that roll the billets before
cutting them in the desired lengths.
Auto-Cutter:
It is an automated cutter that cuts the billets into
the desired lengths. The billets were provided with
a spark that cuts them. In Amreli Steels, the
desired lengths range from 6-12 meters.
Discharge Roller table:
The billets are then split from the discharge table
where one line go for cooling and the other two go
for hot rolling where it goes for manufacturing of
steel bars.

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Over-head cross transfer:
It transfers the billet to the cooling bed.
Turn over cooling bed:
Here hot billets are cooled for further
processes.

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Weight Roller Table:
It weighs the rolling billets and rejects them if
their weight exceeds 2 tons.
Charging Roller Table:
It provides passage for the billets towards the
walking hearth furnace for heating.
Walking Hearth Furnace: (WHF)
Walking hearth furnaces are used for the heat treatment or pre-heating process of the
billets for hot rolling mechanism. Its process involved the transportation of the billets through
the furnace by means of a lift and shift mechanism that involves rollers that guide the billets
towards the Discharge Roller Table.

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Hot Metal Detector Sensors (HMD):
HMDs sensors are installed at various locations in the
assembly line through which the system automatically detects the hot
billet and controls its movement.
Discharge Roller Table: (DRT)
When the billets get pre-heated in WHF, then
the rollers in the furnace are automatically stopped by
means of a sensor called Hot Metal Detectors (HMD)
that sense the hot billets as soon as it reaches the exit
of the furnace, then the hot billets are transferred to
Discharge Roller Table through a lift mechanism.
Kick-Off Machine:
This machine is installed after the DRT. It
detects the temperature of the hot billets by means of
an HMD sensor and kick-off any of the billets having
temperatures less than 1150 degree Celsius (It is done
according to standards).
VR-O1 Roller:
After the billets get discharged, a roller way of 17 stands comprising of vertical and
horizontal rollers having VR-01 configuration gives the passage to the hot billets that
subsequently stretch between the rollers to transform their shapes in the form of bars
subsequently. After 17th roller an additional roller having same configuration is also installed
there for the embossing process of the Amreli steels symbolic pattern on the metallic bars.
There were two shearing cutters that were installed after stand 6 and stand 12 that cuts the
bars at instances when they achieve high speeds accidently that may become the cause of
failure in the assembly line.

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Quenching:
Vertical and Horizontal Roller Stands
Quenching process is a process that
increase toughness and bending power of the bars.
It is done by rapid cooling. In Amreli steels,
quenching is done by the reverse flow of water
against the movement of bars. This is the quality
enhancing process and it produces a martensite
layer on the bars that subsequently increases the
strength. The speed of water is set according to the
size of bars, for example bars having smaller
diameters are supplied with high-speed waters and
those having larger diameters are supplied with less
flowrates of waters.
Pinch Roll:
It is also a type of roller, that provides
passage to the bars by holding them which
increases the stability towards their high-speed
transportation. Also, they reduce the possibility
of vibrations in the bar transportation process.

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Dividing Shear:
The purpose of dividing shear is to cut
the bars according to the size of the cooling
bed. According to the size of cooling bed of
Amreli Steels, it marks the cut at 60mm. This
shear is generally installed before entry to
cooling bed and is driven by the direct DC
motor drive.
Aprons:
In the Rolling Mill Assembly line, aprons
are provided and their main purpose is to
feed and receive the bars. These aprons are
made of high strength as they bear the large
separating forces. The aprons need to be
quickly removed to eject the rolls from the
rolling mill.
Aligning Rollers:
The function of these rollers is to align the rebars into a
single assembly line.

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Chain Carriages:
Their function is to collect the
rebars and carry them in the form of
bundles.
Short Tail Removal Device:
When the rebars are being carried
through, the short tail removal device cut the
exceeding lengths or tails of the rebars to
give them smooth edges.
Cold Shear:
Cold shear machine is used for the process of
cutting the rebars into particular lengths.

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Chain Transfer:
Chain transfer machine is a moving guide
that collects a number of rebars and transfer
them towards bar counter.
Lowering Device:
It is installed to lower the counted
number of rebars on the VR-61 roller way.
Binding Machine:
It collects rebars through roller way and
binds them in stacks of rebars.

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Bending Machine:
Its purpose is to bend the long bundles or
stacks of rebars in order to provide the ease in
transportation. (During our visit, it was not
operational)

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Weighing system:
This system is installed to determine the weight of the bundle of rebars.
Chain Transfer:
Finally, after being weighed, the rebars are transferred through chain transfer mechanism
to the storage department where they are collected and supplied throughout the country.
Quality Control System:
After the rebars are being manufactured, samples are taken from the lot and the quality of
the material and their properties are tested through tests that involve the following tests:
1) Stress test
2) Hardness test
3) Composition test using spectroscope
4) Bending test
5) Shearing test
6) Cold bend test.

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Fume Extraction System:
The smoke from the furnace is being extracted through hoods. At Amreli Steels, two
types of hoods were installed. At Induction Furnace 1,2, and 3, Swivel hood was used while in
the Induction Furnace 4 tornado hood was used. These hoods suck the smoke or the exhaust
gases from the furnace and send them to state of the art cleaning system of smoke termed as
Fumes Extraction System (FES). The main feature of this system is that it is not only responsible
to purify the smoke but also extracts zinc from it that is a very useful by-product for different
chemicals, construction and pharmaceutical industries.
Water System:
Water system is one of the key systems in Amreli Steels that manages the cooling
system in the entire plant. An RO plant is installed that supplies the demineralized water to the
plant. A pumping station pumps the water to the whole plant. As a reserve a huge water tank
was also present that covers the water supplies in case of failure of the pumping station.
The water system was used for cooling in the following units,
1) The coil of the furnaces.
2) Secondary cooling of billets
3) All the rollers in the plant that needed to be cooled to sustain the hot rolling of the
billets and for their long life.

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